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.

该研究项目是根据NSF工程 - 乌克里工程和物理科学研究委员会的机会资助的，NSF 20-510。该赠款将支持研究在产生具有极端热力学兴奋的金属成分中添加剂制造（AM）的潜力。在苛刻的环境中，将高温和振动负荷组合在一起（例如，持续的超音速飞行，空间重新进入，排气洗涤结构，融合反应堆中的断开毯子）通常会遇到疲劳，从而缩短其生命周期。这些类型的结构可能只能少量生产，因此考虑其构造的额外制造是适当的。成功的设计，制造和服务部署了此类组件需要了解该组件从其处女状态，通过摇晃，启动可检测到的非关键损害的进展，并最终导致失败。迄今为止，对于传统的减法制造金属，这种故障演化过程已经相当理解了。但是，对AM金属故障的多尺度材料结构相互作用的基本了解非常有限。由于AM金属的独特微观结构，它们在制造过程中的复杂热史以及存在明显的残留应力，因此假设它们在极端热声负荷下的响应将与传统的对应物有显着不同，尤其是在缺陷驱动的过程中，例如失败。通过了解极端热声负荷下AM金属中这种故障过程的细节，这项研究将揭示如何更好地量身定制添加剂制造方法，以生产最适合在这种不利环境中运作的材料和结构。研究将与PI共同与PI进行与伊斯兰大学的研究人员合作，并将其关注材料的材料，该材料群体，链接，链接，链接到关键的各个方面，链接（链接）链接，链接（链接）（链接），链接（链接）（链接）链接效果（链接）（链接）（链接效果）（链接效果）（链接效果）（链接效果（链接）（链接效果）（链接效果）（结构级（宏观）响应。将使用高分辨率的数字图像相关性来量化微观量的损伤积累，用于循环载荷和全球和局部热梯度的添加金属。在较大的长度上，将使用实时光学和热成像研究在热力学兴奋期间进行热屈曲的加化板，并具有几何加固。一个关键方面是探索AM金属（包括现有的残余应力）与瞬时和耦合热机械负载的复杂热处理历史的相互作用。最后，该项目将确定有关受到高温宽带兴奋的可靠组成部分的基本规则。该奖项反映了NSF的法定任务，并通过使用基金会的知识分子优点和更广泛的影响评估标准来评估NSF的法定任务。

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