I-Corps: Additive manufacturing of nickel titanium aerospace actuators

I-Corps项目更广泛的影响/商业潜力是通过3D打印开发形状记忆合金执行器，这可能与传统的液压执行器的受力能力相竞争。执行器是机器中负责控制系统的部件。一架典型的商用飞机有几个独立的液压系统和一个或两个泵来给系统加压。这些系统用于控制控制飞机在空中运动的飞行表面。这些系统大大增加了飞机的重量。在航天飞行器的研制中，空间和重量一直是人们关注的问题。这项技术有可能通过消除对液压系统的需求来减少飞机上使用的执行器的重量和占地面积。该项目还有一个潜在的额外好处，即降低飞机在空中或着陆时遇到紧急情况的火灾风险。最后，这项技术有潜力帮助具有类似采用动机的卫星和火箭制造业。这个I-Corps项目是基于形状记忆合金增材制造策略的发展。形状记忆合金是一类可以使材料形成所需形状的材料，这种形状称为母形。然后，这种母材形状可以变形，在加热超过一定阈值时，材料将恢复到其母材形状，表现出“形状记忆”。镍和钛很容易合金化，以生产形状记忆合金执行器。然而，由于镍钛合金的高硬度和加工过程中产生的热量有可能改变材料的性能，传统的加工具有挑战性。使用高功率激光熔化粉末金属的增材制造用于解决与传统加工相关的困难。已经开发了特定打印策略的使用，以修改执行器在打印过程中的阈值温度，从而使材料特性能够定制。这种定制可以根据客户的具体需求开发定制的执行器。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。

The broader impact/commercial potential of this I-Corps project is the development of shape memory alloy actuators through 3D printing that may compete with the force capabilities of traditional hydraulic actuators. An actuator is a component of a machine that is responsible for controlling a system. A typical commercial aircraft has several independent hydraulic systems and one or two pumps to pressurize the systems. These systems are used to control the flight surfaces that control the movement of the aircraft in the air. These systems add a great deal of weight to the aircraft. In the development of vehicles for the aerospace industry, space and weight are always of great concern. This technology has the potential to reduce the weight and footprint of actuators used in aircraft by eliminating the need for hydraulic systems. This project has a potential added benefit of also reducing the fire risk for aircraft experiencing an emergency in the air or during landing. Finally, this technology has the potential to aid satellite and rocket manufacturing industries with similar motivations for adoption.This I-Corps project is based on the development of additive manufacturing strategies for shape memory alloys. Shape memory alloys are a class of materials that allow the materials to be formed into a desired shape, which is called the parent shape. This parent shape can then be deformed and upon the application of heat above a certain threshold, the material will revert to its parent shape exhibiting a “shape memory.” Nickle and titanium are readily alloyed to produce shape memory alloy actuators. However, traditional machining of nickel titanium alloys are challenging due to their high hardness and the fact that the heat generated during machining has the potential to change the properties of the material. The use of additive manufacturing using a high-powered laser to melt powdered metals is used to address the difficulties associated with traditional machining. The use of specific printing strategies has been developed to modify the threshold temperature of the actuator during printing and thus, enable the material properties to be tailored. This tailoring allows the development of actuators customized to the customers’ specific needa.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.