Composite Coatings from Layered Precursors: Material Structure Modeling and Thermal Control

本研究项目介绍和分析了金属基复合材料（MMC）涂层沉积的新技术。涂层方法使用新颖的定制前驱体材料，由片状的基体金属和粉末或纤维形式的增强相制成，在分层的夹层板或颗粒芯线中卷曲或扭曲。铝或镍铝化物基体与氧化铝和/或碳化硅增强材料结合使用。通过机器人扫描激光束或等离子弧焊源，在红外热监测和反馈调节热量和质量沉积变量的情况下，将前驱体熔合在衬底上。因此，通过实时、自适应地控制温度分布以参考热条件来获得所需的涂层结构，并通过实验获得并编码在材料数据库中。该技术的优点包括实现简单，消除腔室外壳，涂层几何形状和结构控制，更好的附着力，高材料产量和低成本。塔夫茨大学与东北大学的合作研究，结合互补的资源和专业知识，还扩展到教育活动，包括新的热制造课程和塔夫茨大学与东北大学的热材料加工联合研讨会。

This research project introduces and analyzes new technologies for deposition of metal-matrix composite (MMC) coatings. The coating methods use novel custom precursor materials, made of the matrix metal in sheets and the reinforcing phase in powder or fiber form, rolled or twisted in a layered sandwich sheet or particulate-cored wire. Aluminum or nickel aluminide matrix is used in combination with alumina and/or silicon carbide reinforcement materials. The precursors are fused on the substrate by a robotically scanned laser-beam or plasma-arc welding source, under infrared thermal monitoring and feedback regulating the heat and mass deposition variables. Thus, the desired coating structure is obtained by real-time, adaptive control of the temperature distribution to reference thermal conditions, obtained experimentally and coded in a material database. The advantages of this technology include implementation simplicity, elimination of chamber enclosures, coating geometry and structure control, better adhesion, high material yield and low cost. Diversified applications in the aerospace, automotive, appliance and metalworking industry are explored in cooperation with Honda R&D and Starmet Corp. The collaborative research between Tufts and Northeastern University, combining complementary resources and expertise, also extends to educational activities, including a new Thermal Manufacturing course and a joint Tufts/Northeastern Thermal Material Processing Seminar.