New Chemistries for Metal Matrix Composites

在这项研究计划中，新的合成方法将被用于使新的大块和表面化学的合金和金属基复合材料（MMC）由激光粉末床融合（LPBF）。在LPBF方法中，金属零件基本上是用金属粉末激光3D打印的，允许创建具有复杂形状和其他方法无法获得的特性的金属零件。然而，LPBF部件的组成受到用于制造金属粉末的喷雾雾化方法的限制。此外，尽管非常理想，但Al的表面化学性质使得Al基合金成为最难以通过LPBF加工的合金之一。需要新的化学物质来解决这些问题。还非常希望由金属基质复合材料（MMC）制造LPBF部件，其中增强陶瓷颗粒结合在合金中。MMC对于轻质结构部件非常有用，以提高飞机和汽车的燃料经济性。然而，MMC通常与LPBF方法不兼容。在这项研究计划中，将使用新的合成方法来显着增加通过LPBF方法获得的合金的化学成分。这项研究是通过最近在Obrovac实验室开发的干颗粒微造粒技术实现的，该技术可以将球磨粉末转化为光滑的球形粉末，其形态与LPBF相容。此外，可以将表面涂层、内部组成梯度和甚至陶瓷增强颗粒引入颗粒中。这使得各种各样的合金基质化学、表面化学和增强化学能够用于LPBF中，进一步使得能够通过该方法制造新的MMC。独立于颗粒组成的颗粒形态的精确控制也允许对LPBF过程的化学进行基础研究。这些新方法从未应用于合金的合成。本研究计划将结合联合收割机块体合金化学，表面化学，合金合成，和纳米尺度的颗粒设计，给学生一个丰富和宝贵的培训经验。这项研究计划的成果是使用由于成本、颗粒流动特性差或安全问题而受到阻碍的成分和微观结构生产新的合金零件。这可以通过提供廉价和轻质的高强度部件，大大有利于环境和加拿大汽车和航空航天工业;从而降低成本，提高燃油经济性并改善电动汽车的范围。

In this research program new synthesis methods will be used to enable new bulk and surface chemistries of alloys and metal matrix composites (MMCs) made by laser powder bed fusion (LPBF). In the LPBF method, metal parts are essentially 3D printed with a laser from metal powders, allowing the creation of metal parts with complex shapes and with properties not otherwise attainable. However, the composition of LPBF parts is limited by the spray atomization method used to make metal powders. In addition, although highly desirable, the surface chemistry of Al makes Al-based alloys amongst the most difficult to process by LPBF. New chemistries are required to solve these issues. It would also be highly desirable to make LPBF parts from metal matrix composites (MMCs), in which reinforcing ceramic particles are incorporated in the alloy. MMCs are highly useful for lightweight structural components to increase fuel economy in aircraft and automobiles. However, MMCs are generally incompatible with LPBF methods. In this research program new synthesis methods will be used to significantly increase the chemical compositions of alloys obtainable by the LPBF method. This research is enabled by dry particle microgranulation, recently developed in the Obrovac lab, which can convert ball milled powders into smooth, spherical powders with morphologies that are compatible with LPBF. In addition, surface coatings, internal composition gradients and even ceramic reinforcing particles may be introduced into the particles. This enables a wide variety of alloy matrix chemistries, surface chemistries and reinforcing chemistries to be used in LPBF, further enabling new MMCs to be made by this process. The precise control of particle morphology, independent of particle composition, also allows fundamental studies of the chemistry of the LPBF process. These new methods have never been applied to the synthesis of alloys. This research program will combine bulk alloy chemistry, surface chemistry, alloy synthesis, and nano-scale particle design, giving students a rich and valuable training experience. Outcomes of this research program are the production of new alloy parts using compositions and microstructures that have been otherwise hindered because of cost, poor particle flow characteristics or safety issues. This could greatly benefit the environment and Canadian automotive and aerospace industries by providing inexpensive and lightweight high strength parts; thereby reducing cost, improving fuel economy and improving the range of EVs.