Manager for Numerical Modelling and Optimisation - TWI Ltd
Additive Manufacturing Technology: Enhancing Process Optimisation and Part Performance through Simulation
Metal Additive Manufacturing (AM) technology has developed rapidly in the last decade and has demonstrated significant potential to reduce the costs and improve the quality and efficiency of parts and components across all industry sectors. This can be realised through improved design freedom and light-weighting via topology optimisation; improved buy-to-fly ratios; and a reduction of tooling costs – all of which have a demonstrable impact on the carbon footprint and waste in manufacture.
However, there are many factors that affect the final quality (and certification) of AM parts, including the feedstock material characteristics and the thermal transients seen buy the part during processing. The complex geometry of topology optimised parts – designed to take advantage of the flexibility of AM processing – means that almost every location in the build sees a unique thermal history. As thermal history controls microstructure, distortion and residual stress, there is significant uncertainty in the performance of and lack of homogeneity within metal AM parts.
This presentation highlights some of the ways the Integrated Computational Materials Engineering (ICME) concepts are influencing how industry approaches and realises the potential impacts of AM technology. It considers multiple AM methods (selective laser melting and wire-arc additive) and how engineering analysis can significantly reduce trial-and-error costs and improve our fundamental understanding of AM processes.
Tyler London is the Manager for Numerical Modelling and Optimisation at TWI Ltd, an international R&D and consultancy organisation focusing on materials, joining and structural integrity technologies. Tyler joined TWI in 2010 and has detailed experience applying non-linear finite element modelling to a range of engineering disciplines including welding simulations, additive manufacturing, and failure investigations. He is Professional Simulation Engineer, Chartered Engineer, Chartered Mathematician and Chartered Scientist and actively participates in NAFEMS Working Groups, British Standard 7910, UK Nuclear Industry R6, and EN 13094 sub-committees to increase the adoption of engineering analysis in codes and standards.