ERI: Making High-Temperature Alloyed Components by Combining Additive Manufacturing and Spark Plasma Sintering: Enabling Shape Complexity and Predicting Microstructures

ERI：结合增材制造和火花等离子烧结制造高温合金部件：实现形状复杂性并预测微观结构

• 批准号: 2138421
• 负责人: Elisa Torresani
• 金额: $ 19.76万
• 依托单位: San Diego State University Foundation
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2022
• 资助国家: 美国
• 起止时间: 2022-01-01 至 2024-12-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2138421&HistoricalAwards=false
• 关键词: ERI; Making; Temperature; Alloyed; Components

This award is funded in whole or in part under the American Rescue Plan Act of 2021 (Public Law 117-2).Spark plasma sintering is a well-known manufacturing technology, in which pressurizing and rapid heating are simultaneously applied to achieve particle-to-solid consolidation with a low level of defects even for high-temperature metals, such as tungsten alloys. Despite significant interest in this technology, it has been, however, limited to simple-shaped components (i.e., in cylindrical forms). On the other hand, though additive manufacturing has empowered the design freedom, ideal for making parts of sophisticated geometry, fabrications of high temperature alloys have not been reliably successful. In this project, a combination of additive manufacturing, such as binder jetting, and spark plasma sintering will be employed to overcome such limitations. The studied technology integration represents a novel and promising approach to produce complex-shaped components, made of high-temperature alloys, in an efficient and cost-effective manner, and yet, ensure the quality in part dimensions as well as microstructures. Moreover, the project will explore new possibilities for the investigation into the fundamentals of the field-assisted sintering processes. In addition, the project will contribute to the education, outreach and retaining of undergraduate and graduate students from minorities and to engaging high school students with hands-on experiences with high-end technologies such as additive manufacturing and spark plasma sintering via the collaboration with industry partners involved, e.g., California Nanotechnologies.The overall goal of this project is to understand and develop the net-shaping capability of the spark plasma sintering technology to produce complex-shaped parts, such as helical bevel gears, made of material systems difficult to be fabricated using either traditional or additive manufacturing. The project will address this challenge through the “controllable interface” concept, which combines the additive manufacturing capability to produce complex shapes with the full consolidation potential of the spark plasma sintering. The controllable interface is represented by a three-dimensionally printed deformable volume of a sacrificial material introduced inside common spark plasma sintering tooling. To achieve the desired design of the controllable interface, comprehensive modeling of the spark plasma sintering process will be researched. The intricate nature of the starting porous assembly involved in this combined technology requires extending the current powder sintering modeling framework to better understand thermal and non-thermal nonequilibrium phenomena in spark plasma sintering to predict the final processing outcomes in terms of the microstructure and geometry of end products.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.

该奖项的全部或部分资金来自《2021年美国救援计划法案》(公共法律117-2)。放电等离子烧结是一种著名的制造技术，它同时应用加压和快速加热来实现颗粒到固体的凝固，即使对于高温金属，如钨合金，缺陷水平也很低。尽管人们对这项技术非常感兴趣，但它一直局限于简单形状的部件(即圆柱形部件)。另一方面，尽管添加剂制造赋予了设计自由，这是制造复杂几何形状部件的理想选择，但高温合金的制造并没有可靠地成功。在这个项目中，将采用粘结剂喷射和放电等离子烧结等添加剂制造相结合的方法来克服这些限制。所研究的技术集成代表了一种新的、有前途的方法，以高效和经济的方式生产由高温合金制成的复杂形状的部件，同时确保零件尺寸和微观结构的质量。此外，该项目还将探索研究现场辅助烧结过程基本原理的新可能性。此外，该项目将有助于教育、推广和留住来自少数族裔的本科生和研究生，并通过与相关行业合作伙伴(如加利福尼亚纳米技术公司)合作，让拥有高端技术实践经验的高中生参与进来，如添加剂制造和放电等离子烧结。该项目的总体目标是了解和发展火花等离子烧结技术的净成形能力，以生产复杂形状的零件，如螺旋锥齿轮，这些零件是用传统或添加剂制造难以制造的材料系统制成的。该项目将通过“可控界面”概念解决这一挑战，该概念将生产复杂形状的添加剂制造能力与放电等离子烧结的完全固结潜力相结合。可控界面由三维打印的可变形体积的牺牲材料表示，该牺牲材料引入普通的放电等离子烧结工具内。为了实现理想的可控界面设计，需要对放电等离子烧结过程进行全面的建模研究。这项组合技术涉及的启动多孔组件的复杂性质要求扩展当前的粉末烧结建模框架，以更好地了解放电等离子烧结中的热和非热非平衡现象，并根据最终产品的微观结构和几何形状来预测最终的加工结果。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。