Synergetic interactions between metal powder tailoring, additive manufacturing and heat treatment

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Prof. Brochu has focused his entire research career on the synergic and integrative multi-disciplinary optimisation linking powder metallurgy, rapid solidification welding and additive manufacturing to democratise advanced materials and manufacturing processes. To realise Prof. Brochu's long term research vision, this current DG proposal involves integrating, solving and optimizing the fundamental competitive interactions between the starting materials, alloy composition and its solidification, processing strategies and post-processing heat treatments. The innovative research program was designed to encompass four short term objectives: (1) Linking powder passivation and surface quality to their melting/sintering behavior, in order to address the knowledge gap corresponding to the variability in powder surface properties that is ultimately one of the causes for defect development during AM. (2) High strength AM alloys, in order to develop new AM-designed self-healing alloys that will increase the currently restraint AM materials offering. (3) LPBF of parts with controlled crystallographic orientation, in order to provide a faster and lower-cost alternative route to manufacture directionally solidified or single crystal components, transformative for the aerospace industry. (4) Linking post-AM thermal processes to deleterious microstructure development, in order to develop new heat treatments adapted to the AM microstructure to prevent the development of the deleterious phases negatively impacting the cyclic mechanical properties. The DG program plans to train 3PDFs, 3 PhDs and 2 MEngs students that will gain synergetic and multi-disciplinary skills encompassing experimentation, coding and modeling. Specifically, cutting edge knowledge and critical skills related to the surface characterisation, optimisation of AM protocols, materials characterisation, modeling of solidification orientation and solid-state phase transformation will be gained by the different HQPs. The DG program, resulting in a highly skilled and knowledgeabled workforce, will transform several fields including metal powder manufacturing, AM printing bureau, original equipment manufacturers, maintenance, repair and overhaul companies, heat treatment-specialised companies, etc. McGill, located in Montreal, is central to these industrial sectors contributing to the aerospace cluster and related supply chain.