Cold Gas Dynamics Manufacturing Process Development for Smart Parts

智能零件的冷气体动力学制造工艺开发

• 批准号: RGPIN-2017-04671
• 负责人: Jodoin, Bertrand
• 金额: $ 2.7万
• 依托单位: University of Ottawa
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2020
• 资助国家: 加拿大
• 起止时间: 2020-01-01 至 2021-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=711155
• 关键词: Cold; Gas; Dynamics; Manufacturing; Process

Portrayed as “the next industrial revolution”, additive manufacturing (AM) is transforming consumer product design and manufacturing. AM differs drastically from traditional manufacturing methods (TMM) such as subtractive (milling or drilling), formative (casting or forging) and joining (welding or fastening) processes. AM of plastic parts is considered as the state-of-the-art. However, AM of metals and ceramics requires more extensive research and development efforts to expand the scope of applications to structural and high-performance functional parts. Efforts are required to reach maturation of AM as more work is required to understand the process parameters/process output relationships at the fundamental level (process mapping). In recent years, uOttawa researchers have been instrumental in advancing the engineering science of Cold Gas Dynamic Spray Additive Manufacturing (CGDSAM). CGDSAM is still in its infancy, and can be considered as a (solid state) Material Jetting AM process for metals and cermets. Despite academic consensus that CGDSAM is a strong candidate for the market of large parts that are difficult/expensive to produce by TMM and early proof-of-concept successes, there is a lack of fundamental knowledge on what controls the process output. As such, the process “mapping” is required to allow process evaluation, improvement, transfer and commercial implementation. Furthermore the use of AM offers the potential to produce sensors allowing in-situ monitoring of AM mechanical parts performance. Studies have shown that CGDSAM can produce complex shapes of small dimension (mm-size) non-structural parts that are now used commercially. Recent work has focused on CGDSAM of titanium parts due to the large potential market as these are expensive and costly to machine using TMM. Demonstration of the CGDSAM process potential for sensor production has also recently been made. Based on these recent progresses for potential market niche applications, the long-term objective of this program is to establish the CGDSAM process “map” and allow the production of cm-size titanium alloy parts imbedded with sensors for wireless in-situ performance monitoring of the produced parts. The outcome will establish the potential of CGDSAM for titanium alloy part production that don't require extremely fine intricate details and assess its advantage due to the process large throughput (orders of magnitudes beyond current existing AM processes) and the absence of “built tray” typically limiting the size of AM parts. The positive outcome of this program will also make monitoring/transmission of in-situ performance possible. This could provide crucial feedback on parts performance for maintenance optimisation and failure prevention. It could also provide feedback for designers to allow refined modeling and revision of new designs.

添加剂制造（AM）被描绘成“下一个工业革命”，正在改变消费产品设计和制造。 AM与传统制造方法（TMM）（例如减法（铣削或钻孔），形成性（铸造或锻造）和连接（焊接或固定）过程）截然不同。 塑料零件的AM被认为是最先进的。但是，金属和陶瓷的AM需要更广泛的研究和开发工作，以将应用范围扩大到结构和高性能功能部分。需要努力以达到AM的成熟，因为需要更多的工作才能了解基本级别（过程映射）的过程参数/过程输出关系。 近年来，乌塔瓦研究人员在推进冷气动态喷雾添加剂制造（CGDSAM）的工程科学方面发挥了作用。 CGDSAM仍处于起步阶段，可以被视为金属和Cermets的（固态）材料喷射AM工艺。尽管学术共识认为CGDSAM是TMM和早期概念验证成功率很难/昂贵的大型市场的有力候选者，但缺乏控制过程输出的基本知识。因此，需要“映射”过程以允许过程评估，改进，转移和商业实施。此外，AM的使用提供了产生传感器的潜力，允许对AM机械零件性能的原位监视。 研究表明，CGDSAM可以产生小维度（MM大小）非结构性部分的复杂形状，这些零件现在在商业上被商业使用。由于潜在的市场庞大，因此最近的工作集中在钛零件的CGDSAM上，因为使用TMM昂贵且昂贵。最近还制作了CGDSAM过程潜力的CGDSAM工艺潜力。 基于这些潜在市场利基应用程序的最新进展，该计划的长期目标是建立CGDSAM过程“地图”，并允许生产CM大小的钛合金零件，这些零件嵌入了传感器，用于对生产零件的无线现场性能监测。 结果将确定CGDSAM对于钛合金零件生产的潜力，由于该过程大量吞吐量（超出当前现有AM流程的尺寸），因此不需要极为精细的细节和评估其优势，并且缺乏“构建托盘”通常会限制AM零件的大小。 该计划的积极结果还将使监视/传播原位性能成为可能。这可以为维护优化和预防故障的零件性能提供至关重要的反馈。它还可以为设计师提供反馈，以允许对新设计的精制建模和修订。