Manufacturing by Design

在高度工程化的材料中，微尺度的缺陷可以在部件/系统尺度上决定失效模式。虽然X射线CT的独特之处在于能够在微尺度上无损地成像、发现和跟踪缺陷，但目前它只能对毫米大小的样品做到这一点。这对制造设计和安全寿命预测造成了很大的限制，其中缺陷的性质和位置是制造过程的直接结果。例如，在加法制造中，制造试件时产生的缺陷可能与三维复杂加法制造的工程部件中的缺陷有很大不同。同样，对于复合材料，小尺度样本通常不够大，不足以恰当地表示控制结构行为的所有等级尺度。欧洲辐射研究机构(ESRF)和国家实验室CT研究机构(NRF)之间的这一合作将导致通过开发和开发新的光束线(BM18)，能够以微米分辨率进行X射线成像的材料体积增加100万倍。此外，这种对能量高达400keV的X射线的无与伦比的分辨率使人们能够探测高Z物质以及复杂的环境阶段。这代表着一种范式的转变，使我们能够从小范围试件中的缺陷转移到制造的部件和设备中的缺陷。此外，还将更好地了解此类缺陷是如何在制造和组装过程中引入的。它还将使我们能够侦察和放大制造的结构，以确定更广泛的缺陷分布，然后作为机械或环境载荷的函数，以时间推移的方式跟踪特定缺陷的演变，以了解它们如何导致服务中的快速故障。这将有助于指导针对单个部件几何/体系结构量身定做的更智能制造工艺的设计，并帮助建立添加剂和复合材料制造工艺的数字孪生。其次，我们将利用新的ESRF-极亮源升级带来的可用流量增加的ID19上的高帧频成像，来研究在添加剂制造过程中引入缺陷的机制，以及缺陷如何导致非常快速的故障，如电池中的热失控。在本项目中，我们将特别关注添加剂制造、复合材料制造和电池制造，以及这些制造产品的现场和操作性能和退化，这些能力正在传播，并通过NRF更广泛地提供给英国学术界和工业界。这种协作还将导致开发新的数据处理和分析程序，能够处理将获得的数据的非常显著的增加，并将导致多个地点实时协作进行实验。这将使我们能够在项目上作为一个多地点团队进行合作，从而减少旅行，并抵消新冠肺炎对苛刻实验带来的一些限制。

In highly engineered materials, microscale defects can determine failure modes at the compo-nent/system scale. While X-ray CT is unique in being able to image, find, and follow defects non-destructively at the microscale, currently it can only do so for mm sized samples. This currently presents a significant limitation for manufacturing design and safe life prediction where the nature and location of the defects are a direct consequence of the manufacturing process. For example, in additive manufacturing, the defects made when manufacturing a test-piece may be quite different from those in a three dimensionally complex additively manufactured engineering component. Similarly, for composite materials, small-scale samples are commonly not large enough to properly represent all the hierarchical scales that control structural behaviour. This collaboration between the European Research Radiation Facility (ESRF) and the National Research Facility for laboratory CT (NRF) will lead to a million-fold increase in the volume of material that can be X-ray imaged at micrometre resolution through the development and exploitation of a new beamline (BM18). Further, this unparalleled resolution for X-rays at energies up to 400keV enables high Z materials to be probed as well as complex environmental stages. This represents a paradigm shift allowing us to move from defects in sub-scale test-pieces, to those in manufactured components and devices. This will be complemented by a better understanding of how such defects are introduced during manufacture and assembly. It will also allow us to scout and zoom manufactured structures to identify the broader defect distribution and then to follow the evolution of specific defects in a time-lapse manner as a function of mechanical or environmental loads, to learn how they lead to rapid failure in service. This will help to steer the design of smarter manufacturing processes tailored to the individual part geometry/architecture and help to establish a digital twin of additive and composite manufacturing processes.Secondly, we will exploit high frame rate imaging on ID19 exploiting the increased flux available due to the new ESRF-extremely bright source upgrade to study the mechanisms by which defects are introduced during additive manufacture and how defects can lead to very rapid failures, such as thermal runaway in batteriesIn this project, we will specifically focus on additive manufacturing, composite materials manufacturing and battery manufacturing and the in situ and operando performance and degradation of such manufactured articles, with the capabilities being disseminated and made more widely available to UK academics and industry through the NRF. The collaboration will also lead to the development of new data handling and analysis processes able to handle the very significant uplift in data that will be obtained and will lead to multiple site collaboration on experiments in real-time. This will enable us to work together as a multisite team on projects thereby involving less travelling and off-setting some of the constraints on demanding experiments posed by COVID-19.