Introduction
Much of the recent technology we enjoy has been made possible through materials design.
Recent examples of it include ultra-light case aluminium alloys for the Apple Watch and re-entry rockets skin materials. Such ‘Materials by Design’ concept, is based on a systems-engineering analysis where the desired performance of components, such as a smart watch or a reusable rocket, are related to the processing schedules needed to produce and shape the material into the final component. Such processing is related to the material microstructure, ultimately influencing properties. Only by relating the product engineering performance with its underlying microstructure and properties, can we confidently ensure the component safety and reliability.
The processing – microstructure – properties – performance (PMPP) linkage necessitates computational models; but the full complexity of such links escapes the power of physical modelling. Additionally, the need to reduce emissions upon materials production, increase their circularity, and in general maximise their sustainability, imposes even more complex constraints to materials design. AI provides a suite of models that can accelerate handling large datasets where the complex PMPP interactions can be captured more reliably, expediting the development of novel sustainable materials.
This project will combine AI and physical models for sustainable materials design.
Our focus will be powder-based alloys for additive manufacturing (3D printing). Five groups of alloys will be considered: steel, aluminium, titanium, nickel, and high-entropy alloys. Although each of those alloy families have their own metallurgy, a more or less general approach to tackle them is shown in Fig. 9 in https://www.mdpi.com/2071-1050/15/20/15081. Towards the end of the project we will have developed methods to maximise the sustainability through AI-powered alloy design for 3D printed aerospace components.
Research Questions
Link an alloy producer (Globus Metal Powders) and aerospace components manufacturer (GKN Aerospace) to develop a methodology to evolve metallic powder additive manufacturing technology towards greater sustainability.
Demonstrate the methodology by applying it first to the development of additively manufactured sustainable nickel-based superalloys.