Cold Spray Solid-State Additive Manufacturing:Process-Structure-Performance Link

冷喷涂固态增材制造：工艺-结构-性能链接

• 批准号: RGPIN-2020-05135
• 负责人: Jahed, Hamid
• 金额: $ 2.84万
• 依托单位: University of Waterloo
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2021
• 资助国家: 加拿大
• 起止时间: 2021-01-01 至 2022-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=740406
• 关键词: Cold; Spray; Solid; State; Additive

Manufacturing is undergoing a revolutionary paradigm shift, driven primarily by the emergence of additive manufacturing (AM) techniques which is expected to represent a $100-250 billion market by 2025. Despite its promising future in automotive, aerospace, power and consumer product industries, additive manufacturing is facing challenges related to process defects and shortfalls that result in lower-than-expected properties and performances. Defects include solidification-related oxidation, porosity, and detrimental residual stresses, as well as lack of fusion and/or particle re-melt defects limit the mechanical properties and performance of products, hindering their market readiness. Many of these defects emanate from the high melting temperature required for particles bonding. Cold spray, as an emerging AM, however, is operating and lower-than-melting temperature and therefore is free of mentioned solidification-related issues. Cold spray is a process that uses kinetic energy to print metal powders at lower-than-melting temperatures. Micro-sized metal powders are accelerated through a convergent-divergent nozzle to supersonic velocities using a heated pressurized gas. Upon collision with substrate the impact energy makes severe local plastic deformation in particle and substrate, resulting in mechanical interlocking. The bonding is therefore free of oxidation, pore-free and highly dense, and crack-free. Moreover, the peening effect of high velocity impact creates beneficial compressive residual stresses. The cold spray technology has widely been used as a coating technology in the geometrical and structural restoration of defected parts such as corroded turbine blades. However, more recently because of its flexibility in printing large objects with complex geometries, fast rate of printing, and no need for controlled environment the technology is considered for manufacturing parts. With the benefits of cold spray additive manufacturing (CSAM) in printing metal/ceramic powders on metal and non-metallic substrates, cold spray technology will have a sizable share in AM market. The proposed research is focused on understanding the process physics of lightweight metal powder deposition by cold spray technology to discover the link between the process parameters with the cohesion and adhesion properties of cold sprayed parts. The outcomes of this research will result in manufacturing of more durable and reliable performance-based component for the automotive, aerospace, power and consumer product industries. Graduate students trained in this program will develop skills in process modeling, CSAM material characterisation, and product performance optimization which are highly sought after in these industries.

制造业正在经历革命性的范式转变，这主要是由添加剂制造（AM）技术的出现驱动，预计到2025年，该技术将代表到2025年的100-250亿美元市场。尽管它在汽车，航空航天，电力和消费产品行业方面具有前途的未来，但添加剂在自动化，权力和消费产品行业方面，添加剂的挑战仍面临着与较低的属性相关的挑战，并表现出较低的性能。缺陷包括与固化相关的氧化，孔隙率和有害的残留应力，以及缺乏融合和/或颗粒重融合缺陷限制了产品的机械性能和性能，从而阻碍了他们的市场准备就绪。这些缺陷中的许多从颗粒粘结所需的高熔化温度中散发出来。然而，随着新兴AM的运行和低于融化的温度，冷喷雾剂没有上述与固化相关的问题。 冷喷雾是一个使用动能在低于融化的温度下打印金属粉末的过程。微型金属粉末通过使用加热的加压气体的收敛性喷嘴加速到超音速速度。与底物发生碰撞后，影响能量使粒子和底物的局部塑性变形严重，从而导致机械互锁。因此，粘结不含氧化，无孔，高度致密和无裂纹。此外，高速影响的固定效应会产生有益的压缩残留应力。冷喷雾技术已被广泛用作涂料技术，用于缺陷零件（例如腐蚀的涡轮叶片）的几何和结构恢复。但是，最近，由于它具有具有复杂几何形状，快速印刷速率的大型物体的灵活性，并且不需要受控环境，因此该技术被考虑用于制造零件。借助冷喷雾添加剂制造（CSAM）在金属和非金属基板上印刷金属/陶瓷粉末中，冷喷雾技术将在AM市场上具有相当大的份额。拟议的研究重点是理解冷喷雾技术轻巧金属粉末沉积的过程物理，以发现过程参数与冷喷涂零件的内聚和粘附特性之间的联系。这项研究的结果将导致为汽车，航空航天，电力和消费产品行业制造更耐用和可靠的基于性能的组件。接受该计划的培训的研究生将发展过程建模，CSAM材料表征和产品性能优化的技能，这些技能在这些行业中受到了极大的追捧。