GOALI: Characterization of Material Transfer in Friction Stir Processing With a Consumable Tool

GOALI：使用消耗工具表征摩擦搅拌加工中的材料转移

• 批准号: 1763147
• 负责人: Scott Miller
• 金额: $ 42.89万
• 依托单位: University of Hawaii
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2018
• 资助国家: 美国
• 起止时间: 2018-07-15 至 2022-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1763147&HistoricalAwards=false
• 关键词: GOALI; Characterization; Material; Transfer; Friction

This Grant Opportunity for Academic Liaison with Industry (GOALI) project will address the fundamental issue of material transfer from one metal to another at high force and temperature, called friction surfacing. This is based on friction stir welding technology in which a rotating tool is forced into a material to simultaneously deform, heat, and mix material. There is an increasing need for dissimilar material surfacing and coating applications. The major advantage of this technique is material adheres by mechanical bonding at relatively low temperature, resulting in high bonding strength, high tolerance to contamination, low environmental impact, and at low cost. The technical challenge centers on the nature of material transfer, adhesion and deposited material properties. This is collaborative research between the University of Hawaii at Manoa and General Motors. Two target applications have been identified for this research 1) Automotive - Conventional coating processes have not proven particularly suitable for steel and lightweight materials and have had limited success. What is therefore needed is an efficient and easily-operated technique to modify the surface composition of metal parts to make them more corrosion resistant. 2) Naval - the seals in ships are susceptible to corrosion and the current electroplating protection method is not adequate for coating nickel alloys onto the corroded, unclean steel hull. These industries are central to American national security and economic welfare. This research will also impact remanufacturing applications as an alternative method of coating/cladding by mechanical transfer of material. The PIs will work with native Hawaiian students on this research through the Native Hawaiian Science & Engineering Mentorship Program at the University of Hawaii at Manoa.The goal of this project is to characterize material transfer in friction surfacing with a consumable tool. The research will generate knowledge about parameters and conditions for transfer of material from one surface to another, which is important for all friction stir processes. The properties of tool and substrate for which material is being transferred will be characterized. The nature of adhesion between transferred material and substrate will be studied through a series of fundamental experimental measurements, metallurgy, and modeling to establish the relationship among the process parameters, process conditions, material transfer, and adhesion to the work material. The plan is to 1) experimentally measure the effects of process parameters and conditions on amount and quality of transferred material from the consumable tool to the rigid surface 2) establish metallurgy of the transferred material and adhesion 3) model the process for knowledge about distribution of stress, strain, and temperature throughout the material and 4) quantify the comparative performance and properties of the new coatings. This is a new direction for friction stir processing. General Motors is contributing much expertise and guidance to this project, which will enhance its technical relevance.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

与工业联络（Goali）项目的学术联络机会的赠款机会将解决从一种金属转移到另一种金属的基本问题，称为摩擦浮出水面。 这是基于摩擦搅拌焊接技术的基础，其中旋转工具被迫与材料同时变形，热和混合材料。 越来越多的材料表面和涂料应用的需求。 该技术的主要优点是材料在相对较低的温度下通过机械粘合而粘附，从而导致高粘结强度，对污染的高耐受性，低环境影响和低成本。 技术挑战集中在材料转移，粘附和沉积材料特性的性质上。 这是夏威夷大学马诺阿大学与通用汽车之间的合作研究。 这项研究已经确定了两个目标应用1）汽车 - 常规涂料过程尚未证明特别适合钢和轻质材料，并且成功的成功有限。因此，需要的是一种有效且易于操作的技术，可以修饰金属零件的表面组成，以使其更具耐腐蚀性。 2）海军 - 船中的密封件易受腐蚀，当前的电镀保护方法不足以将镍合金涂在腐蚀的，不干净的钢船体上。这些行业是美国国家安全和经济福利的核心。这项研究还将影响再制造应用，作为通过材料机械传递的涂层/覆层的替代方法。 PIS将与夏威夷本土科学与工程指导计划在Manoa的夏威夷本土科学与工程指导计划一起工作。该项目的目的是用一种消耗的工具来表征摩擦表面中的材料转移。 该研究将产生有关将材料从一个表面转移到另一个表面转移的参数和条件的知识，这对于所有摩擦搅拌过程都很重要。将表征要转移材料的工具和基材的属性。将通过一系列基本的实验测量，冶金和建模来研究转移材料和底物之间的粘附性质，以在过程参数，过程条件，材料转移和与工作材料的粘附之间建立关系。计划是1）在实验上测量过程参数和条件对从易于工具到刚性表面转移的材料的数量和质量的影响2）建立转移的材料和粘附的冶金学3）模拟有关在整个材料中分布压力，应变和温度分布和4的过程，并量化新涂层的比较性能和特性。这是摩擦搅拌处理的新方向。 通用汽车为该项目贡献了很多专业知识和指导，这将增强其技术相关性。该奖项反映了NSF的法定任务，并被认为是值得通过基金会的知识分子优点和更广泛影响的评估标准通过评估来支持的。

项目成果

Friction Surfacing Deposition by Consumable Tools

• DOI: 10.1115/1.4050924
• 发表时间: 2021-04
• 期刊: Journal of Manufacturing Science and Engineering-transactions of The Asme
• 影响因子: 4
• 作者: Ebrahim Seidi;Scott N. Miller;B. Carlson

Friction Surfacing From Radial Surface of A6063 Aluminum Alloy Consumable Tool Onto A36 Carbon Steel

• DOI: 10.1115/imece2020-23502
• 发表时间: 2020-11
• 期刊: Volume 2A: Advanced Manufacturing
• 作者: Ebrahim Seidi;Scott F. Miller

A Novel Approach to Friction Surfacing: Experimental Analysis of Deposition from Radial Surface of a Consumable Tool

• DOI: 10.3390/coatings10111016
• 发表时间: 2020-11-01
• 期刊: COATINGS
• 影响因子: 3.4
• 作者: Seidi, Ebrahim;Miller, Scott F.
• 通讯作者: Miller, Scott F.

Feasibility of Multilayer Solid-State Deposition via Lateral Friction Surfacing for Metal Additive Manufacturing

• DOI: 10.1016/j.jmrt.2022.07.158
• 发表时间: 2022-08
• 期刊: Journal of Materials Research and Technology
• 作者: Ebrahim Seidi;Scott F. Miller

Lateral friction surfacing: experimental and metallurgical analysis of different aluminum alloy depositions

• DOI: 10.1016/j.jmrt.2021.11.049
• 发表时间: 2021-11-26
• 期刊: JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
• 影响因子: 6.4
• 作者: Seidi, Ebrahim;Miller, Scott F.
• 通讯作者: Miller, Scott F.