SBIR Phase I: Repair, Weld, and Build Metallic Parts with Fill Impact Welding

SBIR 第一阶段：使用填充冲击焊修复、焊接和构建金属零件

• 批准号: 2322343
• 负责人: Anupam Vivek
• 金额: $ 27.5万
• 依托单位: APPLIED IMPULSE INC.
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2023
• 资助国家: 美国
• 起止时间: 2023-09-01 至 2024-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2322343&HistoricalAwards=false
• 关键词: SBIR; Phase; Repair; Weld; Build

The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase I project seeks to develop a welding technology that will improve the repair, joining, and additive manufacturing of metallic parts and features. First applications include material additions to repair gouges and mis-drilled holes during aircraft production and service, both of which represent significant financial opportunities. Repairs to the structural material are not currently permissible in a production environment due to adverse effects of currently available repair methods on base material properties, usually due to extreme temperatures. Aerostructure manufacturers have a strong incentive to minimize the weight of the aircraft structure, often at the significant financial and environmental expense of scrapping a whole panel. Maintenance, repair and overhaul often entails total replacement of damaged components with new ones as improper repairs of critical components can cause catastrophic harm. Replacement of parts is expensive and has long lead times due to high-value, low-volume nature of the aerospace industry. This project will develop an effective restoration method to repair of metallic components, while being agnostic to the material and part geometry. Reclamation of previously unrepairable parts made from materials such as titanium, nickel, and aluminum has a large positive environmental impact. Additionally, by broadly enabling solid-state joining, this technology will disrupt the welding industry, globally valued at $20 billion. The foundational technology platform, led in the US, will produce new jobs in science, technology and engineering fields while bolstering domestic manufacturing supply chains.The innovation underpinning this project involves the sequential, tactical, and controlled deposition of metals using explosive welding. Explosive welding uses coin-sized metallic elements launched to speeds in the range of 300-1000m/s without explosives. While it is known that explosive welding can weld large plates together, the method is not suited to automation or conventional industrial settings. Impact welding will be developed as a fill-welding technique, much like a filler metal in conventional welding, and will use wrought sheet metal as feedstock. Here, electrically vaporized metallic foils will be used as the driver for the fill elements and the research will focus on whether those elements can be launched reproducibly to develop large bond areas and reproducible positioning. The ability to control element shape and orientation during flight and produce an interface that is fully welded are the most high-risk aspects of the technology. Mechanical testing, scanning electron microscopy, and inline process monitoring such as photonic Doppler velocimetry will be performed. This effort will develop a new process-structure-property loop, with the goal of producing parts that are better than those made with a competing technology such as cold spray as measured by total energy consumption, cost, and mechanical properties.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.

这项小型企业创新研究（SBIR）I阶段项目的更广泛/商业影响旨在开发一种焊接技术，以改善金属零件和功能的维修，加入和增材制造。最初的申请包括在飞机生产和服务过程中修复凿子和漏洞的材料增加，这两者都代表了重要的财务机会。由于当前可用的维修方法对基础材料特性的不利影响，通常在生产环境中不允许对结构材料进行维修。航空结构制造商有很大的动力来最大程度地减少飞机结构的重量，通常是取消整个面板的大量财务和环境费用。维护，维修和大修通常需要用新组件的全部替换成分，因为不当维修临界组件可能会造成灾难性危害。由于航空航天行业的高价值，低量的性质，零件的替换价格昂贵，并且有很长的交付时间。该项目将开发一种有效的恢复方法来修复金属成分，同时对材料和部分几何形状不可知。通过钛，镍和铝等材料制成的以前无法修复的零件的填充具有很大的积极环境影响。 此外，通过广泛启用固态加入，该技术将破坏焊接行业，全球价值为200亿美元。在美国领导的基础技术平台将在加强国内制造供应链的同时，在科学，技术和工程领域创造新的就业机会。该项目的创新涉及使用爆炸性焊接的金属的顺序，战术和控制沉积。 爆炸性焊接使用硬币大小的金属元件，该金属元素发行，速度在300-1000m/s的速度范围内，没有炸药。尽管众所周知，爆炸性焊接可以将大型板焊接在一起，但该方法不适合自动化或常规工业环境。冲击焊接将作为一种填充焊接技术开发，就像传统焊接中的填充金属一样，并将使用锻造板金属作为原料。在这里，发电的金属箔将被用作填充元素的驱动程序，研究将重点介绍是否可以重现这些元素来开发大型债券区域和可重复的定位。在飞行过程中控制元素形状和方向并产生完全焊接的接口的能力是该技术最高风险的方面。将执行机械测试，扫描电子显微镜和内联过程监测，例如光子多普勒速度法。这项工作将开发出新的流程结构循环，其目的是产生比用竞争技术（如冷喷雾）（如通过总能源消耗，成本和机械性能所衡量的）更好的零件。该奖项反映了NSF的法定任务，并通过使用基金会的知识优点和广泛的影响来评估NSF的法定任务，并被认为是值得的支持。