3D printing process development and optimization: application to Binder Jetting and Direct Metal Laser Melting.

增材制造（AM）也被称为3D打印，由于对具有附加功能的高性能材料的需求大幅增加，例如内部冷却通道或内部晶格结构，这些材料难以用传统制造工艺制造，并且几何设计的复杂性增加，因此越来越受到关注。运输、航空航天和能源等行业正在积极寻求增材制造的新应用。该CRD计划旨在推进最先进的金属增材制造技术。更具体地说，我们寻求整合新材料系统，对GE的两项战略技术：粘结剂喷射（BJ）和直接金属激光熔化（DMLM）提出不同的挑战。

Additive manufacturing (AM), also known as 3D printing, is gaining attention due to a substantial increase in the demand for high-performance materials with added functionalities, such as internal cooling channels or internal lattice structures, which are difficult to fabricate with conventional manufacturing processes, and increased complexities in geometrical design. Industries like transportation, aerospace and energy are aggressively pursuing new applications for AM. This CRD program aims to advance state-of-the-art technologies using AM of metals. More particularly, we seek to integrate new materials systems that pose different challenges to GE's two strategic technologies: Binder jetting (BJ) and direct metal laser melting (DMLM). BJ and DMLM are two complementary AM technologies. BJ is a cheaper and faster technology that allows the production of larger engineering parts, while DMLM is a more versatile technology capable of producing a wider spectrum of materials with better properties. The two technologies also complement each other in the type of materials they can produce. Brittle materials can be easily fabricated with BJ, while DMLM can be used to produce parts with materials that are hard to sinter. GE could leverage the two technologies with the large spectrum of engineering applications used in its different lines of business. GE Canada is taking an active part in the efforts to develop the next generation of aero engine. AM is required to produce new part designs that will enable a more efficient propulsion and reduce manufacturing costs. This project proposes to support GE Canada's efforts through two primary objectives: processing aluminum alloy (Al) powder using BJ to produce heat exchangers with a better heat dissipation capacity; seeking to build RENÉ65 superalloy with DMLM to produce the new 3D designed compressor vanes. Processing Al powder is challenging for manufacturing technologies because of its oxide film, which makes it difficult to sinter. We will innovate by using BJ to inject sintering agent on the surface of Al powder through fine nozzles, which should disrupt the oxide film chemically and allowing sintering to occur. High ?' superalloys, like RENÉ65, are hard to produce using DMLM due to their high cracking susceptibility, residual stress build-up, and poor understanding of the processing-microstructure. The second objective will focus on developing know-how to build RENÉ65 thin-wall components with DMLM. This research project will help GE's Canadian plants to instigate new AM technologies. GE Bromont and GE Additive in Saint-Eustache, for example, could act as technology receptors. Additional benefits to Canada come from the technology transfer of this research to numerous aerospace, automotive, and materials companies. AM technology will facilitate the customized production of strong lightweight products, allow designs that were not possible with previous manufacturing techniques, and reduce costs associated with assembled components.