Shock Wave Induced Freeform Technique (SWIFT) for Manufacturing of Diamond Microtools

该奖项的研究目标是将冷烧结原理应用于金刚石微刀具的自由曲面制造，并确定宽高比、表面粗糙度、边缘半径和烧结参数之间的定量关系。该方法包括利用激光诱导冲击波对纳米金刚石粉末进行逐层增材机械烧结，并利用多尺度物理模型对实验数据进行验证。利用飞秒脉冲激光进行后精加工处理，可以制造出各种自由几何形状的三维微部件，以获得紧密的公差、光滑的光洁度和精确的几何形状。更广泛的影响包括降低制造成本，易于获得和提高金刚石微工具的性能。另一个好处是能够构建多功能材料，以定制所需的性能。研究将促进行业采用新的制造工艺，以解决与金刚石微工具相关的生产率和质量问题。教育和推广成果包括培训先进制造领域的女性和少数民族研究生，将研究数据纳入制造课程，让本科生参与研究团队进行研究培训，通过期刊出版物、会议、行业访问和研讨会传播研究成果，以及创建一个网站来报告新的增材制造系统的成果。

The research objective of the award is to apply the principles of cold sintering for the freeform fabrication of diamond microtools and determine quantitative relationships among aspect ratio, surface roughness, edge radius and sintering parameters. The approach consists of employing laser-induced shock waves to mechanically sinter nanodiamond powders through layer-by-layer additive manufacturing and utilizing multiscale physics models to validate the experimental data. Three-dimensional microparts in various freeform geometries will be fabricated with a post-finishing treatment by the femtosecond pulsed laser for close tolerance, smooth finish and precise geometry. The broader impacts include a reduction in the manufacturing cost, easy availability and enhanced performance of diamond microtools. An additional benefit is the capability to build multifunctional materials for tailoring the required properties. Research will facilitate the industry adoption of the new manufacturing process to address the productivity and quality issues associated with diamond microtools. Education and outreach outcomes include training of women and minority graduate students in advanced manufacturing field, incorporation of the research data into manufacturing courses, undergraduates research training by involving them in the research team, dissemination of the research results through journal publications, conferences, industry visits and workshops, and creation of a website to report results of the new additive manufacturing system.