Development of non-destructive evaluation methods for the determination of machining deformation of high-performance Ni-based superalloys

该项目旨在开发一种无损工具，用于评估加工过程中的变形，并将有助于向工业4.0过渡。在过去的几年里，人们一直致力于开发可用于无损评估加工变形的方法。AMRC开发的一种具有相当前景的方法是使用x射线衍射，该方法已被证明可以定性地确定加工变形。该项目旨在以AMRC现有的工作为基础，进一步发展这种方法，以允许对ni基高温合金部件的变形进行定量评估，最终目标是开发一种可以集成到加工钻机上的工艺，提供变形积累的实时数据。因此，该项目将大大节省成本，因为工具寿命将实时确定，同时还提供精确的变形测量，进一步帮助数据驱动的制造过程转型。为了实现概述的目标，该项目将专注于开发镍基高温合金的方法，该方法在加工和衍射方面提供了独特的挑战组合，这将使一种可靠的方法得以确定并扩展到基于实验室的系统。项目目标是：-通过使用同步辐射对不同变形程度的加工样品进行高分辨率实验，开发方法和提高理解。-将从同步加速器衍射中吸取的经验教训扩展到实验室的非原位方法，包括确定实验室系统中理论的可用极限和建立数据分析协议和算法。-加工钻机现场集成试验。

The project aims to develop a non-destructive tool for the evaluation of deformation during machining operations and will aid the transition to Industry 4.0. Over the past few years efforts have concentrated on the development of methodologies that can be used to non-destructively evaluate machining deformation. A method developed at the AMRC that has exhibited considerable promise is the use of X-ray diffraction that has been shown to qualitatively determine machining deformation. This project aims to build upon the existing body of work at the AMRC to develop this methodology further to allow the quantitative evaluation of deformation on Ni-based superalloy components with the ultimate aim of developing a process that can be integrated onto machining rigs providing real-time data of deformation accumulation. The project will hence result in significant cost savings to be realised as tool-life will be determined in real-time, whilst also providing an accurate measure of deformation further aiding in the data-driven transformation of manufacturing processes. In order to achieve the aims outlined, the project will concentrate on developing the methodology on Ni-based superalloys that offer a unique combination of challenges both in machining and diffraction that will enable a robust methodology to be determined and extended to lab-based systems. The project objectives are: -Methodology development and advanced understanding through high resolution experiments using synchrotron radiation on machined samples with different levels of deformation. -Extension of lessons learned from synchrotron diffraction to lab-based ex-situ methodologies including the determination of the usable limits of theory in lab-based systems and the establishment of data analysis protocols and algorithms. -Trials of in situ integration to machining rigs.