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3D in-situ based methodology for optimizing the mechanical performance of selective laser melted aluminium alloys

用于优化选择性激光熔化铝合金机械性能的 3D 原位方法

基本信息

批准号：
EP/R021694/1
负责人：
Mehmet Kartal
金额：
$ 12.85万
依托单位：
University of Aberdeen
依托单位国家：
英国
项目类别：
Research Grant
财政年份：
2018
资助国家：
英国
起止时间：
2018 至无数据
项目状态：
已结题

来源：
https://gtr.ukri.org/projects?ref=EP%2FR021694%2F1
关键词：
3D situ based methodology optimizing

项目摘要

Additive Manufacturing (AM), also known as 3D printing, is a common term used to describe the technology in which three-dimensional (3D) objects are fabricated by successive layers of material. The UK has been at the forefront of global innovation in AM and has also set up applications for commercialisation of this technology. While AM has been commonly employed for producing prototypes and tooling for decades, UK manufacturing industry has more recently been making revolution by using this technology for end-use products in various key sectors due to its economic and technical benefits in comparison with traditional manufacturing techniques. Once the current barrier to adoption of AM (i.e., quality, uncertainty of the final component and expertise) has been addressed, it is expected that this new emerging time-efficient AM technology has obvious capability to considerably boost UK economic production.Selective laser melting (SLM) is one of the most promising metal AM methods where 3D components are fabricated by using a high-energy laser beam to fuse the pre-deposited metal powder. The use of SLM has been progressively increasing in a number of UK industrial sectors (i.e., aerospace, automotive, medical, oil & gas, marine and defence etc.) owing to its capability to produce near-net shape complex components from a CAD model and hence offering robust design flexibility without the constraints of conventional manufacturing methods that require a series of manufacturing processes, more material consumption, higher cost and energy. For manufacturing industry that targets to fabricate their products rapidly and access to wider purchaser markets, SLM appears to be an ideal route for their businesses if the inter-related relationships between process parameters and their ultimate effect on the structural integrity and performance has been established.SLM is prevalently used to build in a range of metallic materials including stainless steel, titanium, nickel and aluminium alloys. Unlike the other alloys, manufacturing aluminium alloys by SLM involves more complexities due to being their high reflectivity and thermal conductivity which contribute to stimulate porosity in manufactured parts. Hence, there is presently a lack of understanding about the effect of SLM process parameters on microstructure and material performance in aluminium alloys. Determining such unknown relationships are an essentially important engineering mission that presently represents a major barrier to widespread usage of SLM processed aluminium alloys.The overall aim of this First Grant proposal is to develop a robust methodology to optimize the manufacture of aluminium alloy components using selective laser melting. In achieving this, the combined use of X-ray microcomputed tomography with an in-situ microtensile testing stage (allowing observations of the 3D in-situ deformation) will be employed to investigate the impact of process parameters on porosity, material properties and failure behaviour. In addition, an experimentally based porous plasticity finite element model will be developed to understand the effect of void size and shape on deformation behaviour.

增材制造（AM），也被称为3D打印，是一个常用术语，用于描述由连续的材料层制造三维（3D）物体的技术。英国一直处于全球增材制造创新的前沿，并已建立了该技术商业化的应用程序。虽然增材制造几十年来一直被广泛用于生产原型和工具，但由于与传统制造技术相比，增材制造具有经济和技术上的优势，英国制造业最近通过将该技术用于各个关键部门的最终用途产品而进行了革命。一旦目前采用增材制造的障碍（即质量，最终组件和专业知识的不确定性）得到解决，预计这种新兴的高效率增材制造技术将有明显的能力大大促进英国的经济生产。选择性激光熔化（SLM）是最有前途的金属增材制造方法之一，利用高能激光束熔化预沉积的金属粉末来制造3D部件。SLM的使用在英国许多工业部门（即航空航天，汽车，医疗，石油和天然气，海洋和国防等）逐渐增加，因为它能够从CAD模型生产近净形状复杂的部件，从而提供强大的设计灵活性，而不受传统制造方法的限制，这些制造方法需要一系列制造工艺，更多的材料消耗，更高的成本和能源。对于目标是快速制造产品并进入更广泛的买方市场的制造业来说，如果工艺参数之间的相互关系及其对结构完整性和性能的最终影响已经建立，那么SLM似乎是其业务的理想途径。SLM普遍用于构建一系列金属材料，包括不锈钢，钛，镍和铝合金。与其他合金不同的是，由于铝合金具有高反射率和高导热性，因此通过SLM制造铝合金涉及到更多的复杂性，这有助于在制造的零件中产生孔隙。因此，目前对SLM工艺参数对铝合金组织和材料性能的影响还缺乏了解。确定这种未知的关系是一项本质上重要的工程任务，目前是SLM加工铝合金广泛使用的主要障碍。第一笔拨款提案的总体目标是开发一种强大的方法来优化使用选择性激光熔化的铝合金部件的制造。为了实现这一目标，将x射线微计算机断层扫描与原位微拉伸测试阶段（允许观察3D原位变形）相结合，以研究工艺参数对孔隙率、材料性能和破坏行为的影响。此外，将建立基于实验的多孔塑性有限元模型，以了解孔隙尺寸和形状对变形行为的影响。