GOALI: Additive Manufacturing of Multi-material Structures

与单材料、多部件结构相比，具有不同功能的多材料结构可以为工程问题提供独特的解决方案。然而，制造多材料结构的传统方法涉及每个零件的单独工艺，然后是连接操作。这种方法成本很高，而且容易出错。在许多情况下，不相容的材料不能用这种方法处理。这项学术与工业联络资助机会（GOALI）奖将使基础研究能够通过测量物理、机械、热和生物特性来了解计算机辅助微结构设计和多材料界面成分变化的影响，以解决航空航天和生物医学应用中使用的结构长期存在的多材料制造挑战。多材料增材制造结构可以在用户定义的位置设计和制造性能改进，并根据需要精确选择硬度、耐腐蚀性和环境适应性等特性的变化。这样的方法可以允许用户、设计师和制造商创建具有多功能的创新组件设计。可以帮助美国在各种多功能多材料结构的下一代制造中处于领先地位。多学科方法将有助于扩大代表性不足的群体参与研究和培训，从而对工程教育产生积极影响。多材料增材制造为材料加工提供了一种新的范式。然而，目前还没有针对多材料增材制造的设计、加工和表征的制造指南。这项研究将解决关键的科学挑战，并利用基于定向能沉积的增材制造系统填补与多材料增材制造相关的知识空白。研究小组将通过评估物理、机械、热和生物特性，了解最小化不相容离子扩散以防止界面冶金失效的机制。研究团队还将进行初步的有限元分析，以了解增材制造过程中热应力积累如何影响微观结构。来自增材制造设备制造行业专家的直接投入将是帮助学生准备面对现实世界工程挑战的宝贵工具。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

Multi-material structures with varying functionality can offer unique solutions to engineering problems compared to single-material, multi-part structures. However, traditional approaches to manufacture multi-material structures involve separate processes for each part, followed by joining operation/s. Such approaches are cost intensive and failure prone. In many cases, incompatible materials cannot be processed using such approaches. This Grant Opportunities for Academic Liaison with Industry (GOALI) award will enable fundamental research to understand the influence of computer-aided microstructural designs and compositional variations at multi-material interfaces by measuring physical, mechanical, thermal and biological properties to solve long-standing multi-material manufacturing challenges for structures used in aerospace and biomedical applications. Multi-material additive manufacturing structures can be designed and manufactured with performance improvements in user-defined locations, with variations in properties like hardness, corrosion resistance, and environmental adaptation selected exactly where needed. Such an approach can allow users, designers and manufacturers to create innovative component designs with multi-functionality. and can help the US to lead in the next generation manufacturing of a variety of multifunctional multi-material structures. The multi-disciplinary approach will help broaden participation of underrepresented groups in research and training to positively impact engineering education. Multi-material additive manufacturing offers a new paradigm in materials processing. However, there are no manufacturing guidelines for design, processing and characterization of multi-material additive manufacturing. This research will address critical scientific challenges and fill the knowledge gaps related to multi-material additive manufacturing using a directed energy deposition-based additive manufacturing system. The research team will understand mechanisms for minimizing diffusion of incompatible ions to prevent metallurgical failures at interfaces through evaluation of physical, mechanical, thermal and biological properties. The research team will also do preliminary finite element analysis to understand how thermal stress accumulation influences microstructure during additive manufacturing. Direct input from experts in the additive manufacturing equipment manufacturing industry will be a valuable tool towards preparing students to face real world engineering challenges.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.