Processing and Testing of Materials using New Advanced Powder Metallurgy and Additive Manufacturing Strategies

使用新型先进粉末冶金和增材制造策略加工和测试材料

• 批准号: RGPIN-2014-05866
• 负责人: Brochu, Mathieu
• 金额: $ 2.55万
• 依托单位: McGill University
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2018
• 资助国家: 加拿大
• 起止时间: 2018-01-01 至 2019-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=646285
• 关键词: Processing; Testing; Materials; using; New

Prof. Brochu's research group is one of the leading group to develop and validate advanced powder metallurgy processes for consolidation of nanostructured powders and rapid solidification-based additive manufacturing technologies focused on materials suffering from solidification cracking, mainly aluminum alloys. This research program will further elevate the industrial impact of his research in four fronts. Firstly, Prof. Brochu will develop new surface engineering processes to facilitate the sintering of nanostructured materials through super solidus sintering. This program will raise the powder metallurgy (PM) forecasted economical growth of 5.31% over the 2012-2016 period by the availability of low-cost improved properties powders (nanograined), which will improve the performance of the manufactured parts. This will be seen in various industries, including automotive, biomedical and aerospace. Secondly, Prof. Brochu will translate systematic studies on the relationship between field assisted sintering towards hardware prototypes. The novel furnaces will permit heating rate reaching easily 1000C/min and consequently reducing the overall sintering runs. As sintering represent 73% of the energy consumption in the flowchart, these new concepts will reduce the economical and energetic footprint of the PM industry. Thirdly, the research program will provide a step growth of the additive manufacturing technology on three fronts: (1) Provide new strategies and developing new hardware to obtain mechanical properties equivalent to wrought, which will circumvent the current concept of "better than cast, worst than wrought". (2) Develop new approaches to perform additive manufacturing (AM) of materials suffering from solidification cracking, which are typically associated with high strength alloys. This program will open AM to almost all families of materials, which will be a quantum jump compared to the approximately currently commercialised 8 families of alloys. (3) Engineer solidification paths through alloy engineering to permit AM of ultra fine grained materials, materials that are currently fabricated by severe plastic deformation followed by extensive machining. Overall, this program will contribute to the existing global market of $1,843.2 million in 2012, and growth to $3,471.9 million by 2017, and further increase the AM footprint and industrial integration. (4) The program will also develop new localized testing strategies to assess the regions more susceptible to fracture initiation using nano-impact and nano-fatigue indentation technique. The outcome will be the creation of a low-cost and rapid innovative testing technique to assess the service properties of these advanced materials. This program will train four new Master students, six new and one continuing Ph.D students in fields including materials processing, characterization and testing, and design of new hardware. The training methodology will link the design of novel processes/devices with design of new materials and supported by analytical modeling to graps all underlying phenomena. The HQPs will develop graduate attributes such as analytical tools, decision-making, teamwork attributes, and will be augmented by soft skills such as IP, management, leadership and public speaking. They will be well trained for the reality of the Canadian employment markets, including coating industry, equipment design and fabrication, metallic materials processing and transformation, and materials performance assessment.

Brochu 教授的研究小组是开发和验证用于固结纳米结构粉末的先进粉末冶金工艺和基于快速凝固的增材制造技术的领先小组之一，该技术专注于遭受凝固裂纹的材料（主要是铝合金）。该研究计划将进一步提升他在四个方面的研究的工业影响力。首先，Brochu教授将开发新的表面工程工艺，以通过超固相线烧结促进纳米结构材料的烧结。该计划将通过提供低成本改进性能粉末（纳米颗粒），将 2012 年至 2016 年期间粉末冶金 (PM) 的经济增长预测提高 5.31%，从而提高制造零件的性能。这将在汽车、生物医学和航空航天等各个行业中看到。其次，Brochu教授将把现场辅助烧结之间关系的系统研究成果转化为硬件原型。新型熔炉将使加热速率轻松达到 1000C/min，从而减少总体烧结运行。由于流程图中烧结占能源消耗的 73%，因此这些新概念将减少粉末冶金行业的经济和能源足迹。第三，该研究计划将从三个方面推动增材制造技术的逐步发展：（1）提供新策略并开发新硬件以获得与锻造相当的机械性能，这将规避当前“比铸造更好，比锻造更差”的概念。 (2) 开发新方法对遭受凝固裂纹的材料进行增材制造 (AM)，这种材料通常与高强度合金相关。该计划将向几乎所有材料族开放增材制造，与目前商业化的大约 8 族合金相比，这将是一个巨大的飞跃。 (3) 通过合金工程设计凝固路径，以允许超细晶粒材料的增材制造，这些材料目前是通过严重的塑性变形和广泛的机加工制造的。总体而言，该计划将于 2012 年为现有全球市场贡献 18.432 亿美元，到 2017 年将增长至 34.719 亿美元，并进一步扩大增材制造足迹和工业一体化。 (4) 该计划还将开发新的局部测试策略，以使用纳米冲击和纳米疲劳压痕技术评估更容易发生断裂的区域。其结果将是创建一种低成本、快速的创新测试技术来评估这些先进材料的使用性能。该项目将在材料加工、表征和测试以及新硬件设计等领域培训四名新硕士生、六名新生和一名继续博士生。培训方法将新颖工艺/设备的设计与新材料的设计联系起来，并由分析模型支持以掌握所有潜在现象。总部项目将培养毕业生的属性，例如分析工具、决策、团队合作属性，并将通过知识产权、管理、领导力和公共演讲等软技能来增强。他们将接受针对加拿大就业市场实际情况的良好培训，包括涂料行业、设备设计和制造、金属材料加工和转化以及材料性能评估。