GOALI: Direct High-Efficiency Production of Sheet and Foil by Single-Stage Deformation Processes

这个GOALI学术联系机会(GOALI)项目将发展一种基于混合机械加工的生产金属板和铝箔的工艺的科学，在这种工艺中，切割和挤压在一个变形阶段同时进行。这种方法与目前用于生产薄板和铝箔的传统多阶段轧制工艺完全不同，因为变形可以控制并限制在一个小区域内，通过变形本身的局部加热和施加较大的静液压力。其结果是抑制了失效的变形条件，从而即使在加工性能较低的合金中也能实现较大的形状变化。将研究变形条件(应变、应变率和温度)，以确定如何使用特殊的应力/温度状态和应变路径来提高变形效率、控制组织和性能并消除缺陷。本研究将从缩尺、能量、工具磨损和成本等方面进行实验和分析，以确定工艺效率，并与传统工艺进行基准比较。这项研究将使金属薄板和铝箔能够在单一变形阶段直接由钢锭生产，从而显著降低能源、成本和排放。基于机械加工的变形方法对于加工钛和镁等加工性能低的合金也将具有重要的优势，为打破目前阻碍这些轻质合金在商业运输系统中大规模应用的成本障碍提供关键技术。该工艺提供了有利的晶体织构，同时控制晶粒度，以实现卓越的成形性和性能。这项研究将推进制造过程的成本分析，并为学生提供与行业合作伙伴直接互动和发展创业技能的机会。该项目是普渡大学、M4 Sciences LLC、福特和工具制造商共同参与的研究。

This Grant Opportunity for Academic Liaison with Industry (GOALI) project will develop the science of a hybrid machining-based process for producing metal sheet and foil in which cutting and extrusion occur simultaneously in a single stage of deformation. The approach is radically different from the conventional multi-stage rolling processes currently used to produce sheet and foil, in that the deformation can be controlled and confined to a small region, with localized heating from the deformation itself and imposition of large hydrostatic pressures. The result is a deformation condition that suppresses failure, thereby enabling large shape changes even in alloys of low workability. Deformation conditions (strain, strain rate and temperature) will be investigated to determine how special stress/temperature states and strain paths can be used to increase deformation efficiency, control microstructure and properties, and eliminate defects. Experiments and analyses on scaling, energy, tool wear and costs will be conducted in order to characterize process efficiency and for benchmarking against conventional processes.This research will enable metal sheet and foil to be produced directly from ingot in a single stage of deformation, with significant reductions in energy, cost and emissions. The machining-based deformation approach will also have important advantages for processing alloys of low workability such as titanium and magnesium, providing critical technology for breaking down the cost barriers currently prohibiting these lightweight alloys from large-scale application in commercial transportation systems. The process imparts advantageous crystallographic textures, while simultaneously controlling grain-size to achieve superior formability and properties. The research will advance cost analysis of manufacturing processes and provide opportunities for students to interact directly with industry partners and develop entrepreneurial skills. The project is a collaborative study involving Purdue University, M4 Sciences LLC, Ford, and tool manufacturers.