Sustainable materials and additive manufacturing processes for the automotive sector

汽车行业的可持续材料和增材制造工艺

• 批准号: 580559-2022
• 负责人: Vlasea, MihaelaML
• 金额: $ 7.29万
• 依托单位: University of Waterloo
• 依托单位国家: 加拿大
• 项目类别: Alliance Grants
• 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=760398
• 关键词: Sustainable; materials; additive; manufacturing; processes

Metal additive manufacturing (AM) has seen a significant growth in both use and capabilities, with an increased adoption in industrial and consumer markets. The prohibitive challenges in this space remain cost of feedstock, the production yield, and reliable/suitable part performance. To tackle these challenges, this project will focus on (1) lowering the cost barriers by using custom low-cost water atomized (WA) alloy steels (2) deploying binder jetting additive manufacturing (BJAM) which is capable of highest build rate among the AM techniques, (3) enabling custom-tailoring of properties and performance by in-situ alloying. The overall objective of the project is to demonstrate that metal AM via BJAM can be deployed as a low-cost and reliable alternative to metal part production with a direct application to the spare parts market and automotive industry. This study will be conducted in close collaboration with Rio Tinto (QC), a leading metals and mining company involved in the manufacture of metal powders, Dana Canada Corporation (ON), a leader in the design and manufacture of highly efficient propulsion and energy-management solutions, and Nanogrande ( QC), a Canadian-based 3D printer manufacturing company. The methodology to achieve the proposed objective will be deployed in four stages. Firstly, a comprehensive survey including classification of challenges in using WA feedstocks will be performed and long-term opportunities will be identified. In the second stage, solid state sintering aids (delivered by mechanical mixing or via binder) will be used to enhance densification of printed parts in a controlled manner. In the third stage, solid state additives will be mixed with the steel systems to tailor the mechanical properties. The work on sintering aids and additives includes powder characterization, printing process optimization, discovery and simulation of sintering protocols and characterization of final products such as mechanical properties as well as microstructural analysis. The fourth stage includes design optimization according to AM principles and tailored for BJAM for specific automotive components. Part demonstrators with target properties will be manufactured using the strategies developed.

金属增材制造 (AM) 的用途和能力均显着增长，在工业和消费市场的采用率不断提高。该领域面临的严峻挑战仍然是原料成本、产量和可靠/合适的零件性能。为了应对这些挑战，该项目将重点关注 (1) 通过使用定制的低成本水雾化 (WA) 合金钢来降低成本障碍 (2) 部署粘合剂喷射增材制造 (BJAM)，该技术能够在同类产品中实现最高的构建率AM 技术，(3) 通过原位合金化实现特性和性能的定制。该项目的总体目标是证明通过 BJAM 进行的金属增材制造可以作为金属零件生产的低成本且可靠的替代方案进行部署，并直接应用于备件市场和汽车行业。这项研究将与力拓（QC）（一家从事金属粉末制造的领先金属和采矿公司）以及德纳加拿大公司（ON）（高效推进和能源设计和制造领域的领导者）密切合作进行。管理解决方案，以及加拿大 3D 打印机制造公司 Nanogrande (QC)。实现拟议目标的方法将分四个阶段部署。首先，将进行全面调查，包括对使用 WA 原料的挑战进行分类，并确定长期机会。在第二阶段，固态烧结助剂（通过机械混合或通过粘合剂提供）将用于以受控方式增强打印部件的致密化。在第三阶段，固态添加剂将与钢系统混合以调整机械性能。烧结助剂和添加剂方面的工作包括粉末表征、印刷工艺优化、烧结方案的发现和模拟以及最终产品的表征，例如机械性能以及微观结构分析。第四阶段包括根据AM原理进行设计优化，并为BJAM针对特定汽车零部件量身定制。具有目标特性的零件演示器将使用开发的策略进行制造。