Abstract: A system and method of additive manufacturing is disclosed herein which when run or performed form a product with a powder-based additive manufacturing device by adding sequential layers of material on top of one another. As each sequential layer of material is added, the system and method can include monitoring the sequential layer with a defect analysis subsystem to detect whether the sequential layer has any defects. For a detected defect, it can be determined whether defect correction is required. For a required defect correction, one or more correction parameters for the required defect correction can be identified; and a correction command including the one or more correction parameters can be sent to the additive manufacturing device, the correction command causing the additive manufacturing device to help correct the detected defect in the sequential layer according to the correction parameters prior to moving on to a next sequential layer.

Abstract: A system and method for determining surface contact fatigue life may use a finite element method to determine when components, such as a power transmission component, may fail in operation. The method may generate a finite element model based on the material parameters related to a power transmission component, generate a surface pressure time history for a loading event based on one or more loading parameters, determine, based on the surface pressure time history for a loading event, a finite element solution that describes stress in the grain structure, calculate damage in the finite element solution using a damage model, and determine whether a damage threshold is exceeded.

Abstract: A method for modeling performance in a part manufactured using an additive manufacturing (AM) process may include obtaining geometric parameters, material parameters, AM parameters, or loading parameters. The method may include generating a process model based on the geometric parameters, the material parameters, and the AM parameters. The method may include generating a microstructure model based on the material parameters and the AM parameters. The method may include generating a performance model based on the loading parameters. The method may include performing performance simulation, including running the process model to produce a simulated part or a surface roughness mapping, running the microstructure model to produce a simulated grain structure or a simulated porosity profile of the simulated part, and running the performance model to determine a simulated performance life based on the simulated grain structure, the simulated porosity profile, or the surface roughness mapping.

Abstract: A method for modeling performance in a part manufactured using an additive manufacturing (AM) process may include obtaining geometric parameters, material parameters, AM parameters, or loading parameters. The method may include generating a process model based on the geometric parameters, the material parameters, and the AM parameters. The method may include generating a microstructure model based on the material parameters and the AM parameters. The method may include generating a performance model based on the loading parameters. The method may include performing performance simulation, including running the process model to produce a simulated part or a surface roughness mapping, running the microstructure model to produce a simulated grain structure or a simulated porosity profile of the simulated part, and running the performance model to determine a simulated performance life based on the simulated grain structure, the simulated porosity profile, or the surface roughness mapping.

Abstract: A system and method of additive manufacturing is disclosed herein which when run or performed form a product with a powder-based additive manufacturing device by adding sequential layers of material on top of one another. As each sequential layer of material is added, the system and method can include monitoring the sequential layer with a defect analysis subsystem to detect whether the sequential layer has any defects. For a detected defect, it can be determined whether defect correction is required. For a required defect correction, one or more correction parameters for the required defect correction can be identified; and a correction command including the one or more correction parameters can be sent to the additive manufacturing device, the correction command causing the additive manufacturing device to help correct the detected defect in the sequential layer according to the correction parameters prior to moving on to a next sequential layer.

Abstract: A system and method for determining surface contact fatigue life may use a finite element method to determine when components, such as a power transmission component, may fail in operation. The method may generate a finite element model based on the material parameters related to a power transmission component, generate a surface pressure time history for a loading event based on one or more loading parameters, determine, based on the surface pressure time history for a loading event, a finite element solution that describes stress in the grain structure, calculate damage in the finite element solution using a damage model, and determine whether a damage threshold is exceeded.

Abstract: A system and method for determining surface contact fatigue life may use a finite element method to determine when components, such as a power transmission component, may fail in operation. The method may generate a finite element model based on the material parameters related to a power transmission component, generate a surface pressure time history for a loading event based on one or more loading parameters, determine, based on the surface pressure time history for a loading event, a finite element solution that describes stress in the grain structure, calculate damage in the finite element solution using a damage model, and determine whether a damage threshold is exceeded.

Abstract: A system and method for determining surface contact fatigue life may use a finite element method to determine when components, such as a power transmission component, may fail in operation. The method may generate a finite element model based on the material parameters related to a power transmission component, generate a surface pressure time history for a loading event based on one or more loading parameters, determine, based on the surface pressure time history for a loading event, a finite element solution that describes stress in the grain structure, calculate damage in the finite element solution using a damage model, and determine whether a damage threshold is exceeded.

Abstract: A system and method for determining surface contact fatigue life may use a finite element method to determine when components, such as a power transmission component, may fail in operation. The method may generate a finite element model based on the material parameters related to a power transmission component, generate a surface pressure time history for a loading event based on one or more loading parameters, determine, based on the surface pressure time history for a loading event, a finite element solution that describes stress in the grain structure, calculate damage in the finite element solution using a damage model, and determine whether a damage threshold is exceeded.