ERI: Making High-Temperature Alloyed Components by Combining Additive Manufacturing and Spark Plasma Sintering: Enabling Shape Complexity and Predicting Microstructures

ERI：结合增材制造和火花等离子烧结制造高温合金部件：实现形状复杂性并预测微观结构

• 批准号: 2138421
• 负责人: Elisa Torresani
• 金额: $ 19.76万
• 依托单位: San Diego State University Foundation
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2022
• 资助国家: 美国
• 起止时间: 2022-01-01 至 2024-12-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2138421&HistoricalAwards=false
• 关键词: ERI; Making; Temperature; Alloyed; Components

This award is funded in whole or in part under the American Rescue Plan Act of 2021 (Public Law 117-2).Spark plasma sintering is a well-known manufacturing technology, in which pressurizing and rapid heating are simultaneously applied to achieve particle-to-solid consolidation with a low level of defects even for high-temperature metals, such as tungsten alloys. Despite significant interest in this technology, it has been, however, limited to simple-shaped components (i.e., in cylindrical forms). On the other hand, though additive manufacturing has empowered the design freedom, ideal for making parts of sophisticated geometry, fabrications of high temperature alloys have not been reliably successful. In this project, a combination of additive manufacturing, such as binder jetting, and spark plasma sintering will be employed to overcome such limitations. The studied technology integration represents a novel and promising approach to produce complex-shaped components, made of high-temperature alloys, in an efficient and cost-effective manner, and yet, ensure the quality in part dimensions as well as microstructures. Moreover, the project will explore new possibilities for the investigation into the fundamentals of the field-assisted sintering processes. In addition, the project will contribute to the education, outreach and retaining of undergraduate and graduate students from minorities and to engaging high school students with hands-on experiences with high-end technologies such as additive manufacturing and spark plasma sintering via the collaboration with industry partners involved, e.g., California Nanotechnologies.The overall goal of this project is to understand and develop the net-shaping capability of the spark plasma sintering technology to produce complex-shaped parts, such as helical bevel gears, made of material systems difficult to be fabricated using either traditional or additive manufacturing. The project will address this challenge through the “controllable interface” concept, which combines the additive manufacturing capability to produce complex shapes with the full consolidation potential of the spark plasma sintering. The controllable interface is represented by a three-dimensionally printed deformable volume of a sacrificial material introduced inside common spark plasma sintering tooling. To achieve the desired design of the controllable interface, comprehensive modeling of the spark plasma sintering process will be researched. The intricate nature of the starting porous assembly involved in this combined technology requires extending the current powder sintering modeling framework to better understand thermal and non-thermal nonequilibrium phenomena in spark plasma sintering to predict the final processing outcomes in terms of the microstructure and geometry of end products.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.

该奖项是根据2021年《美国救援计划法》的全部或部分资助（公共法117-2）。Spark等离子体烧结是一种众所周知的制造技术，在该技术中，仅将加压和快速加热用于实现粒子到固体固结，甚至对于高磁铁的缺陷，也可以用于诸如高磁铁的金属，例如高磁铁。尽管对这项技术产生了浓厚的兴趣，但它一直限于简单形的组件（即圆柱形式）。另一方面，尽管令人上瘾的制造业赋予了设计自由，这是制造一部分几何形状的理想选择，但高温合金的制造尚未可靠地成功。在这个项目中，将采用添加剂制造（例如粘合剂喷射和火花等离子体烧结）的结合来克服此类局限性。研究菌的技术集成代表了一种新颖而有希望的方法，可以以有效且具有成本效益的方式生产由高温合金制成的复杂形成组件，但要确保部分尺寸以及微观结构的质量。此外，该项目将探讨投资于现场辅助烧结过程的基本面的新可能性。此外，该项目将有助于来自少数群体的本科生和研究生的教育，宣传和保留，并通过与高端技术（例如添加剂制造业）的动手经验吸引高中生，并通过与所涉及的行业合作伙伴的合作（例如，加利福尼亚州的纳米技术的整体攻击能力）来了解NET-SHAPS的整体攻击能力。复杂形的零件，例如螺旋斜角齿轮，由很难使用传统或添加剂制造制造的物料系统制成。该项目将通过“可控制界面”概念来应对这一挑战，该概念结合了增强的制造能力，以产生复杂形状和火花等离子体烧结的全合并潜力。控制器界面由三维印刷的可变形体积的牙龈材料表示。为了实现控制器界面的所需设计，对这种组合技术涉及的启动多孔组装的复杂性质的火花等离子体的全面建模需要扩展当前的粉末烧结建模框架，以更好地理解热热和非热的无水性现象在火花等离子体中的最终处理，以预测最终的处理，以预测最终的处理。法定使命，并使用基金会的知识分子优点和更广泛的影响标准通过评估被认为是宝贵的支持。