Materials and process modelling

Materials and process modeling, also referred to as Integrated Computational Materials Engineering (ICME), is emerging as a significant technology that will enable significantly enhanced systems through holistic design methods. 

Rolls-Royce is actively investing in and utilising materials and process modelling technology. 

Development and integration of physics-based modelling and simulation tools support the linkage of multi-disciplinary functions required for optimal material, manufacturing process and component/system design.  Component location-specific designing allows the potential of greatly reduced component weight, lower costs and enhanced performance.  An example of component location-specific microstructure/mechanical property optimisation is the application of dual-microstructure discs, where each location within the component is optimised for a specific set of mechanical property requirements.

Linkage of multi-disciplinary analytical tools provides an effective approach for design optimisation and enables design-for-performance, design-for-cost and design-for-manufacture.  Utilising materials and process predictive tools provides for greater product definition during initial design, manufacture and qualification.

Below is an example model output showing a phase-field model prediction of gamma-prime precipitation in a superalloy.

Mechanical property predictions

This modelling shows how materials (microstructure) and processing (strain, cooling history) information can be linked to provide component location-specific mechanical property predictions (e.g. yield strength properties – ksi).