SBIR Phase I: Repair, Weld, and Build Metallic Parts with Fill Impact Welding
SBIR 第一阶段:使用填充冲击焊修复、焊接和构建金属零件
基本信息
- 批准号:2322343
- 负责人:
- 金额:$ 27.5万
- 依托单位:
- 依托单位国家:美国
- 项目类别:Standard Grant
- 财政年份:2023
- 资助国家:美国
- 起止时间:2023-09-01 至 2024-08-31
- 项目状态:已结题
- 来源:
- 关键词:
项目摘要
The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase I project seeks to develop a welding technology that will improve the repair, joining, and additive manufacturing of metallic parts and features. First applications include material additions to repair gouges and mis-drilled holes during aircraft production and service, both of which represent significant financial opportunities. Repairs to the structural material are not currently permissible in a production environment due to adverse effects of currently available repair methods on base material properties, usually due to extreme temperatures. Aerostructure manufacturers have a strong incentive to minimize the weight of the aircraft structure, often at the significant financial and environmental expense of scrapping a whole panel. Maintenance, repair and overhaul often entails total replacement of damaged components with new ones as improper repairs of critical components can cause catastrophic harm. Replacement of parts is expensive and has long lead times due to high-value, low-volume nature of the aerospace industry. This project will develop an effective restoration method to repair of metallic components, while being agnostic to the material and part geometry. Reclamation of previously unrepairable parts made from materials such as titanium, nickel, and aluminum has a large positive environmental impact. Additionally, by broadly enabling solid-state joining, this technology will disrupt the welding industry, globally valued at $20 billion. The foundational technology platform, led in the US, will produce new jobs in science, technology and engineering fields while bolstering domestic manufacturing supply chains.The innovation underpinning this project involves the sequential, tactical, and controlled deposition of metals using explosive welding. Explosive welding uses coin-sized metallic elements launched to speeds in the range of 300-1000m/s without explosives. While it is known that explosive welding can weld large plates together, the method is not suited to automation or conventional industrial settings. Impact welding will be developed as a fill-welding technique, much like a filler metal in conventional welding, and will use wrought sheet metal as feedstock. Here, electrically vaporized metallic foils will be used as the driver for the fill elements and the research will focus on whether those elements can be launched reproducibly to develop large bond areas and reproducible positioning. The ability to control element shape and orientation during flight and produce an interface that is fully welded are the most high-risk aspects of the technology. Mechanical testing, scanning electron microscopy, and inline process monitoring such as photonic Doppler velocimetry will be performed. This effort will develop a new process-structure-property loop, with the goal of producing parts that are better than those made with a competing technology such as cold spray as measured by total energy consumption, cost, and mechanical properties.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.
该小型企业创新研究(SBIR)第一阶段项目的更广泛/商业影响旨在开发一种焊接技术,以改善金属零件和特征的修复,连接和增材制造。第一个应用包括在飞机生产和服务期间添加材料以修复凿槽和误钻孔,这两者都代表着重要的财务机会。由于当前可用的修复方法通常由于极端温度而对基础材料性能产生不利影响,因此目前在生产环境中不允许对结构材料进行修复。飞机结构制造商有强烈的动机来最小化飞机结构的重量,通常以报废整个面板的显著的财务和环境代价为代价。维护、修理和大修通常需要用新部件完全更换损坏的部件,因为关键部件的不当修理可能造成灾难性的损害。由于航空航天工业的高价值、小批量的性质,更换零件是昂贵的,并且具有较长的交货时间。该项目将开发一种有效的修复方法来修复金属部件,同时对材料和部件几何形状不可知。回收以前无法修复的钛、镍和铝等材料制成的零件对环境有很大的积极影响。 此外,通过广泛实现固态连接,这项技术将颠覆全球价值200亿美元的焊接行业。由美国牵头的基础技术平台将在科学、技术和工程领域创造新的就业机会,同时支持国内制造业供应链。该项目的创新基础包括使用爆炸焊接进行连续、战术和受控的金属沉积。 爆炸焊接使用硬币大小的金属元件,以300- 1000米/秒的速度发射,而不使用炸药。虽然已知爆炸焊接可以将大的板焊接在一起,但是该方法不适合于自动化或传统的工业设置。冲击焊将发展为一种填充焊技术,很像传统焊接中的填充金属,并将使用锻造金属板作为原料。在这里,电蒸发金属箔将被用作填充元件的驱动器,研究将集中在这些元件是否可以重复发射,以开发大的键合区域和可重复的定位。在飞行过程中控制元件形状和方向以及产生完全焊接的界面的能力是该技术的最高风险方面。将进行机械测试、扫描电子显微镜和在线过程监测,如光子多普勒测速仪。这一努力将开发一种新的工艺-结构-性能循环,其目标是生产出比采用冷喷涂等竞争技术生产的零件更好的零件,如总能耗、成本和机械性能。该奖项反映了NSF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(0)
专著数量(0)
科研奖励数量(0)
会议论文数量(0)
专利数量(0)
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Anupam Vivek其他文献
Joining Aluminium Alloy 5A06 to Stainless Steel 321 by Vaporizing Foil Actuators Welding with an Interlayer
通过中间层焊接汽化箔致动器将铝合金 5A06 与不锈钢 321 连接起来
- DOI:
10.3390/met9010043 - 发表时间:
2019-01 - 期刊:
- 影响因子:2.9
- 作者:
Shan Su;Shujun Chen;Yu Mao;Jun Xiao;Anupam Vivek;Glenn Daehn - 通讯作者:
Glenn Daehn
气化冲击焊飞板碰撞速度测量及影响因素分析
- DOI:
- 发表时间:
2018 - 期刊:
- 影响因子:0
- 作者:
陈树君;苏珊;肖珺;毛羽;Anupam Vivek;Glenn Daehn - 通讯作者:
Glenn Daehn
Vaporizing Foil Actuator: A Versatile Tool for High Energy-rate Metal Working
- DOI:
10.1016/j.proeng.2014.10.297 - 发表时间:
2014-01-01 - 期刊:
- 影响因子:
- 作者:
Anupam Vivek;Glenn S. Daehn - 通讯作者:
Glenn S. Daehn
Anupam Vivek的其他文献
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