A powder bed fusion forming method for realizing organization performance customization of a nickel-based alloy by using double lasers and a nickel-based alloy part
By using dual-laser alternating printing technology, the microstructure and properties of nickel-based alloy parts can be controlled, solving the problem of customizing the properties of nickel-based alloy parts in the existing technology. This achieves a balance between tensile strength and yield strength in the mechanical properties of nickel-based alloy parts, meeting the performance requirements under specific application conditions.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- SOUTHERN UNIVERSITY OF SCIENCE AND TECHNOLOGY
- Filing Date
- 2022-10-25
- Publication Date
- 2026-06-09
Smart Images
Figure CN115673338B_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of laser additive manufacturing technology, specifically relating to a powder bed melting forming method for nickel-based alloys using dual lasers to achieve customized microstructure and properties, and nickel-based alloy parts. Background Technology
[0002] Additive manufacturing (AM) technology, also known as 3D printing, has attracted increasing attention from industry and research. In this technology, objects are generated layer by layer. Before continuously slicing a 3D model into a sequence of two-dimensional (2D) cross-sectional layers of specific thickness, the 3D model is prepared using computer-aided design (CAD) software or 3D scanning. Each layer represents a cross-section of the part. These 2D layers are then sent as source files to the 3D printer to control the entire manufacturing process. The machine executes a specific process to shape each layer, then stacks them from bottom to top until the entire part is created. Selective Laser Melting (SLM) is a type of powder melting technology and one of the most widely used techniques in additive manufacturing, particularly in the production of metal materials. This technology uses a laser as an energy source, scanning layer by layer through a bed of metal powder according to a path planned in the 3D CAD slicing model. The scanned metal powder melts and solidifies to achieve a metallurgical bond, ultimately obtaining the metal part designed in the model.
[0003] The aerospace industry has a long-standing need for materials with excellent mechanical properties, good oxidation and corrosion resistance, and good stability at high temperatures. Nickel-based superalloys have become the preferred material for high-temperature applications when performance under static, fatigue, and creep conditions is required. Nickel-based superalloys typically operate at temperatures exceeding 800°C, such as in turbine disks and blades.
[0004] Nickel-based alloys obtained through existing laser additive manufacturing methods are materials with uniform microstructure. However, the material properties of nickel-based alloys obtained by different processing methods vary greatly, making it difficult to customize specific properties of nickel-based alloy materials. Summary of the Invention
[0005] To address the problem that existing laser additive manufacturing methods for nickel-based alloys are unable to achieve customized material properties, this invention provides a powder bed melting forming method for nickel-based alloys using dual lasers to achieve customized microstructure and properties, as well as nickel-based alloy parts.
[0006] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows:
[0007] On one hand, the present invention provides a powder bed melting forming method for nickel-based alloys to achieve customized microstructure and properties using dual lasers, comprising the following steps:
[0008] Import the 3D model into a 3D printer for processing;
[0009] Printing the first nickel-based alloy layer: The first layer of nickel-based alloy powder is laid to obtain the first nickel-based alloy powder bed. The first nickel-based alloy powder bed is scanned with the first laser to obtain the first nickel-based alloy layer. The operation is repeated n times to obtain n layers of the first nickel-based alloy layer.
[0010] Printing the second nickel-based alloy layer: A second layer of nickel-based alloy powder is laid to obtain a second nickel-based alloy powder bed. The second nickel-based alloy powder bed is scanned with a second laser to obtain the second nickel-based alloy layer. The spot diameter of the second laser is larger than that of the first laser. The operation is repeated m times to obtain m layers of the second nickel-based alloy layer.
[0011] By alternating between the "printing the first nickel-based alloy layer" and "printing the second nickel-based alloy layer" operations, a nickel-based alloy part with n alternating first nickel-based alloy layers and m alternating second nickel-based alloy layers along the laser printing direction is obtained.
[0012] Optionally, the spot diameter of the first laser is 30~100μm, and the spot diameter of the second laser is 300~700μm.
[0013] Optionally, the thickness of each first nickel-based alloy layer is 10~100μm, and the thickness of each second nickel-based alloy layer is 10~100μm.
[0014] Optionally, n is selected from an integer from 1 to 500, and m is selected from an integer from 1 to 500.
[0015] Optionally, the average particle size of the nickel-based alloy powder is 10~105μm.
[0016] Optionally, the nickel-based alloy powder comprises the following components by weight percentage:
[0017] The content of Cr is 15-22%, the content of Co is 0-2%, the content of Mo is 2.5-3.5%, the content of Fe is 15-25%, the content of Al is 0.2-0.8%, the content of Ti is 0.6-1.2%, the content of Nb is 4.5-6%, the content of Mg is 0-0.05%, the content of B is 0-0.01%, the content of Si is 0-0.4%, the content of Mn is 0-0.4%, the content of P is 0-0.02%, the content of S is 0-0.02%, the content of C is 0.01-0.08%, the content of Cu is 0-0.5%, the content of O is 0-0.05%, the content of N is 0-0.05%, and the balance is Ni.
[0018] Optionally, the laser power of the first laser is 100~700W and the scanning speed is 100~10000mm / s; the laser power of the second laser is 500~1000W and the scanning speed is 100~10000mm / s.
[0019] Optionally, both the "printing the first nickel-based alloy layer" and "printing the second nickel-based alloy layer" operations are performed under a protective atmosphere.
[0020] On the other hand, the present invention provides a nickel-based alloy part, which is prepared by the powder bed melt forming method described above.
[0021] Optionally, the yield strength of the nickel-based alloy part is 400~1100MPa and the tensile strength is 500~1300MPa.
[0022] In the forming process of nickel-based alloy parts, the laser spot diameter has a significant impact on the microstructure and mechanical properties of the formed parts. Smaller diameter lasers generate finer grain structures, which improves the strength of the parts but has little effect on their toughness; conversely, smaller diameter lasers can generate coarser grain structures, which improves the toughness of the parts. The powder bed melting forming method provided by this invention uses lasers of different diameters to print samples with alternating stacks and alternating microstructures. Compared to parts printed using only large-diameter lasers or only small-diameter lasers, the mechanical properties of the alternatingly printed parts, including tensile strength and yield strength, fall between the two. This achieves the goal of customizing the microstructure and properties of high-temperature alloy laser powder bed melting. Under certain application conditions, it can simultaneously meet the requirements for the tensile strength and yield strength of the material, satisfying specific application requirements. Attached Figure Description
[0023] Figure 1 These are optical micrographs of the printed parts provided in Embodiment 1, Comparative Example 1, and Comparative Example 2 of the present invention;
[0024] Figure 2 These are electron backscattering microstructures of the printed parts provided in Embodiment 2, Comparative Example 1, and Comparative Example 2 of the present invention;
[0025] Figure 3 This is a scanning electron microscope image of the nickel-based alloy powder used in this invention. Detailed Implementation
[0026] To make the technical problems solved, the technical solutions, and the beneficial effects of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
[0027] In this invention, the additive manufacturing process includes depositing a continuous layer of nickel-based alloy powder, and then selectively melting and / or sintering the nickel-based alloy powder by laser to form a nickel-based alloy product layer by layer.
[0028] An embodiment of the present invention provides a powder bed melting forming method for nickel-based alloys to achieve customized microstructure and properties using dual lasers, comprising the following steps:
[0029] Import the 3D model into a 3D printer for processing;
[0030] Printing the first nickel-based alloy layer: The first layer of nickel-based alloy powder is laid to obtain the first nickel-based alloy powder bed. The first nickel-based alloy powder bed is scanned with the first laser to obtain the first nickel-based alloy layer. The operation is repeated n times to obtain n layers of the first nickel-based alloy layer.
[0031] Printing the second nickel-based alloy layer: A second layer of nickel-based alloy powder is laid to obtain a second nickel-based alloy powder bed. The second nickel-based alloy powder bed is scanned with a second laser to obtain the second nickel-based alloy layer. The spot diameter of the second laser is larger than that of the first laser. The operation is repeated m times to obtain m layers of the second nickel-based alloy layer.
[0032] By alternating between the "printing the first nickel-based alloy layer" and "printing the second nickel-based alloy layer" operations, a nickel-based alloy part with n alternating first nickel-based alloy layers and m alternating second nickel-based alloy layers along the laser printing direction is obtained.
[0033] In the forming process of nickel-based alloy parts, the laser spot diameter has a significant impact on the microstructure and mechanical properties of the formed part. Smaller diameter lasers generate finer grain structures, which improve the strength of the part; larger diameter lasers generate coarser grain structures, which reduce the strength of the part. The dual-laser powder bed melting forming method provided by this invention uses lasers of different diameters to print samples with alternating stacks and alternating microstructures. Compared with parts printed using only a large-diameter laser or only a small-diameter laser, the mechanical properties of the alternatingly printed parts, including tensile strength and yield strength, are between the two, thus achieving the goal of customizing the microstructure and properties of high-temperature alloy laser powder bed melting.
[0034] For example, under certain specific conditions, the mechanical properties of parts obtained by laser additive manufacturing using large-diameter lasers and small-diameter lasers alone cannot meet the performance requirements of the application environment. This manifests as follows: the yield strength and tensile strength of parts prepared using small-diameter lasers alone are too high; the yield strength and tensile strength of parts prepared using large-diameter lasers alone are insufficient. In this case, the dual-laser powder bed melting forming method provided by this invention can be used for alternating printing to obtain additive manufacturing materials that can meet both yield strength and tensile strength requirements.
[0035] In some embodiments, the spot diameter of the first laser is 50~90μm, and the spot diameter of the second laser is 400~600μm.
[0036] In a preferred embodiment, the spot diameter of the first laser is 65~75μm, and the spot diameter of the second laser is 450~550μm.
[0037] In some embodiments, the thickness of the first nickel-based alloy layer is 20-50 μm, and the thickness of the second nickel-based alloy layer is 50-80 μm.
[0038] In some embodiments, n is selected from an integer from 1 to 450, and m is selected from an integer from 1 to 450.
[0039] In a preferred embodiment, n is 1 and m is 1, and the resulting nickel-based alloy part is an alternating layer of a single-layer first nickel-based alloy layer and a single-layer second nickel-based alloy layer.
[0040] In some embodiments, the average particle size of the nickel-based alloy powder is 15~53 μm.
[0041] The preparation methods of the nickel-based alloy powder include gas atomization, water atomization, centrifugal atomization, ultrasonic atomization, electrolytic deposition, chemical reduction, and mechanical grinding.
[0042] In some embodiments, the nickel-based alloy powder comprises the following components by weight percentage:
[0043] The content of Cr is 17-21%, the content of Co is 0-1%, the content of Mo is 2.8-3.3%, the content of Fe is 16-22%, the content of Al is 0.3-0.7%, the content of Ti is 0.75-1.15%, the content of Nb is 4.75-5.5%, the content of Mg is 0-0.01%, the content of B is 0-0.006%, the content of Si is 0-0.35%, the content of Mn is 0-0.35%, the content of P is 0-0.015%, the content of S is 0-0.015%, the content of C is 0.02-0.06%, the content of Cu is 0-0.3%, the content of O is 0-0.03%, the content of N is 0-0.02%, and the balance is Ni.
[0044] It should be noted that the above are only preferred nickel-based alloy powder compositions of the present invention. In other embodiments, those skilled in the art may select other types of nickel-based alloy powders.
[0045] In some embodiments, the laser power of the first laser is 200~600W and the scanning speed is 100~1000mm / s; the laser power of the second laser is 600~900W and the scanning speed is 100~500mm / s.
[0046] In some embodiments, both the "printing of the first nickel-based alloy layer" and "printing of the second nickel-based alloy layer" operations are performed under a protective atmosphere.
[0047] The protective atmosphere can be selected from nitrogen, rare gases, etc., to prevent the nickel-based alloy from oxidizing during laser melting, which would affect the material properties.
[0048] Another embodiment of the present invention provides a nickel-based alloy part, which is prepared by the powder bed melt forming method described above.
[0049] The nickel-based alloy parts are prepared by the powder bed melt forming method described above, and have good customizable mechanical properties, effectively taking into account the advantages of different mechanical properties of nickel-based alloys.
[0050] In some embodiments, the yield strength of the nickel-based alloy part is 500~1000MPa and the tensile strength is 600~1200MPa.
[0051] The present invention will be further illustrated by the following examples.
[0052] Example 1
[0053] This embodiment illustrates the nickel-based alloy parts and their preparation method disclosed in this invention, and includes the following steps:
[0054] Inconel 718 powder was selected as the nickel-based alloy powder. Inconel 718 is a precipitation-hardening nickel-iron-based superalloy containing niobium and molybdenum, with an austenitic microstructure. The Inconel 718 alloy used in this embodiment was produced by Jiangsu Xinde Huarui Company using vacuum atomization technology. According to the quantitative chemical composition analysis report provided by Jiangsu Xinde Huarui Materials Testing Center, the chemical composition of the 718 alloy powder used in the experiment meets national standards, as shown in Table 1. Figure 3 Figures a and 3b show the morphology of Inconel 718 alloy powder obtained using a scanning electron microscope.
[0055] Table 1 Chemical composition (wt%) of Inconel 718 alloy powder.
[0056]
[0057] Printing was performed alternately using laser 1 (70 μm spot diameter) and laser 2 (500 μm spot diameter) on an SLM Solutions 280HL device. The layer thickness of the alternating stacks was 0.3 mm. The single layer thickness of laser 1 was 0.03 mm, with 10 layers forming one stacking cycle (0.03 × 10 = 0.3 mm). The single layer thickness of laser 2 was 0.06 mm, with 5 layers forming one stacking cycle (0.06 × 5 = 0.3 mm). A total of 90 stacked layers were formed. The dimensions of the nickel-based alloy sample were 10 mm × 10 mm × 27 mm (0.3 × 90 = 27 mm). The printing parameters for the two lasers are shown in Table 2.
[0058] Table 2 Printing parameters for the two lasers.
[0059]
[0060] Example 2
[0061] This comparative example is used to illustrate the nickel-based alloy parts and their preparation method disclosed in this invention, including most of the operational steps in Example 1, with the following differences:
[0062] Printing was performed alternately using laser 1 (70 μm spot diameter) and laser 2 (500 μm spot diameter) on an SLM Solutions 280HL device. The layer thickness of the alternating stacks was 0.6 mm. The single layer thickness of laser 1 was 0.03 mm, and 20 layers constituted one stacking cycle (0.03 × 20 = 0.6 mm). The single layer thickness of laser 2 was 0.06 mm, and 10 layers constituted one stacking cycle (0.06 × 10 = 0.6 mm). A total of 45 stacked layers were formed. The size of the nickel-based alloy sample was 10 mm × 10 mm × 27 mm (0.6 × 45 = 27 mm).
[0063] Example 3
[0064] This comparative example is used to illustrate the nickel-based alloy parts and their preparation method disclosed in this invention, including most of the operational steps in Example 1, with the following differences:
[0065] Printing was performed alternately using laser 1 (70 μm spot diameter) and laser 2 (500 μm spot diameter) on an SLM Solutions 280HL device. The layer thickness of the alternating stacks was 13.5 mm. The single layer thickness of laser 1 was 0.03 mm, and 450 layers constituted one stacking cycle (0.03 × 450 = 13.5 mm). The single layer thickness of laser 2 was 0.06 mm, and 225 layers constituted one stacking cycle (0.06 × 225 = 13.5 mm). A total of 2 stacked layers were formed. The size of the nickel-based alloy sample was 10 mm × 10 mm × 27 mm (13.5 × 2 = 27 mm).
[0066] Comparative Example 1
[0067] This comparative example is used to illustrate the nickel-based alloy parts and their preparation method disclosed in this invention, including most of the operational steps in Example 1, with the following differences:
[0068] The nickel-based alloy sample was printed using only laser number one.
[0069] Comparative Example 2
[0070] This comparative example is used to illustrate the nickel-based alloy parts and their preparation method disclosed in this invention, including most of the operational steps in Example 1, with the following differences:
[0071] The nickel-based alloy sample was printed using only the No. 2 laser.
[0072] Performance testing
[0073] The nickel-based alloy samples prepared above were subjected to the following performance tests:
[0074] I. Organizational Analysis
[0075] Microstructure analysis of nickel-based alloy samples was performed using optical microscopy and electron backscatter diffraction, and the results are as follows: Figure 1 and Figure 2 As shown.
[0076] Figure 1 a and 1f, Figure 1 b and 1g, Figure 1 c and 1h Figure 1 d and 1i Figure 1 e and 1j are microstructure diagrams of the nickel-based alloy samples provided in Comparative Example 1, Comparative Example 2, Example 1, Example 2, and Example 3, respectively.
[0077] Depend on Figure 1It can be seen that the nickel-based alloy samples obtained in Examples 1, 2, 3, Comparative Example 1 and Comparative Example 2 do not have obvious defects (pores, cracks). Meanwhile, the nickel-based alloy samples obtained in Examples 1, 2 and 3 show obvious interlocking and stacking of microstructures.
[0078] Figure 2 middle, Figure 2 (a) Electron backscattering microstructure of the nickel-based alloy sample provided in Comparative Example 1. Figure 2 (b) Electron backscattering microstructure of the nickel-based alloy sample provided in Comparative Example 2. Figure 2 (c) is an electron backscattering microstructure of the nickel-based alloy sample provided in Example 2.
[0079] Depend on Figure 2 It can be seen that the nickel-based alloy sample provided in Comparative Example 1 has finer grains, the nickel-based alloy sample provided in Comparative Example 2 has coarser grains, while the nickel-based alloy sample provided in Example 2 exhibits a microstructure with alternating layers of fine and coarse grains. Relatively speaking, the finer microstructure has higher strength, while the coarser microstructure has lower strength.
[0080] 2. The yield strength and tensile strength of the prepared nickel-based alloy samples were tested, and the test results were filled in Table 3.
[0081] Table 3 shows the yield strength and tensile strength of the prepared nickel-based alloy samples.
[0082]
[0083] As can be seen from the test results in Table 3, the nickel-based alloy sample provided in Comparative Example 1 has high yield strength and tensile strength; the nickel-based alloy sample provided in Comparative Example 2 has insufficient yield strength and tensile strength; while the various mechanical properties of the nickel-based alloy samples provided in Examples 1 to 3 are between those of Comparative Example 1 and Comparative Example 2. It can be seen that by controlling the number of stacked layers of lasers with different spot diameters, it is possible to design nickel-based alloys with yield strength and tensile strength between those of Comparative Example 1 and Comparative Example 2, thereby achieving the purpose of performance customization.
[0084] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A powder bed melting forming method for nickel-based alloys using dual lasers to achieve customized microstructure and properties, characterized in that, The following steps are included: Import the 3D model into a 3D printer for processing; Printing the first nickel-based alloy layer: The first layer of nickel-based alloy powder is laid to obtain the first nickel-based alloy powder bed. The first nickel-based alloy powder bed is scanned with the first laser to obtain the first nickel-based alloy layer. The operation is repeated n times to obtain n layers of the first nickel-based alloy layer. Printing the second nickel-based alloy layer: A second layer of nickel-based alloy powder is laid to obtain a second nickel-based alloy powder bed. The second nickel-based alloy powder bed is scanned with a second laser to obtain the second nickel-based alloy layer. The spot diameter of the second laser is larger than that of the first laser. The operation is repeated m times to obtain m layers of the second nickel-based alloy layer. The diameter of the first laser spot is 30~100μm, and the diameter of the second laser spot is 300~700μm; The nickel-based alloy powder comprises the following components by weight percentage: The content of Cr is 15-22%, the content of Co is 0-2%, the content of Mo is 2.5-3.5%, the content of Fe is 15-25%, the content of Al is 0.2-0.8%, the content of Ti is 0.6-1.2%, the content of Nb is 4.5-6%, the content of Mg is 0-0.05%, the content of B is 0-0.01%, the content of Si is 0-0.4%, the content of Mn is 0-0.4%, the content of P is 0-0.02%, the content of S is 0-0.02%, the content of C is 0.01-0.08%, the content of Cu is 0-0.5%, the content of O is 0-0.05%, the content of N is 0-0.05%, and the balance is Ni. The operation of "printing the first nickel-based alloy layer" and "printing the second nickel-based alloy layer" is alternately cycled to obtain a nickel-based alloy part with n layers of the first nickel-based alloy layer and m layers of the second nickel-based alloy layer alternating along the laser printing direction, where n is an integer selected from 1 to 500 and m is an integer selected from 1 to 500.
2. The powder bed melt forming method according to claim 1, characterized in that, The thickness of each first nickel-based alloy layer is 10~100μm, and the thickness of each second nickel-based alloy layer is 10~100μm.
3. The powder bed melt molding method according to claim 1, characterized in that, The average particle size of the nickel-based alloy powder is 10~105μm.
4. The powder bed melt molding method according to claim 1, characterized in that, The first laser has a laser power of 100~700W and a scanning speed of 100~10000mm / s; the second laser has a laser power of 500~1000W and a scanning speed of 100~10000mm / s.
5. The powder bed melt molding method according to claim 1, characterized in that, Both the "printing the first nickel-based alloy layer" and "printing the second nickel-based alloy layer" operations are performed under a protective atmosphere.
6. A nickel-based alloy part, characterized in that, It is prepared by the powder bed melt forming method as described in any one of claims 1 to 5.
7. The nickel-based alloy part according to claim 6, characterized in that, The yield strength of the nickel-based alloy part is 400~1100MPa, and the tensile strength is 500~1300MPa.