GOALI: Direct High-Efficiency Production of Sheet and Foil by Single-Stage Deformation Processes

这个学术与工业联络资助机会（GOALI）项目将发展一种基于混合加工的工艺科学，用于生产金属板材和箔，在这种工艺中，切割和挤压在单一变形阶段同时发生。这种方法与目前用于生产薄板和箔的传统多阶段轧制工艺完全不同，因为变形可以被控制并限制在一个小区域内，变形本身产生的局部加热和施加大的静水压力。结果是一种抑制失效的变形条件，从而即使在低加工性的合金中也能实现大的形状变化。将研究变形条件（应变、应变速率和温度），以确定如何使用特殊的应力/温度状态和应变路径来提高变形效率、控制微观结构和性能以及消除缺陷。将对结垢、能源、刀具磨损和成本进行实验和分析，以表征工艺效率并对传统工艺进行基准测试。这项研究将使金属片和箔在单一变形阶段直接从铸锭生产，显著降低能源，成本和排放。基于加工的变形方法在加工低加工性合金（如钛和镁）方面也具有重要优势，为打破目前禁止这些轻质合金在商业运输系统中大规模应用的成本障碍提供了关键技术。该工艺赋予有利的晶体织构，同时控制晶粒尺寸，以实现优越的成形性和性能。这项研究将促进制造过程的成本分析，并为学生提供与行业合作伙伴直接互动和发展创业技能的机会。该项目是一项由普渡大学、M4科学有限责任公司、福特和工具制造商参与的合作研究。

This Grant Opportunity for Academic Liaison with Industry (GOALI) project will develop the science of a hybrid machining-based process for producing metal sheet and foil in which cutting and extrusion occur simultaneously in a single stage of deformation. The approach is radically different from the conventional multi-stage rolling processes currently used to produce sheet and foil, in that the deformation can be controlled and confined to a small region, with localized heating from the deformation itself and imposition of large hydrostatic pressures. The result is a deformation condition that suppresses failure, thereby enabling large shape changes even in alloys of low workability. Deformation conditions (strain, strain rate and temperature) will be investigated to determine how special stress/temperature states and strain paths can be used to increase deformation efficiency, control microstructure and properties, and eliminate defects. Experiments and analyses on scaling, energy, tool wear and costs will be conducted in order to characterize process efficiency and for benchmarking against conventional processes.This research will enable metal sheet and foil to be produced directly from ingot in a single stage of deformation, with significant reductions in energy, cost and emissions. The machining-based deformation approach will also have important advantages for processing alloys of low workability such as titanium and magnesium, providing critical technology for breaking down the cost barriers currently prohibiting these lightweight alloys from large-scale application in commercial transportation systems. The process imparts advantageous crystallographic textures, while simultaneously controlling grain-size to achieve superior formability and properties. The research will advance cost analysis of manufacturing processes and provide opportunities for students to interact directly with industry partners and develop entrepreneurial skills. The project is a collaborative study involving Purdue University, M4 Sciences LLC, Ford, and tool manufacturers.