Near-net Shape Processing of Functionally Graded Structural Material

本研究的目的是通过数学和物理建模优化，一种用于精确控制性能的多孔结构材料的近净形状生产的方法。该方法，压力辅助燃烧合成（PACS），结合了传统的自蔓延高温合成和发泡在一个操作。该研究方法有理论和实验组成部分。开发了该过程的多尺度数学模型，以量化微观结构-性能关系，并建立用于生产所需微观结构的参数空间。PACS然后被用来合成多孔金属间化合物材料，利用从数学模型获得的工艺条件。生产的材料经过显微镜和机械测试，结果用于验证数学模型，识别缺陷并优化工艺。可扩展性包括跨维度的建模和分析工具、学生教育以及报告、期刊和论文中的研究结果文档。这项研究如果成功，将为生产具有所需微观结构和机械性能的多孔结构材料提供一种具有成本效益，能源效率和环境友好的方法。 示例应用包括优化净形生物医学结构植入物的生产，以改善假体手术的结果，降低成本，降低故障率，并提高假体患者的生活质量。该方法也适用于更广泛的一类复杂的材料过程，涉及非线性耦合运输反应现象与移动接口。许多这样的工艺与用于高速民用运输燃烧室的材料（例如近净形整体陶瓷或陶瓷复合材料）的关键防御和商业需求相关。 本科生和研究生将参与研究，并将受益于课堂教学和材料加工，反应工程，热科学和数值方法等不同领域的多学科培训。

The objective of this research is to optimize through mathematical and physical modeling, a method for near-net shape production of porous structural materials with accurately controlled properties. The method, pressure-assisted combustion synthesis (PACS), combines conventional self-propagating high-temperature synthesis and foaming in one operation. The research approach has theoretical and experimental components. A multi-scale mathematical model of the process is developed to quantify the microstructure-property relationship and establish the parameter space for production of the desired microstructure. PACS is then used to synthesize porous intermetallic material, utilizing the processing conditions obtained from the mathematical model. The materials produced are subjected to microscopy and mechanical testing, and the results are used to validate the mathematical model, identify deficiencies and optimize the process. Deliverables include modeling and analysis tools across dimensional scales, student education, and documentation of research results in reports, journals, and theses. This research, if successful, will provide a cost-effective, energy efficient and environmentally benign method for producing porous structural materials with desired microstructure and mechanical properties. Example application includes optimization of the production of net-shape biomedical structural implants to improve the outcomes of prostheses procedures, reduce costs, reduce failure rates, and enhance the quality of life of patients with prostheses. The methodology is also applicable to a wider class of complex materials processes involving non-linear coupled transport-reaction phenomena with moving interfaces. Many such processes are relevant to critical defense and commercial needs for materials such as near-net shape monolithic ceramics or ceramic composites for the High Speed Civil Transport combustors. Undergraduate and graduate students will be engaged in the research, and will benefit from classroom instruction and the multidisciplinary training in diverse fields of materials processing, reactive engineering, thermal science and numerical methods.