Transient Thermo-Fluid Behavior in Metal Laser Powder-Bed Fusion Process: Exploring the Size Effect in Making Small Features
金属激光粉末床熔融工艺中的瞬态热流体行为:探索制造小特征时的尺寸效应
基本信息
- 批准号:1921263
- 负责人:
- 金额:$ 41.6万
- 依托单位:
- 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:2019-09-01 至 2024-08-31
- 项目状态:已结题
- 来源:
- 关键词:
项目摘要
Metal additive manufacturing in the laser powder-bed fusion group has greatly enabled novel designs with sophisticated part geometry of cellular arrangements or optimized topology for applications like lightweight high-strength structures, nature-inspired biomedical implants and high-efficiency heat exchangers, etc. Such integrated design and manufacturing innovations have the potential to realize products that improve the quality of life and maturing the technological capability of the U.S. industry. However, in making components with complex geometries, there are many small features (e.g., 0.5 mm or less) which do not share the same processing characteristics as larger sized bulk components. These unknown characteristics pose difficulty in ensuring part quality and impedes adopting the laser powder-bed fusion to produce parts with delicate features. This award addresses the above-mentioned challenges by advancing the process science in tackling small length scales, where the process characteristics become sensitive to the feature dimensions. The fundamental science that needs to be explored is the time-varying response of the temperatures and the molten flows in high-power laser scanning of metallic particles of stochastic distributions during short scanning. Further, outreach activities with the Women in Manufacturing, Kentucky Chapter will establish a platform that helps engage women to promote a diverse manufacturing workforce.The goal of this project is to understand the size effect in the metal laser powder-bed fusion process, in particular, to elucidate the coupled dynamic thermal and fluid fields during the start and end of laser scanning. The research focuses on one-dimensional line scans, two-dimensional raster-area scans and three-dimensional individual strut fabrications for the process physics study, as well as lattice-included specimens for mechanical evaluations related to the small geometry and process conditions. A two-stage approach will be employed to numerically study the process: a discrete element method to simulate powder particle spreading and multi-physics modeling to simulate the thermo-fluid phenomena for single-track, single-layer as well as multi-layer single strut fabrications, with particular emphases in the melt-pool dynamic response and solidified morphology. The experimental study will employ a laser powder-bed fusion system using titanium alloyed powder to fabricate designed specimens, with melt pool measurements and microstructures analysis to validate the process model and quantify the size effect on process characteristics. The research, if successful, will unveil the basic comprehension of the thermal and fluid behavior during short-distance and small-area laser scanning. The knowledge obtained will be practical for effective additive manufacturing of complex geometry parts with improved and reliable quality.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.
激光粉末-床融合集团的金属添加剂制造极大地实现了具有复杂部件几何结构或优化拓扑的新颖设计,适用于轻型高强度结构、受自然启发的生物医学植入物和高效热交换器等应用。这种集成设计和制造创新具有实现提高美国工业生活质量和成熟技术能力的潜力。然而,在制造具有复杂几何形状的部件时,存在许多小特征(例如,0.5 mm或更小),它们不具有与较大尺寸的大块部件相同的加工特性。这些未知的特征给保证零件质量带来了困难,阻碍了采用激光粉床熔化技术生产具有精细特征的零件。该奖项通过在处理小长度尺度方面推进工艺科学来解决上述挑战,其中工艺特征对特征尺寸变得敏感。需要探索的基础科学是高功率激光扫描随机分布的金属颗粒在短扫描过程中温度和熔体流动的时变响应。此外,与肯塔基州制造业妇女分会的外联活动将建立一个平台,帮助妇女促进多样化的制造业劳动力。该项目的目标是了解金属激光粉末-床融合过程中的尺寸效应,特别是阐明激光扫描开始和结束时的动态热场和流动场。研究重点是用于工艺物理研究的一维线扫描、二维栅格区扫描和三维单个支柱制造,以及用于与小几何形状和工艺条件相关的力学评估的晶格包含试件。采用两步法对该过程进行数值研究:离散元方法模拟粉末颗粒扩散,多物理模型模拟单道、单层和多层单支柱结构的热流体现象,重点研究熔池动态响应和凝固形态。实验研究将使用钛合金粉末的激光粉床融合系统来制造设计的试件,通过熔池测量和显微组织分析来验证工艺模型并量化尺寸对工艺特性的影响。这项研究如果成功,将揭开人们对短距离小区域激光扫描过程中热和流体行为的基本理解。所获得的知识将对提高质量和可靠性的复杂几何零件的有效添加制造具有实用价值。该奖项反映了NSF的法定使命,并已通过使用基金会的智力优势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
期刊论文数量(4)
专著数量(0)
科研奖励数量(0)
会议论文数量(0)
专利数量(0)
Build surface study of single-layer raster scanning in selective laser melting: Surface roughness prediction using deep learning
选择性激光熔化中单层光栅扫描的构建表面研究:使用深度学习预测表面粗糙度
- DOI:10.1016/j.mfglet.2022.07.088
- 发表时间:2022
- 期刊:
- 影响因子:3.9
- 作者:Fotovvati, Behzad;Chou, Kevin
- 通讯作者:Chou, Kevin
Multi-layer thermo-fluid modeling of powder bed fusion (PBF) process
粉末床熔融 (PBF) 过程的多层热流体建模
- DOI:10.1016/j.jmapro.2022.09.003
- 发表时间:2022
- 期刊:
- 影响因子:6.2
- 作者:Fotovvati, Behzad;Chou, Kevin
- 通讯作者:Chou, Kevin
An Investigation Into Multi-Track Deposition in Laser Powder-Bed Fusion: Transient Regions Analysis and Scan Length Effects
激光粉末床融合中多轨沉积的研究:瞬态区域分析和扫描长度效应
- DOI:
- 发表时间:2022
- 期刊:
- 影响因子:0
- 作者:Rauniyar, S.;Shrestha, S.;Chou, K
- 通讯作者:Chou, K
Transient Melt Pool Formation in Laser-Powder Bed Fusion Process
激光粉末床熔融过程中瞬态熔池的形成
- DOI:
- 发表时间:2020
- 期刊:
- 影响因子:0
- 作者:Rauniyar, S.;Chou, K.
- 通讯作者:Chou, K.
{{
item.title }}
{{ item.translation_title }}
- DOI:
{{ item.doi }} - 发表时间:
{{ item.publish_year }} - 期刊:
- 影响因子:{{ item.factor }}
- 作者:
{{ item.authors }} - 通讯作者:
{{ item.author }}
数据更新时间:{{ journalArticles.updateTime }}
{{ item.title }}
- 作者:
{{ item.author }}
数据更新时间:{{ monograph.updateTime }}
{{ item.title }}
- 作者:
{{ item.author }}
数据更新时间:{{ sciAawards.updateTime }}
{{ item.title }}
- 作者:
{{ item.author }}
数据更新时间:{{ conferencePapers.updateTime }}
{{ item.title }}
- 作者:
{{ item.author }}
数据更新时间:{{ patent.updateTime }}
Kevin Chou其他文献
Surface roughness and image analyses of contour scanning offset effects on sloping topography in laser powder bed fusion
- DOI:
10.1007/s00170-025-15745-y - 发表时间:
2025-05-23 - 期刊:
- 影响因子:3.100
- 作者:
Nismath Valiyakath Vadakkan Habeeb;Kevin Chou - 通讯作者:
Kevin Chou
Oral administration of an immunomodulatory peptide attenuates colitis in mice and non-human primates
- DOI:
10.1016/s0016-5085(00)84464-9 - 发表时间:
2000-04-01 - 期刊:
- 影响因子:
- 作者:
Suhasini Iyer;Yaping Chen;Kevin Chou;Jeff Roberts;Richard Boismenu;Roland Buelow - 通讯作者:
Roland Buelow
On morphology and roughness of upskin surfaces in laser powder-bed fusion additive manufacturing – Contouring strategy effects
- DOI:
10.1016/j.mfglet.2024.09.114 - 发表时间:
2024-10-01 - 期刊:
- 影响因子:
- 作者:
V.H. Nismath;Beytullah Aydogan;David Jaggers;Kevin Chou - 通讯作者:
Kevin Chou
Kevin Chou的其他文献
{{
item.title }}
{{ item.translation_title }}
- DOI:
{{ item.doi }} - 发表时间:
{{ item.publish_year }} - 期刊:
- 影响因子:{{ item.factor }}
- 作者:
{{ item.authors }} - 通讯作者:
{{ item.author }}
{{ truncateString('Kevin Chou', 18)}}的其他基金
Intergovernmental Personnel Award
政府间人才奖
- 批准号:
2031008 - 财政年份:2020
- 资助金额:
$ 41.6万 - 项目类别:
Intergovernmental Personnel Award
Thermomechanical and Powder Sintering Aspects in Electron Beam Additive Manufacturing - Applications to Overhang Support Designs
电子束增材制造中的热机械和粉末烧结方面 - 在悬垂支撑设计中的应用
- 批准号:
1739435 - 财政年份:2017
- 资助金额:
$ 41.6万 - 项目类别:
Standard Grant
Thermomechanical and Powder Sintering Aspects in Electron Beam Additive Manufacturing - Applications to Overhang Support Designs
电子束增材制造中的热机械和粉末烧结方面 - 在悬垂支撑设计中的应用
- 批准号:
1335481 - 财政年份:2013
- 资助金额:
$ 41.6万 - 项目类别:
Standard Grant
Conference Support for Student Participation at the 2010 ASME International Manufacturing Science and Engineering Conference; Erie, Pennsylvania, October 12-15, 2010
为学生参加 2010 年 ASME 国际制造科学与工程会议提供会议支持;
- 批准号:
1019150 - 财政年份:2010
- 资助金额:
$ 41.6万 - 项目类别:
Standard Grant
GOALI/Collaborative Research: Interface Engineered Diamond Coatings for Dry Machining
GOALI/合作研究:用于干式加工的界面工程金刚石涂层
- 批准号:
0928627 - 财政年份:2009
- 资助金额:
$ 41.6万 - 项目类别:
Continuing Grant
Nano-Diamond Coated Cutting Tools: Modeling Tool Geometry Effects
纳米金刚石涂层切削刀具:建模刀具几何效应
- 批准号:
0728228 - 财政年份:2007
- 资助金额:
$ 41.6万 - 项目类别:
Standard Grant
相似国自然基金
Thermo-TDR技术监测根区土壤物理性状:根系的影响机理及校正
- 批准号:41977011
- 批准年份:2019
- 资助金额:62.0 万元
- 项目类别:面上项目
风寒湿介导Thermo-TRPs/HSPs串话调控膝骨关节炎及温通中药的干预机制研究
- 批准号:81973874
- 批准年份:2019
- 资助金额:55.0 万元
- 项目类别:面上项目
相似海外基金
Development of mathematical model of thermo-fluid phenomena in microchannel with stochastic connections using determinism and probability theory
使用确定论和概率论开发具有随机连接的微通道中热流体现象的数学模型
- 批准号:
22K18769 - 财政年份:2022
- 资助金额:
$ 41.6万 - 项目类别:
Grant-in-Aid for Challenging Research (Exploratory)
hypergolic phenomena based on innovative thermo-fluid analysis considering detailed reaction mechanism in liquid phase
基于考虑液相详细反应机制的创新热流体分析的自热现象
- 批准号:
22H01725 - 财政年份:2022
- 资助金额:
$ 41.6万 - 项目类别:
Grant-in-Aid for Scientific Research (B)
Performance Enhancement of Thermo-electrochemical Conversion Integrated with Forced Convection Cooling Through Investigation of Working Fluid Property
通过研究工作流体性质增强热电化学转换与强制对流冷却相结合的性能
- 批准号:
21J14183 - 财政年份:2021
- 资助金额:
$ 41.6万 - 项目类别:
Grant-in-Aid for JSPS Fellows
Development and calibration of thermo-fluid flowmeters for use in multi-unit residential buildings
用于多单元住宅楼的热流体流量计的开发和校准
- 批准号:
543937-2019 - 财政年份:2020
- 资助金额:
$ 41.6万 - 项目类别:
Collaborative Research and Development Grants
Electromagnetic Thermo-Fluid Analysis of Arc Plasma, Metal and Slag Behaviors in Powder Flux
粉末熔剂中电弧等离子体、金属和熔渣行为的电磁热流体分析
- 批准号:
20K14650 - 财政年份:2020
- 资助金额:
$ 41.6万 - 项目类别:
Grant-in-Aid for Early-Career Scientists
Development and calibration of thermo-fluid flowmeters for use in multi-unit residential buildings
用于多单元住宅楼的热流体流量计的开发和校准
- 批准号:
543937-2019 - 财政年份:2019
- 资助金额:
$ 41.6万 - 项目类别:
Collaborative Research and Development Grants
Mechanism of two phase thermo-fluid behavior in porous media and its high accuracy numerical analysis based on multi-scale effect
多孔介质中两相热流体行为机理及其基于多尺度效应的高精度数值分析
- 批准号:
19KK0109 - 财政年份:2019
- 资助金额:
$ 41.6万 - 项目类别:
Fund for the Promotion of Joint International Research (Fostering Joint International Research (B))
Creation of Functional Thermo-Fluid Control Device Based on Understanding of Thermo-Hydraulic Phenomena under Space Environment
基于对空间环境下热工水力现象的理解,创建功能性热流体控制装置
- 批准号:
18H01630 - 财政年份:2018
- 资助金额:
$ 41.6万 - 项目类别:
Grant-in-Aid for Scientific Research (B)
Robust and Thermo-energetically Optimized Temperature Control of Machine Tools' Frames by Means of Fluid Power Systems (T02#)
通过流体动力系统对机床框架进行稳健且热能优化的温度控制 (T02
- 批准号:
324586244 - 财政年份:2017
- 资助金额:
$ 41.6万 - 项目类别:
CRC/Transregios (Transfer Project)
Thermo-fluid and solid modelling of a novel heat exchanger
新型热交换器的热流体和实体建模
- 批准号:
512254-2017 - 财政年份:2017
- 资助金额:
$ 41.6万 - 项目类别:
University Undergraduate Student Research Awards