GOALI/Collaborative Research: Integrated Microstructure and Melt Pool Dimension Control for Electron Beam Additive Manufacturing

该学术联络与工业（GOALI）合作研究项目的目标是为电子束增材制造中的熔池尺寸和微观结构的综合控制提供基础和实验验证的指导方针，电子束增材制造是一类新兴的制造工艺，通过局部熔化金属并逐层建造来构建几何特征。研究方法包括在学术机构进行的数值模拟，以及由工业和政府合作者进行的电子束沉积实验。模拟结果将在广泛的电子束功率、行进速度、材料进料速率和沉积几何形状范围内呈现，并将指导工业和政府合作者进行关键实验的选择。模型和实验将包括通过电子束在零件表面的快速运动来局部调整熔池内和周围温度的影响。如果成功，这项研究的好处不仅包括对电子束过程变量与最终零件质量的关系的基本理解，而且还包括同时控制熔池几何和微观结构的实践基础。这将对航空航天和其他商业应用的电子束制造工艺的资格认证做出重大贡献。研究活动将与两个学术机构正在进行的nsf支持的教育研究项目相结合。参与本项目研究的学生将在制造、固体力学、传热和材料方面获得综合知识，这将使他们在工业界和学术界具有很高的价值。

The objective of this Grant Opportunity for Academic Liaison with Industry (GOALI) Collaborative research project is to provide fundamental and experimentally-verified guidelines for integrated control of melt pool dimensions and microstructure in electron beam additive manufacturing, a class of emerging manufacturing processes which build geometric features by locally melting metal and building it up layer-by-layer. The research approach involves numerical modeling performed at the academic institutions in conjunction with electron beam deposition experiments performed by the industrial and government collaborators. Simulation results will be presented across a wide range of electron beam powers, travel speeds, material feed rates, and deposit geometries, and will guide the choice of critical experiments conducted by the industrial and government collaborators. Models and experiments will include the effects of local tailoring of temperatures in and around the melt pool by rapid movement of the electron beam across the part surface. If successful, the benefits of this research will include not only a fundamental understanding of how electron beam process variables relate to final part quality, but also a practical basis for simultaneous control of melt pool geometry and microstructure. This will represent a significant contribution toward qualification of electron beam manufacturing processes for aerospace and other commercial applications. Research activities will be integrated with ongoing NSF-supported educational research projects at both academic institutions. Students performing research on this project will develop a combined manufacturing, solid mechanics, heat transfer and materials background that will make them highly valuable in industry and academics.