GOALI: Engineering of Functionality Graded Magnesium Composite Surfaces

这项授予工业学术联系机会(GOALI)奖的目的是发展机械表面生成的加工科学，以便能够设计出具有特定微观结构的镁合金/复合材料表面，以提高磨损性能。该方法包括分析机械表面产生的基础单元相互作用下的大应变变形的力学--滑动刀具与工件表面的相互作用。利用先进的实验力学技术，可将工件表面的大应变变形现场表征为可控工艺变量的函数。将使用电子显微镜、微拉伸测试和微/纳米摩擦学方法在多个长度尺度上分析表面的组织和性能，生成变形-组织-性能图。结合晶级塑性的有限元分析将被用来预测和优化变形，以产生具有理想性能的梯度表面组织。将建立一个预测框架，通过控制工艺变量来设计耐磨表面。这项工作将影响离散产品部门广泛关注的表面生成过程，包括抛光、表面机械磨损、微精加工、磨损和摩擦搅拌处理。科学上的好处将是加深对六方密排金属中的变形现象的理解，以及结构镁合金的变形-组织-性能关联。技术上的好处将是创造具有新属性的镁合金表面的新工艺或改进工艺，从而能够开发用于运输的超轻型动力总成和结构子系统。更广泛的影响包括提高汽车、航空航天或其他运输系统的燃油经济性和随之而来的环境效益；以及将有助于培养一支精通先进工艺和工业应用结构材料的劳动力的强大教育组成部分。教育和培训计划还包括研究生在工业领域的实习，通过与罗切斯特理工学院国家聋人技术学院的合作，为残疾学生提供本科研究培训，以及适度关注在研究生学习中培养企业家精神。

The objective of this Grant Opportunity for Academic Liaison with Industry (GOALI) award is to develop the processing science for mechanical surface generation so as to enable engineering of magnesium alloy/composite surfaces with specific microstructures that enhance wear performance. The approach involves analysis of mechanics of large strain deformation underlying the unit interaction fundamental to mechanical surface generation - sliding tool interacting with a workpiece surface. Large strain deformation on the workpiece surface will be characterized, in situ, as a function of controllable process variables using advanced experimental mechanics techniques. Microstructure and properties of the surface will be analyzed at multiple length scales using electron microscopy, micro-tensile test, and micro/nano tribology methods, resulting in deformation-microstructure-property maps. Finite element analysis incorporating grain-level plasticity will be used to predict and optimize the deformation in order to create graded surface microstructures with desirable properties. A predictive framework will be established to engineer wear resistant surfaces by control of process variables. Surface generation processes of wide-ranging interest to the discrete products sector including burnishing, surface mechanical attrition, microfinishing, wear and friction stir processing will be impacted by this work. The scientific benefits will be enhanced understanding of deformation phenomena in hexagonal close packed metals and deformation-microstructure-property correlations for structural magnesium alloys. The technological benefits will be new or improved processes for creating magnesium alloy surfaces with novel attributes enabling development of ultra-lightweight powertrain and structural sub-systems for transportation. Broader impacts include improved fuel economy in automotive, aerospace, or other transportation systems and concomitant environmental benefits; and a strong educational component that will contribute towards a workforce competent in advanced processes and structural materials for industrial applications. The education and training program also includes graduate student internships in industry, undergraduate research training for physically challenged students via collaboration with the National Technical Institute for the Deaf, Rochester Institute of Technology, and a modest focus on fostering entrepreneurship in graduate study.