Collaborative Research: Solid-State Additive Manufacturing of Metal Matrix Composites via Cold Spray

冷喷涂是一种很有前途的结构材料添加剂制造技术。它在固态下运行，克服了传统铸造和基于熔融的添加剂制造的许多限制。虽然在了解金属和合金的冷喷涂加工科学方面取得了进展，但通过冷喷涂制造金属基复合材料的知识仍然有限。本项目的目标是对冷喷涂金属基复合材料添加剂制造的工艺-组织-性能关系有一个基本的了解。从这个项目中获得的知识可以转化为航空航天、能源和国防工业，用于结构应用的金属基复合材料的可靠制造、维修和安全操作。该团队将专注于培养下一代学生，通过一系列有针对性的、高影响力的举措，为他们在添加剂制造领域脱颖而出做好准备。这些举措包括指导来自代表性不足群体的本科生研究人员，开发综合在线课程模块，以及通过具有用户友好的基于网络的门户的虚拟微观结构库向公众推广。该项目的目标是发展冷喷涂金属基复合材料的制造科学，并从机理上理解这些材料的变形和破坏。新型核壳粉末粒子和双增强粉末粒子将被设计并用于冷喷涂金属基复合材料。控制冷喷涂复合材料行为的潜在机制将通过现场实验进行研究：(I)侧重于加工的单个粉末颗粒，以及(Ii)侧重于机械性能的块状材料。利用激光诱导粒子碰撞试验(LIPIT)系统地探索单粒子碰撞，以了解不同双相系统中潜在的结合机制。从单粒子撞击实验中获得的信息将指导块状复合材料的沉积，并将使用时间分辨3DX射线计算机层析(XCT)和衍射对其进行全面表征。根据微观结构和孔隙密度，对具有最理想特性的样品进行进一步的现场测试，以阐明其力学行为和断裂机理。该项目有可能将冷喷涂的适用性显著扩展到更广泛的材料和应用，使研究人员和工程师能够定制具有特定属性和性能特征的材料。该奖项由土木、机械和制造创新部门的先进制造计划和材料研究部门的金属和金属纳米结构计划共同资助。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。

Cold spray is a promising technique for additive manufacturing of structural materials. It operates in the solid state and overcomes many limitations of traditional casting and fusion-based additive manufacturing. While progress has been made in understanding the processing science of cold spray for metals and alloys, the knowledge of manufacturing metal matrix composites via cold spray remains limited. The objective of this project is to develop a fundamental understanding of the process-microstructure-property relationships for additive manufacturing of metal matrix composites via cold spray. The knowledge gained from this program can be translated to aerospace, energy, and defense industries for reliable manufacturing, repair, and safe operation of metal matrix composites for structural applications. The team will focus on developing the upcoming generation of students, preparing them to excel in the area of additive manufacturing through a series of targeted, high-impact initiatives. These initiatives include mentoring undergraduate student researchers from underrepresented groups, developing integrated online course modules, and outreach to the general public via a virtual microstructure library with a user-friendly, web-based portal.The goal of the project is to develop manufacturing science for cold spraying metal matrix composites and to develop a mechanistic understanding of deformation and failure in these materials. Novel core-shell powder particles and double reinforced powder particles will be designed and used for cold spraying metal matrix composites. Underlying mechanisms that control the behavior of cold-sprayed composites will be studied with in situ experiments: (i) individual powder particles with a focus on processing, and (ii) bulk materials with a focus on mechanical performance. A systematic exploration of single-particle impacts using Laser-Induced Particle Impact Test (LIPIT) will be used to understand the underlying bonding mechanisms in the different bi-phase systems. The information obtained from the single-particle impact experiments will guide the deposition of bulk-scale composites, which will be fully characterized using time-resolved 3D x-ray computed tomography (XCT) and diffraction. The samples with the most desirable characteristics, based on microstructure and pore density, will be further tested in situ to elucidate the mechanical behavior and fracture mechanisms. This project has the potential to significantly expand the applicability of cold spray to a broader range of materials and applications, enabling researchers and engineers to tailor materials with specific attributes and performance characteristics.This award is co-funded by the Advanced Manufacturing Program of the Division of Civil, Mechanical and Manufacturing Innovation and the Metals and Metallic Nanostructures Program of the Division of Materials Research.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.