Overview:

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The primary aim of the DRAMA project was to accelerate the uptake of metal powder bed additive manufacturing (AM) within the UK aerospace additive supply chain. To achieve this, a multi-scale AM modelling capability was developed to facilitate informed process optimisation through the introduction of an AM-modelling digital thread.

 

Streamlining AM Modelling:

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The project streamlined AM modelling through several key developments:

 

Meso-Scale Representative Volume Element (RVE) Models: Development of coupled thermo-mechanical Finite Element Analysis (FEA) models for accurate laser energy mapping at the meso-scale. This approach enhanced the understanding of how laser parameters affect the material's thermal response.

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Surrogate Models: Introduction of surrogate models derived from a series of RVEs to expedite component-level simulations. This allowed for quicker assessments of performance without the need for extensive computational resources.

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Component-Level Models: Development of models that predict additive manufacturing residual stresses and temperature distributions. These models are crucial for understanding the mechanical properties of the final product.

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Key Findings:

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The results from the DRAMA project demonstrated notable improvements in predicting AM-induced residual stresses. This enhancement contributes to the geometrical tolerance of reverse-engineered components, offering significant advantages over conventional CAD-based designs and existing commercial platform solutions. By optimising the modelling processes, the project has paved the way for more reliable and efficient use of additive manufacturing in aerospace applications.​​