Development of the Conform Process to Recycle Titanium Alloy Swarf into Wire for Sustainable Additive Manufacturing Feedstock

开发将钛合金切屑回收为可持续增材制造原料线材的 Conform 工艺

• 批准号: 2879603
• 金额: --
• 依托单位: University of Sheffield
• 依托单位国家: 英国
• 项目类别: Studentship
• 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=studentship-2879603
• 关键词: Development; Conform; Process; Recycle; Titanium

Compared to metal powder, wire feedstock has significant advantages in terms of ease of handling for additive manufacturing processes. In addition, powder specifications on morphology and size mean that large volumes of powder can be surplus to requirements. In wire fed additive manufacturing (AM) pro-cesses, 100% of the material is used. This makes solid state processes such as continuous extrusion or Conform even more important in the future. Such severe plastic deformation processes can convert sur-plus powder, particulate or waste product, such as machining swarf, into a rod/wire form. This can then be further cold drawn into <5 mm diameter wire for direct energy deposition (DED) processes. Conform has been used since the 1970s for copper and aluminium rod feedstocks. However, over recent years at the University of Sheffield and BWE Ltd, it has been demonstrated that Conform can be adapted to con-vert CP-Ti powder and Ti-6Al-4V swarf into fully consolidated wire with a fine, equiaxed grain struc-ture. The figure below shows a schematic of the Conform process used for the the production of CP-Ti wire from powder. In this EngD project a key aim will be to (1) design, make (using field-assisted sintering technology) and test high temperature, wear resistant tooling from aerospace nickel superalloy waste in order to enable titanium alloy swarf to be continuous extruded at prolonged rates that are deemed affordable for the aer-ospace manufacturing industry. (2) determine the effect of swarf/particulate characteristics on wire mi-crostructure and properties, including downstream cold drawability. The aim will be to design tooling optimised for titanium swarf and powder feedstocks - which will require finite element modelling. The long term ambition is to develop and de-risk the Conform process as a disruptive, sustainable manufac-turing technology to recycle machining waste.During your EngD you will develop core skills in process metallurgy, materials science such as micro-structural characterisation, FE modelling and data analytical approaches. You will work collaboratively with our Engineering Leads and technical staff and will have access to high performance manufacturing and characterisation facilities in the Henry Royce Institute. You will develop an insight into the technical advanced manufacturing challenges in the aerospace sector and work closely with metallurgists at DSTL

与金属粉末相比，线材原料在增材制造工艺的易于处理方面具有显著优势。此外，粉末的形态和尺寸规格意味着大量粉末可能超出要求。在线进给增材制造（AM）工艺中，100%使用材料。这使得固态工艺如连续挤出或Conform在未来变得更加重要。这种严重的塑性变形过程可以将剩余的粉末、颗粒或废品（例如机加工切屑）转化成棒/线形式。然后可以将其进一步冷拉成直径小于5 mm的线材，用于直接能量沉积（DED）工艺。自20世纪70年代以来，Conform一直用于铜和铝棒原料。然而，近年来，谢菲尔德大学和BWE有限公司已经证明，Conform可用于将CP-Ti粉末和Ti-6Al-4V切屑转化为具有细小等轴晶粒结构的完全固结线材。下图显示了用于从粉末生产CP-Ti丝的Conform工艺示意图。在该EngD项目中，主要目标是（1）设计、制造（使用现场辅助烧结技术）和测试来自航空航天镍超合金废料的高温耐磨工具，以使钛合金切屑能够以航空航天制造业可承受的长时间速率连续挤出。(2)确定切屑/颗粒特性对线材微观结构和性能的影响，包括下游冷拉性。其目的是为钛切屑和粉末原料设计优化的模具-这将需要有限元建模。长期目标是将Conform工艺作为一种颠覆性的、可持续的制造技术来开发和降低风险，以回收加工废料。在EngD期间，您将培养工艺冶金、材料科学（如微观结构表征、有限元建模和数据分析方法）方面的核心技能。您将与我们的工程领导和技术人员合作，并将有机会使用亨利罗伊斯研究所的高性能制造和表征设施。您将深入了解航空航天领域的技术先进制造挑战，并与DSTL的专家密切合作