Characterizing the Dynamics of the Laser Metal Deposition Additive Manufacturing Process

表征激光金属沉积增材制造工艺的动态

• 批准号: 2011354
• 负责人: Lianyi Chen
• 金额: $ 31.88万
• 依托单位: University of Wisconsin-Madison
• 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 2023-05-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2011354&HistoricalAwards=false
• 关键词: Characterizing; Dynamics; Laser; Metal; Deposition

Laser metal deposition (LMD), also called blown-powder direct laser deposition, is an important additive manufacturing technique for producing customized and functionally-graded parts for a variety of applications in the aerospace, automobile, biomedical and defense industries. Even though investment in current research in, and development of, LMD technology is growing quickly, significant challenges remain in production of metal parts with repeatable and predictable properties. This research project will explore in detail the processes of LMD; identify the sources of defect formation and part quality uncertainties; and lay the groundwork for creating repeatable and predictable properties in LMD manufacturing. The research project includes rich educational and outreach components, which will provide undergraduate and graduate students with exposure to additive manufacturing. An e-Learning module will be developed to disseminate the data and knowledge obtained by this project. The knowledge allow modelers to improve and validate models and simulation tools. This research will therefore advance competitiveness of U.S. industry, supporting domestic economic growth and national defense.The overall objective of this research is to characterize the dynamics of the LMD process beneath the surface of the melt pool at a high spatial and temporal resolution to understand the fundamental mechanisms of the LMD process. The specific objectives of this research project are to characterize: (1) the dynamics of melt pool formation and evolution, and melt flow within the melt pool; (2) the dynamics of pore formation and evolution; (3) the material mixing behavior during blowing powders with different compositions; and (4) the dynamics of the solidification process during LMD. The research approach uses in-situ high-speed high-energy and high-resolution synchrotron x-ray imaging and high-speed high-energy x-ray diffraction. This project will significantly advance the fundamental understanding of the LMD additive manufacturing process. The dynamics of melt pool, pore, material mixing, and solidification during the LMD process will be revealed. The fundamental mechanisms of melting, mixing, defects formation, and microstructure evolution during LMD process will be unraveled.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.

激光金属沉积(LMD)，又称吹塑粉末直接激光沉积，是一种重要的添加剂制造技术，用于生产航空航天、汽车、生物医学和国防工业中各种应用的定制和功能梯度零件。尽管目前对LMD技术的研究和开发的投资正在快速增长，但在生产具有可重复和可预测性能的金属部件方面仍然存在重大挑战。这项研究项目将详细探索LMD的工艺；确定缺陷形成和零件质量不确定性的来源；并为在LMD制造中创造可重复和可预测的性能奠定基础。该研究项目包括丰富的教育和推广部分，将为本科生和研究生提供接触添加剂制造的机会。将开发一个电子学习单元，以传播该项目获得的数据和知识。这些知识使建模人员能够改进和验证模型和模拟工具。因此，这项研究将提高美国工业的竞争力，支持国内经济增长和国防。本研究的总体目标是以高时空分辨率表征熔池表面下LMD过程的动力学，以了解LMD过程的基本机制。本研究项目的具体目标是：(1)熔池形成和演化的动力学，以及熔池内的熔体流动；(2)气孔形成和演化的动力学；(3)不同成分粉末吹炼过程中的物料混合行为；(4)LMD过程中凝固过程的动力学。该研究方法采用现场高速高能高分辨率同步加速器X射线成像和高速高能X射线衍射。该项目将极大地促进对LMD添加剂制造工艺的基本了解。将揭示LMD过程中熔池、气孔、材料混合和凝固的动力学。LMD过程中熔化、混合、缺陷形成和微观结构演变的基本机制将被揭开。这一奖项反映了NSF的法定使命，并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

Bulk-Explosion-Induced Metal Spattering During Laser Processing

• DOI: 10.1103/physrevx.9.021052
• 发表时间: 2019-06
• 期刊: Physical Review X
• 影响因子: 12.5
• 作者: Cang Zhao;Qilin Guo;Xuxiao Li;N. Parab;K. Fezzaa;W. Tan;Lianyi Chen;T. Sun

In-situ full-field mapping of melt flow dynamics in laser metal additive manufacturing

• DOI: 10.1016/j.addma.2019.100939
• 发表时间: 2020-01-01
• 期刊: ADDITIVE MANUFACTURING
• 影响因子: 11
• 作者: Guo, Qilin;Zhao, Cang;Chen, Lianyi
• 通讯作者: Chen, Lianyi

Pore elimination mechanisms during 3D printing of metals

• DOI: 10.1038/s41467-019-10973-9
• 发表时间: 2019-07-12
• 期刊: NATURE COMMUNICATIONS
• 影响因子: 16.6
• 作者: Hojjatzadeh, S. Mohammad H.;Parab, Niranjan D.;Chen, Lianyi
• 通讯作者: Chen, Lianyi

Phase transformation dynamics guided alloy development for additive manufacturing

用于增材制造的相变动力学引导合金开发

• DOI: 10.1016/j.addma.2022.103068
• 发表时间: 2022
• 期刊: Additive Manufacturing
• 影响因子: 11
• 作者: Guo, Qilin;Qu, Minglei;Chuang, Chihpin Andrew;Xiong, Lianghua;Nabaa, Ali;Young, Zachary A.;Ren, Yang;Kenesei, Peter;Zhang, Fan;Chen, Lianyi
• 通讯作者: Chen, Lianyi

Revealing melt flow instabilities in laser powder bed fusion additive manufacturing of aluminum alloy via in-situ high-speed X-ray imaging

• DOI: 10.1016/j.ijmachtools.2022.103861
• 发表时间: 2022-02-28
• 期刊: INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
• 影响因子: 14
• 作者: Guo, Qilin;Qu, Minglei;Chen, Lianyi
• 通讯作者: Chen, Lianyi