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.

该 I-Corps 项目更广泛的影响/商业潜力是开发一种新的金属增材制造技术，该技术旨在通过单一工艺打印包含多种金属合金的零件。这些多金属零件被称为“金属混合体”，该系统可以设计和制造具有复杂几何形状以及在不同沉积位置使用不同金属的金属零件。这是当今任何单一制造工艺都无法实现的。金属混合部件可以设计得与现有的单一金属部件一样坚固，但重量更轻，同时提供卓越的耐热性、耐磨性和耐腐蚀性。这项技术的发展预计将颠覆广泛的高温应用和系统，通过减少技术足迹来提高增材制造工艺的效率，降低制造成本，减少对复杂装配和连接操作的需求，并减少零件数量。这适用于航空航天、汽车和能源行业。该 I-Corps 项目基于增材制造技术的开发，该技术允许在称为粉末床融合的增材制造系统中以薄层形式同时沉积和混合不同的金属粉末。然后使用激光束熔化沉积的多金属粉末层，并且该过程逐层继续，直到零件建成。此外，还开发了一种机器学习算法来确定合适的激光参数，以正确熔化具有不同成分的多金属粉末。 所提出的沉积技术和工艺参数预测模型不仅将向工业界引入新一代金属零件，还将扩展对增材制造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价值和更广泛的影响审查标准进行评估，被认为值得支持。