Additive manufacturing and processing by forming of Al-Ti metallic composites

本项目的目的是对增材制造铝钛金属复合材料的生产和成形性有一个基本的了解。这种复合材料首次由铝和钛通过冷喷涂和模锻热成形制成。首先，必须确定喷雾参数，才能生产出低孔隙率的层。为了符合固体增材制造的性质，必须实现大层厚度。这意味着超出了以前生产的热喷涂层厚度的限制。由于没有关于冷气体喷涂涂层成形的信息，因此要对其在实际条件下的成形行为进行表征。因此，在不同的工艺参数和应力条件下，采用模锻成形方法制备了喷涂复合材料。采用不同的研究技术，对制备的复合材料和随后形成的复合材料的微观结构和力学性能进行了评估。这使得沿着整个工艺链的微观结构-性能关系的确定和基本理解成为可能。为了将研究结果转移到进一步的研究中，在确定力学性能的基础上并考虑实际的固体结构，对成形过程进行了数值模拟。

The purpose of this project is a fundamental understanding of the production and formability of additive manufactured Al-Ti metallic composites. For the first time, such composites are produced from aluminum and titanium by cold gas spraying and are hot-formed by die forging. First of all, the spray parameters have to be determined that layers with low porosity can be produced. In order to correspond to the nature of an additive manufacturing of solids, a large layer thickness has to be realised. That means an extension beyond the limits of previously produced thermal sprayed layer thicknesses.Since no information is available on the forming of cold gas sprayed coatings, their forming behaviour under realistic conditions is to be characterized. Therefore, the sprayed composites are formed under different process parameters and stress conditions by die forging. The microstructure and mechanical properties are evaluated on both, the composites produced and the subsequently formed composites using different investigation techniques. This allows the determination and fundamental understanding of the microstructure-property relationship along the entire process chain. In order to transfer the findings to further investigations, the numerical modeling of the forming process is performed on the basis of the determined mechanical properties and considering the actual solid structure.