3D metal Printing in Aerospace: optimization framework for Direct energy deposition (FEM)

Functie

Background

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.

Assignment

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 therefor 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.

Result

• Finite element model framework that can be used for process parameter optimization.

Duration

Between 3 and 9 months

Profiel

Profile

• HBO or WO student of data engineering/science Mechenical of Aerospace engineering (or other relevant field)
• Experience in coding and python scripting is a plus
• Experience with finite element modelling or metal additive manufacturing
• Assertive and self-motivated, able to be part of the project team and also proceed individually

Arbeidsvoorwaarden

What we offer

• A challenging graduation project/internship in a high-tech result orientated work environment
• Weekly supervision and availability of the technical staff for support
• An internship allowance
• Working in an actual R&D project as part of the team
• Internship results to be used in the current and future projects

Informatie

About NLR

Royal NLR has been the ambitious research organisation with the will to keep innovating for over 100 years. With that drive, we make the world of transportation safer, more sustainable, more efficient and more effective. We are on the threshold of breakthrough innovations. Plans and ideas start to move when these are fed with the right energy. Over 650 driven professionals work on research and innovation. From aircraft engineers to psychologists and from mathematicians to application experts.

Our colleagues are happy to tell you what it’s like to work at NLR.

This assignment will be managed by the computational mechanics group within the collaborative engineering (AVCE) department.

Solliciteren

Interested?

Send your application, together with your motivation letter and CV to jos.vroon@nlr.nl and we will contact you as soon as possible.