New open source code improves safety and performance of manufactured parts

A new open-source code developed by researchers at Los Alamos National Laboratory accurately simulates the performance of manufactured parts, taking into account microstructure, to make them stronger, safer and more efficient.

Fierro is characterized by its ability to perform multi-scale and multi-physics simulations. This means that the code can simultaneously simulate different aspects of physical systems and their interactions across different time and length scales. Particularly noteworthy is the autonomous design function, which uses artificial intelligence to find the optimal design from millions of possible design options and uses the flexibility of the additive manufacturing process, i.e. 3D printing, to produce the component.

“Codes such as these are essential to understanding the relationship between manufacturing processes and part performance,” said Nathaniel Morgan, a scientist at Los Alamos National Laboratory and lead developer of Fierro. “Adjusting processes to give a superior microstructure yields a stronger product. The need to better understand the impact of microstructure on part performance is critical, and creates pathways to adopt modern manufacturing methodologies.”

This is particularly relevant in critical applications where the microstructure of a component can make the difference between life and death. A well-known example is the failure of an aircraft engine component in 1996, which led to a fatal accident due to a lack of consideration of the microstructure.

Compared to other existing codes, Fierro offers unique multiphysics solvers that are combined with advanced multiscale models. These enable high-precision simulation of the performance of components depending on their material microstructure or the complex topology of additively manufactured lattice structures. The use of modern supercomputers, including GPU-based machines, allows Fierro to perform sophisticated simulations on a routine basis. This could be particularly beneficial in the aerospace and automotive industries by improving the power-to-weight ratio and thus reducing energy consumption.

Fierro has also proven to be efficient in conventional manufacturing processes such as rolling, punching or extrusion. The combination of physical solvers and multi-scale material models allows a wide range of materials to be processed, reducing both energy consumption and waste while increasing manufacturing efficiency.