I-Corps: Mechanistic solid-state welding model for materially efficient metal extrusions

I-Corps：用于高效金属挤压件的机械固态焊接模型

• 批准号: 2042608
• 负责人: Daniel Cooper
• 金额: $ 5万
• 依托单位: Regents of the University of Michigan - Ann Arbor
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2021
• 资助国家: 美国
• 起止时间: 2021-01-01 至 2023-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2042608&HistoricalAwards=false
• 关键词: Corps; Mechanistic; solid; state; welding

The broader impact/commercial potential of this I-Corps project is the development of a sustainable manufacturing process that reduces the costs and time to market for light metal extrusions increasingly used in electric vehicles, machinery, and buildings. This development has the potential to double an extruder’s profit margin, make U.S. manufacturers more competitive, and ultimately save the global industry around $4 billion per year. The proposed process may accelerate the adoption of efficient extrusion designs, leading to lighter vehicles and less pollution from transport. In addition, this process may make U.S. manufacturing more environmentally sustainable by reducing the scrap that is generated in conventional extrusion by 25-50%. If successful, this will increase the energy efficiency and reduce the carbon footprint of U.S. industry. Furthermore, the underlying science on solid-state welding developed for this technology may inform the development of other joining technologies to prevent undesirable welds from forming.This I-Corps project is based on the development of mechanistic solid-state welding models, extrusion simulations, and algorithms for designing new light metal extrusion tools and billet shapes. This development may reduce the scrap generated in direct extrusion of aluminum and magnesium components. Currently, around one-quarter of the extruded material fails to make it to a final product and is scrapped within the manufacturing process. One source of manufacturing scrap is the removal of the weak, solid-state weld that forms between consecutively extruded metal billets. The proposed technology controls the geometry of the final transverse weld and the deformation conditions across the evolving interface as it passes through the extrusion die. This in turn determines the interface oxide fragmentation, normal and shear contact stresses at the interface, and subsequently the weld strength. This technology is designed to shorten the weld (reducing the quantity of the profile that must be removed) and increase the weld’s strength (negating the need to remove the weld in many non-critical applications). Early physical trials and simulations on aluminum billets indicate that the new technology may reduce the generation of extrusion scrap by at least 25%.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I-Corps项目的更广泛的影响/商业潜力是开发可持续制造过程，该工艺减少了越来越多地用于电动汽车，机械和建筑物中使用的轻质金属扩展的成本和时间。这种开发有可能使挤出机的利润率加倍，使美国制造商更具竞争力，并最终每年节省全球行业约40亿美元。拟议的过程可能会加速采用有效的扩展设计，从而导致较轻的车辆和运输的污染更少。此外，通过将常规扩展中的废料降低25-50％，这一过程可能使美国制造业在环境上更可持续。如果成功，这将提高能源效率并减少美国行业的碳足迹。此外，为该技术开发的固态焊接科学的基础科学可能会为其他连接技术的开发提供信息，以防止不良的热量形成。该I-Corps项目基于开发机械固态焊接模型，扩展模拟，扩展模拟和设计新的轻型金属扩展工具和计算机形状的算法。这种发展可能会减少铝和镁成分直接扩展时产生的废料。目前，大约四分之一的挤压材料无法进入最终产品，并在制造过程中被废弃。制造废料的一种来源是去除弱的固态焊缝，这种焊缝在不断扩展的金属方块之间形成。所提出的技术控制最终横向焊缝的几何形状以及整个不断发展的界面的变形条件，它通过扩展模具。这反过来决定了界面界面碎片，界面处的正常和剪切接触应力，以及随后的焊缝强度。该技术旨在缩短焊缝（减少必须删除的轮廓的数量）并增加焊缝的强度（否定了在许多非关键应用中卸下焊缝的需求）。早期的物理试验和对铝制钢筋的模拟表明，新技术可能会将扩展废料的产生至少减少25％。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和更广泛的影响来评估标准，被视为通过评估而被视为珍贵的支持。