Accelerated development of aluminum alloys for additive manufacturing

加速开发用于增材制造的铝合金

• 批准号: RGPIN-2020-03868
• 负责人: Bishop, Donald
• 金额: $ 3.35万
• 依托单位: Dalhousie University
• 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=753108
• 关键词: Accelerated; development; aluminum; alloys; additive

Additive manufacturing (AM), a.k.a. 3D printing, refers to technologies that convert a computer aided drawing directly into a finished product in a layer-by-layer fashion; commonly, this involves a powdered feed stock that is consolidated with the aid of a laser. Viewed by many as technology that will soon disrupt the entire manufacturing enterprise, valuation of the global market for AM products is soaring upward with the annual economic impact of AM expected to surpass $250B by 2025. As a pioneering force in AM of metallic products, Canada is poised to be one of the major benefactors of this growth such that our national AM market will mature to $14B/yr over this same time frame. Confidence in such predictions is certainly warranted as Canada's influence on AM continues to expand aggressively. For instance, it is now home to a series of leading metal powder producers, AM equipment manufacturers, firms that are commercially producing metallic products via AM, and a growing list of world-class AM research facilities. To fully capitalize on Canada's momentum in AM and maximize national capacity to exploit the opportunities that exist, research is needed on several fronts. Of these, alloy development is exceptionally critical and timely. For instance, in the case of aluminum AM, only a single alloy (AlSi10Mg) has achieved ASTM recognition yet mature aluminum forming technologies (wrought, cast) can access over 600. HQP shall strive to address this technology gap by developing advanced aluminum alloys for AM in an accelerated fashion. Here, HQP will be empowered with the capacity to complete hands-on experiments at all stages of production - powder fabrication (gas atomization), powder consolidation (laser powder bed fusion (L-PBF), laser directed energy deposition (L-DED)), post-AM processing, and material characterization. The pace of alloy discovery will be intensified by utilizing a combinatorial-type of approach that leverages the capacity of the L-DED to produce numerous test specimens with unique chemistries under wide ranges of process parameters in a single build cycle. HQP shall also investigate a fundamental constraint that has dampened industry uptake of aluminum AM (heightened laser reflectivity). Dr. Bishop is very well versed in the development and commercialization of innovative aluminum powders for the related field of powder metallurgy (PM). Several of the outcomes patented by his team are now exploited in the industrial fabrication of a growing number of ground-breaking automotive components. Two of these have received prolific industry awards, ushered in completely new forums of growth for the PM sector, and facilitated tangible reductions in greenhouse gas emissions. Coupling his comprehensive experience with aluminum powders together with his recent launch of a new facility for AM research, he is in an excellent position to now develop and commercialize innovative aluminum powders for his latest challenge - the AM sector.

增材制造（AM），又名3D打印是指以逐层方式将计算机辅助绘图直接转换为成品的技术;通常，这涉及在激光辅助下固结的粉末原料。被许多人视为将很快颠覆整个制造企业的技术，AM产品的全球市场估值正在飙升，预计到2025年AM的年度经济影响将超过2500亿美元。作为金属产品增材制造的先驱力量，加拿大有望成为这一增长的主要受益者之一，这样我们的国家增材制造市场将在同一时间内成熟到140亿美元/年。随着加拿大对AM的影响力继续积极扩大，对此类预测的信心当然是有道理的。例如，它现在是一系列领先的金属粉末生产商，AM设备制造商，通过AM商业生产金属产品的公司以及越来越多的世界级AM研究设施的所在地。 为了充分利用加拿大在增材制造方面的势头，最大限度地提高国家利用现有机会的能力，需要在几个方面进行研究。其中，合金开发尤为关键和及时。例如，在铝AM的情况下，只有一种合金（AlSi 10 Mg）获得了ASTM的认可，但成熟的铝成形技术（锻造，铸造）可以达到600多个。HQP将努力通过加速开发先进的AM铝合金来解决这一技术差距。在这里，HQP将有能力在生产的所有阶段完成动手实验-粉末制造（气体雾化），粉末固结（激光粉末床熔合（L-PBF），激光定向能量沉积（L-DED）），后AM处理和材料表征。合金发现的步伐将通过利用组合型方法来加快，该方法利用L-DED的能力，在单个构建周期中在广泛的工艺参数范围内生产具有独特化学性质的众多试样。HQP还应调查抑制铝AM行业吸收的基本限制（提高激光反射率）。 Bishop博士精通粉末冶金（PM）相关领域的创新铝粉的开发和商业化。他的团队获得专利的几项成果现在已被用于越来越多的突破性汽车零部件的工业制造。其中两项获得了多产的行业奖项，为PM行业带来了全新的增长论坛，并促进了温室气体排放的切实减少。结合他在铝粉方面的全面经验以及他最近推出的AM研究新设施，他现在处于一个非常有利的位置，可以为他的最新挑战-AM行业开发和商业化创新铝粉。