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Title page. Materials by Design  -Reality and Prospects. G. B. Olson. Northwestern University and QuesTek Innovations LLC. MTL/SRG. NRL A Spanos. ARL/WMD B Montgomery.

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  1. Title page Materials by Design -Reality and Prospects G. B. Olson Northwestern University and QuesTek Innovations LLC

  2. MTL/SRG NRL A Spanos ARL/WMD B Montgomery AFRL C,D Woodward Miracle PURDUE-CALUMET B Abramowitz KTH (Stockholm) C Agren LEHIGH C Harlow WISCONSIN-MAD C,D Perepezko VIRGINIA D Poon IIT D Nash C) Superalloys (DARPA-AIM; AF-MEANS, RMCI, MDT) A) Cybersteel 2020 (ONR D3D/Grand Challenge) D) Bulk Metallic Glasses (DARPA-SAM) B) HT Carburizing Steels (DOE-OIT; GM, P&W) UNIVERSITY GOVERNMENT INDUSTRY QUESTEK A,B,C,D NORTHWESTERN A,B,C,D NAWC/AD A Lee Jung Misra Rathbun Tang Kuehmann Huang Jou Kern Tufts Wang Wright Isheim Jerome Liu Moran Voorhees Olson Brinson Espinosa Fine Freeman CATERPILLAR A,B Chen Johnson High Resolution Microanalysis ALLVAC STEEL A,B Lippard Stevenson GIT A McDowell MITTAL STEEL A Bhattacharya MICHIGAN A Pollock GM B Mishra Sachdev CSM A,C Eberhart PRATT & WHITNEY B,C,D Fowler Schirra Watson OHIO STATE A,C Fraser Mills REFERENCE METALS C Carneiro MIT A,D HOWMET D Wolter Parks WPI/CHTE B Apelian BOEING D Bowden

  3. Perspective

  4. System chart

  5. Hierarchy of Design Models Solidification Design LM SEM/EDS DICTRA TC/L 10 m Transformation Design LM, TEM MQD, DSC TC/MART CASIS, MAP 1.0 m Micromechanics Design LM, TEM JIC, i ABAQUS/SPO TC, V 0.1 m Nano Design SANS, XRD APFIM, AEM y , H TC(Coh)/DICTRA ABAQUS/EFG PrecipiCalc™ 1.0 nm Quantum Design SAM FLAPW DVM KGB() RW-S 0.1 nm

  6. Current sales Ferrium C61 Ring and Pinion Camshafts

  7. S53: Nanotechnology Now

  8. Specify Processing Implementation Concept Yes Yes Meet Objectives? Meet Objectives? Production Heat No Design No A A A Prototype Design Data Process Optimization Sample Production Meet Objectives? Meet Objectives? Application & Process Design Full Scale Heat No A Yes No Yes A A Materials Development Cycle Materials by Design™ AIM Methodologies

  9. Integration Infrastructure iSIGHT framework provided by Engineous Software Core Utilities Analysis Components Models provided by Pratt & Whitney, General Electric, Questek, and others. Integrated by Engineous into the DKB architecture via iSIGHT AIM ARCHITECTURE Documentum eMatrix Oracle Work Flow Information Repository Microsoft Access Geometric Modeling Exploration Tech. 3RD Party tools to extend iSIGHT’s integration capabilities Analysis Structural Modeling Networking DRM * Thermal Modeling Java/HTML Gamma Prime Model LSF/Java Gamma Prime Model Microsoft Excel PrecipiCalc KBE * Distributed Resource Management

  10. UG Subrotor_orig.prt iSIGHT forge.iges ugbatch.bat Subrotor_exp ht_zones.data t Output_deform mach.prt .prl mach.inp forge.inp BC file baseload ANSYS DEFORM .inp mach.ecn Modeling Modeling & Analysis Analysis Post- & Post- mach.sye processing processing N_Burst Impact of DARPA AIM Initiative • Material behavior intimately linked and particpiating in the design process • Ø4 months to improved capability Rim hole Bore

  11. Probabilistic Modeling of Manufacturing Variation:PrecipiCalc™ Forecast of Minimum Design Properties Sim Sim Sim+15 Sim+15 Probability (Weibull scale) 620°C 20°C n=129 n=701 Yield Strength, ksi Part File Heat Transfer PrecipiCalc YS Model YS Distribution East Hartford Salt Lake City Evanston Salt Lake City Mechanistic simulation + (n=15) gives good prediction of 1% minimum YS.

  12. Our vision

  13. Dept. Capstone Design Elective Design phases IDEA 298 IDEA 398 or Design Elective IDEA 308 EDC Design Elective 399 399 399 EMBODIMENT DESIGN User Feedback Refine Specification Alpha prototype Design review Vendor selection DETAIL DESIGN Working prototypes User testing Lab testing Agency approval Revisions Vendor release PRE-PRODUCTION Tooling design Tool revision Pilot runs Testing Revision Inspired by the HLB Process; courtesy Walter Herbst

  14. MSC 390 Materials Design 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 Spring 2005 Design Projects

  15. Civil Shield Technologies Affordable Civilian Anti-Terrorist Blast Mitigation Team BlastTruss: • Matthieu Chardon • Micheal McCarren • Kelvin Chuu • Stephanie Fruth • Constance Lee • Timothy Forbes • Erick Haro • Dennis Kouo IDEA 298/398 Professors Olson and Herbst

  16. NRL Atlas Ductile Fracture [Moran, Liu, Parks] Fatigue Nucleation [McDowell, Olson] LOM Tomography [Olson, Voorhees] Toughness, Fatigue Strength [Olson, Kern] DesignResearchTools matCATCharacterization & Visualization Toolset FSL(SEM/TEM) Tomography [Pollock] Shear Instability [Olson, Kern] Microvoid Shear [Moran, Liu, Parks] Fatigue Propagation [McDowell] DFrac-3D LEAP Tomography [Seidman] Yield Strength [Olson, Kern] Transformation Toughening [Parks, Olson] Precipitation Strengthening [Voorhees, Wang, Jou] PrecipiCalc-3D Semicoherent IPB Adhesion [Freeman, Jerome, Wang] iSIGHT/CMD Integration FLAPW Bond Topological S/P Relations [Eberhart] TECD

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