I-Corps: Hybrid additive manufacturing that provides computational solutions to fabricate geometrically complex components

I-Corps：混合增材制造，提供计算解决方案来制造几何复杂的组件

• 批准号: 2319679
• 负责人: Michael Sealy
• 金额: $ 5万
• 依托单位: Purdue University
• 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: 2022-10-01 至 2024-05-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2319679&HistoricalAwards=false
• 关键词: Corps; Hybrid; additive; manufacturing; provides

The broader impact/commercial potential of this I-Corps project is the development of a software platform that provides hybrid manufacturing solutions for designing light-weight mechanical systems with predictable short- and long-term failure rates. Providing a targeted hybrid manufacturing solution may extend service life and reduce operational costs by improving strength and production quality. As a result, additive manufacturing becomes accessible to aerospace and biomedical applications that have strict functional design and reliability requirements or geometrically complex structures. Geometric complexity and lattice structures are becoming a staple in modern design. Current tools such as topology optimization are incapable of maximizing strength-to-weight ratios. This software platform provides a hybrid manufacturing solution that optimizes weight while it proactively increases strength through interlayer cold working. In aerospace components, this lowers the buy-to-fly ratio by saving weight, which lowers fuel cost. In addition, this software platform addresses maintenance and reliability issues of legacy aircraft and tool-and-die components by significantly reducing lead times for replacement parts with enhanced aftermarket performance. The technology may provide industry with software solutions to best manufacture components requiring weight savings or known times to failure. This I-Corps project is based on the development of a hybrid additive manufacturing technology that combines three-dimensional printing with secondary material strengthening processes, such as laser peening, to improve functional performance. Laser peening is a surface treatment that induces favorable compressive residual stress in components to increase hardness and strength throughout large build volumes. The technical barrier addressed by this technology is understanding when, where, and how much laser peening is needed throughout the build volume. The proposed technology provides computational solutions for hybrid additive manufacturing that identify optimal locations for interlayer peening needed to achieve the highest possible strength-to-weight ratios without compromising functionality or performance. The model is able to simulate distortion and strength from cumulative residual stress fields induced by interlayer peening. This technology has been shown to increase toughness of stainless steel by 50% and increase corrosion resistance of a biomedical-grade magnesium alloy by 70% compared to traditional additive manufacturing.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.

I-Corps项目更广泛的影响/商业潜力是开发一个软件平台，为设计具有可预测的短期和长期故障率的轻型机械系统提供混合制造解决方案。提供有针对性的混合制造解决方案可以通过提高强度和生产质量来延长使用寿命并降低运营成本。因此，增材制造可以应用于具有严格功能设计和可靠性要求或几何结构复杂的航空航天和生物医学应用。几何复杂性和晶格结构正在成为现代设计的主要内容。目前的工具，如拓扑优化，无法最大化强度重量比。该软件平台提供了一种混合制造解决方案，可以优化重量，同时通过层间冷加工主动增加强度。在航空部件中，这通过减轻重量来降低购买飞行比，从而降低燃料成本。此外，该软件平台通过显著缩短更换零件的交货时间，提高售后市场性能，解决了传统飞机和模具部件的维护和可靠性问题。该技术可以为工业提供软件解决方案，以最好地制造需要减轻重量或已知故障时间的组件。I-Corps项目基于混合增材制造技术的开发，该技术将三维打印与二次材料强化工艺（如激光喷丸）相结合，以提高功能性能。激光强化是一种表面处理，在部件中诱导有利的压残余应力，以提高整个大构建体积的硬度和强度。该技术解决的技术障碍是了解在整个构建体积中何时，何地以及需要多少激光强化。所提出的技术为混合增材制造提供了计算解决方案，可以确定层间强化的最佳位置，从而在不影响功能或性能的情况下实现最高的强度重量比。该模型能够模拟层间强化引起的累积残余应力场的变形和强度。与传统的增材制造相比，该技术已被证明可以将不锈钢的韧性提高50%，将生物医学级镁合金的耐腐蚀性提高70%。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。