Low residual stress coatings and additively manufactured components by high pressure cold spraying of cermet nanocomposites

今天，据估计，全球45%的温室气体排放来自能源生产和工业制造，使它们成为全球变暖的主要贡献者之一。人们正在有意识地努力寻找环境可持续的解决方案，使用更少的材料，减少制造过程中的浪费，并以更低的成本制造持久的产品。*工业革命即将到来，Industrie 4.0，一种高性能材料设计与网络物理网络中的精密制造相结合的方法，是对满足上述标准的及时回应，为制造商的生存和繁荣铺平了道路。在当地工业车间应用先进材料和制造工艺的学术研究是应对这一挑战的重点战略。只有当研究人员以自下而上的方式看待材料时，才能取得预期的成功，方法是利用无数支持技术在材料中展示其纳米级的物理特性。前提是必须在材料晶体结构的原子水平上设计新的部件，以便在其生命周期的非常早期阶段就植入新的功能，并能够预测其宏观的机械和物理性能。*拟议的研究涉及纳米结构陶瓷-金属(金属陶瓷)复合材料的设计和开发，以及利用加法制造原理沉积作为涂层和3D功能梯度(FG)物体的金属陶瓷颗粒，从而与传统的减法方法不同。其目的是创造纳米结构金属陶瓷的新知识，并为暴露在结构/非结构应用中的工业材料开发先进的表面保护解决方案，包括高速流体流动泥浆冲刷、高温氧化腐蚀和疲劳。通过工程纳米金属陶瓷颗粒和高压冷喷涂(HPCS)的设计、预测建模、加工、表征/测试和现场试验分析，实现了开发低残余应力、高温、耐疲劳涂层和3D FG部件的目标，从而取代了现有的低性能高速氧燃料技术，创造了更少浪费的制造未来。*研究的成功取决于HQP与三项主要技术的集成：高能机械合金化到固态纳米结构颗粒合成，流态化中的颗粒球化/功能化，床启动的化学气相沉积，并在一次操作中喷洒HPCS中的原料颗粒，减少材料浪费。这项工作将为加拿大工业公司创造社会经济机会，并对环境产生积极影响。

Today an estimated 45% of world's greenhouse gas emissions come from energy generation and industrial manufacturing, making them among the major contributors to global warming. A conscious effort is building towards finding environmentally-sustainable solutions using less material, reducing waste in manufacturing, and fabricating long-lasting products at lower costs.***On the verge of industrial revolution, Industrie 4.0, a combinatory approach of high-performance material design with precision manufacturing in cyber-physical network presence is a timely response to meet the above criteria, paving the way for manufacturers to survive and prosper. The application of academic research in advanced materials and manufacturing processes in local industrial shops is a focused strategy to take on this challenge. The desired success can only be achieved when researchers look at materials from a 'bottom-up' approach, by taking advantage of a myriad of supporting technologies to unfold their nano-scale physical characteristics in them. The premise is that the new components must be built into the design at the atomic level of material crystal structures so that novel functionalities are implanted at a very early stage in their life cycle, with the ability to predict their macro-scale mechanical and physical properties.***The proposed research deals with design and development of nanostructured ceramic-metallic (cermet) composites and the deposition of cermet particles as coatings and 3D, functionally-graded (FG) objects using an additive manufacturing principle, thereby deviating from traditional 'subtractive' methods. The aim is to create new knowledge in nanostructured cermets and to develop advanced surface protective solutions for industrial materials exposed to structural/nonstructural applications, including high-velocity fluid flow slurry erosion, high-temperature oxidation-corrosion, and fatigue. The objective of developing low-residual-stress and high-temperature, fatigue-resistant coatings and 3D FG components is met through design, predictive modeling, processing, characterization/testing, and field trial analysis of engineered nanocrystalline cermet particles and high pressure cold spraying (HPCS), thereby replacing current low-performance high velocity oxy-fuel technology, and creating a less wasteful manufacturing future.***The success of the research depends on the integration of HQP working with three principal technologies: high-energy mechanical alloying to solid-state nanostructured particle synthesis, particle spheroidization/functionalization in fluidized, bed reactor-enabled chemical vapor deposition, and spraying of feedstock particles in HPCS in a single operation, reducing material waste. The work will create socio-economic opportunities for Canadian industrial companies, and have a positive environmental impact.