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: 2022
• 资助国家: 加拿大
• 起止时间: 2022-01-01 至 2023-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=746870
• 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%，占劳动力的近10%（加拿大统计局）。增材制造 (AM) 或 3D 打印是一种新的制造方法，其中三维组件逐层构建，形成复杂的 3D 零件。这种制造方法与传统制造有很大不同。通常，部件经过设计和铸造，然后进行热加工和冷加工、热处理和机加工。增材制造为重新设计组件提供了创新的新机会。增材制造正在经历急剧增长，2017 年增长超过 21.5 亿美元，行业整体增长 21%。必须开发新的金属合金，以满足迄今为止认为不可能制造的部件创新设计的特殊需求。 创新设计包括在增材制造组件中使用桁架网格。这使得具有尚未用于工程应用的新颖成分的粉末合金成为可能。铝铜合金 (Al-Cu) 就是一个例子，传统上，由于轻量化目标和提高强度，铜含量被限制在 ~4.5wt%。随着增材制造桁架设计的出现，可以使用更高铜含量的合金，同时生产密度比传统整体材料更轻且强度显着增加的部件。建议通过研究共晶和近共晶成分的 Al-Cu 和 Al-Ni 来开始该计划。最初感兴趣的是共晶形成的工艺条件。随后，将研究通过时效使共晶金属间化合物成分球化的能力。然后，这些粉末将与 Mech E UofA 的 Qureshi 教授合作用于增材制造设备。这将刺激由行业和 NSERC 资助的使用这些新型粉末制造增材制造部件的新项目。将使用扫描电子显微镜、中子散射和 3D 显微断层扫描对共晶微观结构进行定量表征。球形金属间化合物的演变将按照 Ho 和 Weatherly 的定义进行定义。将使用定量图像分析和机器学习技术来测量金属间颗粒之间的间距及其尺寸。最后，这些测量将与对老化样品进行的维氏显微硬度测量相关。四名研究生将接受为期五年的培训。两个将处理 Al-Cu，两个将处理 Al-Ni。一组两名学生将解决该项目的快速凝固问题，而另外两名学生将解决粉末的老化处理问题。这将为所有 4 名学生提供高温实验、表征方法、3D 显微断层扫描、定量金相学以及合金凝固路径建模以及凝固发展的微观结构与所得性能之间关系的培训。该提案中描述的努力为我们的研究带来了新的推动力。