U N I V E R S I T Y O F P I T T S B U R G H | S W A N S O N S C H O O L O F E N G I N E E R I N G

Integrated Design Tool Development for High Potential AM Applications

FUNDING AGENCY: America Makes (NAMII)AMOUNT: $961,112 (cost share $1.7M)DURATION: 18 months, expected to start late 2015PI: Albert ToCORPORATE PARTNERS: Aerotech, ANSYS , EOS of North America, ExOne, Honeywell, Marcus Machinery, Materials Sciences Corporation, RTI International Metals (Alcoa Titanium & Engineered Products), United Technologies Research Center, and the U.S. Army Aviation and Missile Research Development and Engineering Center

OBJECTIVEAM technologies are now capable of producing very complex geometries and topologies, tremendously expanding the limited design space allowed by traditional manufacturing methods. However, existing CAD/CAE software packages to date have not taken full advantage of the enormous design freedom afforded by AM. This project team seeks to create an integrated design suite that can be rapidly commercialized, helping to minimize time of the design phase, lower manufacturing cost, and reduce time to market for new AM product development.

Parametric Design of Functional Support Structures for Metal Alloy Feedstocks

FUNDING AGENCY: America Makes (NAMII)AMOUNT: $805,966 + $880,297 (cost share) = $1,686,263DURATION: 18 months, expected to start late 2015PI: M. Ravi ShankarCORPORATE PARTNERS: ITAMCO, Johnson & Johnson, and the University of Notre Dame

OBJECTIVEThis project will strive to codify the design rules for support structures used in Direct Metal Laser Sintering (DMLS) to inform and then automatically recommend the optimal part orientation and the designs for optimized supports. Currently during part builds, support structures are not only essential to laying part foundations and providing structural support, but also are critical to eliminating part warp during powder recoating and improving heat extraction. However, few rules exist for designing support structures.

Design, Fabrication, and Performance Characterization of Near-Surface Embedded Cooling Channels with an Oxide Dispersion Strengthened Coating Layer

FUNDING AGENCY: Department of Energy’s National Energy Technology Laboratory (NETL), University Turbine Systems Research ProgramAMOUNT: DOE: $798,594 + Non DOE: $216,896 = $1,015,490DURATION: 6/1/2015-6/1/2018PI: Minking ChyuCO-PI: Bruce Kang, West Virginia UniversityCORPORATE PARTNERS: Siemens, Solar Turbines.

OBJECTIVEThe primary goal of this research is to develop an innovative approach to provide an immensely improved level of thermal protection for hot-section components, such as turbine airfoils, in modern and future gas turbines, which has inlet temperatures well beyond the substrate melting temperature, typically ranging from ~1400°C-1800°C. The proposed approach will make use of Oxide Dispersion Strengthened (ODS) material to form a thermal-oxidation protection layer over a single crystal superalloy substrate, in conjunction with the concept of near-wall cooling. The ultimate goal for this research is to design, build, and test realistic ODS- cooling modules or coupons. At the conclusion of this project, the resulting data and new technology will be readily available for turbine OEMs to implement as part of their hot-section management portfolios.

Multiscale Structure-Mechanical Property Investigation of Additive Manufactured Components for Development of a Reliable Qualification Method

FUNDING AGENCY: NSFAMOUNT: $300,000DURATION: 08/01/14 - 07/31/17PI: Albert ToCO-PIs: Markus Chmielus, Minking Chyu

OBJECTIVEStandard qualification methods for traditional manufacturing are not suitable for additive manufactured parts because these methods only take into account flaws near the surface. This proposed research is to develop a highly reliable, low-cost, and efficient qualification method for additive manufactured components based on a combined approach of validated computer simulations and non-destructive evaluation techniques. The developed qualification method will potentially lead to much wider adoption of additive manufacturing and will impact applications requiring complex, high value, time-sensitive, and customized products and prototypes.

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RECENTLY FUNDED Additive Manufacturing Projects

Developing Topology Optimization Tools that Enable Efficient Design of Additive Manufactured Cellular Structures

Funding Agency: America Makes (NAMII)AMOUNT: $437,889 + $525,648 (cost share) = $963,537DURATION: 03/01/2014-08/31/2015PI: Albert ToCO-PIs: Kevin P. Chen, David Schmidt

OBJECTIVEThe goal of this project is to develop robust software for design and optimization of AM structural designs based on cellular structures. The key innovation in this technology is the utilization of micromechanics models for capturing the effective behavior of cellular structures in finite element analysis (FEA). This will enable solving topology optimization problems via FEA much more efficiently. The M&S technology developed will help cut time in design phase, lower manufacturing cost, and reduce time to market for new AM structural product development.

Additive Manufacturing of Biomedical Devices from Bioresorbable Metallic Alloys for Medical Applications

Funding Agency: America Makes (NAMII)Amount: $590,000 + $56,146 (cost share) = $646,146Duration: 03/01/2014-08/31/2015PI: Prashant KumtaCo-PI: Howard Kuhn

OBJECTIVEThis project will investigate additive manufacturing techniques for constructing complex 3-D printed bone and tissue scaffolds composed of advanced biocompatible and biodegradable metal alloys. Additive manufacturing enables the precise targeting of biodegradable alloys such as iron-manganese within these structures, which can then be used for bone or tissue replacement and repair. Precisely controlling the location and degradation rate of these alloys through additive manufacturing will have far-reaching positive impacts in the field of regenerative medicine and beyond.

Automation Tools for Modeling AM Process of Complex Geometries in ABAQUS

Funding Agency: Research for Advanced Manufacturing in Pennsylvania program (RAMP)Amount: $150,000 + $90,302 (cost share) = $240,302Duration: 08/01/14 - 07/31/15PI: Albert To Co-PIs: Markus Chmielus, Minking Chyu

OBJECTIVEThe goal of this project is to develop computer codes to automate 1) model setup for simulating certain AM process in ABAQUS and 2) calibration of model parameters using experimental and simulation results. To demonstrate the capability of the codes developed, the fabrication of a complex Ti6Al4V part using the laser engineered net shaping (LENS) process will be modeled and simulated.

A Database Relating Powder Properties to Fatigue Strength for Binder Jet Printed Inconel

Funding Agency: Research for Advanced Manufacturing in Pennsylvania program (RAMP)Amount: $149,999 + $99,510 (cost share) = $249,509Duration: 08/01/14 - 07/31/15PI: Markus Chmielus Co-PI: Albert To

OBJECTIVEIn this project, Pitt researchers, ExOne and Acutec Precision Machining will collaborate to improve the mechanical properties of IN625 BJP by creating a database linking different powders (production, porosity, size) with properties of the produced parts (microstructure, static and fatigue). By developing this database, tensile and fatigue strength can be optimized accordingly, and engineers can design parts built by the BJP process with higher confidence.

The information printed in this document was accurate to the best of our knowledge at the time of printing and is subject to change at any time at the University’s sole discretion.

The University of Pittsburgh is an affirmative action, equal opportunity institution. 08/2015

University of Pittsburgh | Swanson School of EngineeringAndrew Falk, Executive Director of Corporate and Foundation Relations 104 Benedum Hall | 3700 O’Hara Street | Pittsburgh, PA 15261 412-624-6085 adf23@pitt.edu engineering.pitt.edu

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