AFRL and its primary collaborators (ARCTOS, The Barnes Global Advisors) have identified the main challenges in Q&C being:

1. effective/efficient non-destructive inspection techniques;
2. how to handle as-printed surfaces and articulate their debit to performance; and
3. lack of harmony in current Q&C approaches (multiple standards including AWS D20.1, NASA-STD-6033, AMS 7032, AMS 7003, EZ-SB-19-01).

The group has determined that adopting validated defect- and microstructure-inclusive modeling is the path forward to reduce the testing burden. They will explore the benefits of available modeling tools by comparing a “full testing” example to a “reduced testing” example that includes modeling, and demonstrating equivalent confidence between the two approaches. The proposed “reduced testing” example would take advantage of specimen-level testing (which is less expensive and time-consuming) to collect microstructure and defect data to inform the models. These models would then be used to predict equivalent initial damage size (EIDS) distributions and performance for a fully sized and geometrically complex part. Limited physical testing of parts would be used to validate the model-assisted analyses.

VEXTEC’s approach of model-assisted AM qualification aligns seamlessly with AFRL’s objective. Our VPS-MICRO® Software integrates materials science principles with standard structural engineering tools such as finite element analysis to model fatigue performance at the microstructural level, where damage actually occurs. Our tool has been used by both the Department of Defense as well as the private sector to predict the risk of cyclic fatigue failure of AM parts based on location-specific microstructure, defects, residual stress and surface roughness. Last month, VEXTEC was invited to participate in a QUASAR Program Update at AFRL offices in Dayton, Ohio. VEXTEC’s digital tools were highlighted as a means to integrate AM as-printed surface features.

AFRL QUASAR Program

VEXTEC looks forward to continuing our long-standing collaboration efforts with AFRL, and advocating for materials-based computational tools that lower barriers to AM adoption in the aerospace industry.

• integration of many conventional components into a single AM build;
• complex shapes and orientations;
• product volume control (short runs for sustainment vs. longer runs for new production); and
• limited post-build machining.

AM can bring 30-60% cost savings on complex, high-value parts in the aerospace industry. The limited post-build machining aspect is particularly attractive, in that it can eliminate many steps between production and end-use. As much as 20% of a part’s cost can be incurred during post-build machining to remove surface roughness effects. Another major potential for savings is reducing part count in complex assemblies, which creates internal and other hard-to-access surfaces that cannot be machined. Therefore, it is advantageous to computationally predict the impact of an AM as-printed surface (APS) on fatigue performance for metal parts. This can be done using our VPS-MICRO predictive software, by differentiating the APS from the machined surface in terms of stress and material properties.

While VPS-MICRO does not explicitly perform AM process modeling, it can model the effects on fatigue performance that result from a wide range of manufacturing processes such as surface roughness, residual stress, and heat treatment layers (carburizing, nitriding, etc.). The roughness due to APS typically comes from features like raised bumps due to AM powder unmelt, as well as extensive crevices (which likely exist along microstructural grain boundaries). These features can be effectively evaluated and measured using microscopy and/or serial sectioning.

After measuring these APS features, a 3D spatially varying probabilistic structural finite element analysis (FEA) can then be used to statistically model the stress effects from the features – some act as stress concentrations of undulating peaks and valleys, others act as sharp crack-like stress intensities. These can be represented by stress gradients which act on different size scales (micro-gradients and macro-gradients). It is the interactions between the stress concentrations and the stress intensities that contribute to fatigue crack nucleation and small flaw growth at the rough surface. These gradients from the FEA are direct inputs into VPS-MICRO.

Other contributing factors to fatigue of APS parts are found in the microstructure of the APS material itself. There can be material properties in the surface layer that are not found in the material’s core: voids of different sizes and shapes, depleted amounts of precipitates like carbides, etc. The core microstructure will be similar to the material of a smooth specimen (the APS being machined away). These layer differences can cause variations in local strength properties. While collecting the surface layer microstructural properties can be challenging, there are microcopy techniques available to assist. VPS-MICRO allows for input of multiple material layers, to effectively model these microstructural gradients.

The previously mentioned APS features can then be overlaid onto a standard VPS-MICRO analysis of a smooth, machined specimen. The resulting simulations provide quantitative information about how much fatigue debit there would be if the APS layer was not machined away. This type of computational analysis can help to avoid the “build-test-fail-repeat” iterative cycle that expends valuable resources during certification of an AM as-printed component.

FOR IMMEDIATE RELEASE:

Brentwood, TN (September 4, 2024) – VEXTEC Corporation was selected by Bechtel Plant Machinery, Inc. (BPMI) to provide its VPS-MICRO Software for virtual testing and prediction of fatigue performance of metallic components, supporting the U.S. Navy. Software training for BPMI personnel has recently been completed, and BPMI’s initial focus will be to use the software to better understand component fatigue related to U.S. Navy mechanical components.

VPS-MICRO gives engineering teams and technical directors quantitative information to make quick decisions on component fatigue reliability and durability, by supplementing physical testing and providing increased confidence in accelerated qualification of parts. The software is compatible with nearly any material processing condition for metallic structural components: forging, casting, weldments, additive manufacturing (AM), surface treatments, etc. Clients have used the software to accelerate the push of AM into standard production and to identify causes of component fatigue failure.

VPS-MICRO, developed with the help of the U.S. government’s Small Business Innovation Research (SBIR) Program, addresses a gap in the existing capabilities of computer-aided design (CAD), finite element analysis (FEA) and physical material testing. VEXTEC’s technology effectively integrates these disciplines with probabilistic modeling into a single computational framework that accounts for material and processing variabilities.

“We are pleased BPMI has purchased a subscription of VPS-MICRO to add to its engineering toolbox,” said Bob Tryon, CEO and President of VEXTEC. “The virtual testing capabilities of our software can augment physical testing, reducing costly iterative testing loops and other resource burdens related to certification protocols. We are committed to fully supporting BPMI in its implementation and use of VPS-MICRO.”

About VEXTEC
Since 2000, VEXTEC Corporation has provided predictive analytics prognostics and life extension capabilities for hundreds of applications and products. VEXTEC’s clients include leading multinationals in the aerospace, automotive, electronics, heavy industry and medical device manufacturing sectors, as well as many federal government agencies. VEXTEC has seven U.S. patents related to its software technology. For more information on VEXTEC and VPS-MICRO software, visit vextec.com.

About Bechtel Plant Machinery, Inc.
Bechtel Plant Machinery, Inc. (BPMI) provides the U.S. Naval Nuclear Propulsion Program high quality nuclear power plant components for submarines and aircraft carriers. For more information, visit www.bpmionline.com.

VEXTEC is honored to present at this year’s ASTM International Conference on Advanced Manufacturing (ICAM 2023), held October 30 – November 3 2023 in Washington D.C. VEXTEC’s CTO Dr. Bob Tryon is speaking on “Computational Fatigue Models to Assist in Risk-Based Certification of Additively Manufactured Metallic Parts” on November 1 at 4:00pm ET.

The presentation focuses on physics-based models to provide predictive analytics for certification in Additive Manufacturing (AM). The models integrate computational material engineering to simulate the costliest aspects of AM certification testing, reducing test repeats and significantly lowering the cost of certification. Statistical distributions of properties including microstructure, voids and surface roughness are used in the modeling, as well as structural finite element analysis and Monte Carlo techniques to simulate fatigue of a large population of components with complex loading. Simulated fatigue results are compared to laboratory fatigue testing data, and a standard work protocol is created for AM replacement of an aircraft engine throttle linkage component, and AM repair of foreign object damage to an aircraft engine airfoil.

More information on ASTM ICAM 2023: https://amcoe.org/event/icam2023/

More information on VEXTEC’s VPS-MICRO® commercial software for AM fatigue performance prediction: https://vextec.com/additive-manufacturing/

FOR IMMEDIATE RELEASE

VEXTEC Secures AFWERX Phase II Program for Additive Manufacturing

VEXTEC Builds on its Relationships with AFRL and Lockheed Martin for Analytical tools in AM

(BRENTWOOD, Tennessee) – VEXTEC announces it has been selected by AFWERX for a SBIR Phase II award focused on predictive analytics for certification in Additive Manufacturing, to address the most pressing challenges in the Department of the Air Force (DAF). The Air Force Research Laboratory and AFWERX have partnered to streamline the Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) process by accelerating the small business experience through faster proposal to award timelines, changing the pool of potential applicants by expanding opportunities to small business and eliminating bureaucratic overhead by continually implementing process improvement changes in contract execution. The DAF began offering the Open Topic SBIR/STTR program in 2018 which expanded the range of innovations the DAF funded and now on July 21, 2023, VEXTEC will start its journey to create and provide innovative capabilities that will strengthen the national defense of the United States of America.

“AM processes have struggled to demonstrate sufficient repeatability to be viable options for the creation of primary structures, due to high reliability requirements and testing and certification costs,” noted Dr. Bob Tryon, Chief Technology Officer at VEXTEC. “There has historically been a lack of analytical tools that can handle the variability in AM-produced materials’ mechanical responses when compared with traditional wrought materials. The probabilistic modeling capability of our VPS-MICRO® software, which can integrate structural and materials analyses, is an ideal solution to meet this challenge in AM. We look forward to working with AFRL/RQVS and our OEM partner Lockheed Martin in this program.”

The views expressed are those of the author and do not necessarily reflect the official policy or position of the Department of the Air Force, the Department of Defense, or the U.S. government.

About VEXTEC
VEXTEC Corporation is the home of VPS-MICRO, a unique microstructural fatigue durability prediction software. This technology fills a gap in the existing capabilities provided by CAD/CAM, FEA, statistical modeling, and physical material and component testing, by effectively integrating them into a single computational processing framework. Since 2000, VEXTEC has provided predictive analytics prognostics and life extension capabilities for hundreds of different products. VEXTEC’s clients include leading multinationals in the aerospace, automotive, electronics, energy, heavy industry and medical device manufacturing sectors, as well as many federal government agencies. VEXTEC has seven U.S. patents related to its technology. For more information on VEXTEC and VPS-MICRO software, visit: www.vextec.com.

About Air Force Research Laboratory (AFRL)
Sole organization leading the planning and execution of U.S. Air Force & U.S. Space Force science & technology programs. Orchestrates a world-wide government, industry & academia coalition in the discovery, development & delivery of a wide range of revolutionary technology. Provides leading-edge warfighting capabilities keeping air, space and cyberspace forces the world’s best. Employs 10,800 military, civilian and contractor personnel at 17 research sites executing an annual $4B budget. For more information, visit: www.afresearchlab.com.

About AFWERX
The innovation arm of the DAF and a directorate within AFRL. Brings cutting-edge American ingenuity from small businesses and start-ups to address the most pressing challenges of the DAF. Employs approximately 215 military, civilian and contractor personnel at five hubs and sites executing an annual $1.4B budget. Since 2019, has executed 4,671 contracts worth more than $2B to strengthen the U.S. defense industrial base and drive faster technology transition to operational capability. For more information, visit: www.afwerx.com.

Company Press Contact:
Michael Oja
Sales and Project Manager
moja@vextec.com

FOR IMMEDIATE RELEASE:

Brentwood, TN, December 05, 2022 – AFWERX – the innovation arm of the US Department of the Air Force (DAF) – has selected VEXTEC for a new Phase I SBIR program, intended to create greater visibility within the DAF for its computational predictive software, VPS-MICRO^®.  The software tool enables risk-based certification of parts by predicting failure characteristics from microstructural data. The 3-month program focuses on identifying strong potential customer leads for proven, innovative technology throughout the Air Force and Space Force.

The overall mission of AFWERX and its AFVentures division is to fill capability gaps for the DAF and to transition promising technologies at scale. Phase I SBIR awardees are placed in a cohort which provides them with Air Force resources and tools to facilitate meaningful interactions between small businesses and Air Force customers and end-users. VEXTEC’s VPS-MICRO software for Additive Manufacturing (AM) was a differentiating factor in awarding the Phase I program.

“The Department of the Air Force is a very large customer for many small businesses like ours,” noted Dr. Bob Tryon, Chief Technology Officer at VEXTEC. “We are excited to use this opportunity to reach out to DoD groups organized under the DAF, and inform them about our Digital Engineering solution for analyzing performance of critical metallic components in their platforms. And as metal AM continues to gain momentum, the need for techniques to aid in certification of AM parts will only increase.”

About VEXTEC:

VEXTEC Corporation is the home of VPS-MICRO, a unique microstructural fatigue durability prediction software based on ICME (Integrated Computational Materials Engineering). This technology fills a gap in the existing capabilities provided by CAD/CAM, FEA, statistical modeling, and physical material and component testing, by effectively integrating them into a single computational processing framework. Since 2000, VEXTEC has provided predictive analytics prognostics and life extension capabilities for hundreds of different products. VEXTEC’s clients include leading multinationals in the aerospace, automotive, electronics, energy, heavy industry and medical device manufacturing sectors, as well as many federal government agencies. VEXTEC has seven US patents related to its technology. For more information on VEXTEC and VPS-MICRO software, visit: http://vextec.com.