TSE: Collaborative Research: Environmentally Benign Manufacturing - Casting By Design

TSE：协作研究：环保制造 - 设计铸造

• 批准号: 0124730
• 负责人: Paul Steen
• 金额: $ 31.86万
• 依托单位: Cornell University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2001
• 资助国家: 美国
• 起止时间: 2001-10-01 至 2004-09-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0124730&HistoricalAwards=false
• 关键词: TSE; Collaborative; Research; Environmentally; Benign

This National Science Foundation and Environmental Protection Agency Technologies for a Sustainable Environment project proposes a new technology to enable continuous casting of molten metals, in a single step, to the specifications of the designer. Bessemer's vision (1865) of solidifying raw material directly into final product, without downstream processing steps (rolling, annealing), may now be realized for thin flat product, to marked environmental advantage. To cast aluminum foil, e.g., in a single step, would reduce CO2 emissions to the atmosphere by 250,000 tons per year, in the US alone. Every kilogram of aluminum saved in reducing manufacturing waste translates into electricity saved at the energy-hungry smelter. The technology is based on controlling length scales previously inaccessible to control. The idea is a marriage between laser and single-roll spin casting technologies. The laser offers a unique way to bring energy into the zone of contact between molten metal and substrate. The contact zone is a region of adverse conditions, generally inhospitable to mechanical intrusion. Successful casting by design, or tunable casting, will use laser energy to manipulate product quality. One approach is to condition the substrate by imposing thermal gradients before the contact zone. Grey-scales in ink-jet printing are produced by the spacing and arrangements of ink dots of the same size. In much the same way, the proposed gradients will be established with arrangements and spacing of hot spots. Laser heating will induce the hot spots at fine scales. This project will have significant societal benefits in reducing environmental impact and energy consumption, as well as providing improved scaled-down processing requirements for industry.

这项针对可持续环境项目的国家科学基金会和环境保护局技术提出了一项新技术，以使熔融金属的连续铸造达到设计师的规格。贝塞默（Bessemer）的视力（1865）将原材料直接固化为最终产品，而没有下游处理步骤（滚动，退火），现在可以实现薄纯产品，以明显的环境优势。 仅在美国就将二氧化碳排放量减少250,000吨，例如，仅在美国将二氧化碳排放量减少，仅在美国就将二氧化碳排放量减少。减少制造废物中的每公斤铝都可以转化为节省渴望能量的冶炼厂的电力。 该技术基于以前无法控制的控制长度尺度。这个想法是激光和单次旋转铸造技术之间的婚姻。 激光提供了一种将能量带入熔融金属和底物之间的接触区域的独特方法。 接触区是一个不利条件的区域，通常对机械入侵不可行。 通过设计或可调式铸造成功铸造将使用激光能量来操纵产品质量。 一种方法是通过在接触区之前施加热梯度来调节底物。 喷墨印刷中的灰色尺度是通过相同尺寸的墨水点的间距和排列产生的。 以几乎相同的方式，将通过排列和热点的间距建立提议的梯度。激光加热将在细尺度上诱导热点。 该项目将在减少环境影响和能源消耗方面具有重大的社会利益，并为行业提供改进的缩小处理要求。