Developing new metallic alloys for Additive Manufacturing

开发用于增材制造的新型金属合金

• 批准号: RGPIN-2020-04379
• 负责人: Henein, Hani
• 金额: $ 4.01万
• 依托单位: University of Alberta
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2022
• 资助国家: 加拿大
• 起止时间: 2022-01-01 至 2023-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=746870
• 关键词: Developing; new; metallic; alloys; Additive

Canadian manufacturing accounts for 10% of GDP and nearly 10% of the labour force (Statistics Canada). Additive manufacturing (AM), or 3D printing, is a new manufacturing approach where three dimensional components are built layer by layer forming a complex 3D part. This manufacturing approach deviates significantly from traditional manufacturing. Typically, components are designed and cast followed by hot and cold working, heat treatment and machining. AM provides innovative new opportunities for re-designing components. AM is undergoing a dramatic rise expanding in 2017 by more than $2.15 billion and a 21% overall growth in the industry. New metallic alloys must be developed to meet the special needs for innovative designs of components hitherto thought impossible to make. Innovative designs include the use of truss lattices in AM components. This enables the use of powdered alloys with novel compositions not yet used for engineering applications. Aluminum-copper alloys (Al-Cu) is one example, where traditionally the copper content is limited to ~4.5wt% due to light-weighting goals and increased strength. With the advent of truss designs for AM, higher copper content alloys may be utilised while producing components with lighter densities than traditional monolithic materials and with a considerable increase in strength. It is proposed to begin this program by studying Al-Cu and Al-Ni of eutectic and near-eutectic compositions. Of initial interest is the process conditions under which eutectics form. Subsequently, the ability to spheroidize the intermetallic constituent of the eutectic by aging will be studied. The powders will then be used in AM equipment in collaboration with Prof Qureshi, Mech E UofA. This will stimulate new projects funded by industry and NSERC using these novel powders in making AM components. The eutectic microstructures will be quantitatively characterized using scanning electron microscopy, neutron scattering and 3D micro-tomography. The evolution of spherical intermetallics will be defined following Ho and Weatherly. The spacing between intermetallic particles and their size will be measured using quantitative image analysis and machine learning techniques. Finally, these measurements will be related to Vickers micro hardness measurements to be made on aged samples. Four graduate students will be trained over the duration of 5 years. Two will tackle Al-Cu and two Al-Ni. One set of two students will address the rapid solidification aspects of the project while the other two will address the ageing processing of the powders. This will provide all 4 students training in the conduct of high temperature experiments, characterisation methods, 3D microtomography, quantitative metallography as well as modelling of solidification paths of alloys and the relationship between solidification-developed microstructure and resulting properties. The effort described in this proposal initiates a new thrust in our research.

加拿大的制造业占国内生产总值的10%，占劳动力的近10%（加拿大统计局）。增材制造（AM）或3D打印是一种新的制造方法，其中三维组件逐层构建，形成复杂的3D部件。这种制造方法与传统制造有很大的不同。通常，组件是设计和铸造，然后是热加工和冷加工，热处理和机械加工。增材制造为重新设计组件提供了创新的新机会。AM正在经历急剧增长，2017年增长超过21.5亿美元，行业整体增长21%。必须开发新的金属合金，以满足对迄今认为不可能制造的部件进行创新设计的特殊需要。创新设计包括在增材制造组件中使用桁架网格。这使得使用具有新成分的粉末合金尚未用于工程应用。铝铜合金（Al-Cu）就是一个例子，由于轻量化目标和提高强度，传统上铜含量限制在~4.5wt%。随着增材制造桁架设计的出现，在生产密度比传统单片材料更轻、强度显著提高的部件时，可以使用铜含量更高的合金。建议从研究共晶和近共晶成分的Al-Cu和Al-Ni开始。首先关心的是形成共晶的工艺条件。随后，将研究通过时效使共晶金属间成分球化的能力。然后，这些粉末将与ufa的库雷希教授合作，用于AM设备。这将刺激由工业和NSERC资助的新项目，使用这些新型粉末制造AM组件。利用扫描电子显微镜、中子散射和三维显微层析技术对共晶微观结构进行定量表征。球形金属间化合物的演化将在Ho和Weatherly之后定义。金属间颗粒之间的间距及其尺寸将使用定量图像分析和机器学习技术进行测量。最后，这些测量将与对老化样品进行的维氏显微硬度测量有关。四名研究生将接受为期五年的培训。两组处理铝铜，两组处理铝镍。一组两名学生将解决项目的快速凝固方面，而另外两名学生将解决粉末的老化处理。这将为所有4名学生提供高温实验、表征方法、3D显微断层扫描、定量金相学、合金凝固路径建模以及凝固微观结构与最终性能之间关系的培训。本提案中所描述的努力为我们的研究开创了新的推动力。