Development of Aerospace Materials Using Integrated Numerical and Physical Simulation
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https://doi.org/10.1007/s11837-020-04319-w 2020 The Minerals, Metals & Materials Society
PRACTICAL RESEARCH IN PROCESSING SCIENCE
Development of Aerospace Materials Using Integrated Numerical and Physical Simulation BRUCE F. ANTOLOVICH ,1,2 ANTHONY BANIK,1 JOHN W. FOLTZ,1 JOHN V. MANTIONE,1 and RAMESH S. MINISANDRAM1 1.—ATI Specialty atimetals.com
Materials,
Monroe,
NC
28110,
USA.
2.—e-mail: bruce.antolovich@
The introduction of new alloys and process improvements that promise increased material performance to the aerospace and defense industries is a long and costly venture due to ensuring flight safety by way of data analysis and field service. Changes to the supply chain require the use of a phased approach, typically technical readiness level (TRL), to reduce risk. The techniques in the TRL methodology include both physical simulation, such as demonstrators, and computational simulation within the Integrated Computational Materials Engineering (ICME) framework. The typical approach consists of designing a methodology using computational processing, conducting pilot-scale trials, and using a TRL approach for scaling the technology. A balanced combination of physical and numerical simulations aids in understanding the role of metalworking processes in microstructure and property development. This in turn ensures the development of new and improved products in an accelerated manner. This paper reviews simulation methods, both computational and physical, available in the metals industry and discusses examples of how the use has accelerated deployment of new products.
INTRODUCTION To ensure both process robustness and flight safety, new alloys and process improvements in the aerospace and defense industries are generally long and costly ventures. Changes to the supply chains incorporate a phased or technical readiness level (TRL) approach, which reduces uncertainty of a product’s service readiness. Included in this TRL approach can be both numerical and physical simulations, the former widespread and the latter still used in systems like aerodynamic wind tunnels. Physical simulations of metalworking processes have decreased over the past decades with a concomitant increase in the use of computational modeling. A balanced combination of physical and computational simulation processes in understanding metalworking and its role in microstructure and property development is critical to ensure swift development of new and improved products.
(Received June 15, 2020; accepted July 28, 2020)
TRLs were adopted across the aerospace industry after NASA first documented it as a tool in 1989,1 and expanded when ISO 162902 was published in 2013 to standardize it for space hardware. Similar tools, such as tool maturity levels, are more focused on modeling tools and the integrated computational materials engineering (ICME) approach. In all such scales, the most lagging evaluation sets the base assessment level for the program. TRL is typically described on a 1–9 scale, with 1 representing a new idea with only basic pr
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