Additive Manufacturing of Load and Energy Absorbing Materials through an Integrated Experimental and Modelling Approach

通过综合实验和建模方法增材制造负载和能量吸收材料

基本信息

批准号：
1853893
负责人：
Kathy Lu
金额：
$ 60.42万
依托单位：
Virginia Polytechnic Institute and State University
依托单位国家：
美国
项目类别：
Standard Grant
财政年份：
2019
资助国家：
美国
起止时间：
2019-05-15 至 2023-04-30
项目状态：
已结题

来源：
https://www.nsf.gov/awardsearch/showAward?AWD_ID=1853893&HistoricalAwards=false
关键词：
Additive Manufacturing Load Energy Absorbing

项目摘要

This multi-PI advanced manufacturing project aims to understand and explore phase transformation mechanisms of zirconia ceramic in copper and steel metal matrices. Zirconia can convert large mechanical strain into heat recoverably but this potential has not been explored for metal matrix composites. In addition, the project studies a new friction-based additive manufacturing process, MELD, with the goal of developing new energy- and stress-absorbing components. Multi-scale computer modeling of the corresponding materials created through MELD will be carried out. Simulation results will be compared with experimental data for improved understanding of microstructure evolution during the MELD manufacturing process and the component behaviors during infrastructure use. The integrated understanding from the experimental and modeling efforts is expected to bring in new capabilities for infrastructure improvement and repair. Because of its broad applicability, this manufacturing process can directly impact the ability of buildings, aircraft, and automobiles to withstand demanding loads, and therefore directly impacts the economic welfare and national security of the United States. The knowledge generated will be widely disseminated to the scientific community, to the general public, and to K-12 students. We will also enrich our current curricula by bringing the most relevant technical and societal issues to classrooms/labs. The PI/Co-PIs will lead extensive outreach efforts to increase the enrollment of females and minorities in STEM. Specific efforts include participation in summer camps that focus on underrepresented students, collaboration with a minority serving institution, and outreach activities through Science Museum of Western Virginia.This research will study a novel type of metal matrix composites by leveraging a unique stress and energy dissipation mechanism based on zirconia martensitic phase transformation. The fundamentals of a new and scalable additive manufacturing process--MELD will be investigated, and multi-scale and multi-physics simulations for enhanced microstructure-property understanding and prediction will be integrated. The theoretical work will be correlated with both in-situ and ex-situ microstructure characterization and property evaluation results. The research approaches are: 1) study stress/energy dissipation mechanisms in metal matrix composites to improve the resilience of structures at different length scales, 2) understand the influence of the composite synthesis and additive deposition variables, and develop fundamental understanding of the heat/mass flow processes during MELD in order to create new structures and enable new properties, 3) simulate mass and heat flows during MELD and predict microstructure-derived performance at multi-scales under cyclic loading and energy shock conditions, and 4) build quantitative relations between the stress/energy absorbing capabilities and zirconia-enhanced metal composite synthesis and MELD manufacturing. This project will provide detailed understanding to the unique and reversible phase transformation of zirconia in metal matrices, especially regarding its functions in energy and stress absorption. It will also offer fundamental knowledge in MELD, an exciting and scalable additive manufacturing process based on friction stir methods, and create near net shape and fully-dense metal matrix composites. The research will also advance multi-scale, multi-physics simulations of mass flow and heat flow during the MELD process and after the MELD process while providing insight into the structural behaviors of the MELD-enabled composites under complex loading conditions.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

这个多PI高级制造项目旨在了解和探索氧化陶瓷铜和钢金属矩阵的相变机制。氧化锆可以将大型的机械应变转换为热量，但对于金属基质复合材料，尚未探索这种潜力。此外，该项目研究了一个新的基于摩擦的添加剂制造过程，旨在开发新的能量和压力减轻压力的组件。将进行通过MELD创建的相应材料的多尺度计算机建模。将将仿真结果与实验数据进行比较，以改善对MELD制造过程中微观结构演变的了解以及基础设施使用过程中的组件行为。预计实验和建模工作的综合理解将带来新的基础设施改进和维修能力。由于其广泛的适用性，这种制造过程可以直接影响建筑物，飞机和汽车承受要求负载的能力，因此直接影响了美国的经济福利和国家安全。产生的知识将被广泛传播给科学界，公众和K-12学生。我们还将通过将最相关的技术和社会问题带入教室/实验室来丰富当前的课程。 PI/Co-Pis将领导广泛的外展工作，以增加女性和少数群体的入学人数。具体的努力包括参加专注于代表性不足的学生的夏令营，与少数派服务机构的合作以及通过西弗吉尼亚州科学博物馆的宣传活动。这项研究将通过利用独特的压力和能量耗散机制来研究一种新型的金属基质复合材料基于氧化锆马氏体相变。将研究一种新的且可扩展的添加剂制造过程的基本原理 - 将集成多尺度和多物理模拟，以增强微观结构 - 统计的理解和预测。理论工作将与原位和原位微观结构表征和属性评估结果相关。研究方法是：1）在金属基质复合材料中研究应力/能量耗散机制，以提高不同长度尺度的结构的弹性，2）了解复合材料合成和加性沉积变量的影响，并发展对热/的基本了解/键入过程中的质量流动过程为了创建新的结构并启用新的特性，3）模拟键盘期间的质量和热量流，并在循环载荷和能量冲击条件下预测多尺度的微结构衍生的性能，以及4）建立定量关系应力/能量吸收能力以及氧化锆增强的金属复合合成和融合制造。该项目将为金属矩阵中氧化锆的独特和可逆的相变提供详细的理解，尤其是关于其在能量和应力吸收方面的功能。它还将在Meld中提供基本知识，这是一种基于摩擦搅拌方法的令人兴奋且可扩展的添加剂制造过程，并创建近乎净形状和完全密集的金属基质复合材料。这项研究还将推进在MELD过程中和MELD过程中的质量流量和热流的多尺度多物理模拟，同时在复杂的负载条件下洞悉MELD启用的组合材料的结构性行为。这反映了NSF的奖项。法定任务，并被认为是值得通过基金会的智力优点和更广泛影响的审查标准来评估的值得支持的。

项目成果

期刊论文数量（7）

专著数量（0）

科研奖励数量（0）

会议论文数量（0）

专利数量（0）

Viewpoint: Tuning the Martensitic Transformation Mode in Shape Memory Ceramics via Mesostructure and Microstructure Design

DOI：
10.1007/s40830-023-00430-4
发表时间：
2023-03
期刊：
Shape Memory and Superelasticity
影响因子：
2.2
作者：
Donald Erb;H. Rauch;Kendall P. Knight;Hang Z. Yu
通讯作者：
Donald Erb;H. Rauch;Kendall P. Knight;Hang Z. Yu

Morphological and microstructural investigation of the non-planar interface formed in solid-state metal additive manufacturing by additive friction stir deposition

DOI：
10.1016/j.addma.2020.101293
发表时间：
2020-10-01
期刊：
ADDITIVE MANUFACTURING
影响因子：
11
作者：
Perry, Mackenzie E. J.;Griffiths, R. Joey;Yu, Hang Z.
通讯作者：
Yu, Hang Z.

Additive Manufacturing of Yttrium-Stabilized Tetragonal Zirconia: Progressive Wall Collapse, Martensitic Transformation, and Energy Dissipation in Micro-Honeycombs

DOI：
10.1016/j.addma.2022.102692
发表时间：
2022-02
期刊：
Additive Manufacturing
影响因子：
11
作者：
H. Rauch;Huachen Cui;Kendall P. Knight;R. J. Griffiths;Jake K. Yoder;X. Zheng;Hang Z. Yu
通讯作者：
H. Rauch;Huachen Cui;Kendall P. Knight;R. J. Griffiths;Jake K. Yoder;X. Zheng;Hang Z. Yu

Solid-state additive manufacturing of aluminum and copper using additive friction stir deposition: Process-microstructure linkages