Establishing the Relation Between Properties, Microstructures, and Processing Parameters in Innovative Eccentric Friction Based Additive Manufacturing

在基于偏心摩擦的创新增材制造中建立性能、微观结构和加工参数之间的关系

• 批准号: RGPIN-2022-04002
• 负责人: Riahi, Reza
• 金额: $ 2.4万
• 依托单位: University of Windsor
• 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=760498
• 关键词: Establishing; Relation; Between; Properties; Microstructures

The application of additive manufacturing (AM) technologies continues to increase as they reduce manufacturing costs and eliminate/reduce the need for subsequent machining and assembly. The properties of AM parts involving the melting of materials are influenced by rapid solidification, which affects the microstructure. Despite extensive research, fundamental challenges persist, including solidification induced porosities, large thermal gradients, residual stresses, non-homogeneous grain structure, and hot cracking. Therefore, solid-state AM methods, including additive friction stir manufacturing, are being developed, which combine layer-by-layer AM technology with solid-state friction stir welding to address these issues. However, the technique is typically limited to the fabrication of large near-shaped parts and selective area reinforcement for large-scale applications. This research program aims to develop a novel eccentric friction-based AM technique equipped with heaters, allowing feed of small diameter wire materials for narrower deposition of AM layers with higher precision than conventional additive friction stir manufacturing. Therefore, the entire cross-section of the feed material slides against the substrate with a uniform linear velocity and contributes to frictional heating due to the eccentricity of the feed material, depositing AM layers with minimum defects and uniform microstructure and properties. The experimental setup will also be applied to an in-situ configuration incorporating a sapphire substrate and a high depth-of-focus microscope to observe and study the detailed deformation mechanisms in the deformation zone during AM deposition process. This research will systematically study the micromechanisms by which the material deforms and transfers to the substrate/layers and their effects on the microstructure, the porosity/defects, the mechanical properties, corrosion, and wear resistance of the deposited AM layers to establish the relationships between the process parameters and properties of AM Parts. In summary, the results will be used to reduce the cost and increase the efficiency and quality of the metal AM processes by improving the microstructure (through in-situ deformation of the deposited layer) and controlling the strain and strain rate (through texturing, rotational speed, eccentricity, temperature and feed rate of the FM). The program will train nine highly qualified personnel.

增材制造（AM）技术的应用不断增加，因为它们降低了制造成本，消除/减少了后续加工和组装的需要。涉及材料熔化的增材制造零件的性能受到快速凝固的影响，从而影响其显微组织。尽管进行了广泛的研究，但基本的挑战仍然存在，包括凝固引起的孔隙、大的热梯度、残余应力、不均匀的晶粒结构和热裂。因此，固态增材制造方法，包括添加剂搅拌摩擦制造，正在开发中，将逐层增材制造技术与固态搅拌摩擦焊接相结合，以解决这些问题。然而，该技术通常仅限于制造大型近形零件和用于大规模应用的选择性区域增强。本研究项目旨在开发一种新型的偏心摩擦增材制造技术，该技术配备了加热器，允许小直径线材的进料，以比传统的增材搅拌摩擦制造更窄的增材层沉积，精度更高。因此，进料材料的整个横截面以均匀的线速度在基材上滑动，并由于进料材料的偏心而导致摩擦加热，从而沉积出缺陷最小、微观结构和性能均匀的增材制造层。实验装置还将应用于包含蓝宝石衬底和高聚焦显微镜的原位配置，以观察和研究AM沉积过程中变形区的详细变形机制。本研究将系统地研究材料变形和转移到基板/层的微观机制及其对沉积AM层的微观结构、孔隙率/缺陷、机械性能、腐蚀和耐磨性的影响，以建立工艺参数与AM零件性能之间的关系。综上所述，研究结果将用于通过改善微观结构（通过沉积层的原位变形）和控制应变和应变速率（通过FM的织构、转速、偏心、温度和进给速度）来降低成本，提高金属AM工艺的效率和质量。该项目将培养9名高素质人才。