Developing a hybrid waterjet-laser micromachining technology and associated process models for damage-free fabrication of silicon substrates. This hybrid micromachining technology will make it possible for damage-free, fast micro-fabrication of high-integrity devices such as high performance silicon solar cells. It will open new directions for the Australian manufacturing industry in micro-technologies. The environmental and economic benefits to the nation will be highly significant.
High-efficient abrasive waterjet machining of complex curved surfaces. This project aims to develop an abrasive waterjet process technology that is expected to increase the manufacturing efficiency by 4 times for complex curved surface structures such as the integral impellers and blisks used in turbine machines and aeroengines. It will also explore the science associated with the energy dissipation process for ultrahigh velocity abrasive waterjets and the curved surface generation process by th ....High-efficient abrasive waterjet machining of complex curved surfaces. This project aims to develop an abrasive waterjet process technology that is expected to increase the manufacturing efficiency by 4 times for complex curved surface structures such as the integral impellers and blisks used in turbine machines and aeroengines. It will also explore the science associated with the energy dissipation process for ultrahigh velocity abrasive waterjets and the curved surface generation process by the impact of a cloud of numerous particles. The intended outcome will break a technological barrier and make it entirely possible for the wide use of integral impellers and blisks in airplanes to significantly increase fuel efficiency. The economic, social and environmental benefit is expected to be enormous.Read moreRead less
Integrity prediction of ground precision surfaces. This project aims to establish a new approach to enable a reliable and accurate prediction of precision surface grinding. Precision grinding is often the final step in the manufacturing chains for a broad range of metal, ceramic, optical glass and semiconductor components, which must have ultra-high surface integrity and accurate dimensions. To date, the surface integrity of a ground component cannot be predicted due to the involvement of many r ....Integrity prediction of ground precision surfaces. This project aims to establish a new approach to enable a reliable and accurate prediction of precision surface grinding. Precision grinding is often the final step in the manufacturing chains for a broad range of metal, ceramic, optical glass and semiconductor components, which must have ultra-high surface integrity and accurate dimensions. To date, the surface integrity of a ground component cannot be predicted due to the involvement of many random factors and variables in a precision surface grinding process, resulting in high failure rates and processes requiring repeated surface measurements. The novel approach for surface integrity prediction developed by this project will make a vital step forward in advancing the discipline of precision surfacing, establish a new knowledge base and bring about significant technological impacts to the manufacturing industry.Read moreRead less
Enhancing and modelling the abrasive waterjet impact and erosion process. This project aims to understand and improve the ultrahigh pressure abrasive waterjet (AWJ) impact process. The current AWJ machining technology transfers less than 20% of the jet energy to the workpiece, mainly due to the damping effect of a stagnant layer at the jet impact site. This project attempts to remove this effect using ultrasonic vibration and explore the new impact micromechanics under the coupled effect of part ....Enhancing and modelling the abrasive waterjet impact and erosion process. This project aims to understand and improve the ultrahigh pressure abrasive waterjet (AWJ) impact process. The current AWJ machining technology transfers less than 20% of the jet energy to the workpiece, mainly due to the damping effect of a stagnant layer at the jet impact site. This project attempts to remove this effect using ultrasonic vibration and explore the new impact micromechanics under the coupled effect of particle impact and workpiece vibration. The expected outcome is a new AWJ technology for efficient, multi-scale machining, and to increase industry’s capability in fabricating high-integrity products.Read moreRead less
A new lapping process for difficult-to-machine brittle materials. This project aims to address a timely bottleneck issue in the conventional lapping of difficult-to-machine optoelectronic brittle materials. An innovative chemically enhanced lapping technology for fabricating such materials is expected to reduce machined subsurface damage. This is significant because it would shorten the subsequent finishing process and minimise the manufacturing cost. Intended outcomes from this project also inc ....A new lapping process for difficult-to-machine brittle materials. This project aims to address a timely bottleneck issue in the conventional lapping of difficult-to-machine optoelectronic brittle materials. An innovative chemically enhanced lapping technology for fabricating such materials is expected to reduce machined subsurface damage. This is significant because it would shorten the subsequent finishing process and minimise the manufacturing cost. Intended outcomes from this project also include an advanced machining theory and innovations in material removal characterisation. This breakthrough technology should benefit the design and fabrication of high performance electronic devices for energy, medicine and communication sectors with considerable impact on the Australian economy.Read moreRead less
Modelling the cutting process and cutting performance in high-speed abrasive waterjet turning. This project will have a significant impact for the manufacturing industry by providing a new abrasive waterjet turning technology for producing highly reliable products from advanced, but difficult-to-machine, materials. It will also develop into a new branch of science by understanding the mechanics associated with the new turning process.
Designed to last: novel gradient coatings for extreme environments. Hard coatings are frequently applied to equipment operating in harsh environments. Often such coatings are highly brittle and so fragile under stress, especially at high temperatures or in corrosive environments. Premature failure can affect safety and lead to negative economic and environmental consequences. The objective of this project is to combine bioinspired microstructural design with an emerging alloying concept to produ ....Designed to last: novel gradient coatings for extreme environments. Hard coatings are frequently applied to equipment operating in harsh environments. Often such coatings are highly brittle and so fragile under stress, especially at high temperatures or in corrosive environments. Premature failure can affect safety and lead to negative economic and environmental consequences. The objective of this project is to combine bioinspired microstructural design with an emerging alloying concept to produce a breakthrough in the development of engineering coatings; for example, overcoming the long standing trade-off between hardness and toughness. Such an innovative coating is expected to be highly durable in extreme conditions, and in so doing will help transform manufacturing, mining and desalination industries.Read moreRead less
Developing machining technologies for single crystal gallium oxide. Gallium oxide is a new semiconductor material that can be used to make diodes and transistors with lower loss than silicon (Si), and power electronic devices with lower cost and better performance than silicon carbide (SiC) and gallium nitride (GaN). This project aims to understand the nature of deformation and removal of this unique class of materials during machining. A successful outcome will not only develop an enabling mach ....Developing machining technologies for single crystal gallium oxide. Gallium oxide is a new semiconductor material that can be used to make diodes and transistors with lower loss than silicon (Si), and power electronic devices with lower cost and better performance than silicon carbide (SiC) and gallium nitride (GaN). This project aims to understand the nature of deformation and removal of this unique class of materials during machining. A successful outcome will not only develop an enabling machining technology for this next generation power semiconductor, but new understanding of machining and materials science will be generated.Read moreRead less
An integral approach enabling the defect-free manufacture of microlens arrays. Free-form microlens arrays are of central importance to the advancement of science and frontier technologies such as electronics, optics, telecommunication, biotechnology, medical surgery, energy generation, agriculture, resource exploration, environment protection and security. Using an integral approach coupling processing-microstructure-property modelling, multi-scale mechanics and damage-free mould development. Th ....An integral approach enabling the defect-free manufacture of microlens arrays. Free-form microlens arrays are of central importance to the advancement of science and frontier technologies such as electronics, optics, telecommunication, biotechnology, medical surgery, energy generation, agriculture, resource exploration, environment protection and security. Using an integral approach coupling processing-microstructure-property modelling, multi-scale mechanics and damage-free mould development. This research project will establish novel theories and technologies for the defect-free manufacture of microlens arrays. The research outcomes will lay the foundation for defect-free fabrication of a wide class of high-integrity systems.Read moreRead less
High speed multi-channel discharge machining of difficult-to-cut materials. This project aims to develop a novel approach to high speed machining of difficult-to-cut materials by resolving the contradictory surface quality and machining efficiency problem with a new theory. It is expected to advance the fundamental knowledge of electrical machining. The outcomes are new machining theories, novel methods and models of using multiple low energy sparks which occur nearly simultaneously for high spe ....High speed multi-channel discharge machining of difficult-to-cut materials. This project aims to develop a novel approach to high speed machining of difficult-to-cut materials by resolving the contradictory surface quality and machining efficiency problem with a new theory. It is expected to advance the fundamental knowledge of electrical machining. The outcomes are new machining theories, novel methods and models of using multiple low energy sparks which occur nearly simultaneously for high speed machining of a wide range of advanced materials. It should significantly increase machining speed and thus dramatically reduce the costs of producing products such as titanium medical implants, alloyed engine components and new cutting tools which are vital for the biomaterials, aerospace and manufacturing industries.Read moreRead less