Transcript Document

Title page
Materials by Design
-Reality and Prospects
G. B. Olson
Northwestern University and QuesTek Innovations LLC
MTL/SRG
C) Superalloys (DARPA-AIM; AF-MEANS, RMCI, MDT)
D) Bulk Metallic Glasses (DARPA-SAM)
A) Cybersteel 2020 (ONR D3D/Grand Challenge)
B) HT Carburizing Steels (DOE-OIT; GM, P&W)
UNIVERSITY
GOVERNMENT
NAWC/AD
A
Olson
Lee
NRL
Spanos
A
ARL/WMD
Montgomery
B
AFRL
Woodward
Brinson
Espinosa
Fine
Freeman
A,B,C,D
QUESTEK
Kuehmann
Huang
Jou
Kern
Isheim
Jerome
Liu
Moran
Voorhees
A,B,C,D
Jung
Tufts
Misra
Wang
Rathbun Wright
Tang
CATERPILLAR
Chen
A,B
Johnson
High Resolution Microanalysis
C,D
Miracle
PURDUE-CALUMET
Abramowitz
B
KTH (Stockholm)
Agren
C
LEHIGH
Harlow
C
WISCONSIN-MAD
Perepezko
NORTHWESTERN
INDUSTRY
C,D
GIT
McDowell
A
MICHIGAN
Pollock
A
CSM
Eberhart
A,C
OHIO STATE
Fraser
A,C
MIT
IIT
Nash
D
VIRGINIA
Poon
D
WPI/CHTE
Apelian
ALLVAC STEEL
Lippard
A,B
Stevenson
MITTAL STEEL
Bhattacharya
A
GM
Mishra
B
Sachdev
PRATT & WHITNEY
Fowler
Schirra
Mills
A,D
Parks
B,C,D
Watson
REFERENCE METALS
Carneiro
C
HOWMET
Wolter
D
BOEING
Bowden
D
B
Perspective
System chart
Hierarchy of Design Models
Solidification
Design
LM
SEM/EDS
LM, TEM
MQD, DSC
SAM
KGB()
1.0 nm
FLAPW
0.1 nm
TC/MART
1.0 m
ABAQUS/SPO
TC, V
Nano Design
Quantum Design
10 m
CASIS, MAP
JIC, i
SANS, XRD
APFIM, AEM
y , H
TC/L
Transformation
Design
Micromechanics
Design
LM, TEM
DICTRA
DVM
0.1 m
TC(Coh)/DICTRA PrecipiCalc™
ABAQUS/EFG
RW-S
Current sales Ferrium C61
Ring and Pinion
Camshafts
S53: Nanotechnology Now
Materials Development Cycle
Materials by Design™
Concept
Yes
Specify
Processing
Implementation
Yes
No
A
Design
Prototype
Meet
No Objectives?
Meet
Objectives?
Production
Heat
A
Design
Data
Process
Optimization
Full Scale
Heat
Yes
A
Meet
No
A
Objectives?
A
No
Meet
Objectives?
Sample
Production
Yes
Application
& Process
Design
A
AIM Methodologies
AIM ARCHITECTURE
Documentum
Integration Infrastructure
eMatrix
iSIGHT framework
provided by Engineous
Software
Core Utilities
3RD Party tools to extend
iSIGHT’s integration
capabilities
Oracle
Work
Flow
Information
Repository
Microsoft
Access
Geometric
Modeling
Exploration
Tech.
Structural
Modeling
Analysis
Networking
Analysis Components
Models provided by Pratt
& Whitney, General
Electric, Questek, and
others. Integrated by
Engineous into the DKB
architecture via iSIGHT
Thermal
Modeling
DRM *
Java/HTML
Gamma
Prime
Model
LSF/Java
Gamma
Prime
Model
Microsoft
Excel
KBE
* Distributed Resource Management
PrecipiCalc
Impact of DARPA AIM Initiative
• Material behavior intimately linked
and particpiating in the design process
 4 months to improved capability
UG
Subrotor_orig.prt
ugbatch.bat
t
mach.prt
iSIGHT
Subrotor_exp
Output_deform
.prl
mach.inp
Rim hole
forge.iges
ht_zones.data
forge.inp
BC file
baseload
.inp
ANSYS
Modeling
Analysis
& Postprocessing
mach.ecn
mach.sye
N_Burst
DEFORM
Modeling &
Analysis
Postprocessing
Bore
Probabilistic Modeling of Manufacturing Variation:
PrecipiCalc™ Forecast of Minimum Design Properties
Heat Transfer
PrecipiCalc
East
Hartford
Salt Lake
City
Evanston
Mechanistic simulation
+ (n=15) gives good
prediction of 1%
minimum YS.
YS Model
YS Distribution
Salt Lake City
Probability (Weibull scale)
Part File
Sim
Sim
Sim+15
620°C
n=701
20°C
n=129
Yield Strength, ksi
Sim+15
Our vision
Design phases
Design
Elective
IDEA 106
IDEA 306
Dept.
Capstone
or
IDEA 298
EDC
Design
Elective
IDEA 308
IDEA 398
Design
Elective
399
399
399
CONCEPTUAL
DESIGN
EMBODIMENT
DESIGN
DETAIL
DESIGN
PRE-PRODUCTION
Needs discovery
Business planning
Concept generation
QFD
Prelim breadboard
Prelim vendor assess
Prelim specifications
User Feedback
Refine Specification
Alpha prototype
Design review
Vendor selection
Working prototypes
User testing
Lab testing
Agency approval
Revisions
Vendor release
Tooling design
Tool revision
Pilot runs
Testing
Revision
Inspired by the HLB Process; courtesy Walter Herbst
MSC 390 Materials Design
Spring 2005
Design Projects
I.
Blastalloy 120 NM (396/EDC)
Client: ONR, DHS
Advisors: Chris Kern, QuesTek
Padmanava Sadhukhan
IV.
Terminator 4: Biomimetic
Self-Healing Mg Composite
Client: NASA, ARL
Advisor: Michele Manuel
II.
Windmill Steel C64
Client: GE Power Generation
Advisor: Yana Qian
V.
Stentalloy Z: HP-SMA (396)
Client: Medtronic, Memry
Advisor: Matt Bender
III.
NanoDie M60N
Client: ITW Medalist
Advisor: Ben Tiemens
VI.
Noburnium 2: YAGalloy 1300
Client: AFOSR, NASA, RMC
Advisor: Dave Bryan
VII.
Super Bubble (EDC)
Client: QuesTek
Advisor: Les Morgret
Affordable Civilian
Anti-Terrorist
Blast Mitigation
Team BlastTruss:
•Matthieu Chardon
•Constance Lee
•Micheal McCarren
•Timothy Forbes
•Kelvin Chuu
•Erick Haro
•Stephanie Fruth
•Dennis Kouo
IDEA 298/398
Professors Olson and Herbst
NRL
Atlas
LOM
Tomography
[Olson, Voorhees]
Toughness,
Fatigue Strength
[Olson, Kern]
Design Research Tools
FSL(SEM/TEM)
Tomography
[Pollock]
Shear Instability
[Olson, Kern]
LEAP
Tomography
[Seidman]
Yield Strength
[Olson, Kern]
Microvoid Shear
[Moran, Liu, Parks]
Fatigue Propagation
[McDowell]
Transformation
Toughening
[Parks, Olson]
Precipitation
Strengthening
[Voorhees, Wang,
Jou]
Semicoherent IPB
Adhesion
[Freeman,
Jerome, Wang]
Bond Topological
S/P Relations
[Eberhart]
Ductile
Fracture
[Moran,
Liu, Parks]
Fatigue
Nucleation
[McDowell,
Olson]