Low residual stress coatings and additively manufactured components by high pressure cold spraying of cermet nanocomposites

通过金属陶瓷纳米复合材料高压冷喷涂低残余应力涂层和增材制造部件

• 批准号: RGPIN-2018-04440
• 负责人: Saha, Gobinda
• 金额: $ 1.97万
• 依托单位: University of New Brunswick
• 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=761629
• 关键词: Low; residual; stress; coatings; additively

Today an estimated 45% of world's greenhouse gas emissions come from energy generation and industrial manufacturing, making them among the major contributors to global warming. A conscious effort is building towards finding environmentally-sustainable solutions using less material, reducing waste in manufacturing, and fabricating long-lasting products at lower costs.On the verge of industrial revolution, Industrie 4.0, a combinatory approach of high-performance material design with precision manufacturing in cyber-physical network presence is a timely response to meet the above criteria, paving the way for manufacturers to survive and prosper. The application of academic research in advanced materials and manufacturing processes in local industrial shops is a focused strategy to take on this challenge. The desired success can only be achieved when researchers look at materials from a 'bottom-up' approach, by taking advantage of a myriad of supporting technologies to unfold their nano-scale physical characteristics in them. The premise is that the new components must be built into the design at the atomic level of material crystal structures so that novel functionalities are implanted at a very early stage in their life cycle, with the ability to predict their macro-scale mechanical and physical properties.The proposed research deals with design and development of nanostructured ceramic-metallic (cermet) composites and the deposition of cermet particles as coatings and 3D, functionally-graded (FG) objects using an additive manufacturing principle, thereby deviating from traditional 'subtractive' methods. The aim is to create new knowledge in nanostructured cermets and to develop advanced surface protective solutions for industrial materials exposed to structural/nonstructural applications, including high-velocity fluid flow slurry erosion, high-temperature oxidation-corrosion, and fatigue. The objective of developing low-residual-stress and high-temperature, fatigue-resistant coatings and 3D FG components is met through design, predictive modeling, processing, characterization/testing, and field trial analysis of engineered nanocrystalline cermet particles and high pressure cold spraying (HPCS), thereby replacing current low-performance high velocity oxy-fuel technology, and creating a less wasteful manufacturing future.The success of the research depends on the integration of HQP working with three principal technologies: high-energy mechanical alloying to solid-state nanostructured particle synthesis, particle spheroidization/functionalization in fluidized, bed reactor-enabled chemical vapor deposition, and spraying of feedstock particles in HPCS in a single operation, reducing material waste. The work will create socio-economic opportunities for Canadian industrial companies, and have a positive environmental impact.

据估计，今天全球45%的温室气体排放来自能源生产和工业制造，使其成为全球变暖的主要贡献者之一。人们正在有意识地努力寻找使用更少材料的环境可持续解决方案，减少制造中的浪费，以更低的成本制造耐用的产品。在工业革命的边缘，工业4.0，一种将高性能材料设计与精密制造相结合的方法，在信息物理网络中存在，是满足上述标准的及时响应。为制造商的生存和繁荣铺平了道路。将学术研究应用于先进材料和制造工艺，是应对这一挑战的重点战略。只有当研究人员从“自下而上”的方法来看待材料时，通过利用无数的支持技术来展现它们的纳米级物理特性，才能取得预期的成功。前提是新组件必须在材料晶体结构的原子水平上构建到设计中，以便在其生命周期的早期阶段植入新功能，具有预测其宏观力学和物理性能的能力。拟议的研究涉及纳米结构陶瓷金属（金属陶瓷）的设计和开发复合材料和金属陶瓷颗粒的沉积作为涂层和3D，功能梯度（FG）对象使用增材制造原理，从而偏离传统的“减材”方法。其目的是创造纳米结构金属陶瓷的新知识，并为暴露于结构/非结构应用（包括高速流体流浆体侵蚀、高温氧化腐蚀和疲劳）的工业材料开发先进的表面保护解决方案。通过设计、预测建模、加工、表征/测试以及工程纳米晶金属陶瓷颗粒和高压冷喷涂（HPCS）的现场试验分析，实现了开发低残余应力和耐高温、耐疲劳涂层和3D FG部件的目标，从而取代了当前的低性能高速氧燃料技术，并创造一个更少浪费的制造业未来。研究的成功取决于HQP与三项主要技术的整合：高能机械合金化到固态纳米结构颗粒合成，流化中的颗粒球化/功能化，床反应器使能的化学气相沉积，并在HPCS中在单一操作中喷涂原料颗粒，减少材料浪费。这项工作将为加拿大工业公司创造社会经济机会，并对环境产生积极影响。