CETAL | PCE Projects (PN-III-P4-IDPCE) | PCE 57



PCE 57/ 2021 Project

English (Engleză)
Project number: PN-III-P4-ID-PCE-2020-1634

Project title: Use of enhanced topology in engineering of additive manufactured parts made of composite materials

Financial support:
Romanian National Authority for Scientific Research and Innovation, CNCS-UEFISCDI

Periode: January 2021 - December 2023  

Contact Person:
Project Director: Dr. Ing. Andrei Popescu (INFLPR)

National Institute for Laser, Plasma and Radiation Physics - I.N.F.L.P.R.
Atomiștilor 409, Măgurele, Romania
Metal matrix composites are materials with a main metallic constituent in which there is a dispersed phase of ceramic or organic material. They benefit from properties of interest of the metallic material such as low weight, elasticity or biocompatibility and add other properties such as high strength, low or high friction coefficient or high thermal conductivity. During this project, we aim to synthesize in situ composites using a 3D printing method called Laser Melting Deposition in which a powder jet is blown into a laser spot and is locally molten. The matrix will be made of Ti, while the dispersed phase will be a hard ceramic (TiC, ZrC or TiN). After optimizations, we hope to obtain a composite with mechanical properties superior to bare Ti with a microstructure in which the particles are homogeneously dispersed. Once the optimal powder feeding rate is established, a part with optimized topology will be designed in a CAD/CAM software automatically, after analysis of the build constrictions and forces that will act upon the object’s surface. The software generates an optimal shape that will have maximum resistance to the forces acting upon it. Such parts have convoluted shapes and could be difficult (sometimes impossible) to be produced by conventional manufacturing techniques. Additive manufacturing could be therefore the only method to produce in situ metal matrix composite materials simultaneously with building complex shapes with optimized topology.

Project objective:
The main objective of the project is to obtain MMC materials in situ by LMD. There are two distinct paths towards reaching this objective: I) the starting material will be a mixed powder of matrix and dispersed phase materials that will be blown into the laser spot from a single powder feeder and II) matrix powder will be inserted into a powder feeder, while dispersed phase powder will be inserted into a second powder feeder and they will be blown into the laser spot concomitantly with different debit rates in order to reach a desired proportion of dispersed phase into the matrix.

Estimated results:
1. 3 ISI papers
2. 2 invited communications
3. 4 oral communications
4. 3 national patents requests
5. 3 internal presentations for de Institute personnel
6. Project website

Research Team:     
        • Dr. Andrei POPESCU
        • PhD student Diana CHIOIBASU
        • PhD student Raluca IVAN
        • Ms Sabin MIHAI     

Română (Romanian)
Numar proiect: PN-III-P4-ID-PCE-2020-1634

Titlul proiectului: Utilizarea design-ului generativ in fabricarea aditiva a pieselor din materiale compozite

Suport financiar:
Autoritatea Nationala Romana pentru Cercetare Stiintifica si Inovare, CNCS-UEFISCDI

Perioada: Ianuarie 2021 – Decembrie 2023

Persoana de contact:
Director Proiect: Dr. Ing. Andrei Popescu (INFLPR)
Institutul Național pentru Fizica Laserilor, Plasmei și Radiației - I.N.F.L.P.R.
Atomiștilor 409, Măgurele, ROMÂNIA
Compozitele cu matrice metalica sunt materiale cu o faza metalica majoritara in care este dispersat un material ceramic sau organic. Ele beneficiaza de proprietatile materialului metalic, precum masa redusa, elasticitate mare sau biocompatibilitate ridicata, la care se adauga alte proprietati determinate de faza dispersata precum rezistenta ridicata la rupere, coeficient mai bun de frecare sau conductivitate termica mai buna. In acest proiect, vom produce in situ materiale compozite utilizand o metoda de imprimare 3D numita Depunere Laser prin Topire. Matricea va fi realizata din Ti, iar faza dispersata va fi o pulbere de ceramica dura (TiC, ZrC sau TiN). Dupa optimizari, speram sa obtinem un compozit cu proprietati mecanice superioare titanului pur si cu o microstructura in care particulele sunt dispersate omogen. Odata stabilita rata de livrare a pulberii, o piesa cu topologie optimizata va fi proiectata automat intr-un software CAD-CAM, dupa analiza constrangerilor si fortelor care vor actiona asupra piesei. Rezulta astfel o forma optima care va avea rezistenta maxima la fortele care actioneaza asupra sa. Astfel de piese au forme complexe si pot fi dificil (cateodata imposibil) de produs prin tehnici conventionale de fabricare. Fabricarea aditiva ar putea fi de aceea singura metoda pentru a produce in situ compozite cu matrice metalica, simultan cu constructia unor forme complexe cu topologie optimizata.

Obiectivul proiectului:
Principalul obiectiv al proiectului este de a obtine materiale compozite cu matrice metalica in situ prin tehnica LMD. Pentru atingerea obiectivului se vor urmari doua directii: I) materialul cu matrice metalica si faza dispersata vor fi amestecate in prealabil si materialul rezultat va fi suflat in spotul laser prin intermediul unui distribuitor de pulbere plecand dintr-un singur recipientsi II) materialul cu matrice metalica va fi introdus in primul recipient, in timp ce faza dispersata va fi introdusa in cel de-al doilea recipient si cele doua materiale vor fi suflate in spotul laser concomitent in debite de pulbere diferite cu scopul de a obtine proportia dorita de faza dispersata in matricea metalica.
Rezultate estimate:
1. 3 articole stiintifice
2. 2 prezentari orale invitate
3. 4 prezentari orale
4. 3 cereri de brevet de inventie
5. 3 seminarii interne in Institut
6. Pagina web proiect

Echipa de cercetare:     
        • Dr. Andrei POPESCU
        • PhD student Diana CHIOIBASU
        • PhD student Raluca IVAN
        • Ms Sabin MIHAI     


[1] Muhammad Arif Mahmood, Andrei C. Popescu, Mihai Oane, Asma Channa, Sabin Mihai, Carmen Ristoscu, Ion N. Mihailescu “Bridging the analytical and artificial neural network models for keyhole formation with experimental verification in laser melting deposition: A novel approach”, Results in Physics, 26, 2021.
[2] Muhammad Arif Mahmood, Andrei C. Popescu, “3D Printing at Micro-Level: Laser-Induced Forward Transfer and Two-Photon Polymerization”, Polymers 13(13), 2021.
[3] Mihai Oane, Muhammad A. Mahmood, and Andrei C. Popescu "A State-of-the-Art Review on Integral Transform Technique in Laser–Material Interaction: Fourier and Non-Fourier Heat Equations" Materials 14(16), 2021.
[4] Sabin Mihai, Diana Chioibasu, Muhammad A. Mahmood, Liviu Duta, Marc Leparoux, and Andrei C. Popescu "Real-Time Defects Analyses Using High-Speed Imaging during Aluminum Magnesium Alloy Laser Welding" Metals 11(11) 2021.
[5] Asif Ur Rehman, Muhammad A. Mahmood, Fatih Pitir, Metin U. Salamci, Andrei C. Popescu and Ion N. Mihailescu "Mesoscopic Computational Fluid Dynamics Modelling for the Laser-Melting Deposition of AISI 304 Stainless Steel Single Tracks with Experimental Correlation: A Novel Study" Metals 11(10) 2021.
[6] Muhammad Arif Mahmood, Diana Chioibasu, Asif Ur Rehman, Sabin Mihai, Andrei C. Popescu, “Post-Processing Techniques to Enhance the Metallic Parts Quality Produced by Laser Additive Manufacturing” in evaluare.
[7] Muhammad Arif Mahmood, Diana Chioibasu, Sabin Mihai, Mihai Iovea, Ion N Mihailescu, Andrei C. Popescu, “Non-destructive X-ray Characterization of Novel Joining Method based on Laser Melting Deposition Process for AISI 304 Stainless Steel” in evaluare.

Oral presentations:
[1] Andrei C. Popescu Sabin Mihai, Diana Chioibasu, Muhammad A. Mahmood, Mihai Iovea, Ion N Mihailescu, Marc Leparoux, Emerging Techniques for In Situ Monitoring of Laser Welding Process, 4th International Conference on Emerging Technologies in Materials Engineering – EmergeMAT, 4-6 November 2021, Bucharest, Romania.
[2] Ion Mihailescu, Muhammad Arif Mahmood, Mihai Oane, Carmen Ristoscu, Andrei Popescu, Alexandra Bănică, Diana Chioibasu. Laser Melting Deposition: Modelling vs. Experiment. Conference: Frontiers in Lasers and Applications (FLA-2) At: Web-Event Affiliation: University of Nebraska at Lincoln 10.13140/RG.2.2.29017.24164. (2021).