STTR Phase I: Additive manufacturing processes for iron based amorphous metal components

STTR 第一阶段：铁基非晶金属部件的增材制造工艺

• 批准号: 1549770
• 负责人: Mattias Unosson
• 金额: $ 22.48万
• 依托单位: Sindre Metals, Inc
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2016
• 资助国家: 美国
• 起止时间: 2016-01-01 至 2017-03-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1549770&HistoricalAwards=false
• 关键词: STTR; Phase; Additive; manufacturing; processes

The broader impact/commercial potential of this project lies in development of a new class of amorphous metal alloys that could benefit society as a whole. Theoretical calculations have shown that 90% weight reduction of components can be achieved with Iron-based amorphous and nano-composite alloys. By reducing the weight of components in automotive and aerospace, significant fuel savings can be achieved. Fuel savings will result in both reduced cost as well as reduced emissions of greenhouse gases. Another field of application for amorphous ferromagnetic alloys is electromagnetic cores in electrical motors, transformers and filters. Ferromagnetic amorphous alloys allows for reduced energy losses in these applications by up to 80%, which correspond globally to 50 Million tons of CO2 emissions from fossil fuel power plants per year or 1/10 of the nuclear power production per year in the US. Amorphous metal could also have big impact on healthcare. Amorphous metals could address extremely costly metallosis issues currently experienced by the medical implant industry due to recalls and lawsuits.This Small Business Technology Transfer Research (STTR) Phase I project is aimed at demonstrating the feasibility of metal based additive manufacturing (AM) of Iron-based amorphous metal components. AM processes for alloys with superior mechanical and/or magnetic properties will be developed, and increased scientific understanding of the material mechanisms achieved. While preliminary research show promising results for fabricating larger components with amorphous bulk properties, there are still issues that need to be resolved. To address these challenges, it is important that proper process parameters for forming dense, crack-free, material are established by extensive experimental work using both Electron Beam Melting and Direct Metal Laser Sintering technologies. To support the experimental work, phenomenological Finite Element (FE) models will be developed. The FE models will first be validated through initial experiments and then be used to make informed choices regarding process parameters such as building temperature, part orientation and scanning strategy.

这个项目更广泛的影响/商业潜力在于开发一种新的非晶金属合金，可以使整个社会受益。理论计算表明，铁基非晶和纳米复合合金可以使零件重量减轻90%。通过减少汽车和航空航天部件的重量，可以实现显著的燃料节约。节省燃料不仅可以降低成本，还可以减少温室气体排放。非晶铁磁合金的另一个应用领域是电机、变压器和滤波器的电磁铁芯。铁磁非晶合金可将这些应用中的能量损失减少高达80%，这相当于全球化石燃料发电厂每年排放5000万吨二氧化碳，或美国每年核电产量的1/10。非晶金属也可能对医疗保健产生重大影响。非晶金属可以解决极其昂贵的金属问题，目前经历的医疗植入物行业由于召回和诉讼。这个小型企业技术转移研究（STTR）第一阶段项目旨在证明铁基非晶金属部件的金属基增材制造（AM）的可行性。将开发具有优越机械和/或磁性质的合金的增材制造工艺，并增加对材料机制的科学理解。虽然初步的研究显示了制造具有非晶体特性的更大部件的有希望的结果，但仍有一些问题需要解决。为了解决这些挑战，重要的是通过使用电子束熔化和直接金属激光烧结技术进行大量的实验工作，建立合适的工艺参数，以形成致密、无裂纹的材料。为了支持实验工作，将开发现象学有限元（FE）模型。有限元模型将首先通过初始实验进行验证，然后用于对工艺参数（如建筑温度、零件方向和扫描策略）做出明智的选择。

项目成果

Additive manufacturing of an iron-based bulk metallic glass larger than the critical casting thickness

• DOI: 10.1016/j.apmt.2018.02.011
• 发表时间: 2018-06-01
• 期刊: APPLIED MATERIALS TODAY
• 影响因子: 8.3
• 作者: Mahbooba, Zaynab;Thorsson, Lena;Harrysson, Ola
• 通讯作者: Harrysson, Ola

Fabrication of Fe‐based Bulk Metallic Glass via Direct Metal Laser Sintering

通过直接金属激光烧结制备铁基大块金属玻璃

• 发表时间: 2016
• 期刊: Solid Freeform Fabrication Symposium proceedings
• 作者: Mahbooba, Zaynab;Harrysson, Ola;Horn, Timothy;West, Harvey;Thorsson, Lena;Unosson, Mattias
• 通讯作者: Unosson, Mattias