Image-based metrology and tribology of additively manufactured components

用于高风险行业的材料，如生物医学设备，航空航天和汽车制造，长期以来一直要求具有强大的材料性能，并以严格的尺寸公差生产。现在，即使是消费类设备，如移动的手机和平板电脑使用先进的，高耐受性的材料。下一代材料和设备将来自增材制造，也称为3D打印或快速成型。为了确保制造的部件正常工作，需要检查它们的适当尺寸、耐磨性和机械强度。对于增材制造的组件来说，即使是尺寸验证也可能具有挑战性，因为新的设计范例能够实现复杂的表面下内部结构，从而减少材料使用并在特定区域赋予强度。只有基于X射线的方法，如计算机断层扫描（CT），才能提供零件外部和内部的尺寸测量。该提案的总体目标是开发微CT成像方法，以逆向工程和评估材料的几何形状，特别是那些由增材制造制成的材料。成像采集将被优化和自动化，以实现快速，高通量的质量保证，包括已经包装的部件。将检查该成像产生的电离辐射影响扫描部件机械强度的可能性。最后，将评估增材制造系统的尺寸精度，并确定不同原材料和加工增材制造材料的摩擦学特性。总的来说，这项工作将提高微型CT作为工业质量保证平台的能力，并提高对增材制造中使用的材料特性的认识。该计划将非常适合那些将沉浸在理想的多学科培训环境中，与工程师和成像科学家密切合作的学生。学员将掌握成像评估，计算机辅助设计和增材制造，所有适用于广泛行业的尖端技术。

Materials used for high-risk industries such as biomedical devices, aerospace, and automotive manufacturing have long been required to have strong material properties and be produced with tight dimensional tolerances. Now, even consumer devices such as mobile phones and tablet computers utilize advanced, high-tolerance materials. The next generation of materials and devices will come from additive manufacturing, also known as 3D printing or rapid prototyping. To ensure manufactured components will function properly, they need to be examined for appropriate dimensions, wear resistance, and mechanical strength. Even dimensional verification can be challenging for additively manufactured components, due to new design paradigms that enable complex, below the surface internal structures that reduce material use and confer strength in specific regions. Only x-ray based methods such as computed tomography (CT) can provide dimensional measurements for both the outer and inner aspects of a part. The overall goal of this proposal is to develop micro-CT imaging methods to reverse engineer and evaluate the geometry of materials, especially those made from additive manufacturing. Imaging acquisitions will be optimized and automated, to enable rapid, high throughput quality assurance, including of parts that have already been packaged. The potential for ionizing radiation from this imaging to affect the mechanical strength of the scanned parts will be examined. Finally, the dimensional accuracy of additive manufacturing systems will be evaluated and the tribological properties of different raw and processed additively manufactured materials will be determined. Collectively, this work will enhance the capabilities of micro-CT as an industrial quality assurance platform, and advance the state of knowledge on the properties of materials used in additive manufacturing. This program will be well suited for students who will be immersed in an ideal multidisciplinary training environment, working closely with engineers and imaging scientists. Trainees will master imaging assessment, computer aided design, and additive manufacturing, all cutting-edge technologies applicable to a broad range of industries.