Performance-driven design of aluminium alloys for additive manufacturing (PAAM)

用于增材制造的铝合金的性能驱动设计 (PAAM)

• 批准号: EP/W00593X/1
• 负责人: Dmitry Eskin
• 金额: $ 60.84万
• 依托单位: Brunel University London
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2023
• 资助国家: 英国
• 起止时间: 2023 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FW00593X%2F1
• 关键词: Performance; driven; design; aluminium; alloys

Additive manufacturing (AM) makes net-shaped, highly precise, and cost-effective components of intricate design with minimum waste. However, the AM industry faces many technical challenges in the production of high-quality parts due to intrinsic defects, e.g. pores, cracks, distortions and anisotropy. These microstructural discontinuities are related to the material properties and solidification behaviour upon the AM processing conditions, i.e. rapid melting and cooling. The current developments of AM focus mostly on the printing processing, mitigating intrinsic material's deficiencies by process control, such as laser power and scan speed, and much less on the material side, with a majority of the alloys being originally designed and tailored to suit other manufacturing routes, e.g. casting. The quality of AM parts is dominated by the properties and characteristics of the alloy feedstocks - vital aspects that are currently largely overlooked. As a consequence, there is a limited number of materials that are designed specifically for manufacturing high-quality AM components.The synergetic approach in this project is three-fold and aims to (a) develop a new class of hierarchically structured Al-based alloys with fine-tuned structures and compositions at both the nano- and micro-scale, which satisfy the requirements for cracking resistance, structure uniformity, reduced residual stresses and porosity, enabling a unique combination of properties and dimensional precision for AM; (b) test and optimise their performance upon AM using in situ and ex situ high precision characterisation methods; (c) validate the approach by manufacturing AM test parts with enhanced product quality and, hence, with improved properties and performance. Combining these three advances, we will deliver a new class of high-quality AM materials with lightweight, uniform structure and properties, high rigidity, thermal stability, and designed functionality; combining the best processing features of existing diverse alloy groups.While addressing the challenges of AM through dedicated material development, this proposal has a strong and credible pathway to impact other manufacturing processes, e.g. casting and powder metallurgy using the same alloy design paradigm.

增材制造（AM）以最小的浪费制造出具有复杂设计的网状，高精度和成本效益的组件。然而，由于固有缺陷，例如孔隙、裂纹、变形和各向异性，AM行业在生产高质量零件方面面临许多技术挑战。这些微观结构的不连续性与AM加工条件下的材料性质和固化行为有关，即快速熔化和冷却。AM目前的发展主要集中在打印加工上，通过工艺控制（如激光功率和扫描速度）来减轻固有材料的缺陷，而在材料方面的发展要少得多，大多数合金最初都是为了适应其他制造路线而设计和定制的，例如铸造。增材制造零件的质量取决于合金原料的性能和特性-这些重要方面目前在很大程度上被忽视。因此，专门为制造高质量AM组件而设计的材料数量有限。本项目的协同方法有三个方面，旨在（a）开发一类新的分级结构铝基合金，其具有纳米和微米尺度的微调结构和成分，满足抗开裂性，结构均匀性，降低的残余应力和孔隙率，使AM的性能和尺寸精度的独特组合成为可能;（B）使用原位和非原位高精度表征方法测试和优化它们在AM上的性能;（c）通过制造具有提高的产品质量并因此具有改进的性能和性能的AM测试部件来验证该方法。结合这三大进步，我们将提供一种新型的高质量AM材料，具有轻质，均匀的结构和性能，高刚性，热稳定性和设计功能;结合了现有各种合金组的最佳加工特性。在通过专用材料开发应对增材制造挑战的同时，该提案具有影响其他制造工艺的强大而可靠的途径，例如使用相同合金设计范例的铸造和粉末冶金。

项目成果

Light Metals 2023

轻金属 2023

• DOI: 10.1007/978-3-031-22532-1_131
• 发表时间: 2023
• 作者: Beckwith C

Enhancing ambient and elevated temperature performance of hypoeutectic Al-Ce cast alloys by Al3(Sc,Zr) precipitate

通过 Al3(Sc,Zr) 沉淀增强亚共晶 Al-Ce 铸造合金的环境和高温性能

• DOI: 10.1016/j.jmrt.2023.12.021
• 发表时间: 2023
• 期刊: Journal of Materials Research and Technology
• 作者: Mohammed A

In situ characterisation of surface roughness and its amplification during multilayer single-track laser powder bed fusion additive manufacturing

• DOI: 10.1016/j.addma.2023.103809
• 发表时间: 2023-10
• 期刊: Additive Manufacturing
• 影响因子: 11
• 作者: Alisha Bhatt;Yuze Huang;C. L. Leung;Gowtham Soundarapandiyan;S. Marussi;Saurabh Shah;Robert C. Atwood-Robe

Thermoelectric Magnetohydrodynamic Control of Melt Pool Flow During Laser Directed Energy Deposition Additive Manufacturing

• DOI: 10.2139/ssrn.4329316
• 发表时间: 2023-05
• 期刊: SSRN Electronic Journal
• 作者: Xianqiang Fan;Tristan G. Fleming;David Tien Rees;Yuze Huang;S. Marussi;C. L. Leung;R. Atwood

Correlative full field X-ray Compton scattering imaging and X-ray computed tomography for in situ observation of Li ion batteries

• DOI: 10.1016/j.mtener.2022.101224
• 发表时间: 2022-12
• 期刊: Materials Today Energy
• 影响因子: 9.3
• 作者: Chu Lun Alex Leung;M. Wilson;T. Connolley;S. Collins;O. Magdysyuk;Matthieu Boone;Kosuke Suzuki;M. Veale;E. Liotti;F. Van Assche;A. Lui;Chun Huang