Functionally Integrated Materials via Additive Manufacturing
Abstract
Integrated circuits have revolutionized our world through the creation of smaller and faster electronic devices, eliminating the need to assemble multiple discrete electronic components. With the advent of additive manufacturing (AM), especially directed energy deposition (DED) techniques, such as Laser Engineered Net-Shaping (LENS¨), it is now possible, in theory, to spatially control, in three dimensions, material composition and microstructure, and consequently functionality. This 3D functional design of structural components, defined in this research proposal as Functionally Integrated Materials (FIMs), is a novel, visionary concept, which will allow the creation of single-structure yet multi-functional products that avoid the need for machining, joining, assembly, coatings, and maybe even wire interconnects. In the ideal case, complex products such as armor with embedded sensors and energy systems could be created in-situ in one machine, requiring only microstructural or compositional variations on an extremely localized level. This revolutionary concept is currently constrained, however, by the lack of fundamental scientific and engineering level understanding of AM, especially when heterogeneities are introduced, which are essential when creating FIMs. Thus, the overarching goal of the proposed research program is to establish a fundamental scientific framework that will make it possible to design and engineer FIMs with tunable properties by tailoring microstructure and compositional heterogeneities using DED-based AM techniques. Specifically, we aim to design heterogeneities into the as-deposited structure, by creating gradients in grain size, composition and phase/precipitation, in order to manipulate mechanical behavior. For instance, a 3D AM-deposited FIM could be designed that would provide strength in select regions due to precipitates, toughness in others due to coarse grains, and enhanced wear resistance in others due to the presence of hard ceramic particles. But in AM, functionality, which is derived from material behavior, is controlled by microstructure and composition, which is furthermore controlled by deposition conditions and the complex interactions of thermal, mass and materials phenomena, especially in the molten pool. Thus, this research program will utilize a wide range of computational and experimental techniques to elucidate the fundamental processing-microstructure-property relationships that govern the development of FIMs. Our teamÕs unique combination of capabilities in metal AM, real-time in-situ diagnostics, computational simulation and modeling, materials characterization, and mechanical testing will allow us to successfully establish a fundamental understanding of the relationships between heterogeneous structures, as dictated by AM deposition and molten pool solidification conditions, and materials behavior and functionality, thereby setting the foundation to develop and implement FIMs. Our research goals will be accomplished through continuous and close collaborations amongst all participants working iteratively on modeling and experimentation. The University of California, Irvine (UCI), a member of the Association of American Universities (AAU), is a Minority Serving Institution (MSI), designated as an Asian American and Native American Pacific Islander-Serving Institution (AANAPISI) and as a Hispanic-Serving Institution (HSI), is a national leader and global model of inclusive excellence. Thus, UCI is uniquely qualified to provide the educational framework for the proposed research program, which will include educational, outreach, recruitment and retention activities that target women, minorities, and first-generation college students with a focus on integrated mentoring, training and internship opportunities.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Jul 20, 2020
- Source ID
- W911NF2010264
Entities
People
- Julie Schoenung
Organizations
- Army Contracting Command
- Office of the Secretary of Defense
- University of California, Irvine