GOALI/FSI/Postdoctoral Industrial Fellowship: Damage Evolution During Manufacturing of Advanced Materials -- Experiments and Modelling

小行星9510572 在这个GOALI项目中，一名博士后研究员在工业合作伙伴的现场工作，合作进行与先进材料加工相关的基础研究。 本研究所选用的复合材料为非连续增强铝合金。 焦点的加工步骤是二次加工，损伤的产生是由于颗粒尺寸和分布、基体组织和应力状态的影响。 为了评估足够宽的加工条件和增强尺寸范围，将生产平均粒度为5 μ m、15 μ m和50 μ m的不连续增强铝（Al 2 O3），并以1：2 - 1：20的挤压比进行挤压，以研究粒度和加工参数对组件制造过程中损坏演变的影响，并将其与组件的最终性能联系起来。 将通过测量弹性模量和泊松比演变，以及通过定量评估抛光截面上的裂纹颗粒和其他损伤来评估微观结构损伤的水平。 与在工业现场进行工作的实验计划并行，将在大学开发一个使用蒙特卡罗模拟方法的简单模型，以预测通过微损伤的合并在最终组件中产生显著大缺陷的概率。 这项研究将是必不可少的，在理解的演变的微观结构和性能的变化，伴随着各种加工条件，从而有助于制造可靠的可拆卸组件。 使用连续纤维增强材料的先进复合材料目前用于利基应用，如军用飞机和体育用品。 虽然连续纤维要求专门的加工，但不连续纤维提供了以最小的资本影响适应常规加工的机会。 这项研究的成功完成有可能将复合材料的应用扩展到汽车和其他大批量应用中。 此外，通过支持一名来自科洛姆的研究人员在行业环境中生活和呼吸，可以实现研究与实践之间的更大合作。

9510572 Lewandowski In this GOALI project, one postdoctoral researcher works at the site of an industrial partner to collaborate on fundamental research related to advanced materials processing. The composite material chosen for this study is discontinuously reinforced aluminum alloy. The processing step for focus is secondary operations and the damage accrued as a result of particle size and distribution, matrix microstructure and the stress state. In order to assess a sufficiently broad range of processing conditions and reinforcement sizes, discontinuously reinforced aluminum (DRA) with average particle sizes of 5um, 15um and 50um will be produced and extruded to extrusion ratios of 1:2 - 1:20 to study the effects of particle size and processing parameters on the evolution of damage during manufacturing of a component as well as to relate these to the final properties of the component. The level of microstructural damage will be evaluated through measurements of elastic modulus and poisson ratio evolution, as well as by quantitative evaluation of cracked particles and other damage on polished sections. In parallel with the experimental program where work is carried out at the industrial site, a simple model using Monte Carlo simulation approach will be developed at the university to predict the probability of significantly large defects arising in the final components via coalescence of the micro damage. This study will be essential in understanding of the evolution of microstructures and property changes which accompany various processing conditions and thereby aid in the manufacturing of reliable DRA components. Advanced composites using continuous fiber reinforced materials are currently used in niche applications such as military aircrafts and sporting goods. While continuous fibers mandate specialized processing, discontinuous fibers offers the opportunity to fit into conventional processing with minimum capital implications. Successful completion of this research has the po tential to expand the composite use into automotive and other high volume applications. Further, by supporting a researcher from academe to live and breathe in the industry setting, a greater collaboration between research and practice may be realized.