CAREER: The Science of Producing Metallic Parts with Location-Specific Properties Using Additive Manufacturing

职业：使用增材制造生产具有特定位置特性的金属零件的科学

• 批准号: 1846676
• 负责人: Alaa Elwany
• 金额: $ 50万
• 依托单位: Texas A&M Engineering Experiment Station
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2019
• 资助国家: 美国
• 起止时间: 2019-05-01 至 2024-12-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1846676&HistoricalAwards=false
• 关键词: CAREER; Science; Producing; Metallic; Parts

Metal additive manufacturing, where the part is built up layer by layer, can realize parts with great geometrical complexity and with locally varying microstructures. While prediction and control of local microstructures, enabling the control of local material properties, has the potential to realize complex functionalities within monolithic structures, it is not yet fully realized in metal additive processes. Achieving this capability is seen as an important step in realizing components, via a single manufacturing process, that can mimic advantageous bioinspired structures such as a mantis shrimp claw which combines a very hard outer surface with a tough core to give excellent fracture resistance. This Faculty Early Career Development (CAREER) Program award seeks to address this knowledge gap by understanding how additive manufacturing process parameters drive changes in pivotal microstructure characteristics, and hence the final properties, of printed nickel-titanium shape memory alloys. Being able to predict and control location-specific material properties will greatly extend current additive manufacturing capabilities giving further competitive advantage to US manufacturers involved in the production of high end components for aerospace and biomedical industries. This award will also provide opportunities for future manufacturing workforce development through activities such as; 1) internships for graduate students at Lawrence Livermore National Laboratory, 2) study abroad programs, 3) an outreach program for K-12 teachers, and 4) incorporation of a course on additive manufacturing into a larger certificate program aimed at the advanced manufacturing workforce in Texas. The research objective is to enable the fabrication of metallic structures with location-specific properties using laser powder bed fusion additive manufacturing processes. The focus of the research is on how the phase transformation temperature of nickel-titanium alloys varies with processing conditions. Preliminary work suggests that there are three significant factors affecting the transformation temperature; (1) the volume fraction of precipitates, (2) the dislocation density within the material, and (3) the nickel evaporation loss during processing. Experimental tests and subsequent characterization will deconvolve the effects of these factors. Most importantly the results will be considered with respect to the processing conditions and will provide insights on how process parameters such as hatch spacing and laser power influence can be selected to control the microstructure. Nickel-titanium is selected as a proxy for other materials in which microstructural and/or composition changes greatly affect material properties, due to its sensitivity to these changes. It is expected that the knowledge generated in this CAREER research will serve as foundational knowledge to realize location-specific property control in other material systems processed using metal additive manufacturing.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.

金属增材制造，其中零件逐层构建，可以实现具有很大几何复杂性和局部变化的微观结构的零件。虽然局部微观结构的预测和控制，使得能够控制局部材料性能，具有在整体结构内实现复杂功能的潜力，但在金属添加剂工艺中尚未完全实现。实现这种能力被视为通过单一制造工艺实现组件的重要一步，这些组件可以模仿有利的生物启发结构，例如螳螂虾爪，其结合了非常坚硬的外表面和坚韧的核心，以提供出色的抗断裂性。该学院早期职业发展（CAREER）计划奖旨在通过了解增材制造工艺参数如何驱动关键微观结构特征的变化来解决这一知识差距，从而改变印刷镍钛形状记忆合金的最终性能。能够预测和控制特定位置的材料特性将大大扩展当前的增材制造能力，为参与航空航天和生物医学行业高端组件生产的美国制造商提供进一步的竞争优势。该奖项还将通过以下活动为未来的制造业劳动力发展提供机会：1）劳伦斯利弗莫尔国家实验室的研究生实习，2）出国留学计划，3）K-12教师的推广计划，以及4）将增材制造课程纳入针对德克萨斯州先进制造业劳动力的更大证书计划。研究目标是使用激光粉末床熔融增材制造工艺制造具有特定位置特性的金属结构。研究的重点是镍钛合金的相变温度随加工条件的变化。初步工作表明，有三个重要因素影响转变温度：（1）沉淀物的体积分数，（2）材料内的位错密度，和（3）加工过程中的镍蒸发损失。实验测试和随后的表征将去卷积这些因素的影响。最重要的是，结果将被认为是相对于处理条件，并将提供如何选择工艺参数，如舱口间距和激光功率的影响，以控制微观结构的见解。镍钛合金被选为其他材料的替代品，其中微观结构和/或成分变化会极大地影响材料性能，因为它对这些变化很敏感。该奖项反映了NSF的法定使命，通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

项目成果

On the effect of scan strategies on the transformation behavior and mechanical properties of additively manufactured NiTi shape memory alloys

• DOI: 10.1016/j.jmapro.2022.09.051
• 发表时间: 2022-10-14
• 期刊: JOURNAL OF MANUFACTURING PROCESSES
• 影响因子: 6.2
• 作者: Zhang, Chen;Ozcan, Hande;Elwany, Alaa
• 通讯作者: Elwany, Alaa

A printability assessment framework for fabricating low variability nickel-niobium parts using laser powder bed fusion additive manufacturing

使用激光粉末床熔融增材制造制造低变异性镍铌零件的可印刷性评估框架

• DOI: 10.1108/rpj-01-2021-0024
• 发表时间: 2021
• 期刊: Rapid Prototyping Journal
• 影响因子: 3.9
• 作者: Zhang, Bing;Seede, Raiyan;Whitt, Austin;Shoukr, David;Huang, Xueqin;Karaman, Ibrahim;Arroyave, Raymundo;Elwany, Alaa
• 通讯作者: Elwany, Alaa

Laser Powder Bed Fusion of Defect-Free NiTi Shape Memory Alloy Parts with Superior Tensile Superelasticity

• DOI: 10.1016/j.actamat.2022.117781
• 发表时间: 2022-02
• 期刊: Acta Materialia
• 影响因子: 9.4
• 作者: L. Xue;K. Atli;C. Zhang;N. Hite;A. Srivastava;A. Leff;A. Wilson;D. Sharar;A. Elwany;R. Arróyave;I. Karaman

On the Fabrication of Defect-Free Nickel-Rich Nickel–Titanium Parts Using Laser Powder Bed Fusion

利用激光粉末床熔融制造无缺陷富镍镍钛零件

• DOI: 10.1115/1.4054935
• 发表时间: 2022
• 期刊: Journal of Manufacturing Science and Engineering
• 作者: Zhang, Chen;Xue, Lei;Atli, Kadri C.;Arróyave, Raymundo;Karaman, Ibrahim;Elwany, Alaa
• 通讯作者: Elwany, Alaa

A lightweight Fe–Mn–Al–C austenitic steel with ultra-high strength and ductility fabricated via laser powder bed fusion

• DOI: 10.1016/j.msea.2023.145007
• 发表时间: 2023-04
• 期刊: Materials Science and Engineering: A
• 作者: R. Seede;Austin Whitt;J. Ye;S. Gibbons;P. Flater;B. Gaskey;A. Elwany;R. Arróyave;I. Karaman