Internship: 3D metal Printing in Aerospace: Directed Energy Deposition optimized process parameters

3D printing (or additive manufacturing) is a manufacturing process which is gaining popularity within the aerospace sector thanks to the possibilities offered by this technology to manufacture highly optimized and efficient, lightweight structures.

One of the most promising metal additive manufacturing methods is Directed Energy Deposition (DED), in which a laser selectively heats and melts powder in a powder stream that is directed directly at the print. By adding material tracks layer by layer a metal part is built. The mechanics of the melt pool are very important to the whole process and have a large influence on the quality of the print.

The physics of the melt pool are complicated and not well understood.

The aim of the research is to create code/script in python, coupled with finite element simulations, to optimize printing parameters. The goal of this optimization is to prevent overheating and therefore improve the quality of the print. Both part-scale and melt pool-scale simulations can be used in this assignment. This includes a literature study focussing on the relevant parameters affecting temperature distribution and thermal gradients throughout the part.

You will investigate ways to control the thermal behaviour using variable process parameters and demonstrate with a thermal simulation model. For this, different types of software can be used, Abaqus, Simufact, or a MATLAB-based in-house tool. The simulations can be verified/validated with literature, thermal measurement data or thermal camera imaging data (if feasible) from the build job.

The duration of this assignment can vary between 3 and 9 months.

Location:

NLR Marknesse, Voorsterweg 31, 8316 PR Marknesse, Netherlands.

• Aerospace Engineering
• Mechanical Engineering
• Structures and Materials
• Material Science
• Data Science

Note:

NLR requires a recent certificate of conduct (Verklaring Omtrent het Gedrag, VOG) from the applicant.

NLR can support in finding accommodation in the vicinity of Marknesse if necessary.