CAREER: Advanced Surface Coating of Metallic Powders by Vibration-Enhanced High-Power Impulse Magnetron Sputtering for Sintering-Based Manufacturing

职业：通过振动增强高功率脉冲磁控溅射对金属粉末进行先进表面涂层，用于基于烧结的制造

基本信息

批准号：
2042982
负责人：
Carlos Castano
金额：
$ 52.59万
依托单位：
Virginia Commonwealth University
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：
2021-02-01 至 2026-01-31
项目状态：
未结题

来源：
https://www.nsf.gov/awardsearch/showAward?AWD_ID=2042982&HistoricalAwards=false
关键词：
CAREER Advanced Surface Coating Metallic

项目摘要

Sintering is one of the most practical manufacturing processes in producing density-controlled materials from powder feedstock. However, producing industrially applicable powder alloy precursors is challenging. Although pre-mixing pure metal powders have allowed a wide range of compositions by conventional sintering, rapid heating and cooling in modern sintering techniques inevitably results in new but unwanted chemical gradients, as well as microstructural and property anisotropy. This Faculty Early Career Development (CAREER) award will investigate a high-power impulse magnetron sputtering process as an advanced technology to modify the surface of metallic powders. The deposition of thin films on the powders forming core/shell systems can provide solutions to make different alloys with more homogeneous and controlled microstructures when used as powder feedstock. This new class of powders will enable a reliable supply of raw materials for cost-effective sintering of reproducible components in the aerospace, automotive, energy, and healthcare industries. The integrated educational and outreach activities of this project will broadly concentrate on: 1) educating and training women and underrepresented minorities as the future generation of highly-skilled leaders in advanced manufacturing, 2) establishing a pipeline of diverse undergraduate students to pursue graduate studies in collaboration with James Madison University in Virginia through special summer programs, and 3) implementing an online set of virtual laboratories in advanced materials characterization of core/shell structures as well as materials processing. The overall research objective of this project is to establish the scientific underpinnings for the surface modification of micro- and nano-powders into core/shell systems that promote three-phase transformations in sintering-based processes. The core/shell of various combinations (e.g., aluminum-copper, titanium-copper, copper-chromium and nickel-chromium, etc.) will be the eutectic compositions for modeling because of their industrial relevance, an ability to form precipitation hardening alloys, and excellent high-temperature properties. It is hypothesized that high-power impulse magnetron sputtering combined with the vibrational motions of powder holders can achieve conformal thin films on powders, which are desired to produce favorable microstructures. To test the hypothesis, the project will study sputtering discharges to understand the nucleation and growth mechanism of thin films on complex geometries such as spherical powders when including vibrations. This research also aims to understand the role of powder-film interface in the two-phase core/shell diffusion couple and its effect on the final part microstructure from sintering. The combined strategy of the project will lead to a new method of manufacturing core/shell materials suitable for modern sintering processes.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.

烧结是用粉末原料生产密度受控材料的最实用的制造工艺之一。然而，生产工业适用的粉末合金前体具有挑战性。尽管预混合纯金属粉末已允许通过传统烧结获得多种成分，但现代烧结技术中的快速加热和冷却不可避免地会导致新的但不需要的化学梯度，以及微观结构和性能各向异性。该学院早期职业发展（CAREER）奖将研究高功率脉冲磁控溅射工艺作为一种先进技术来修饰金属粉末的表面。在形成核/壳系统的粉末上沉积薄膜可以提供解决方案，使不同的合金在用作粉末原料时具有更均匀和受控的微观结构。这种新型粉末将为航空航天、汽车、能源和医疗保健行业中的可重复部件的经济高效的烧结提供可靠的原材料供应。该项目的综合教育和外展活动将主要集中在：1）教育和培训女性和代表性不足的少数族裔，使其成为先进制造业的未来一代高技能领导者，2）建立多元化本科生在以下领域攻读研究生的渠道：通过特殊的暑期项目与弗吉尼亚州詹姆斯麦迪逊大学合作，以及3）在核/壳结构的先进材料表征以及材料加工方面实施一套在线虚拟实验室。该项目的总体研究目标是为将微米和纳米粉末表面改性为核/壳系统奠定科学基础，从而促进烧结过程中的三相转变。各种组合（例如铝-铜、钛-铜、铜-铬和镍-铬等）的核/壳将成为用于建模的共晶成分，因为它们具有工业相关性、形成沉淀硬化合金的能力、和优异的高温性能。据推测，高功率脉冲磁控溅射与粉末支架的振动运动相结合可以在粉末上实现共形薄膜，这是产生有利的微观结构所需要的。为了验证这一假设，该项目将研究溅射放电，以了解复杂几何形状（例如球形粉末）上薄膜在振动时的成核和生长机制。这项研究还旨在了解粉末-薄膜界面在两相核/壳扩散偶中的作用及其对烧结最终零件微观结构的影响。该项目的综合战略将带来一种制造适合现代烧结工艺的核/壳材料的新方法。该奖项反映了 NSF 的法定使命，并通过使用基金会的智力优点和更广泛的影响审查标准进行评估，被认为值得支持。