ICME Educaon at Northwestern - Carnegie Mellon...
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ICME Educa*on at Northwestern G.B. Olson Northwestern University & QuesTek Innova*ons LLC Evanston, Illinois
Transcript of ICME Educaon at Northwestern - Carnegie Mellon...
ICME Educa*on at Northwestern
G.B. Olson Northwestern University & QuesTek Innova*ons LLC
Evanston, Illinois
Program Goals
Analysis/Knowledge Synthesis/Evalua*on
Mechanis*c Perspec*ve to Problem Solving
Modern Tools
Sound fundamentals of dynamic microstructure
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Apply math and science to engineering
Mechanis*c modeling
Systems Perspec*ve
Design Integra*on
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Theore*cal Conceptual Computa*onal
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13 Experimental Op*miza*on, Sta*s*cal DOE
14 Materials and Processes
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Teamwork ‐ within discipline ‐ mul*disciplinary perspec*ve
Communica*on ‐ wriYen ‐ spoken ‐ graphical
Computa*onal materials science
Basic and advanced instrumenta*on (characteriza*on of structure and proper*es)
Basic and advanced processing prac*ce
Complex problem iden*fica*on and formula*on
User needs ‐ performance
Global/societal context
Professional ethics
Dynamics: Contemporary issues, Lifelong learning
Department of Materials Science & Engineering
201 Princ & Prop Matls
314/315 Thermo
316‐1,2 Micro Dynamics
331 Intro Polymers
332 Mech Behavior
351‐1,2 Intro Physics Matls
361 Cryst & Diffrac*on
390 Materials Design
391 Process Design
396‐1,2 Senior Project
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analysis/knowledge synthesis/evalua*on
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Curriculum Structure/Property Rela*ons
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EDC 1 EDC 2
Thermo 1 Intro MSE
Thermo 2 Mechanics
Micro Dynamics 1
Micro Dynamics 2 Mech Behavior
SS Physics 1 Materials Design SS Physics 2
Process Design Senior Project Senior Project
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MSE Design Curriculum
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Educa*on: Mul*year Design Sequence
Bringing Modern Design to the Research University
DSGN 106‐1,2 Freshman Engineering Design & Communica@on ‐‐ Cross‐Cultural Teaching of Modern Product Design
Mat Sci 390 Materials Design ‐‐ Computa*onal Design of Dynamic Mul*scale Materials
Mat Sci 391 Process Design ‐‐ Sta*s*cal Methods of Experimental Process Op*miza*on
Mat Sci 396‐1,2 Senior Project ‐‐ Experimental Research & Design Valida*on
Perspec*ve
System chart
SANS, XRD APFIM, AEM σy , H
SAM
TC/MART
CASIS, MAP
KGB(Δγ) FLAPW
DVM RW‐S
TC(Coh)/DICTRA
ABAQUS/EFG
LM, TEM
JIC, γi ABAQUS/SPO
TC, ΔV
LM, TEM MQD, DSC
LM
SEM/EDS DICTRA
TC/ΔρL
PrecipiCalc™
Hierarchy of Design Models
Computational Labs: MSc390 Materials Design
Lab 1. CES Ashby Materials Selec*on Sohware: Formula*ng Design Objec*ves
Lab 2. TCW: Basic CALPHAD Calcula*ons
Lab 3. CMD1: TCC‐based Design Modeling
Lab 4. CMD2: Model Integra*on in Parametric Design
Lab 5. DICTRA/PrecipiCalc: Dynamics Simula*on
Example: Design Integra*on with CMD Matrix + Strengthening Dispersion Design
Grain Pinning Dispersion Design
n=701 n=129
Probability(Weibullscale) Sim Sim
Sim+15Sim+15
620°C 20°C
YieldStrength,ksi
Feb 06 – Forging demonstra*on complete.
4th Quarter 09 – T38 MLG ERB Planned – First Flight
Aug 09 – T38 MLG limit and ul*mate tests complete.
March 03 – ESTCP LG Program starts
Aug 08 – A10 MLG qualifica*on complete.
April 08 – A10 MLG tes*ng complete.
Dec 05 – 1st A10 drag brace completed.
Sep 09 – AF matls. ERB
Apr 08 – MMPDS complete
June 05 – Hill AFB ALGLE and MSD Projects start
June 06 – ESTCP RGA Program starts
Jan 06 – DARPA S53 AIM Project starts
Jan 07 – Carpenter license completed
May 09 – T38 MLG fa*gue rig tes*ng complete.
Feb 05 – 2nd produc*on heat is completed and ships.
Oct 06 – AIM driven process reop*miza*on completed.
Nov 07 – 11th heat completed.
Dec 07 – AMS complete.
March 07 – JTP tes*ng complete.
Nov 06 – 5th & 6th heat completed.
Jan – 04 S53 manufacturing specifica*on released for produc*on
June 02 ‐ Series 6 designs demonstrate all mechanical property goals
June 03 ‐ S53A demonstrates scale‐up of tensile proper*es.
June 01 – SERDP Phase II Program starts
Dec 00 – ALGLE Bridge Program starts
S53 Transition Milestones
Dec 99 – SERDP SEED Program starts
Programma@
c & Fun
ding
Mileston
es
Allo
y Design
Mileston
es
Nov 00 –Series 1 & 2 designs demonstrate tensile proper*es in 300 lb heats.
Allo
y Qua
lifica@on
Mileston
es
Compo
nent Qua
lifica@on
Mileston
es
Jan 05 – 1st produc*on S53D meets specifica*on and quality tests.
Feb 06 – 3rd heat completed.
Sept 06 – 4th produc*on heat is out of spec and is scrapped.
Jan 07 – 7th & 8th heat completed.
Feb 07 – 9th & 10th heat completed
Jan 01 ‐ Series 3 designs determine melt prac*ce specifica*ons
Dec 99 Sep 09
Oct 07 – Latrobe license completed
Dec 08 – DoD Corrosion Resistant LG Coopera*ve Program starts
Design AIM
MSc390 Materials Design Spring 2010
Design Projects
I. Civil Shield (EDC) Client: ONR, DHS, Trinity Rail Advisor: Zack Feinberg
V. HP Magnesium Client: ARL, GM, DOE Advisors: Dr. Dennis Zhang Stephanie Chan
IV. FSW Joinable Aluminum Client: Ford, Boeing Advisor: Ryan Glamm
VI. HP Shape Memory Alloy Client: GM, Medtronic Advisor: Tengfei Jiang
III. TRIP800 Automo@ve Steel Client: ArcelorMiYal, GM Advisor: Jiadong Gong
II. Earthquake Steel (EDC) Client: ArcelorMiYal Advisor: George Fraley
TRIP Ti Experimental Msσ Calibra*on/Valida*on
Msσ = ‐67°C
Msσ = 43°C
Msσ = 27°C
Ti5111+740C/4h Ti5111+1Fe+700C/4h
Ti5111 as received
Applied Amorphensite: SuperGum (2008 Undergraduate Design Compe**on)
6.4 inches vs. 10.6 inches (90th percen@le)
10.6 inches vs. 8.5 inches (90th percen@le)
Control Prototype 3 Prototype 3 HB Max
9” 9”
Computational Materials Science Tools
Design Integration:
Macroscopic Processing:
Micromechanics:
Microstructural Evolution:
Phase Stability:
Materials Physics:
390 Theoretical Design 391 Exptl Design
Multiplatform Opt.
iSIGHT (ESI)
Design of Experiments
Design-Expert (Stat-Ease)
DEFORM-HT (SFTC)
Heat Transfer & Diffusion, Deformation Processing Multiphase Deformation
PrecipiCalc (QuesTek)
Precipitation
Thermocalc (TCAB)
Multicomponent Thermodynamics
DICTRA (TCAB)
Multicomponent Diffusion
PWscf (DEMOCRITOS)
Pseudopotential DFT
FLAPW (QMD)
All-Electron DFT
Model Integration
CMD (QuesTek)
315 (ternary)
Note: DEFORM-HT and FLAPW are not yet implemented within the curriculum.
CES
Matls. Selection
318 Mat Selection
351-2
316-2 demo 316-2
demo
Our vision
EMBODIMENT DESIGN
User Feedback Refine Specifica@on Alpha prototype Design review
Vendor selec@on
DETAIL DESIGN
Working prototypes User tes@ng Lab tes@ng
Agency approval Revisions
Vendor release
PRE‐PRODUCTION
Tooling design Tool revision Pilot runs Tes@ng Revision
Inspired by the HLB Process; courtesy Walter Herbst
IDEA 298 IDEA 398
IDEA 308 EDC
Design Elec@ve
Design Elec@ve
Dept. Capstone
Design Elec@ve
399 399 399
or
Design phases
• Matthieu Chardon
• Michael McCarren
• Kelvin Chuu
• Stephanie Fruth
• Constance Lee
• Timothy Forbes
• Erick Haro
• Dennis Kouo
IDEA 298/398 WQ2004
Professors Olson and Herbst
Terminator 4: Biomime.c Self‐Healing Mg Composite Team Members Ben Mangrich Charles Moore Chiew Yen Thai
Kevin Lee Mark Rocco
Team Advisor Michele Manuel
Objec@ves:
• Design and test a magnesium‐based alloy composite embedded with shape memory alloys that demonstrates crack closure and self‐healing.
• Increase toughness of briYle materials through composite toughening: crack bridging and interfacial debonding.
Inspira@on: To mimic both the structure‐property rela*onship and spirit of biological materials to op*mize composite design
Mat. Sci. 390: Materials Design Spring 2005
Predic*ve Science & Engineering Design (PS&ED) Graduate Interdisciplinary Clusters in the Sciences and Engineering
Directors: Wei Chen, Greg Olson & Wing Kam Liu
– Discover, develop, and teach the common principles and techniques underlying PSED
– Engage faculty in collabora*ve, interdisciplinary research to pursue new funding opportuni*es
– Lay a founda*on for future large‐scale interdisciplinary research and educa*on programs
– Provide an alterna*ve intellectual community with “dual ci*zenship”
– Enhance the technical depth of design ini*a*ves – AYract gihed and talented students
Design Integra*on
Qualifica*on
Conceptual
Detail
Embodiment
Parametric
Model Alloys & Mul*ples
Manufacturing Varia*on Predic*on
Prototype Alloys
Component Selec*on
Component Assessment
Database Extension
Model Valida*on
System Process Op*miza*on
Small Heats
Produc*on Heats
Designer Knowledge
Base
LEAP Microanalysis
LOM Tomography
LEAP/FSL FIB/SEM
Tomography
TECD
Strength Simulator
DFrac‐3D DEFORM‐3D
TC/DICTRA FLAPW
PrecipiCalc 3D
NRL Atlas
iSight/CMD/IDL
AIM Materials By Design
iSIGHT Monte Carlo
Model Calibra*on
‐ Shihing the Core
Descrip*ve Science
Explora*on for Discovery
Empirical Measurement
Determinis*c Science
Reduc*onist Analysis
Knowledge Genera*on
Materials
The New Materiallurgy
Predic*ve Science
Pioneering by Design
Validated Simula*on
Probabilis*c Science
Systems Synthesis
Value Crea*on
Concurrent Materials & Structures
