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

这一与业界合作的学术联系机会(GOALI)项目将应用基础研究来控制电子束直接金属粉末床添加剂制造工艺的熔池尺寸和微观结构。具体地说，它将讨论如何将为一个材料系统开发的控制方法转移到另一个材料系统，以减少昂贵和耗时的实验。为了实现这一点，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添加剂制造工艺中使用的不同材料。过程映射方法将应用于使用调查人员可用的添加剂制造设备对多种金属合金进行的实验。直接金属添加剂制造是航空航天、医疗植入物等行业的研究热点。它提供了降低制造成本的前景，大幅减少了制造部件所用的材料量，并能够制造传统制造方法无法实现的结构。在航空航天和其他工业中广泛使用直接金属添加剂制造的两个障碍是：(1)缺乏将工艺知识(例如，如何制造形状)从一个金属合金系统转移到另一个金属合金系统的平台；(2)关于控制任何合金系统的组织和机械性能的知识有限。这些障碍导致了将添加剂制造应用于新材料系统的昂贵、昂贵的试验，以及无法认证已制造部件的机械强度。该项目将通过一个团队完成这两个障碍，该团队包括来自三所大学(北卡罗来纳州立大学、卡内基梅隆大学和莱特州立大学)的学术研究人员，以及目前致力于将直接金属添加剂制造整合到零部件生产中的航空航天行业的合作者(Pratt&amp；Whitney)。

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).