GOALI/Collaborative Research: Process Development across Alloy Systems for Powder Bed Additive Manufacturing

这个合作的学术联络与工业（GOALI）项目的赠款机会将应用基础研究控制熔池尺寸和微观结构的问题，电子束直接金属粉末床增材制造工艺。 具体来说，它将解决如何转移控制方法开发的一个材料系统到另一个材料系统的方式，减少昂贵和耗时的实验。 为了实现这一目标，该项目将开发一种基于建模的工艺映射方法，用于直接金属粉末床增材制造工艺中使用的不同材料。过程映射方法将应用于使用研究人员可用的增材制造设备对多种金属合金进行的实验。直接金属增材制造对航空航天、医疗植入物和其他行业具有极大的兴趣。 它提供了降低制造成本的希望，用于构建组件的材料量的大幅减少，以及制造传统制造方法无法实现的结构的能力。 在航空航天和其他工业中广泛使用直接金属增材制造的两个障碍是（1）缺乏从一种金属合金系统向另一种金属合金系统转移工艺知识（例如，如何构建形状）的平台;以及（2）关于控制任何合金系统的微观结构和机械性能的知识有限。 这些障碍导致在将增材制造应用于新材料系统时进行昂贵的实验，并且无法证明制造部件的机械强度。 该项目将通过一个团队完成的研究来克服这两个障碍，该团队包括来自三所大学（北卡罗来纳州，卡内基梅隆大学和赖特州立大学）的学术研究人员以及来自航空航天工业的合作者，目前正在努力将直接金属增材制造集成到组件生产中（普惠公司）。

This collaborative Grant Opportunities for Academic Liaison with Industry (GOALI) project will apply fundamental research to the problem of controlling melt pool dimensions and microstructure for electron beam direct metal powder bed additive manufacturing processes. Specifically, it will address how to transfer control methods developed for one material system to another material system in a way that reduces costly and time-consuming experimentation. To accomplish this, this project will develop a first-of-its kind modeling-based process mapping approach for application across different materials used in direct metal powder bed additive manufacturing processes. Process mapping methods will be applied to experiments performed on multiple metal alloys using additive manufacturing equipment available to the investigators. Direct metal additive manufacturing is of great interest to the aerospace, medical implant, and other industries. It offers the promise of decreased manufacturing cost, substantial reductions in the amount of material used to build a component, and the ability to fabricate structures not realizable by conventional manufacturing methods. Two barriers to widespread use of direct metal additive manufacturing in the aerospace and other industries are (1) the lack of a platform for transferring process knowledge (for example, how to build shapes) from one metal alloy system to another; and (2) limited knowledge about controlling microstructure and mechanical properties for any alloy system. These barriers lead to expensive, costly experimentation in applying additive manufacturing to new material systems and the inability to certify mechanical strength in fabricated components. This project will overcome both of these barriers through research accomplished by a team that includes academic investigators from three universities (North Carolina State, Carnegie Mellon and Wright State) and a collaborator from the aerospace industry currently working to integrate direct metal additive manufacturing into component production (Pratt & Whitney).