Systems and methods for performing microstructure simulation and implementation of additive manufacturing processes

Patent metadata

Field	Value
Publication number	US-10786849-B2
Application number	US-201916294718-A
Country	US
Kind code	B2
Filing date	Mar 6, 2019
Priority date	Mar 7, 2018
Publication date	Sep 29, 2020
Grant date	Sep 29, 2020

Abstract

Systems and methods are provided for receiving, by a simulation model, a thermal gradient and a cooling rate associated with a 3D printing material as inputs for the simulation model. The systems and methods further include generating, by the simulation model executed by a processing system, characteristics associated with the 3D printing material as outputs of the simulation model based on the thermal gradient and the cooling rate associated with the 3D printing material.

First claim

The invention claimed is:

1. A method comprising:
receiving, by a simulation model, a thermal gradient and a cooling rate associated with a 3D printing material as inputs for the simulation model, wherein the simulation model provides information about a microstructure associated with the 3D printing material, and wherein the thermal gradient comprises a representation of temperature variation across a volume of the 3D printing material, after the 3D printing material has been heated, based on a composition of the 3D printing material; and
generating, by the simulation model executed by a processing system, characteristics associated with the 3D printing material as outputs of the simulation model based on the thermal gradient and the cooling rate associated with the 3D printing material.

2. The method of claim 1 , further comprising:
determining whether a manufactured article fabricated by a 3D printing process associated with the simulation model is within a desired specification based on the generated characteristics associated with the 3D printing material;
in response to determining that the manufactured article is not within the desired specification, adjusting one or more parameters associated with the 3D printing process; and
providing the one or more adjusted parameters to the simulation model.

3. The method of claim 1 , wherein the characteristics associated with the 3D printing material comprise at least one of an orientation of the 3D printing material, a composition of the 3D printing material, a grain size of the 3D printing material, a morphology of the 3D printing material or a concentration(s) of component(s) in the 3D printing material.

4. The method of claim 1 , wherein the simulation model is executed on at least one layer of a manufactured article and wherein the inputs for the simulation model further include data representing one or more scan patterns of a beam used to heat the 3D printing material.

5. The method of claim 1 , wherein generating the characteristics associated with the 3D printing material further comprises:
simulating nucleation on the 3D printing material based on the thermal gradient and the cooling rate associated with the 3D printing material.

6. The method of claim 1 , wherein generating the characteristics associated with the 3D printing material further comprises:
assigning a growth orientation to new nuclei of the 3D printing material based on a heat source position and movement.

7. The method of claim 1 , wherein generating the characteristics associated with the 3D printing material further comprises:
identifying an interface cell associated with the 3D printing material, wherein the interface cell is in contact with a liquid portion of the 3D printing material and a solid portion of the 3D printing material.

8. A data processing system for simulating a 3D printing system comprising:
a memory; and
a processing system executing a 3-dimensional (3D) simulation model, operatively coupled to the memory, to:
receive, by the 3D simulation model, a thermal gradient and a cooling rate associated with a 3D printing material as inputs for the 3D simulation model, wherein the simulation model provides information about a microstructure associated with the 3D printing material, and wherein the thermal gradient comprises a representation of temperature variation across a volume of the 3D printing material, after the 3D printing material has been heated, based on a composition of the 3D printing material; and
generate, by the 3D simulation model executed by the processing system, characteristics associated with the 3D printing material as outputs of the 3D simulation model based on the thermal gradient and the cooling rate associated with the 3D printing material.

9. The data processing system of claim 8 , further comprising:
one or more energy sources, operatively coupled to the processing system, to generate one or more heat sources; and
a scanner, operatively coupled to the one or more energy sources and the processing system, to direct the one or more heat sources to an area of the 3D printing material and wherein the inputs for the simulation model further include data representing one or more scan patterns of a beam used to heat the 3D printing material.

10. The data processing system of claim 8 , further comprising:
one or more sensors, operatively coupled to the processing system, to provide data associated with the 3D simulation model to the processing system.

11. The data processing system of claim 8 , wherein the processing system is further to:
simulate nucleation on the 3D printing material based on the thermal gradient and the cooling rate associated with the 3D printing material.

12. The data processing system of claim 8 , wherein the processing system is further to:
assign a growth orientation to new nuclei of the 3D printing material based on a heat source position and movement.

13. The data processing system of claim 8 , wherein the processing system is further to:
determine whether a manufactured article fabricated by a 3D printing process associated with the simulation model is within a desired specification based on the generated characteristics associated with the 3D printing material;
in response to determining that the manufactured article is not within the desired specification, adjust one or more parameters associated with the 3D printing process; and
provide the one or more adjusted parameters to the simulation model.

14. The data processing system of claim 8 , wherein the characteristics associated with the 3D printing material comprise at least one of an orientation of the 3D printing material, a grain size of the 3D printing material, a morphology of the 3D printing material, a composition of the 3D printing material or a concentration(s) of component(s) in the 3D printing material.

15. A non-transitory computer-readable storage medium including instructions that, when executed by a processing system, cause the processing system to:
receive, by a simulation model, a thermal gradient and a cooling rate associated with a 3D printing material as inputs for the simulation model, wherein the simulation model provides information about a microstructure associated with the 3D printing material, and wherein the thermal gradient comprises a representation of temperature variation across a volume of the 3D printing material, after the 3D printing material has been heated, based on a composition of the 3D printing material; and
generate, by the simulation model, characteristics associated with the 3D printing material as outputs of the simulation model based on the thermal gradient and the cooling rate associated with the 3D printing material.

16. The non-transitory computer-readable storage medium of claim 15 , wherein the processing system is further to:
determine whether a manufactured article fabricated by a 3D printing process associated with the simulation model is within a desired specification based on the generated characteristics associated with the 3D printing material;
in response to determining that the manufactured article is not within the desired specification, adjust one or more parameters associated with the 3D printing process; and
provide the one or more adjusted parameters to the simulation model.

17. The non-transitory computer-readable storage medium of claim 15 , wherein the characteristics associated with the 3D printing material comprise at least one of an orientation of the 3D printing material, a grain size of the 3D printing material, a morphology of the 3D print

Assignees

• Ansys Inc

Inventors

• Akram Javed

Classifications

• B22F12/90

  Means for process control, e.g. cameras or sensors · CPC title

• B22F10/80

  Data acquisition or data processing · CPC title

• B22F10/38

  to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/366

  Scanning parameters, e.g. hatch distance or scanning strategy · CPC title