CAREER: Ultrasonically Assisted Wire Arc Additive Manufacturing of Metal Matrix Nanocomposites for High-strength, Lightweight Structures
职业:用于高强度、轻质结构的金属基纳米复合材料的超声波辅助电弧增材制造
基本信息
- 批准号:2044526
- 负责人:
- 金额:$ 50.19万
- 依托单位:
- 依托单位国家:美国
- 项目类别:Standard Grant
- 财政年份:2021
- 资助国家:美国
- 起止时间:2021-01-01 至 2025-12-31
- 项目状态:未结题
- 来源:
- 关键词:
项目摘要
This Faculty Early Career Development (CAREER) grant focuses on an innovative ultrasonically assisted wire arc additive manufacturing process for fabricating metal matrix nanocomposite structures in freeform and at large scale. Metal matrix nanocomposites are a promising class of lightweight materials with superior mechanical performance attributed to well-dispersed nanoparticles within the bulk. Wire arc additive manufacturing is based on arc welding principles in which a continuously fed metal wire is melted and deposited into a desired complex shape, layer-by-layer. The process enables the direct manufacture of metal matrix nanocomposite functional parts and is advantageous in distinctly high deposition rate and low cost compared with powder-based additive manufacturing processes. This project would facilitate wide applications of metal matrix nanocomposites for lightweight structures, which improves energy efficiency, reduces fuel consumption and benefits various transportation industries, thus contributing to national economy and security. Multidisciplinary and real-world problem-based student training at different levels are well integrated into this project. Research results are transformed into multiple outreach initiatives that increase manufacturing career awareness in young generations and under-represented minorities. The virtual lab tools promote distance and continuing education. All of these contribute to development of globally competitive and diverse STEM workforce. The goal of this research is to investigate ultrasonically assisted wire arc additive manufacturing of metal matrix nanocomposites. While lightweight, high strength components are possible in these materials, achieving superior mechanical properties is challenging due to agglomeration of nanoparticles in the repeated melting cycles, solidification defects, porosity and inferior as-cast microstructure. To improve wire arc additive manufacturing, this research utilizes superimposed ultrasonic vibration to disperse the nanoparticles, refine the microstructure and minimize the defects. Specific objectives are to (1) understand the interaction of acoustic and electromagnetic fields and nanoparticle dispersions on melt pool hydrodynamics, (2) reveal coupling principles of acoustic field and nanoparticles on microstructure evolution in the repeated melting and solidification cycles, and (3) integrate data-driven and physics-based approaches for high fidelity modeling and analysis. The ultrasonically assisted wire arc additive manufacturing system is equipped with multiple sensors for online thermal-mechanical-acoustic analysis for process monitoring and control. Parts built with this hybrid process under different conditions are subject to comprehensive evaluation and multi-scale microstructure characterization. To establish relationships between process parameters, deposition profile, microstructure and mechanical properties, emerging data science tools are utilized, which are regularized by physics-based molten pool, solidification and phase transformation models. This modeling framework enables computational and data efficient tools for analyzing complex nonlinear physics involved in various manufacturing processes.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.
该学院早期职业发展(Career)基金专注于一种创新的超声辅助电弧增材制造工艺,用于自由形状和大规模制造金属基纳米复合材料结构。金属基纳米复合材料是一种很有前途的轻量化材料,由于纳米颗粒在体内分散良好,具有优越的机械性能。焊丝电弧增材制造是基于弧焊原理,其中连续馈电金属丝熔化并逐层沉积成所需的复杂形状。该工艺可以直接制造金属基纳米复合材料功能部件,与粉末增材制造工艺相比,具有明显的高沉积速率和低成本的优势。该项目将促进金属基纳米复合材料在轻量化结构中的广泛应用,提高能源效率,降低燃料消耗,使各种运输行业受益,从而为国家经济和安全做出贡献。不同层次的多学科和现实问题为基础的学生培训很好地融入了这个项目。研究成果转化为多种推广举措,提高年轻一代和代表性不足的少数民族的制造业职业意识。虚拟实验室工具促进了远程教育和继续教育。所有这些都有助于培养具有全球竞争力和多样化的STEM劳动力。本研究的目的是研究超声辅助电弧增材制造金属基纳米复合材料。虽然轻质、高强度的部件在这些材料中是可能的,但由于纳米颗粒在重复熔化循环中聚集、凝固缺陷、孔隙和铸造时的不良微观结构,实现优异的机械性能是具有挑战性的。为了改进丝弧增材制造,本研究利用叠加超声振动来分散纳米粒子,细化微观结构,最大限度地减少缺陷。具体目标是:(1)了解声场和电磁场以及纳米颗粒分散对熔池流体动力学的相互作用;(2)揭示声场和纳米颗粒在重复熔化和凝固循环中对微观结构演变的耦合原理;(3)整合数据驱动和基于物理的方法进行高保真建模和分析。超声辅助电弧增材制造系统配备了多个传感器,用于在线热-机械-声学分析,以实现过程监控。在不同条件下用这种混合工艺制造的零件需要进行综合评价和多尺度的微观结构表征。为了建立工艺参数、沉积剖面、显微组织和力学性能之间的关系,利用了新兴的数据科学工具,这些工具通过基于物理的熔池、凝固和相变模型进行了规范化。该建模框架使计算和数据有效的工具,分析复杂的非线性物理涉及各种制造过程。该奖项反映了美国国家科学基金会的法定使命,并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
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)
Experimental Analysis of Metal Inert Gas Based Wire Arc Additive Manufacturing of Aluminum Nanocomposite AA7075
金属惰性气体基电弧增材制造铝纳米复合材料AA7075的实验分析
- DOI:10.1115/msec2022-85413
- 发表时间:2022
- 期刊:
- 影响因子:0
- 作者:Darnell, Mason;Harwig, Dennis;Liu, Xun
- 通讯作者:Liu, Xun
Ultrasonic effects with different vibration positions on gas tungsten arc wire additive manufactured aluminum nanocomposite
不同振动位置超声对气体钨极电弧丝增材制造纳米铝复合材料的影响
- DOI:10.1016/j.jmapro.2023.09.043
- 发表时间:2023
- 期刊:
- 影响因子:6.2
- 作者:Wang, Tianzhao;Liu, Xun;Darnell, Mason
- 通讯作者:Darnell, Mason
Ultrasonic effects on gas tungsten arc based wire additive manufacturing of aluminum matrix nanocomposite
- DOI:10.1016/j.matdes.2022.110393
- 发表时间:2022-01
- 期刊:
- 影响因子:8.4
- 作者:T. Wang;V. Mazánová;Xun Liu
- 通讯作者:T. Wang;V. Mazánová;Xun Liu
Ultrasonically assisted hot-wire arc additive manufacturing process of AA7075 metal matrix nanocomposite
超声辅助热丝电弧增材制造AA7075金属基纳米复合材料
- DOI:10.1016/j.jallcom.2022.168298
- 发表时间:2023
- 期刊:
- 影响因子:6.2
- 作者:Wang, Tianzhao;Kang, Jiarui;Darnell, Mason;Liu, Xun
- 通讯作者:Liu, Xun
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Xun Liu其他文献
The transcription factor StTINY3 enhances cold-induced sweetening resistance by coordinating starch resynthesis and sucrose hydrolysis in potato
转录因子StTINY3通过协调马铃薯淀粉再合成和蔗糖水解增强冷诱导的甜味抗性
- DOI:
10.1093/jxb/erac171 - 发表时间:
2022 - 期刊:
- 影响因子:0
- 作者:
Weiling Shi;Qiuqin Ma;Wang Yin;Tiantian Liu;Yuhao Song;Yuanya Chen;Linjin Song;Hui Sun;Shuting Hu;Tengfei Liu;Rui Jiang;Dianqiu Lv;Botao Song;Jichun Wang;Xun Liu - 通讯作者:
Xun Liu
How Different Frames of Reference Interact: A Neural Network Model
不同的参考系如何相互作用:神经网络模型
- DOI:
- 发表时间:
2016 - 期刊:
- 影响因子:0
- 作者:
Weizhi Nan;Yanlong Sun;Xun Liu;Hongbin Wang - 通讯作者:
Hongbin Wang
Evaluating the Critical Barriers to Green Construction Technologies Adoption in China
评估中国采用绿色建筑技术的关键障碍
- DOI:
10.3390/su13126510 - 发表时间:
2021-06 - 期刊:
- 影响因子:3.9
- 作者:
Yujing Wang;Dan Chong;Xun Liu - 通讯作者:
Xun Liu
RESEARCH ON RISK MEASUREMENT OF SUPPLY CHAIN FINANCE BASED ON FRACTAL THEORY
基于分形理论的供应链金融风险度量研究
- DOI:
10.1142/s0218348x20400137 - 发表时间:
2020 - 期刊:
- 影响因子:0
- 作者:
Xun Liu;Xia Peng;Martin Stuart - 通讯作者:
Martin Stuart
Academic Adaptation among International Students from East Asian Countries: A Consensual Qualitative Research.
东亚国家国际学生的学术适应:一项一致的定性研究。
- DOI:
10.32674/jis.v8i1.160 - 发表时间:
2018 - 期刊:
- 影响因子:2
- 作者:
Jiaqi Li;Yanlin Wang;Xun Liu;Yusu Xu;Tingting Cui - 通讯作者:
Tingting Cui
Xun Liu的其他文献
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{{ truncateString('Xun Liu', 18)}}的其他基金
GOALI/Collaborative Research: Improving Incremental Sheet Forming by Ultrasonically Enhanced Material Deformation
GOALI/合作研究:通过超声波增强材料变形改进增量板材成型
- 批准号:
2019238 - 财政年份:2020
- 资助金额:
$ 50.19万 - 项目类别:
Standard Grant
An Innovative Hybrid Ultrasonic Resistance Welding Process for Joining Advanced Lightweight and Dissimilar Materials
用于连接先进轻质和异种材料的创新混合超声波电阻焊接工艺
- 批准号:
1853632 - 财政年份:2019
- 资助金额:
$ 50.19万 - 项目类别:
Standard Grant
EAGER/Collaborative Research: Fundamentals of Acousto-Plasticity and Tribology in Ultrasonically Enhanced Incremental Sheet Forming
EAGER/协作研究:超声增强增量板材成形中的声塑性和摩擦学基础
- 批准号:
1841589 - 财政年份:2018
- 资助金额:
$ 50.19万 - 项目类别:
Standard Grant
Collaborative Research: IHCS-Cybersystems: Integration of Protocol and Hardware Design for Securing Internet Communications
合作研究:IHCS-Cybersystems:用于保护互联网通信的协议和硬件设计的集成
- 批准号:
1104354 - 财政年份:2011
- 资助金额:
$ 50.19万 - 项目类别:
Standard Grant
Collaborative Research: IHCS-Cybersystems: Integration of Protocol and Hardware Design for Securing Internet Communications
合作研究:IHCS-Cybersystems:用于保护互联网通信的协议和硬件设计的集成
- 批准号:
0901530 - 财政年份:2009
- 资助金额:
$ 50.19万 - 项目类别:
Standard Grant
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