Cold Gas Dynamics Manufacturing Process Development for Smart Parts

被描述为“下一次工业革命”的添加剂制造(AM)正在改变消费产品的设计和制造。AM与传统的制造方法(TMM)有很大的不同，如减法(铣削或钻孔)、成形(铸造或锻造)和连接(焊接或紧固)工艺。*塑料零件的AM被认为是最先进的。然而，金属和陶瓷的AM需要更广泛的研究和开发工作，以将应用范围扩大到结构和高性能功能部件。随着更多的工作需要在基本层面上理解工艺参数/工艺输出关系(工艺映射)，AM需要努力达到成熟。*近年来，渥太华大学的研究人员在推动冷气动态喷雾添加剂制造(CGDSAM)的工程科学方面发挥了重要作用。CGDSAM还处于起步阶段，可以认为是一种金属和金属陶瓷的(固态)材料喷射AM工艺。尽管学术界一致认为CGDSAM是TMM难以/昂贵生产的大型零件市场的有力候选者，但对于控制工艺输出的因素缺乏基本知识。因此，流程“映射”是必要的，以便进行流程评估、改进、转移和商业实施。此外，AM的使用提供了制造传感器的可能性，允许对AM机械部件的性能进行现场监控。*研究表明，CGDSAM可以生产小尺寸(毫米尺寸)的复杂形状的非结构部件，这些部件现在已在商业上使用。由于巨大的潜在市场，最近的工作集中在钛零件的CGDSAM上，因为使用TMM加工这些零件的成本很高。最近还展示了CGDSAM工艺在传感器生产中的潜力。*基于这些潜在利基市场应用的最新进展，该计划的长期目标是建立CGDSAM工艺“MAP”，并允许生产嵌入传感器的厘米尺寸钛合金零件，用于对所生产的零件进行无线现场性能监测。*结果将确立CGDSAM在不需要非常精细的复杂细节的钛合金零件生产中的潜力，并评估其优势，因为该工艺的产量很大(比当前的AM工艺高出几个数量级)，而且没有通常限制AM零件尺寸的“内置托盘”。*该计划的积极结果还将使现场性能监测/传输成为可能。这可以为维护优化和故障预防提供关键的部件性能反馈。它还可以为设计师提供反馈，以便对新设计进行精细化建模和修改。

Portrayed as “the next industrial revolution”, additive manufacturing (AM) is transforming consumer product design and manufacturing. AM differs drastically from traditional manufacturing methods (TMM) such as subtractive (milling or drilling), formative (casting or forging) and joining (welding or fastening) processes. ******AM of plastic parts is considered as the state-of-the-art. However, AM of metals and ceramics requires more extensive research and development efforts to expand the scope of applications to structural and high-performance functional parts. Efforts are required to reach maturation of AM as more work is required to understand the process parameters/process output relationships at the fundamental level (process mapping).******In recent years, uOttawa researchers have been instrumental in advancing the engineering science of Cold Gas Dynamic Spray Additive Manufacturing (CGDSAM). CGDSAM is still in its infancy, and can be considered as a (solid state) Material Jetting AM process for metals and cermets. Despite academic consensus that CGDSAM is a strong candidate for the market of large parts that are difficult/expensive to produce by TMM and early proof-of-concept successes, there is a lack of fundamental knowledge on what controls the process output. As such, the process “mapping” is required to allow process evaluation, improvement, transfer and commercial implementation. Furthermore the use of AM offers the potential to produce sensors allowing in-situ monitoring of AM mechanical parts performance. *********Studies have shown that CGDSAM can produce complex shapes of small dimension (mm-size) non-structural parts that are now used commercially. Recent work has focused on CGDSAM of titanium parts due to the large potential market as these are expensive and costly to machine using TMM. Demonstration of the CGDSAM process potential for sensor production has also recently been made.************Based on these recent progresses for potential market niche applications, the long-term objective of this program is to establish the CGDSAM process “map” and allow the production of cm-size titanium alloy parts imbedded with sensors for wireless in-situ performance monitoring of the produced parts. ******The outcome will establish the potential of CGDSAM for titanium alloy part production that don't require extremely fine intricate details and assess its advantage due to the process large throughput (orders of magnitudes beyond current existing AM processes) and the absence of “built tray” typically limiting the size of AM parts.***The positive outcome of this program will also make monitoring/transmission of in-situ performance possible. This could provide crucial feedback on parts performance for maintenance optimisation and failure prevention. It could also provide feedback for designers to allow refined modeling and revision of new designs.