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The report includes work conducted in a collaborative research and development program between Eaton Corporation and the U.S. Army Engineer Research and Development Center focused on novel multiscale modeling approaches to optimize metal additive manufacturing (AM) processes. The research focused on developing new lower-length scale thermal history predictions with microstructure to property relationships to computationally study a variety of manufacturing parameters and their correlation to defects generation and mechanical properties. Direct metal laser sintering (DMLS – a powder bed AM method) and directed energy deposition (DED – a blown powder AM method) were studied. The results indicated that the developed tools could rapidly predict optimal manufacturing parameters through fast running layer-by-layer thermal models of each respective AM process. Physical test specimens and prototypes were also produced as part of the study to aid in model calibration and validation through mechanical testing and microstructural characterization. DISCLAIMER: The contents of this report are not to be used for advertising, publication, or promotional purposes. Citation of trade names does not constitute an official endorsement or approval of the use of such commercial products. All product names and trademarks cited are the property of their respective owners. The findings of this report are not to be construed as an official Department of the Army position unless so designated by other authorized documents. DESTROY THIS REPORT WHEN NO LONGER NEEDED. DO NOT RETURN IT TO THE ORIGINATOR.

Additive manufacturing of metallic materials with controlled microstructures : multiscale modeling of direct metal laser sintering and directed energy deposition