CMMI-EPSRC: Thermoacoustic Response of Additively Manufactured Metals: A Multi-Scale Study from Grain to Component Scales

CMMI-EPSRC：增材制造金属的热声响应：从晶粒到部件尺度的多尺度研究

• 批准号: 2027082
• 负责人: John Lambros
• 金额: $ 74.84万
• 依托单位: University of Illinois at Urbana-Champaign
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2020
• 资助国家: 美国
• 起止时间: 2020-09-01 至 2024-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2027082&HistoricalAwards=false
• 关键词: CMMI; EPSRC; Thermoacoustic; Response; Additively

This research project was funded under the NSF Engineering–UKRI Engineering and Physical Sciences Research Council opportunity, NSF 20-510. The grant will support research towards understanding the potential for additive manufacturing (AM) in the production of metallic components subject to extreme thermomechanical excitation. Structures in demanding environments where high temperatures and vibratory loads are combined (e.g., sustained hypersonic flight, space re-entry, exhaust-wash structures, breeder blankets in fusion reactors) often experience fatigue which shortens their lifecycle. It is likely that these types of structures will be produced only in small quantities, making it appropriate to consider additive manufacturing for their construction. Successful design, manufacture and service deployment of such components requires an understanding of the component's progression from its virgin state, through shake-down, towards initiation of detectable non-critical damage, and ultimately to failure. To date, this failure evolution process is fairly well understood for traditional subtractive-manufactured metals. However, there is very limited fundamental understanding of the multi-scale material-structure interactions for failure of AM metals. Because of the unique microstructure of AM metals, their complex thermal history during manufacture, and the presence of significant residual stresses, it is hypothesized that their response under extreme thermoacoustic loading will be significantly different from their traditional counterparts, especially in defect-driven processes such as failure. By understanding the details of this failure process in AM metals under extreme thermoacoustic loading, the results of this study will shed light onto how to better tailor the additive manufacturing approach to produce materials and structures most suitable for operating in such adverse environments.The research will be undertaken jointly by the PI in collaboration with researchers at the University of Liverpool in the United Kingdom, focusing on key aspects that link material-level (micro- and mesoscale) response to the structural-level (macroscale) response. Damage accumulation at the microscale for additively-manufactured metals subjected to cyclic loading and global and local thermal gradients will be quantified using high resolution digital image correlation. At a larger length scale, additively-manufactured plates with geometric reinforcement subjected to thermal buckling during thermo-mechanical excitation will be studied using real-time optical and thermal imaging. A key aspect will be to explore the interaction of the complex thermal processing history of AM metals (including any existing residual stresses) with the transient and coupled thermomechanical loading applied. Finally, the project will identify the fundamental rules governing AM for reliable components subject to high-temperature broadband excitation.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.

该研究项目由 NSF Engineering-UKRI 工程和物理科学研究理事会资助，NSF 20-510，该赠款将支持研究以了解增材制造 (AM) 在生产受极端热机械激励的金属部件中的潜力。在高温和振动载荷相结合的苛刻环境中的结构（例如，持续的高超音速飞行、太空再入、排气清洗结构、聚变反应堆中的增殖毯）经常会经历疲劳，从而缩短其使用寿命。这些类型的结构可能只会少量生产，因此在其构造中考虑增材制造是合适的，此类组件的成功设计、制造和服务部署需要了解组件从其原始状态的进展情况。迄今为止，对于传统减材制造的金属来说，这种失效演变过程已经得到了很好的理解，但是，对多金属的基本了解却非常有限。规模材料-结构相互作用的失效由于增材制造金属独特的微观结构、制造过程中复杂的热历史以及显着残余应力的存在，人们再次认识到它们在极端热声载荷下的响应将与传统的对应物显着不同，特别是在缺陷情况下。通过了解增材制造金属在极端热声载荷下的失效过程的细节，这项研究的结果将揭示如何更好地定制增材制造方法来生产最适合运行的材料和结构。这种不利的环境。研究将该研究由 PI 与英国利物浦大学的研究人员合作共同开展，重点关注将材料级（微观和中观）响应与结构级（宏观）损伤累积联系起来的关键方面。将使用高分辨率数字图像相关性对经受循环载荷以及全局和局部热梯度的增材制造金属的微观尺度进行量化。将使用实时光学和热成像来研究热机械激励，一个关键方面是探索增材制造金属的复杂热处理历史（包括任何现有的残余应力）与所施加的瞬态和耦合热机械载荷的相互作用。最后，该项目将确定管理经受高温宽带激励的可靠组件的增材制造的基本规则。该奖项反映了 NSF 的法定使命，并通过使用基金会的智力价值和更广泛的影响审查标准进行评估，被认为值得支持。

项目成果

Measuring representative volume elements from high‐resolution grain‐scale strain fields

测量高分辨率颗粒尺度应变场中的代表性体积元素

• DOI: 10.1111/str.12423
• 发表时间: 2022
• 期刊: Strain
• 影响因子: 2.1
• 作者: B. Vieira, Renato;Lambros, John
• 通讯作者: Lambros, John