Environmentally Conscious Manufacturing: Manufacturing of Net-Shapes Using Spray Forming, Integration of Process Design, Energy and Environmental Issues

小行星9528684 直接制造成净形状的产品通过最大限度地减少或消除与废料相关的处理问题来节省能源。 研究了一种新的净成形制造工艺，该工艺使用反应喷射沉积来生产细晶粒结构、韧性、高强度的材料，该材料可以超塑性成形为有用的产品。 晶粒细化可以产生具有增强的性能的上级产品。 该研究结合了铝合金、低碳钢和镁合金的计算和实验研究。 实验工作将使用利用液-气和液-固反应的反应喷雾沉积作为将晶粒尺寸细化到超塑性极限以下的第一步。 模型将开发反应雾化和沉积，液滴-颗粒相互作用。 实验和分析测量将确定晶粒尺寸和喷射沉积条件之间的关系，并通过额外的实验来表征这些材料的超塑性行为。 如果成功，该项目将减少制造产品的能源和废料，在铝制品的制造中具有巨大的节能潜力。 ***

9528684 Lavernia Products fabricated directly to net shape save energy by minimizing or eliminating the disposal problems associated with scrap. A new net shape manufacturing process that uses reactive spray deposition to produce a fine grain structure, ductile, high strength material that can be superplastic formed into useful products will be investigated. The grain refinement may produce superior products with enhanced properties. The research combines computational and experimental investigations of aluminum alloys, low carbon steel, and magnesium alloys. Experimental work will use reactive spray deposition using liquid-gas and liquid-solid reactions as the first step in refining grain sizes below the superplastic limit. Models will be developed for reactive atomization and deposition, and droplet-particle interactions. Experiments and analytical measurements will define the relationship between grain size and spray deposition conditions, with additional experiments to characterize the superplastic behavior of these materials. If successful, the project will reduce energy and waste material in fabricating products, with large potential energy savings in the fabrication of aluminum products. ***