CAREER: Understanding the Corrosion Fatigue Behavior of Additively Processed Metals through an Integrated Experimental and Computational Approach

职业：通过综合实验和计算方法了解增材加工金属的腐蚀疲劳行为

• 批准号: 2044972
• 负责人: Yao Fu
• 金额: $ 59.49万
• 依托单位: University of Cincinnati Main Campus
• 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: 2021-10-01 至 2021-10-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2044972&HistoricalAwards=false
• 关键词: CAREER; Understanding; Corrosion; Fatigue; Behavior

This Faculty Early Career Development (CAREER) award will focus on determining the mechanisms governing the corrosion fatigue behavior of additively manufactured metals, especially due to the influence of unique microstructural features and residual stress introduced during processing. Additive manufacturing has gained wide attention in recent years because it can be used to produce geometrically and compositionally complex parts, as well as provide on-demand production and repair capability. Its potential to manufacture true load-bearing parts, however, is not yet fully realized due to several issues. In particular, the complexity of the resultant microstructural features makes it difficult to distinguish their respective effects on fracture and fatigue performance. This project will answer two relevant question with focus on corrosive environments: 1) How does the fatigue behavior of additively processed alloys differ from that of their conventional counterparts under normal and corrosive environments, respectively? and 2) How does the microstructure contribute to the observed differences in behavior? Insights gained from the award will guide the design and manufacture of additively manufactured parts and prolong their service life by limiting the causes of fatigue failure in corrosive environments. Thus, the research will not only promote the progress of science but will also advance national prosperity and welfare by reducing the tremendous financial losses related to corrosion damage. In addition, this award will encourage women in engineering by launching a “Women in Flight” club and perform outreach to high school science teachers and students through creative audiovisual learning modules.The unique microstructure formed in additively manufactured metals merit critical investigation into its effect on environmentally-assisted fatigue behavior. This project will employ a combined computational and experimental approach to: 1) evaluate the macroscopic fatigue properties of conventional and additively manufactured alloys in air and corrosive environment using high-cycle fatigue testing; 2) elucidate effects of microscopic features and defects on the local passivity and corrosion properties using electrochemical microcell and adaptive Kinetic Monte Carlo modeling techniques, and 3) reveal the mechanism and the influence of individual microstructure features and their interaction by developing a microstructure-sensitive multiphysics computational framework based on phase field and crystal plasticity modeling. The features that will be considered are sub-grain dislocation networks, solidification texture, porosity, and chemical heterogeneity, as well as residual stress. It is expected that he experimentally-validated modeling framework will introduce a new capability to advance the mechanistic understanding of deformation and failure of additively manufactured alloys in corrosive environment.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.

该学院早期职业发展（职业）奖将重点确定控制增材制造金属腐蚀疲劳行为的机制，特别是由于加工过程中引入的独特微观结构特征和残余应力的影响，增材制造近年来受到了广泛关注。因为它可用于生产几何形状和成分复杂的零件，并提供按需生产和维修能力，但由于几个问题，其制造真正承重零件的潜力尚未完全实现。结果的复杂性微观结构特征使得很难区分它们各自对断裂和疲劳性能的影响，该项目将回答两个重点关注腐蚀环境的相关问题：1）增材加工合金的疲劳行为与常规胶囊在正常和疲劳状态下的疲劳行为有何不同。 2）微观结构如何影响观察到的行为差异？从该奖项中获得的见解将指导增材制造零件的设计和制造，并通过限制腐蚀环境中疲劳失效的原因来延长其使用寿命。 。因此，该研究不仅将促进科学进步，还将通过减少与腐蚀损害相关的巨大经济损失来促进国家繁荣和福利。此外，该奖项还将通过发起“飞行中的女性”俱乐部来鼓励工程领域的女性。并通过创造性的视听学习模块向高中科学教师和学生进行推广。增材制造金属形成的独特微观结构值得对其对环境辅助疲劳行为的影响进行严格研究。该项目将采用计算和实验相结合的方法来：1。 ）评估常规和使用高周疲劳测试在空气和腐蚀环境中增材制造的合金；2）使用电化学微电池和自适应动力学蒙特卡罗建模技术阐明微观特征和缺陷对局部钝化和腐蚀性能的影响，以及3）揭示其机制和通过开发基于相场和晶体塑性建模的微观结构敏感多物理计算框架，来研究各个微观结构特征及其相互作用的影响，将考虑的特征包括亚晶位错网络、凝固织构、预计经过实验验证的建模框架将引入一种新功能，以促进对腐蚀环境中增材制造合金的变形和失效的机械理解。该奖项反映了 NSF 的法定使命。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，并被认为值得支持。