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

增材制造（AM），也称为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AM的新应用。该CRD计划旨在使用金属AM推进最先进的技术。更具体地说，我们寻求整合新材料系统，这些系统对GE的两项战略技术提出了不同的挑战：粘合剂喷射（BJ）和直接金属激光熔化（DMLM）。BJ和DMLM是两项互补的AM技术。BJ是一种更便宜，更快的技术，可以生产更大的工程部件，而DMLM是一种更通用的技术，能够生产更广泛的材料，具有更好的性能。这两种技术在它们可以生产的材料类型上也是相辅相成的。用BJ可以很容易地制造脆性材料，而DMLM可以用来生产难以烧结的材料的零件。通用电气可以利用这两项技术在其不同业务领域的广泛工程应用。通用电气加拿大公司正在积极参与开发下一代航空发动机的努力。AM需要生产新的部件设计，以实现更有效的推进并降低制造成本。该项目旨在通过两个主要目标来支持GE加拿大的努力：使用BJ加工铝合金（Al）粉末，以生产具有更好散热能力的热交换器;寻求使用DMLM制造RENÉ 65高温合金，以生产新的3D设计的压缩机叶片。处理Al粉末对制造技术具有挑战性，因为其氧化膜使其难以烧结。我们将创新地使用BJ，通过精细的喷嘴将烧结剂喷射到Al粉末表面，这将化学破坏氧化膜并允许烧结发生。像RENÉ 65这样的高温合金很难使用DMLM生产，因为它们的高开裂敏感性，残余应力积累以及对加工微观结构的理解不足。第二个目标是开发使用DMLM制造RENÉ 65薄壁部件的技术诀窍。该研究项目将帮助GE在加拿大的工厂开发新的AM技术。例如，圣厄斯塔什的通用电气Bromont和通用电气添加剂可以作为技术接受者。加拿大的其他好处来自这项研究的技术转让给许多航空航天，汽车和材料公司。增材制造技术将促进坚固轻质产品的定制生产，允许以前的制造技术无法实现的设计，并降低与组装组件相关的成本。

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.