GOALI/Collaborative Research: Integrated Microstructure and Melt Pool Dimension Control for Electron Beam Additive Manufacturing

该研究项目的目的是为电子束增材制造中熔池尺寸和微观结构的综合控制提供基础和实验验证的指导方针，这是一类新兴的制造工艺，通过局部熔化金属并逐层构建几何特征。 研究方法包括在学术机构进行的数值模拟，以及工业和政府合作者进行的电子束沉积实验。 模拟结果将在各种电子束功率、行进速度、材料进给速率和存款几何形状下呈现，并将指导工业和政府合作者进行的关键实验的选择。 模型和实验将包括通过电子束在零件表面上的快速移动对熔池内部和周围温度进行局部剪裁的效果。 如果成功的话，这项研究的好处将不仅包括电子束工艺变量如何与最终零件质量的基本理解，而且还为同时控制熔池几何形状和微观结构的实际基础。 这将代表对航空航天和其他商业应用的电子束制造工艺的鉴定的重大贡献。 研究活动将与两个学术机构正在进行的NSF支持的教育研究项目相结合。 在这个项目上进行研究的学生将开发一个综合的制造，固体力学，传热和材料背景，这将使他们在工业和学术界非常有价值。

The objective of this Grant Opportunity for Academic Liaison with Industry (GOALI) Collaborative research project is to provide fundamental and experimentally-verified guidelines for integrated control of melt pool dimensions and microstructure in electron beam additive manufacturing, a class of emerging manufacturing processes which build geometric features by locally melting metal and building it up layer-by-layer. The research approach involves numerical modeling performed at the academic institutions in conjunction with electron beam deposition experiments performed by the industrial and government collaborators. Simulation results will be presented across a wide range of electron beam powers, travel speeds, material feed rates, and deposit geometries, and will guide the choice of critical experiments conducted by the industrial and government collaborators. Models and experiments will include the effects of local tailoring of temperatures in and around the melt pool by rapid movement of the electron beam across the part surface. If successful, the benefits of this research will include not only a fundamental understanding of how electron beam process variables relate to final part quality, but also a practical basis for simultaneous control of melt pool geometry and microstructure. This will represent a significant contribution toward qualification of electron beam manufacturing processes for aerospace and other commercial applications. Research activities will be integrated with ongoing NSF-supported educational research projects at both academic institutions. Students performing research on this project will develop a combined manufacturing, solid mechanics, heat transfer and materials background that will make them highly valuable in industry and academics.