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.

金属添加剂制造业（AM）的使用和能力都有显着增长，并且在工业和消费市场中的采用率提高。该领域的挑战仍然是原料的成本，生产收益率以及可靠/合适的零件性能。为了应对这些挑战，该项目将重点介绍（1）通过使用定制的低成本水雾化（WA）合金钢（2）部署粘合剂喷射添加剂制造（BJAM），从而降低成本障碍，该工具能够在AM技术中具有最高的构建速率，（3）启用属性和性能的定制性能和性能。该项目的总体目的是证明可以通过直接应用于备件市场和汽车行业的直接应用金属的金属AM作为金属零件生产的低成本且可靠的替代品。这项研究将与Rio Tinto（QC）密切合作，这是一家领先的金属和矿业公司，参与制造金属粉末，Dana Canada Corporation（ON），Dana Canada Corporation（ON）是高效推进和能源管理解决方案的设计和制造的领导者，以及纳米格兰德（QC）（QC），一家基于3D Printering Company（QC）。实现拟议目标的方法将分为四个阶段。首先，将进行一项全面的调查，包括使用WA原料的挑战分类，并确定长期机会。在第二阶段，固态烧结辅助工具（通过机械混合或通过粘合剂传递）将用于以受控方式增强印刷零件的致密化。在第三阶段，固态添加剂将与钢系统混合以调整机械性能。关于烧结辅助工具和添加剂的工作包括粉末表征，打印过程优化，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结构分析。第四阶段包括根据AM原理进行的设计优化，并针对BJAM量身定制，用于特定的汽车组件。具有目标属性的零件示威者将使用开发的策略制造。