Developing new metallic alloys for Additive Manufacturing

开发用于增材制造的新型金属合金

• 批准号: RGPIN-2020-04379
• 负责人: Henein, Hani
• 金额: $ 4.01万
• 依托单位: University of Alberta
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2020
• 资助国家: 加拿大
• 起止时间: 2020-01-01 至 2021-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=717003
• 关键词: Developing; new; metallic; alloys; Additive

Canadian manufacturing accounts for 10% of GDP and nearly 10% of the labour force (Statistics Canada). Additive manufacturing (AM), or 3D printing, is a new manufacturing approach where three dimensional components are built layer by layer forming a complex 3D part. This manufacturing approach deviates significantly from traditional manufacturing. Typically, components are designed and cast followed by hot and cold working, heat treatment and machining. AM provides innovative new opportunities for re-designing components. AM is undergoing a dramatic rise expanding in 2017 by more than $2.15 billion and a 21% overall growth in the industry. New metallic alloys must be developed to meet the special needs for innovative designs of components hitherto thought impossible to make. Innovative designs include the use of truss lattices in AM components. This enables the use of powdered alloys with novel compositions not yet used for engineering applications. Aluminum-copper alloys (Al-Cu) is one example, where traditionally the copper content is limited to ~4.5wt% due to light-weighting goals and increased strength. With the advent of truss designs for AM, higher copper content alloys may be utilised while producing components with lighter densities than traditional monolithic materials and with a considerable increase in strength. It is proposed to begin this program by studying Al-Cu and Al-Ni of eutectic and near-eutectic compositions. Of initial interest is the process conditions under which eutectics form. Subsequently, the ability to spheroidize the intermetallic constituent of the eutectic by aging will be studied. The powders will then be used in AM equipment in collaboration with Prof Qureshi, Mech E UofA. This will stimulate new projects funded by industry and NSERC using these novel powders in making AM components. The eutectic microstructures will be quantitatively characterized using scanning electron microscopy, neutron scattering and 3D micro-tomography. The evolution of spherical intermetallics will be defined following Ho and Weatherly. The spacing between intermetallic particles and their size will be measured using quantitative image analysis and machine learning techniques. Finally, these measurements will be related to Vickers micro hardness measurements to be made on aged samples. Four graduate students will be trained over the duration of 5 years. Two will tackle Al-Cu and two Al-Ni. One set of two students will address the rapid solidification aspects of the project while the other two will address the ageing processing of the powders. This will provide all 4 students training in the conduct of high temperature experiments, characterisation methods, 3D microtomography, quantitative metallography as well as modelling of solidification paths of alloys and the relationship between solidification-developed microstructure and resulting properties. The effort described in this proposal initiates a new thrust in our research.

加拿大制造业占GDP的10％，占劳动力（加拿大统计局）的近10％。增材制造（AM）或3D打印是一种新的制造方法，其中三维组件是通过形成复杂3D部分的图层来构建的三维组件。这种制造方法显着偏离了传统制造业。通常，组件是设计和铸造的，然后是热水和冷工作，热处理和加工。 AM为重新设计组件提供创新的新机会。 AM在2017年的增长幅度超过21.5亿美元，该行业的总体增长超过21.5亿美元。必须开发新的金属合金，以满足迄今认为无法制作的组件创新设计的特殊需求。 创新的设计包括在AM组件中使用桁架格子。这使得使用粉末状合金和尚未用于工程应用的新型组合物。铝合金合金（AL-CU）就是一个例子，传统上，由于实现了轻度加权的目标和增加的强度，铜含量限制为〜4.5wt％。随着AM桁架设计的出现，可以使用较高的铜含量合金，同时生产比传统单片材料较轻的组件，并且强度可观。有人建议通过研究Eutectic和近乎整流性组成的Al-Cu和al-Ni来开始该程序。最初感兴趣的是共晶形成的过程条件。随后，将研究通过衰老来使eutectic的金属间成分的球体间成分的能力。然后，将与Mech E Uofa教授合作将粉末用于AM设备中。这将刺激由行业和NSERC资助的新项目，并使用这些新颖的粉末制作AM组件。 通过扫描电子显微镜，中子散射和3D微型摄影作用，将对共晶的显微结构进行定量表征。球形间层的演变将在HO和Weatherly之后定义。金属间粒子与它们的大小之间的间距将使用定量图像分析和机器学习技术来测量。最后，这些测量结果将与维克斯的微硬度测量有关，要对老年样品进行。 在5年的时间里，将对四名研究生进行培训。两个将解决al-cu和两个al-ni。一组两个学生将解决项目的快速固化方面，而其他两个学生将解决粉末的衰老处理。这将为所有4名学生提供高温实验，表征方法，3D微传输学，定量金理图以及合金固化路径的建模以及固化开发的微结构和产生性能之间的关系。该提案中描述的努力在我们的研究中引起了新的作用。