Supersonic impact-bonding features and micro-forging strengthening principle in cold spray additive manufacturing of high-strength Al alloys
| Project/Area Number |
23K13577
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| Research Category |
Grant-in-Aid for Early-Career Scientists
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| Allocation Type | Multi-year Fund |
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| Review Section |
Basic Section 26050:Material processing and microstructure control-related
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| Research Institution | Osaka University |
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Principal Investigator |
王 倩 大阪大学, 接合科学研究所, 助教 (10961758)
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| Project Period (FY) |
2023-04-01 – 2025-03-31
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| Project Status |
Granted (Fiscal Year 2023)
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| Budget Amount *help |
¥4,420,000 (Direct Cost: ¥3,400,000、Indirect Cost: ¥1,020,000)
Fiscal Year 2024: ¥1,820,000 (Direct Cost: ¥1,400,000、Indirect Cost: ¥420,000)
Fiscal Year 2023: ¥2,600,000 (Direct Cost: ¥2,000,000、Indirect Cost: ¥600,000)
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| Keywords | コールドスプレー / 金属3D積層 / 大変形 / 組織微細化 / 強度評価 / Additive manufacturing / Cold spray / Supersonic impact / Extreme deformation / Grain refinement |
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| Outline of Research at the Start |
An improved cold spray (CS) method is introduced to achieve high-quality, low-cost additive manufacturing (AM) of high-strength aluminum (Al) alloys. This research aims to elucidate the control mechanisms of in-process micro-forging on the three key features by establishing a supersonic impact-bonding simulation model, and to clarify the strengthening principles of the three key features on the overall mechanical performance of the CSAM high-strength Al alloys by establishing cross-scale strength evaluation simulation models.
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| Outline of Annual Research Achievements |
Cold spray (CS) is a highly potential solid-state additive manufacturing (AM) technique. Nevertheless, it is noteworthy that the deposition quality depends largely on the plastic deformation capacity of metallic microparticles. In the past year, the influences of in-process micro-forging on the three key features (void/crack closure, uniform ultra-fine grain, and overall interface bonding) were investigated. During CSAM, the materials with non-linear, non-equilibrium, and high strain-rate responses pose various obstacles to comprehensively understanding the above phenomena. Correspondingly, a multi-physics framework using dislocation dynamics was developed to identify the influences of in-process micro-forging. High-fidelity modeling was verified fully by comparing the experimental and model-reproduced deformation profiles, cell/sub-grain size distributions, and increases in microhardness. The developed model confers a direct correlation among process, microstructure, and performance, which is universal and can be well-expected as a tool for the optimal design of CSAM of various metallic materials. Additionally, the key role of in-process temperature was found to completely solve the delamination issue of CSAM.
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| Current Status of Research Progress |
Current Status of Research Progress
2: Research has progressed on the whole more than it was originally planned.
Reason
Relevant experiments as well as model development used to understand the supersonic impact-bonding features and micro-forging strengthening principle have been conducted. Next, it is hoped to further optimize the CSAM experiment with the developed model, providing scientific guidelines for high-quality and low-cost CSAM of high-strength Al alloys.
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| Strategy for Future Research Activity |
In the next step, the model will be further developed and used to guide process design, with the hope of mapping the process window to provide guidance for high-quality and low-cost CSAM of various hard-to-deform metallic materials, including high-strength Al alloys.
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Report
(1 results)
Research Products
(4 results)
