Principal investigator: Jessica Zhang
University: Carnegie Mellon University
Industry partner: HexSpline3D, LLC
In advanced manufacturing processes such as metal additive manufacturing, thermo-mechanical fracture remains a critical challenge when driven by intense and localized heat input. Rapid thermal cycling generates strong temperature gradients, constrained deformation, and residual stresses, often leading to unpredictable cracking and premature component failure. This project aims to develop a three-dimensional simulation framework for thermo-mechanical fracture in manufacturing conditions. The proposed approach integrates thermo-mechanical phase-field fracture modeling with adaptive three-dimensional virtual element methods. Phase-field models enable natural prediction of crack initiation and propagation without predefined crack paths, while VEM provides exceptional flexibility for handling complex geometries. Localized adaptive refinement with VEM will ensure the efficiency of the technique. The outcome of this research will be a scalable, fracture-aware simulation capability that supports predictive analysis of heat-induced cracking in complex manufacturing components, providing a physics-based foundation for improved process design, defect mitigation, and future digital manufacturing tools.