Dr. Jason Mayeur
Manufacturing Science Division
Oak Ridge National Laboratory

Computational Modeling of Powder Metallurgy Hot Isostatic Pressing

ABSTRACT: Powder metallurgy hot isostatic pressing (PM-HIP) is an advanced manufacturing process capable of producing complex near net-shape parts with homogeneous microstructure and excellent material properties. Broad adoption of the process, which involves filling a hollow pre-form (a HIP capsule/can) with metal powder and consolidating under pressure at elevated temperatures, has been somewhat limited to niche component applications due to the costs associated with complex can fabrication and the iterative nature of the capsule design process resulting from the large non-uniform volumetric shrinkage inherent to the process. An accurate computational PM-HIP process model is essential to the efficient design of HIP can geometries that yield parts meeting dimensional requirements. In this talk, we discuss both rate-independent and rate-dependent constitutive models used to model powder consolidation during PM-HIP and the experiments required to calibrate the models. The calibrated models are then used to simulate the densification and distortion of several PM-HIP components of varying size and geometric complexity. Model predictions of final component shape are shown to be in good agreement with experimental results, and we conclude the talk with discussion of future research directions and opportunities for model refinement.

BIOGRAPHY: Dr. Mayeur is a senior researcher in the Deposition Science and Technology Group in the Manufacturing Sciences Division at Oak Ridge National Laboratory. He obtained his master of science and Ph.D. degrees in Mechanical Engineering from the Georgia Institute of Technology and his bachelor of science degree in Mechanical Engineering from the University of Kentucky. After completing his Ph.D., he joined the Theoretical Division at Los Alamos National Laboratory where he spent six years working as a post-doctoral researcher and staff scientist. Prior to joining Oak Ridge National Laboratory, Dr. Mayeur spent a few years in Huntsville, Alabama working as a research engineer at CFD Research and as an assistant professor in the Mechanical and Aerospace Engineering Department at the University of Alabama in Huntsville. His research lies at the intersection of materials science and mechanical engineering and uses computational models to study the deformation and failure of structural materials with a focus on understanding the relationships between material processing, microstructure, and performance. Areas of expertise include multi-scale modeling, computational plasticity and damage, and constitutive model development. Current research interests include: material/microstructure informatics, surrogate modeling, additively manufactured metallic lattice structures, and powder metallurgy hot isostatic pressing.