I-Corps: Metal hybrid multi-metal parts made possible by additive manufacturing technology

I-Corps：通过增材制造技术实现金属混合多金属零件

• 批准号: 2053109
• 负责人: Frank Pfefferkorn
• 金额: $ 5万
• 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: 2021
• 资助国家: 美国
• 起止时间: 2021-01-01 至 2023-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2053109&HistoricalAwards=false
• 关键词: Corps; Metal; hybrid; multi; metal

The broader impact/commercial potential of this I-Corps project is the development of a new metal additive manufacturing technique that is designed to print parts in a single process containing multiple metal alloys. These multi-metal parts are called “metal hybrids,” and this system enables the design and manufacturing of metal parts with complex geometries and different metals used in various deposition locations. This is something that no single manufacturing process can achieve today. The metal hybrid parts may be designed to be just as strong but lighter in weight than existing single-metal parts while offering superior thermal, wear, and corrosion resistance. The development of this technology is expected to be disruptive to a wide range of high-temperature applications and systems, increase the efficiency of additive manufacturing processes by reducing technological footprints, reduce manufacturing costs, reduce the need for complex assemblies and joining operations, and reduce part count. This has applications for aerospace, automotive, and energy industries.This I-Corps project is based on the development of a additive manufacturing technique that allows for the simultaneous deposition and mixing of different metal powders, in thin layers, within a type of additive manufacturing system referred to as powder bed fusion. The deposited multi-metal powder layer is then melted using a laser beam and the process continues layer by layer until the part has been built. In addition, a machine learning algorithm has been developed to determine suitable laser parameters for correctly melting the multi-metal powders with varying composition. This proposed deposition technique and process parameter prediction model will not only introduce a new generation of metal parts to industry, but also will expand the fundamental understanding of the relationship between the manufacturing process parameters and material properties of additively manufactured multi-metal components.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.

这个i-Corps项目的更广泛的影响/商业潜力是开发一种新的金属添加剂制造技术，该技术旨在通过包含多种金属合金的单一工艺打印部件。这些多金属部件被称为“金属混合体”，该系统能够设计和制造具有复杂几何形状的金属部件，并在不同的沉积位置使用不同的金属。这是当今任何一种制造工艺都无法实现的。金属混合零件可以设计成与现有的单一金属零件一样坚固，但重量更轻，同时提供优异的耐热、耐磨和耐腐蚀性能。这项技术的开发预计将对广泛的高温应用和系统产生颠覆性影响，通过减少技术足迹提高添加剂制造工艺的效率，降低制造成本，减少复杂组装和连接操作的需要，并减少部件数量。该i-Corps项目基于一种添加剂制造技术的开发，该技术允许在一种称为粉床熔化的添加剂制造系统中以薄层同时沉积和混合不同的金属粉末。然后用激光熔化沉积的多金属粉末层，这个过程一层接一层地进行，直到零件成形。此外，还开发了一种机器学习算法来确定合适的激光参数，以正确地熔化不同成分的多金属粉末。这项拟议的沉积技术和工艺参数预测模型不仅将向工业中引入新一代金属部件，还将扩大对添加制造的多金属部件的制造工艺参数和材料性能之间关系的基本理解。该奖项反映了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。