CAREER: Understanding Joining Mechanisms in Dissimilar Metal Additive Manufacturing

职业：了解异种金属增材制造中的连接机制

• 批准号: 2338253
• 负责人: Somayeh Pasebani
• 金额: $ 75.57万
• 依托单位: Oregon State 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: 2024-04-01 至 2029-03-31
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2338253&HistoricalAwards=false
• 关键词: CAREER; Understanding; Joining; Mechanisms; Dissimilar

This Faculty Early Career Development (CAREER) grant focuses on research to create strong joints between dissimilar alloys, a critical aspect of making multi-alloy components through the laser-based additive manufacturing or three-dimensional (3D) printing process. This approach achieves multi-functional parts with enhanced properties combined in a single component. These components are of particular interest to defense, health, manufacturing, space, and energy sectors where high quality, complex, and customized parts with the most desired performance are needed, which impacts US industry and economy. The research goal is to understand how laser-melting of mixed metals and alloys in a wire-feed, powder-feed process affects the joining of different alloys towards the fabrication of defect-free dissimilar metal components. To achieve this, thermal and fluid flow behavior within the melted dissimilar alloys is studied using computational modeling and experimental processing. This research enables the desired properties in 3D printed multi-material components to be spatially varied. This project aims to integrate research with teaching, mentoring, and training of students at different levels, especially, women and underrepresented minorities. In support of the notion that the Arts activate creative thinking, the project offers summer programs involving hands-on activities based on Art and STEM integration to encourage K-12 students to pursue science and engineering fields.Additive manufacturing (AM) allows for the simultaneous achievement of design freedom and the incorporation of spatially varying properties in the production of multi-material components. The research objective is to gain a comprehensive understanding of the effects of additive manufacturing process physics on dissimilar joining mechanisms. This is achieved by investigating the role of process-induced mixing at the dissimilar alloy interfaces. The central hypothesis is that the microstructure of the mixing-resultant alloy is directly influenced by the degree of process-induced mixing, which, in turn, is governed by thermal fluid flow and thermal history of the melt-pool. This phenomenon is predominantly driven by the combined effects of additive manufacturing process parameters and thermo-physical properties at the dissimilar interface. The researched framework integrates multi-scale, multi-physics modeling with laser-based wire-feed, powder-feed directed energy deposition (DED) fabrication experiments and microstructural analysis. Additionally, DFT and CALPHAD models are created to analyze the thermal history, composition, and melt pool dimensions of the dissimilar melt-pools. This information aids in identifying the specific joining mechanisms in dissimilar metal additive manufacturing, such as bimetallic joints, compositional gradient joints, and transition layer joints. This research advances the field of additive manufacturing to enable the creation of innovative high performance multi-material components with enhanced functionality.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.

这项教师早期职业发展（职业）的重点是研究，以在不同的合金之间建立强大的关节，这是通过基于激光的增材制造或三维（3D）打印过程制造多合金组件的关键方面。这种方法可实现具有单个组件组合的增强属性的多功能部分。这些组成部分特别感兴趣的是防御，健康，制造，空间和能源部门，在这些部门中，需要最高质量，复杂和定制的零件，这会影响美国的工业和经济。研究目的是了解电线馈电粉中混合金属和合金的激光融化如何影响不同合金与无缺陷不同的金属组件的结合。为了实现这一目标，使用计算建模和实验处理研究了熔化的合金中的热和流体流动行为。 这项研究使3D打印多物质组件中的所需属性在空间上变化。该项目旨在将研究与教学，指导和培训不同，尤其是妇女和代表性不足的少数群体。为了支持艺术激活创意思维的观念，该项目提供了涉及基于艺术和STEM整合的动手活动的夏季节目，以鼓励K-12学生从事科学和工程领域。AddiveStirant（AM）允许同时实现设计自由的同时实现设计自由以及在多种构成组合的生产中的空间变化。研究目标是对添加剂制造过程物理对不同连接机制的影响有全面的了解。这是通过研究过程诱导的混合在不同合金界面上的作用来实现的。中心假设是混合抗性合金的微观结构直接受过程诱导的混合程度的影响，这又受热流体流量和熔体池的热历史的影响。这种现象主要是由添加剂制造过程参数和在不同界面上的热物质特性的综合作用驱动的。研究的框架将多尺度的多物理模型与基于激光的电线馈电，粉末馈送的能量沉积（DED）制造实验和微结构分析相结合。此外，创建了DFT和Calphad模型，以分析不同熔体池的热历史，组成和熔体池尺寸。该信息有助于识别不同金属添加剂制造中的特定连接机制，例如双金属接头，成分梯度接头和过渡层关节。这项研究促进了添加剂制造领域的领域，以使创新的高性能多物质组件具有增强的功能。该奖项反映了NSF的法定任务，并被认为是通过基金会的智力优点和更广泛影响的审查标准通过评估来获得支持的。