The Exascale Additive Manufacturing Project (ExaAM) has been initiated as an integrated collaboration between U.S. Dept. of Energy laboratories (ORNL, LLNL and LANL) as part of the Exascale Computing Project (ECP). ECP is a broad program that includes hardware, system software, system acquisition, and science application development. ExaAM is one of the applications selected for the development and implementation of models that would not be possible on more moderate computational systems. Starting from a top-down systems engineering approach, an integrated computational materials engineering (ICME) approach can be used to accelerate the qualification and adoption of newly additively manufactured parts by enabling up-front assessment of manufacturability and performance. The project includes an integration of all the computational components of the AM process into a coupled exascale modeling environment, where each simulation component itself is an exascale simulation. In order to expose the physics fidelity needed to enable part qualification, the continuum scale build simulation is tightly coupled to mesoscale simulations of microstructure and defect development and evolution from which location-specific properties are determined for performance simulations. The project is driven by a series of demonstration problems that are amenable to experimental observation and validation. In particular, in situ experiments on instrumented AM machines will be used to measure local defects and microstructures during build that give rise to macroscopic properties such as residual stress. Here, we present our coupled exascale simulation environment for additive manufacturing and its initial application to AM builds.
Jim Belak is a Senior Scientist in the Materials Science Division at Lawrence Livermore National Laboratory. His career has centered around the application of High Performance Computing to equilibrium and non-equilibrium problems in Materials Physics, including: order-disorder phase transition in solids; indentation, metal cutting and tribology of interfaces; shock propagation and spallation fracture; structure and dynamics of grain boundaries and defects in solids; and kinetics of phase evolution in extreme environments, and additive manufacturing. These applications have required the development of new algorithms and application codes for emerging high performance parallel computers and the use of novel x-ray synchrotron techniques (3D x-ray tomography and small-angle x-ray scattering) to guide and validate the simulations. Jim was Co-PI on the DOE CRADA that created the LAMMPS MD code and currently is Co-Principle Investigator and Deputy Director for the DOE Exascale Computing Project (ECP) Application Development Project "Transforming Additive Manufacturing though Exascale Computing" (ExaAM) and the Co-design Center for Particle Methods (CoPA).