CAREER: Understanding Processing-Structure-Property Relationships in Co-Axial Wire-Feed, Powder-Feed Laser Directed Energy Deposition

职业：了解同轴送丝、送粉激光定向能量沉积中的加工-结构-性能关系

• 批准号: 2338951
• 负责人: Amrita Basak
• 金额: $ 59.87万
• 依托单位: Pennsylvania State Univ University Park
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2024
• 资助国家: 美国
• 起止时间: 2024-08-01 至 2029-07-31
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2338951&HistoricalAwards=false
• 关键词: CAREER; Understanding; Processing; Structure; Property

This Faculty Early Career Development (CAREER) grant supports fundamental research aimed at understanding the processing-structure-property relationships in metallic components consolidated through co-axial wire feed-powder feed laser directed energy deposition (DED). This technique offers the opportunity to construct and repair parts in layers using both powder and wire feedstocks. Wire feedstocks necessitate high laser energy for melting and may form unstable melt pools resulting in reduced processability. Conversely, powder particles, being smaller and possessing a higher surface area, are easier to melt and fuse with reduced instability. This research project integrates the advantages of both powder and wire deposition – powder's improved processability and wire's higher deposition rate – to establish a new manufacturing paradigm of co-axial wire feed-powder feed laser directed energy deposition. The resulting knowledge enables wider adoption of wire-based additive manufacturing, holding the potential to fabricate sound large-scale parts for power generation, propulsion, and space exploration at reduced cost and material waste. Thus, the research augments U.S. manufacturing, competitiveness, and economy. Furthermore, this research is complemented by educational and outreach initiatives that empower future engineers and scientists to achieve professional excellence while prioritizing personal well-being. The project provides comprehensive professional and leadership training, facilitates strategic networking opportunities, and assists individuals in making informed career choices.The specific goal of this research is to unveil the fundamental mechanisms governing the relationships between processing, microstructure, and properties in co-axial wire feed-powder feed laser directed energy deposition (DED) of metals. The fundamental differences in parts created by DED using wire or powder feedstocks under as-built conditions are laser-material interactions, melting and solidification phenomena, and the overall bulk behavior. Consequently, the research objectives of this project encompass: (i) comparing deposit formations in the co-axial wire feed-powder feed process with singular powder and wire feed processes; (ii) assessing the evolution of melt pools and quantifying crucial microstructural characteristics; and (iii) establishing correlations between tensile strengthening mechanisms and a spectrum of varying wire-to-powder feed ratios. By pursuing these research objectives, the project aims to address fundamental questions, including: (i) the impact of powder addition on the processability of wire DED such as reduction in Rayleigh-Plateau melt instabilities; (ii) the specific role played by powder particles in influencing the shape of melt pools and the development of solidification microstructures; and (iii) the variations in individual tensile strengthening mechanisms due to powder incorporation. The results obtained from these investigations provide critical insights into the mechanistic understanding of co-axial wire feed-powder feed laser DED.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.

这项教师的早期职业发展（职业）赠款支持基础研究，旨在了解通过同轴饲料饲料饲料饲料激光指示能量存款（DED）合并的金属组件中的加工结构 - 特质关系。这项技术提供了使用粉末和铁丝原料构建和修理零件的机会。线原料需要高激光能量进行熔化，并可能形成不稳定的熔体池，从而减少加工。相反，粉末颗粒较小并且具有较高的表面积，易于融化并与不稳定性减少融合。该研究项目集成了粉末和电线沉积的优势 - 粉末的改进加工和较高的沉积速率 - 建立了新的同轴线进料饲料饲料饲料激光有向能量沉积的制造范式。最终的知识可广泛采用基于电线的添加剂制造，以降低成本和材料浪费来制造声音大规模零件，以供发电，推进和太空探索。这项研究增强了美国的制造，竞争力和经济。此外，这项研究是由教育和推广计划完成的，这些计划使未来的工程师和科学家能够在优先考虑个人福祉的同时，取得卓越的职业卓越。该项目提供全面的专业和领导培训，促进战略网络机会，并协助个人做出知情的职业选择。这项研究的具体目标是揭示有关处理，微观结构和共同轴轴向饲料饲料饲料饲料饲料饲料饲料式有指导的能量（DED）金属的基本机制。使用线或粉末原料在原生成条件下使用电线或粉末原料创建的零件的基本差异是激光材料相互作用，熔化和固化现象以及整体体积行为。因此，该项目的研究目标包括：（i）将同轴饲料饲料进料过程中的沉积物形成与单数粉末和电线进料过程进行比较； （ii）评估熔体池的演变并量化关键的微观结构特征； （iii）通过追求这些研究目标来建立拉伸强化机制与A之间的相关性，该项目旨在解决基本问题，包括：（i）粉末添加对电线DED的处理的影响，例如降低Rayleigh-Plateau Melelt Insmelt Insmelt insibilitys降低了电线； （ii）粉末颗粒影响熔体池形状和凝固微结构的发展的特定作用； （iii）由于粉末收入而引起的单个拉伸加强机制的变化。从这些投资中获得的结果为对同轴饲料饲料饲料激光的机械理解提供了关键的见解。该奖项反映了NSF的法定任务，并通过使用基金会的知识分子和更广泛的影响评估标准来通过评估来评估。