This work presents solutions to Challenge 2 within the Air Force Research Laboratory Materials Inform Data-Driven Design for AM Structures (MID3AS) AM (Additive Manufacturing) Challenge. The solutions are for quasi-steady-state and transient Nth-track cross-sectional predictions as a function of scan paths. Tracks are deposited successively to produce a pad and overlap each other; their cross section is defined using four dimensions: total depth, remelt depth, half width, and width increment due to the addition of the latest (Nth) track. There are six pads for which the pad dimensions, build height, power, scan speed, hatch spacing, and number of tracks are varied. There also are two thin walls that consist of 10 single tracks deposited on top of each other. The track cross sections are to be reported at three measurement planes defined orthogonal to the scan path at varying distances from the start of a track in the quasi-steady-state and transient melt-pool regions. The predictions are generated using the Additive Manufacturing Parameter Predictor (AMP²) software that performed multi-scale simulations for the six pads and two thin walls. Two types of melt-pool simulations were performed: a quasi-steady-state, thermal-computational fluid dynamics simulation and a transient thermal simulation. The statistics of track dimensions were estimated using discrete element modeling to predict the local variation in recoat powder density and correcting for the additive mass consolidated by a track cross section accordingly. Applied Optimization, Inc. achieved third place for the accuracy of predictions required by Challenge 2 in the MID3AS AM Challenge.

这项工作为空军研究实验室材料通知数据驱动的 AM 结构设计 (MID3AS) AM（增材制造）挑战中的挑战 2 提供了解决方案。解决方案是针对作为扫描路径函数的准稳态和瞬态第N道横截面预测。轨道依次沉积以产生焊盘并相互重叠；它们的横截面使用四个维度来定义：总深度、重熔深度、半宽和由于添加最新的宽度（Nth) 跟踪。有六个焊盘，其焊盘尺寸、构建高度、功率、扫描速度、填充间距和轨道数量各不相同。还有两个薄壁，由 10 条相互叠加的单轨组成。轨道横截面将在三个测量平面上报告，三个测量平面与扫描路径正交，在准稳态和瞬态熔池区域中距轨道起点的不同距离处。预测是使用增材制造参数预测器 (AMP ²) 对六个焊盘和两个薄壁执行多尺度模拟的软件。进行了两种类型的熔池模拟：准稳态热计算流体动力学模拟和瞬态热模拟。轨道尺寸的统计数据是使用离散元素建模来估计的，以预测重涂粉末密度的局部变化，并相应地校正由轨道横截面固结的添加剂质量。Applied Optimization, Inc. 在 MID3AS AM 挑战赛中挑战 2 所需的预测准确性获得第三名。