CAREER: Development of Hyperplastic and Superplastic Microforming Processes and Related Educational Activities

该CAREER项目将利用基础和应用相结合的研究方法来创建有效的超塑性（高应变率）和超塑性（高温小晶粒尺寸）微成形工艺。 在宏观尺度上，这些方法太慢且能量密集，对于高生产率应用来说是不实用的，但是在微观尺度上，由于能量和力需求的降低，这些方法将提供低成本、紧凑的加工技术。 然而，尺寸效应的基础研究，防止优化的宏观成型工艺简单地小型化到微观尺度上的组件，必须进行相对于材料和工艺参数。 这些知识将被应用于设计有效的微成形工艺，以更快的速度，更低的成本和更高的纵横比生产更精确的零件。 预期的具体科学和技术成果是：（a）对材料行为和工艺参数的尺寸效应的科学理解，（B）开发模型和方法以帮助微元件设计者，和（c）基于微工厂概念创建有效的微成形系统。 首先，通过微尺度研究获得的知识将导致能源生产，环境监测和生物医学应用的微尺度系统的进步，从而使整个社会受益。 此外，本科生和研究生将受益于研究成果融入课程材料，国际经验，并参与这一行业相关的多学科研究。 最后，增生和超塑性成形的性质适合于PI积极参与的高中外展活动，通过物理原理，如冲击力学和化学原理，如粒度和结构。

This CAREER project will utilize a combined fundamental and applied research approach to create effective hyperplastic (high strain rate) and superplastic (elevated temperature with small grain size) microforming processes. At the macroscale, these processes are too slow and energy intensive to be practical for high production rate applications, but at the microscale due to the reduced energy and force requirements, these processes will provide for a low cost, compact processing technique. However, basic research on size effects, which prevent optimized macroforming processes to be simply miniaturized to components on the microscale, must be conducted with respect to material and processing parameters. This knowledge will then be applied to devise effective microforming processes that will produce more accurate parts faster, for less cost, and with higher aspect ratios. The anticipated specific scientific and technological outcomes are: (a) scientific understanding of the size effects on material behavior and process parameters, (b) development of models and methods to aid microcomponent designers, and (c) creation of effective microforming systems based on the microfactory concept.Several broader impacts will be created through this research. First, the knowledge gained through this research at the microscale will lead to the advancement of microscale systems for energy generation, environmental monitoring, and biomedical applications and thus will benefit society as a whole. Also, the undergraduate and graduate students will benefit from the integration of research results into course material, international experiences, and involvement in this industrial relevant, multidisciplinary research. Finally, the nature of the hyperplastic and superplastic forming lends itself to high school outreach activities, which the PI is actively involved, through physics principles such as impact mechanics and chemistry principles such as grain size and structure.