Collaborative Research: Solid-State Additive Manufacturing of Metal Matrix Composites via Cold Spray

合作研究：通过冷喷涂进行金属基复合材料的固态增材制造

• 批准号: 2330319
• 负责人: Mostafa Hassani
• 金额: $ 36万
• 依托单位: Cornell University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2024
• 资助国家: 美国
• 起止时间: 2024-06-01 至 2028-05-31
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2330319&HistoricalAwards=false
• 关键词: Collaborative; Research; Solid; State; Additive

Cold spray is a promising technique for additive manufacturing of structural materials. It operates in the solid state and overcomes many limitations of traditional casting and fusion-based additive manufacturing. While progress has been made in understanding the processing science of cold spray for metals and alloys, the knowledge of manufacturing metal matrix composites via cold spray remains limited. The objective of this project is to develop a fundamental understanding of the process-microstructure-property relationships for additive manufacturing of metal matrix composites via cold spray. The knowledge gained from this program can be translated to aerospace, energy, and defense industries for reliable manufacturing, repair, and safe operation of metal matrix composites for structural applications. The team will focus on developing the upcoming generation of students, preparing them to excel in the area of additive manufacturing through a series of targeted, high-impact initiatives. These initiatives include mentoring undergraduate student researchers from underrepresented groups, developing integrated online course modules, and outreach to the general public via a virtual microstructure library with a user-friendly, web-based portal.The goal of the project is to develop manufacturing science for cold spraying metal matrix composites and to develop a mechanistic understanding of deformation and failure in these materials. Novel core-shell powder particles and double reinforced powder particles will be designed and used for cold spraying metal matrix composites. Underlying mechanisms that control the behavior of cold-sprayed composites will be studied with in situ experiments: (i) individual powder particles with a focus on processing, and (ii) bulk materials with a focus on mechanical performance. A systematic exploration of single-particle impacts using Laser-Induced Particle Impact Test (LIPIT) will be used to understand the underlying bonding mechanisms in the different bi-phase systems. The information obtained from the single-particle impact experiments will guide the deposition of bulk-scale composites, which will be fully characterized using time-resolved 3D x-ray computed tomography (XCT) and diffraction. The samples with the most desirable characteristics, based on microstructure and pore density, will be further tested in situ to elucidate the mechanical behavior and fracture mechanisms. This project has the potential to significantly expand the applicability of cold spray to a broader range of materials and applications, enabling researchers and engineers to tailor materials with specific attributes and performance characteristics.This award is co-funded by the Advanced Manufacturing Program of the Division of Civil, Mechanical and Manufacturing Innovation and the Metals and Metallic Nanostructures Program of the Division of Materials Research.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.

冷喷雾是一种用于结构材料增材的有前途的技术。它以固态运行，克服了传统铸造和基于融合的添加剂制造的许多局限性。尽管在了解金属和合金的冷喷雾剂的加工科学方面取得了进展，但通过冷喷雾剂制造金属基质复合材料的知识仍然有限。该项目的目的是通过冷喷雾剂对金属基质复合材料的添加剂生产进行基本了解。从该计划中获得的知识可以转化为航空航天，能源和国防行业，用于可靠的制造，维修和安全的结构应用金属基质复合材料的安全操作。该团队将专注于发展即将到来的学生，使他们通过一系列有针对性的高影响力计划在增材制造领域中脱颖而出。这些举措包括来自代表性不足的小组的指导本科生的研究人员，开发综合的在线课程模块，并通过虚拟微观结构库向公众推广，该虚拟微观结构库具有一个基于用户友好的，基于网络的门户网站。新型的芯壳粉末颗粒和双增强粉末颗粒将被设计和用于冷喷涂金属基质复合材料。控制冷种复合材料行为的基本机制将通过原位实验进行研究：（i）侧重于加工的单个粉末颗粒，以及（ii）重点是机械性能的大量材料。使用激光诱导的颗粒冲击测试（LIPIT）对单粒子撞击的系统探索将用于了解不同的双相系统中的潜在粘结机制。从单粒子冲击实验获得的信息将指导散装尺度复合材料的沉积，该复合材料将使用时间分辨的3D X射线计算机层析成像（XCT）和衍射。基于微观结构和孔密度最理想特征的样品将进一步进行原位测试，以阐明机械行为和断裂机制。该项目有可能显着扩展冷喷雾剂在更广泛的材料和应用中的适用性，使研究人员和工程师能够量身定制具有特定属性和性能特征的材料。该奖项由民用，机械和制造业部的先进制造计划共同资助，机械和制造创新和金属和金属纳米结构的宣传奖和金属统计效果。通过使用基金会的知识分子和更广泛影响的评论标准来通过评估来支持。