Incremental manufacturing platform for the fabrication of lightweight high-strength aluminum vehicle structures

用于制造轻质高强度铝制车辆结构的增量制造平台

• 批准号: 571071-2021
• 负责人: Yue, StephenS
• 金额: $ 7.47万
• 依托单位: McGill University
• 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=761076
• 关键词: Incremental; manufacturing; platform; fabrication; lightweight

Metal additive manufacturing has today demonstrated a strong potential for producing small-dimension (= 1m), very complex parts, offering increased performance with a major saving in weight (up to 80% for certain parts), especially when coupled with topological optimization techniques for the design of parts. Unfortunately, the current processes involving the melting of materials are limited for large components using high strength aluminum alloys, thus limiting their use. Cold spray is a technique for depositing material in the solid state capable of depositing with very few constraints, benefiting in particular from a high deposition rate (several kg / h). Its other advantages make this technique particularly attractive for overcoming the limitations of fusion based additive manufacturing processes. The McGill University-NRC cold spray facility, created in 2007, has positioned itself as a world leader in the development of additive manufacturing by cold spray of all metals. However, significant challenges remain in applying this process on a large scale and in physically and economically viable ways with aluminum alloys of interest to the transport industry, e.g. Al 6061 or Al7075.This project, which brings together the NRC, McGill University, ETS and members of the industrial group of METALTec, aims to develop and demonstrate the potential of additive manufacturing by cold spraying for large components (up to several meters in length) using high performance aluminum alloys. The project will focus in particular on the implementation of an innovative solution for the cold spraying of high performance aluminum alloys, while developing material and digital solutions to measure, model and control the evolution of geometry, online, of the 3D part to be produced. The success of this project will be based on the combination of McGill-NRC's expertise in cold spraying, NRC's expertise in process simulation and 3D vision and ETS's knowledge in metrology mechanical simulation. The project is connected with industry via the more than 29 METALTec members forming a network around metal fabrication for the transport industry, covering the entire value chain, from raw materials finished products, in Quebec, Canada and international.

如今，金属增材制造已展现出生产小尺寸 (= 1m)、非常复杂零件的强大潜力，可提高性能并大幅减轻重量（某些零件最多可减轻 80%），特别是与拓扑优化技术相结合时零件的设计。不幸的是，目前涉及材料熔化的工艺仅限于使用高强度铝合金的大型部件，从而限制了它们的使用。 冷喷涂是一种沉积固态材料的技术，能够在很少的限制下进行沉积，特别受益于高沉积速率（几公斤/小时）。它的其他优点使得该技术对于克服基于融合的增材制造工艺的局限性特别有吸引力。麦吉尔大学-NRC 冷喷涂设施于 2007 年创建，在全金属冷喷涂增材制造开发领域处于世界领先地位。然而，以物理上和经济上可行的方式大规模应用这一工艺仍然存在重大挑战，适用于运输行业感兴趣的铝合金，例如铝合金。 Al 6061 或 Al7075。该项目汇集了 NRC、麦吉尔大学、ETS 和 METALTec 工业集团的成员，旨在开发和展示通过冷喷涂大型部件（长度可达几米）增材制造的潜力）采用高性能铝合金。该项目将特别侧重于实施高性能铝合金冷喷涂创新解决方案，同时开发材料和数字解决方案，以在线测量、建模和控制待生产 3D 零件的几何形状演变。 该项目的成功将基于 McGill-NRC 在冷喷涂方面的专业知识、NRC 在过程模拟和 3D 视觉方面的专业知识以及 ETS 在计量机械模拟方面的知识的结合。该项目通过超过 29 个 METALTec 成员与行业联系起来，形成了一个围绕运输行业金属制造的网络，覆盖魁北克、加拿大和国际的从原材料成品到整个价值链。