Ceramic reinforced metal matrix composite based on water guided laser and method for manufacturing thereof

Abstract

The application discloses a ceramic reinforced metal matrix composite based on water-guided laser and a preparation method thereof, and the method comprises the following steps: S1, a first laser is passed through a coupling solution cavity to form a solution beam fiber, the solution beam fiber reaches the surface of a metal matrix semi-finished product, and then the solution is decomposed in situ on the surface of the metal matrix semi-finished product to form ceramic phase particles; S2, a second laser is introduced to locally sinter the region where the ceramic phase particles are located, so that the ceramic particles are dispersedly distributed in the region, and then heat treatment is performed to obtain the ceramic reinforced metal matrix composite. The application combines the water-guided laser technology with the ceramic reinforced metal matrix composite preparation method, does not need to consider the focusing and defocusing characteristics of the laser beam, and the solution beam fiber can process complex curved surfaces and multi-layer composite structures on a stable length, so that any large-size and complex geometric part can be formed, and the defects of traditional processing methods are compensated. Meanwhile, the powdering process of ceramic particles is omitted, and the cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing technology, and in particular to a ceramic-reinforced metal matrix composite material based on water-guided laser and its preparation method. Background Technology

[0002] With the development of modern technology, materials with single properties are no longer sufficient to meet the requirements of modern industry and production. Composite materials have become increasingly prominent, and the preparation of high-performance composite materials has become an important topic. Ceramic-reinforced metal matrix composites are a new type of composite material. They are formed by continuously and uniformly dispersing ceramic particles into a metal matrix through a process. They not only possess the ductility and toughness of metals but also exhibit high strength and stiffness. They are widely used in high-load, high-wear, and high-temperature environments in aerospace and automotive fields, becoming an important industrial material.

[0003] Currently, common processing methods for ceramic-reinforced metal matrix composites include stir casting, powder metallurgy, extrusion casting, and spray molding. However, each method has its drawbacks. For example, stir casting is prone to ceramic particle deposition and agglomeration, introducing porosity; extrusion casting is difficult to process large-sized parts. In recent years, the rise of additive manufacturing technology has provided a new processing approach for ceramic-reinforced metal matrix composites. Additive manufacturing can meet the free forming requirements of complex geometric parts and the processing needs of ceramic-reinforced metal matrix composites. Currently, the main process for processing parts through additive manufacturing is: pre-mixing metal matrix powder and ceramic reinforcing phase particles, followed by laser sintering. However, during the powder mixing process, factors such as the compatibility between the reinforcing particles and the metal matrix, particle surface contamination, surface chemical treatment processes, and whether the two powders can be fully mixed, and whether particle deposition and agglomeration will occur, all need to be considered. This makes it difficult for additive manufacturing to fully utilize the advantages of the reinforcing phase. In summary, existing methods for processing ceramic-reinforced metal matrix composites lack an efficient and rapid approach.

[0004] Water-guided laser technology couples a high-energy laser beam into a fine water jet, which guides the laser to the workpiece surface for processing. The cooling effect of the water jet significantly reduces the heat-affected zone, thermal stress, microcracks, and physicochemical deformation of the material, and significantly reduces the surface roughness of the processed surface, exhibiting excellent performance. Currently, water-guided lasers are mainly used for cutting, and there are few reports of their application in additive manufacturing. Summary of the Invention

[0005] To address the shortcomings of existing processing methods for ceramic-reinforced metal matrix composites, this invention provides a method for preparing ceramic-reinforced metal matrix composites based on water-guided laser technology. This method involves coupling an inorganic salt solution with a laser, using laser energy to thermally decompose the inorganic salt solution into ceramic phase particles. These particles are then locally sintered to obtain the ceramic-reinforced metal matrix composite, and finally, the entire composite is sintered to obtain the final ceramic-reinforced metal matrix composite. Combining water-guided laser technology with the processing method for ceramic-reinforced metal matrix composites results in a simple and efficient process that avoids particle deposition and agglomeration, fully leveraging the advantages of the reinforcing phase, and offering significant advantages in the molding of complex components.

[0006] To achieve the above objectives, the present invention provides a method for preparing ceramic-reinforced metal matrix composite materials based on water-guided lasers, comprising,

[0007] S1. The first laser is coupled through a solution cavity to form a solution bundle fiber. The solution bundle fiber reaches the surface of the metal-based semi-finished product. Subsequently, the solution decomposes in situ on the surface of the metal-based semi-finished product to form ceramic phase particles.

[0008] S2. A second laser is introduced to locally sinter the region where the ceramic phase particles are located, so that the ceramic particles are dispersed in the region, and then heat treatment is performed to obtain a ceramic-reinforced metal matrix composite material.

[0009] Furthermore, after the solution bundle fiber is formed in step S1, it passes through a gas-liquid coupling cavity to wrap the solution bundle fiber with an annular gas bundle. Wrapping the solution bundle fiber with an annular gas bundle can enhance the focus of the processing area and effectively prevent water accumulation in the processing area, thus preventing water accumulation from damaging the water bundle and affecting laser transmission.

[0010] A solution bundle optical fiber containing a ring-shaped gas beam reaches the surface of a metal-based semi-finished product, where the solution decomposes in situ to form ceramic phase particles.

[0011] Furthermore, the solution in the coupling solution cavity is at least one of aluminum ion solution, magnesium ion solution, or silicon ion solution.

[0012] Furthermore, the ion concentration of the solution in the coupling solution chamber is 0.1–2 mol / L.

[0013] In inorganic salt solutions, the solute is uniformly dissolved during preparation, and the heating is also relatively uniform after total laser reflection. The stable solution flow provides a vertical scouring stress to the precipitated ceramic particles, resulting in a more uniform distribution of ceramic phase particles within the metal matrix. The laser energy distribution within the solution jet cross-section is also more uniform, rather than Gaussian, leading to a smoother surface in the reaction plane between the ceramic particles and the metal matrix. Compared to current powder metallurgy and additive manufacturing methods for ceramic-reinforced metal matrix composites, this approach avoids the deposition and agglomeration of ceramic particles, resulting in a significant strengthening effect. By introducing laser light into the solution, uneven surfaces generated during laser sintering can be effectively avoided. The cooling effect of the solution significantly reduces the heat-affected zone, thermal stress, microcracks, and physicochemical deformation of the material. Simultaneously, the scouring effect of the solution reduces the roughness of the processed surface, resulting in higher-quality surface morphology or structure.

[0014] After preparation is completed in the embodiments of the present invention, the solution in the coupling solution chamber can be recycled and reused.

[0015] Furthermore, the power of the first laser is 1000W to 1500W, which allows for a solution layer thickness of 10 to 20 μm to be separated. The first laser is provided by a first laser source, which has multiple laser beams, allowing for adjustment of the number of laser beams, strengthening or weakening the coupling power of the laser beams in the solution, and adjusting both the laser energy and the inorganic salt precipitation efficiency.

[0016] Furthermore, the power of the second laser is 200-400W and the scanning speed is 200-800mm / s.

[0017] Furthermore, the metal-based semi-finished product is obtained by laser sintering of metal powder, with the laser parameters being as follows.

[0018] Furthermore, the metal powder is at least one of aluminum powder, magnesium powder, copper powder, iron powder, titanium powder, nickel powder, and cobalt powder.

[0019] Furthermore, the heat treatment involves sintering at 1000–1500°C. This temperature range is higher than the thermal decomposition temperature of the inorganic salt solution. Holding at this temperature ensures the complete decomposition of the remaining inorganic salts, which are then dispersed in situ within the metal matrix, thus providing further dispersion strengthening.

[0020] The present invention also provides a ceramic-reinforced metal matrix composite material, which is prepared by the above method.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] This invention utilizes water-guided laser technology combined with a method for preparing ceramic-reinforced metal matrix composites. It eliminates the need to consider the focusing and defocusing characteristics of the laser beam. The solution-beamed optical fiber can process complex curved surfaces and multi-layered composite structures at a stable length, thus enabling the forming of any large-sized and complex geometric parts, overcoming the shortcomings of traditional processing methods. At the same time, it eliminates the need for the powdering process of ceramic particles, reducing costs. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 A schematic diagram of the apparatus used in an embodiment of the present invention is shown;

[0025] Figure 2 A flowchart of Embodiment 2 of the present invention is shown. Detailed Implementation

[0026] The technical solutions of the present invention will be clearly and completely described below with reference to specific embodiments and accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] The apparatus used in the embodiments can refer to existing water-guided laser devices, such as the water-guided laser drilling system and method disclosed in CN113751900A. The apparatus structure in the embodiments is simplified as follows: Figure 1 It should be noted that the device is not an improvement on the present invention.

[0028] Example 1

[0029] The preparation method of ceramic-reinforced metal matrix composites based on water-guided lasers includes the following steps:

[0030] S1. Prepare a 0.5 mol / L Al2(SO4)3 solution and load it into the coupling solution chamber; lay AlCrCoFeNiTi metal powder, which is widely used in additive manufacturing, and obtain a metal-based semi-finished product by laser sintering. The laser power is 275W, the laser scanning speed is 760mm / s, the laser filling spacing h is 0.12mm, and the thickness of each printing layer is 40μm, finally obtaining a metal-based semi-finished product with a length, width and height of 2cm×2cm×1mm; set the power of the first laser to 1000W, the power of the second laser to 300W, and the scanning speed to 500mm / s;

[0031] S2. Turn on the first laser and the coupling solution cavity. The first laser emitted by the first laser undergoes total internal reflection through the inner surface of the coupling solution cavity to form a solution bundle fiber. The solution bundle fiber reaches the surface of the metal-based semi-finished product. Subsequently, the solution decomposes in situ on the surface of the metal-based semi-finished product to form ceramic phase particles.

[0032] S3. Turn on the second laser and introduce the second laser to perform local sintering on the area where the ceramic phase particles are located, so that the ceramic particles are dispersed in the area.

[0033] S4. The product obtained in step S3 is sintered at 1200℃ to obtain a ceramic-reinforced metal matrix composite material.

[0034] Example 2

[0035] like Figure 2 As shown, the preparation method of ceramic-reinforced metal matrix composite material based on water-guided laser includes the following steps:

[0036] S1. Prepare a 0.5 mol / L Al2(SO4)3 solution and load it into the coupling solution chamber; lay AlCrCoFeNiTi metal powder, which is widely used in additive manufacturing, and obtain a metal-based semi-finished product by laser sintering. The laser power is 275W, the laser scanning speed is 760mm / s, the laser filling spacing h is 0.12mm, and the thickness of each printing layer is 40μm, finally obtaining a metal-based semi-finished product with a length, width and height of 2cm×2cm×1mm; set the power of the first laser to 1000W, the power of the second laser to 300W, and the scanning speed to 500mm / s;

[0037] S2. Turn on the first laser, the coupling solution cavity and the gas-liquid coupling cavity. The first laser emitted by the first laser undergoes total internal reflection through the inner surface of the coupling solution cavity to form a solution bundle fiber. Then, it passes through the gas-liquid coupling cavity to form a solution bundle fiber wrapped with an annular gas bundle. The solution bundle fiber wrapped with an annular gas bundle reaches the surface of the metal-based semi-finished product. Subsequently, the solution decomposes in situ on the surface of the metal-based semi-finished product to form ceramic phase particles.

[0038] S3. Turn on the second laser and introduce the second laser to perform local sintering on the area where the ceramic phase particles are located, so that the ceramic particles are dispersed in the area.

[0039] S4. The product obtained in step S3 is sintered at 1200℃ to obtain a ceramic-reinforced metal matrix composite material.

[0040] Comparative Example

[0041] Preparation methods of ceramic-reinforced metal matrix composites

[0042] S1. Prepare a 0.5 mol / L Al2(SO4)3 solution; lay up AlCrCoFeNiTi metal powder, which is widely used in additive manufacturing, and obtain a metal-based semi-finished product by laser sintering. The laser power is 275W, the laser scanning speed is 760mm / s, the laser filling spacing h is 0.12mm, and the thickness of each printing layer is 40μm, finally obtaining a metal-based semi-finished product with a length, width and height of 2cm×2cm×1mm; coat the metal-based semi-finished product with a 0.5 mol / L Al2(SO4)3 solution, the thickness of the solution is 50μm; dry the Al2(SO4)3 solution at 300℃, and ceramic phase particles are formed on the metal-based semi-finished product;

[0043] S2. The product obtained in step S2 is sintered at 1200℃ to obtain a ceramic-reinforced metal matrix composite material.

[0044] Observation of the appearance of the ceramic-reinforced metal matrix composites prepared in Examples 1, 2, and the comparative example revealed that, compared to the comparative example, Examples 1 and 2 exhibited significantly lower surface roughness and fewer microcracks, especially Example 2. This is because the stable solution flow provides a vertical scouring stress to the precipitated ceramic particles, resulting in a more uniform distribution of ceramic phase particles in the metal matrix, preventing deposition and agglomeration of ceramic particles, and significantly enhancing the strengthening effect. In Example 2, compared to Example 1, an annular gas beam is used to wrap around the solution-bundled optical fiber, enhancing the focus of the processing area and effectively preventing water accumulation in the processing area, thus avoiding water damage to the water beam and affecting laser transmission.

[0045] In summary, this invention utilizes laser energy to thermally decompose an inorganic salt solution into ceramic phase particles, which are then locally sintered to obtain the aforementioned ceramic-reinforced metal matrix composite material. Finally, the entire composite material is sintered to obtain the final ceramic-reinforced metal matrix composite material. Combining water-guided laser technology with the processing method of ceramic-reinforced metal matrix composite materials results in a simple and efficient process that avoids particle deposition and agglomeration, fully leveraging the advantages of the reinforcing phase, and offering significant advantages in the molding of complex components.

[0046] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing ceramic-reinforced metal matrix composites based on water-guided lasers, characterized in that, Includes the following steps, S1. The first laser is coupled through a solution cavity to form a solution bundle fiber. The solution bundle fiber reaches the surface of the metal-based semi-finished product. Subsequently, the solution decomposes in situ on the surface of the metal-based semi-finished product to form ceramic phase particles. S2. A second laser is introduced to locally sinter the region where the ceramic phase particles are located, so that the ceramic particles are dispersed in the region, and then heat treatment is performed to obtain a ceramic-reinforced metal matrix composite material. The solution in the coupling solution chamber is at least one of aluminum ion solution, magnesium ion solution or silicon ion solution; The ion concentration of the solution in the coupling solution chamber is 0.1~2 mol / L; The power of the first laser is 1000W~1500W; Introducing laser into the solution can effectively avoid the uneven surface generated during laser sintering. The cooling effect of the solution can significantly reduce the heat-affected zone, thermal stress, microcracks and physicochemical deformation of the material. At the same time, the scouring effect of the solution can reduce the roughness of the processed surface and obtain a higher quality surface morphology or structure. The metal-based semi-finished product is obtained by laser sintering of metal powder.

2. The method for preparing ceramic-reinforced metal matrix composite material based on water-guided laser according to claim 1, characterized in that, After the solution bundle fiber is formed in step S1, it passes through a gas-liquid coupling cavity to wrap the solution bundle fiber with an annular gas bundle. A solution bundle optical fiber containing a ring-shaped gas beam reaches the surface of a metal-based semi-finished product, where the solution decomposes in situ to form ceramic phase particles.

3. The method for preparing ceramic-reinforced metal matrix composite material based on water-guided laser according to claim 1, characterized in that, The power of the second laser is 200~400W and the scanning speed is 200~800mm / s.

4. The method for preparing ceramic-reinforced metal matrix composite material based on water-guided laser according to claim 1, characterized in that, The metal powder is at least one of aluminum powder, magnesium powder, chromium powder, copper powder, iron powder, titanium powder, nickel powder, and cobalt powder.

5. The method for preparing ceramic-reinforced metal matrix composite material based on water-guided laser according to claim 1, characterized in that, The heat treatment involves sintering at 1000~1500℃.

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