Method for high-magnesium element doped additive manufacturing of nickel-based superalloy material and application thereof

Abstract

This invention belongs to the field of metal additive manufacturing, and relates to a method for additive manufacturing of nickel-based superalloy materials with high magnesium doping and its application. Nickel-based superalloy powder and NiMg master alloy powder are used as raw materials for additive manufacturing; wherein, the mass of Mg in the NiMg master alloy powder is 0.06–0.21 wt.% of the total alloy powder mass, and the total alloy powder mass is the sum of the masses of the nickel-based superalloy powder and the NiMg master alloy powder. The method of this invention not only enables the manufacture of complex parts through additive manufacturing, but also improves the morphology of carbides, significantly enhancing the mechanical properties of additively manufactured nickel-based superalloy components.

Description

Technical Field

[0001] This invention belongs to the field of metal additive manufacturing, and relates to a method for additive manufacturing of nickel-based superalloy materials with high magnesium doping and its application. Background Technology

[0002] The information disclosed in this background section is intended only to enhance understanding of the overall background of the invention and is not necessarily to be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.

[0003] Nickel-based superalloys are materials developed from Cr20Ni80 alloys. They possess high strength, good oxidation resistance, good creep strength and endurance strength, and resistance to combustion gas corrosion under high-temperature conditions. They are mainly used to manufacture hot-end components such as flame tubes and combustion chambers in advanced aero-engines, as well as some high-temperature corrosion-resistant components in the chemical industry. However, the structures of these components are generally complex, and processing them using traditional forming processes such as casting and forging suffers from long development cycles and high processing costs.

[0004] Meanwhile, to meet the service requirements in high-temperature environments, a large number of strengthening elements are added to nickel-based superalloys to ensure their excellent high-temperature performance. Different alloying elements have vastly different effects on phase stability within the alloy. For example, Co, Cr, Fe, and W can strengthen γ-phase solid solution, Al, Ti, Nb, and Ta can strengthen precipitation, and C, B, Hf, and Mg can strengthen grain boundaries. As temperature increases, both grain strength and grain boundary strength decrease. However, due to the irregular atomic arrangement at grain boundaries, diffusion easily occurs through them, leading to a faster decrease in grain boundary strength. Therefore, for superalloys, the grain boundary state has a significant impact on the high-temperature service performance. Adding carbon (C) to the alloy can improve grain boundary bonding and form carbides that act as grain boundary pinning agents, hindering grain boundary sliding and thus improving the alloy's high-temperature service performance. However, excessive addition of C will increase the size of the carbides. For example, after heat treatment, large blocky carbides will form at the grain boundaries of alloys such as IN718 and IN738, becoming stress concentration points during load-bearing and deteriorating the alloy's performance. Therefore, larger grain boundary carbides need to undergo modification treatment. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide a method for additive manufacturing of nickel-based superalloy materials with high magnesium doping and its application. This method not only enables the manufacturing of complex components through additive manufacturing, but also improves the morphology of carbides and significantly enhances the mechanical properties of additively manufactured nickel-based superalloy components.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows:

[0007] On one hand, a method for additive manufacturing of nickel-based superalloy materials with high magnesium doping involves using nickel-based superalloy powder and NiMg master alloy powder as raw materials for additive manufacturing; wherein, the mass of Mg in the NiMg master alloy powder is 0.06 to 0.21 wt.% of the total alloy powder mass, and the total alloy powder mass is the total mass of the nickel-based superalloy powder and the NiMg master alloy powder.

[0008] This invention employs additive manufacturing, based on the forming principle of layered manufacturing. Software can be used to slice the three-dimensional model of a part into layers, and a high-power-density heat source is used to stack the material point-by-point and layer-by-layer, directly obtaining high-performance, high-density parts. The ultra-high degree of freedom in the additive manufacturing process allows for the integrated forming of parts with arbitrarily complex three-dimensional structures, with virtually no need for subsequent processing.

[0009] As a grain boundary strengthening element, magnesium (Mg) segregates at grain boundaries, reducing grain boundary energy and phase boundary energy. It also improves the morphology of grain boundary carbides, effectively pinning grain boundaries, inhibiting grain boundary movement and grain growth, and reducing stress concentration caused by large carbides at grain boundaries. This positively impacts alloy strength, creep performance, and impact toughness. Furthermore, Mg can purify grain boundaries, reducing the harmful effects of impurities such as O, S, and P. However, Mg powder is extremely reactive; it releases a large amount of heat and spontaneously combusts when exposed to moisture, posing significant safety hazards during its production, transportation, storage, and use, making it difficult to directly apply to the additive manufacturing process of nickel-based superalloys. Moreover, during vacuum arc melting and powder preparation, Mg is easily burned off, making it difficult to precisely control the Mg content in additive nickel-based alloy powders. Therefore, this invention adds NiMg master alloy powder, utilizing the fact that the melting temperature of NiMg master alloy is higher than that of pure magnesium, reducing Mg burn-off and achieving precise control of the Mg content in additive nickel-based alloy powders.

[0010] However, magnesium (Mg) is a grain boundary segregation element with an extremely high equilibrium distribution coefficient. Studies have shown that even if the Mg content in an alloy is only 0.002 wt.%, the Mg content at the grain boundaries can reach 4.1 wt.%. When the Mg content is too high, a Ni-Ni2Mg low-melting-point eutectic (1095℃) will appear at the grain boundaries, greatly deteriorating the hot working properties of the alloy. Therefore, the Mg content in existing Mg-containing nickel-based superalloys is generally below 0.01 wt.%. However, this trace amount of Mg is far from sufficient to modify the large carbides in nickel-based superalloys. The additive manufacturing method used in this invention has a high temperature gradient and cooling rate, which allows the material to form fine cellular structures and precipitates. At the same time, by using NiMg master alloy powder with Mg content of 0.06–0.21 wt.% of the total alloy powder mass, the Mg content in the nickel-based superalloy is increased, thereby causing the large carbides at the grain boundaries to disappear and the length and width of the chain carbides to be significantly reduced. Although this invention adds a relatively large amount of Mg, the increased number of grain boundaries prevents Mg from becoming excessively concentrated at any particular grain boundary, thereby inhibiting the formation of low-melting-point eutectics and significantly improving the mechanical properties of additively manufactured nickel-based superalloy components.

[0011] On the other hand, a nickel-based superalloy product is obtained using the above method.

[0012] Thirdly, the application of the aforementioned nickel-based high-temperature alloy product in aerospace, medical devices, marine vessels, or petrochemicals.

[0013] Fourthly, the application of a mixed alloy powder in additive manufacturing of nickel-based superalloy products, wherein the mixed alloy powder comprises nickel-based superalloy powder and NiMg master alloy powder, wherein the mass of Mg in the NiMg master alloy powder is 0.06 to 0.21 wt.% of the total alloy powder mass, and the total alloy powder mass is the total mass of the nickel-based superalloy powder and the NiMg master alloy powder.

[0014] The beneficial effects of this invention are as follows:

[0015] (1) The present invention uses NiMg master alloy powder to introduce Mg element into nickel-based high-temperature alloy powder for additive manufacturing. Compared with using elemental Mg powder directly, it is safer and more suitable for actual production applications, and at the same time improves the problem of difficulty in controlling the amount of element added due to Mg element burn-off.

[0016] (2) The NiMg master alloy powder added in this invention contains only two main alloying elements, Ni and Mg, which can avoid introducing other unnecessary elements into the original nickel-based high-temperature alloy and prevent defects in the additively manufactured parts.

[0017] (3) Experiments show that after additive manufacturing using NiMg master alloy powder and nickel-based superalloy powder, no obvious defects (macroscopic cracking, porosity, microcracks, etc.) are generated in the formed parts. Compared with the original powder formed parts, the microhardness of the Mg-doped powder formed parts is increased by about 24%. In addition, after heat treatment, the large carbides at the grain boundaries of the Mg-doped powder formed parts disappear, and the length and width of the chain carbides are significantly reduced. Attached Figure Description

[0018] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0019] Figure 1 Metallographic photographs of the molded parts prepared in Example 1 and the comparative example of the present invention, (a) is the comparative example, and (b) is Example 1;

[0020] Figure 2 The graph shows the microhardness test results of the molded parts prepared in Example 1 and the comparative example of the present invention.

[0021] Figure 3 The images shown are scanning electron microscope (SEM) images of the molded parts prepared in Example 1 and the comparative example of the present invention. (a) is a low-magnification SEM of the comparative example, (b) is a low-magnification SEM of Example 1, (c) is a high-magnification SEM of part c in (a), and (d) is a high-magnification SEM of part d in (b). Detailed Implementation

[0022] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0023] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0024] The term "Ni-Cr-Co alloy" refers to a precipitation-strengthened nickel-based superalloy used in additive manufacturing. Its main components are: Cr+Co: 24.1–25.8 wt.%; Mo+W: 3.9–4.7 wt.%; Al+Ti+Ta: 6.3–8.1 wt.%; B+Zr+C: 0.5–0.7 wt.%. Under optimized process parameters, samples formed by selective laser melting (SLM) show no obvious defects (macroscopic cracking, porosity, microcracks, etc.).

[0025] The term "Ni-Cr-Co(Mg) alloy" refers to a Ni-Cr-Co alloy doped with Mg.

[0026] The term "Ni-Cr-W alloy" refers to a solid solution strengthened nickel-based superalloy used in additive manufacturing. Its main components are: Cr+W: 33.5–39.4 wt.%; Mo+Co: 3.4–4.7 wt.%; Al+Ti+Ta: 0.2–0.4 wt.%; B+Zr+C: 0.4–0.6 wt.%. Under optimized process parameters, the samples formed by SLM (Solar Laminate Manufacturing) show no obvious defects (macroscopic cracking, porosity, microcracks, etc.).

[0027] The term "Ni-Cr-W(Mg) alloy" refers to a Ni-Cr-W alloy doped with Mg.

[0028] The term "Ni-Fe-Cr alloy" refers to a precipitation-strengthened nickel-based superalloy used in additive manufacturing. Its main components are: Fe+Cr: 35.1–38.8 wt.%; Mo+Co+Nb: 8.6–9.7 wt.%; Al+Ti+Ta: 0.3–0.5 wt.%; B+Zr+C: 0.3–0.4 wt.%. Under optimized process parameters, the samples formed by SLM (Self-Made Metallic Lubrication) show no obvious defects (macroscopic cracking, porosity, microcracks, etc.).

[0029] The term "Ni-Fe-Cr(Mg) alloy" refers to a Ni-Fe-Cr alloy doped with Mg.

[0030] The term "forming direction" refers to the direction perpendicular to the printed substrate during the SLM forming process.

[0031] The term "γ′ phase" refers to Ni3(Al,Ti) phase, which is produced during the SLM forming process of nickel-based superalloys. It can precipitate in the matrix and play a certain role in strengthening the alloy.

[0032] The term "carbide" refers to the product obtained by the reaction of carbon with metal at high temperatures. In nickel-based superalloys, the main carbide-forming elements are W, Cr, Mo, and Ti. Small, granular carbides are distributed at grain boundaries, which can prevent intergranular sliding and crack propagation.

[0033] The term "strain aging crack" refers to the formation of microcracks due to the precipitation of the "γ′ phase" under the coupling effect of thermal stress and strain. These cracks are called "strain aging cracks" and are characterized by most of them being perpendicular to the printing direction.

[0034] The term "hot crack" refers to microcracks formed during the SLM forming process, characterized by cracks that are parallel to the SLM forming direction.

[0035] Given the current shortcomings of nickel-based superalloys in preparing complex structural components, such as long development time, high processing cost, and excessive addition of carbon leading to deterioration of alloy performance, this invention proposes a method for additive manufacturing of nickel-based superalloy materials with high magnesium doping and its application.

[0036] A typical embodiment of the present invention provides a method for additive manufacturing of nickel-based superalloy materials with high magnesium doping, wherein nickel-based superalloy powder and NiMg master alloy powder are used as raw materials for additive manufacturing; wherein the mass of Mg in the NiMg master alloy powder is 0.06 to 0.21 wt.% of the total alloy powder mass, and the total alloy powder mass is the total mass of nickel-based superalloy powder and NiMg master alloy powder.

[0037] Excessive magnesium content will lead to unstable molten pool behavior, resulting in process porosity and excessive spatter, severely affecting the surface quality of the formed parts. Simultaneously, excessive Mg content will promote the formation of large-sized Ni-Ni2Mg low-melting-point eutectic, increasing crack sensitivity and deteriorating hot working performance.

[0038] Additive manufacturing methods include selective electron beam melting, selective laser melting, and fused deposition modeling. In some embodiments, selective laser melting is used. Studies have shown that selective laser melting works better with NiMg master alloy powder. Specifically, the parameters are: laser power 180–200 W, scanning speed 800–1000 mm / s, layer thickness 30–50 μm, and scanning spacing 100–120 μm.

[0039] In some embodiments, nickel-based superalloy powder and NiMg master alloy powder are uniformly mixed before additive manufacturing. Ensuring uniform Mg distribution better eliminates large carbide deposits at grain boundaries.

[0040] In one or more embodiments, high-speed centrifugal stirring is used for mixing, with a speed of 900–1300 rpm. This method offers higher mixing efficiency and allows for better distribution of magnesium. During mixing, the mixture is cooled for 10–20 minutes after every 1–2 minutes of mixing to avoid excessively high temperatures that could lead to powder oxidation.

[0041] In some embodiments, the NiMg master alloy powder is one or more of NiMg20 master alloy powder, NiMg30 master alloy powder, and NiMg50 master alloy powder.

[0042] In some embodiments, the particle size distribution of the NiMg master alloy powder is 0.5 to 1.5 μm; this particle size range is selected to make the NiMg master alloy powder more uniformly distributed in the nickel-based superalloy powder.

[0043] In some embodiments, the particle size distribution of the nickel-based superalloy powder is 15–53 μm; this particle size range is selected because the powder has better flowability, which is beneficial for powder spreading and feeding, and the surface quality of the formed parts is also better.

[0044] Another embodiment of the present invention provides a nickel-based superalloy product obtained by the above method.

[0045] The product described in this invention can be a molded part, such as a component or part, or it can be a material.

[0046] A third embodiment of the present invention provides an application of the above-mentioned nickel-based high-temperature alloy product in aerospace, medical devices, marine vessels, or petrochemicals.

[0047] In aerospace applications, such as hot-end components of aircraft engines, including flame tubes and combustion chambers.

[0048] Applications in marine vessels, such as ship engines.

[0049] In petrochemical applications, such as drilling equipment, pipelines, valves, and heat exchangers.

[0050] A fourth embodiment of the present invention provides an application of a mixed alloy powder in additive manufacturing of nickel-based superalloy products. The mixed alloy powder includes nickel-based superalloy powder and NiMg master alloy powder, wherein the mass of Mg in the NiMg master alloy powder is 0.06 to 0.21 wt.% of the total alloy powder mass, and the total alloy powder mass is the total mass of the nickel-based superalloy powder and the NiMg master alloy powder.

[0051] In some embodiments, the NiMg master alloy powder is one or more of NiMg20 master alloy powder, NiMg30 master alloy powder, and NiMg50 master alloy powder.

[0052] In some embodiments, the average particle size of the NiMg master alloy powder is 0.5–1.5 μm.

[0053] In some embodiments, the particle size distribution of the nickel-based superalloy powder is 15–53 μm.

[0054] In some embodiments, the nickel-based superalloy powder is Ni-Cr-Co alloy powder, Ni-Cr-W alloy powder, or Ni-Fe-Cr alloy powder.

[0055] To enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be described in detail below with reference to specific embodiments and comparative examples.

[0056] Example 1

[0057] A method for additive manufacturing of nickel-based superalloy components, comprising the following specific steps:

[0058] (1) Ni-Cr-Co alloy powder with an average particle size of 27.6 μm and NiMg30 master alloy powder with an average particle size of 1 μm were selected and prepared into Ni-Cr-Co(Mg) alloy powder theoretically containing 0.12 wt.% Mg by mass ratio of 99.6:0.4. After detection by inductively coupled plasma atomic emission spectrometry (ICP), it was confirmed that the powder did contain approximately 0.12 wt.% Mg.

[0059] (2) Next, the Ni-Cr-Co(Mg) alloy powder is subjected to double centrifugal high-speed mixing. The mixing speed is 1100 rpm and the time is 1 minute and 30 seconds each time. After each mixing, the powder is cooled for 15 minutes before the next mixing is carried out until the powder is mixed evenly and there is no obvious agglomeration.

[0060] (3) The Ni-Cr-Co(Mg) powder obtained in the previous step was formed using a Concept Laser Mlab 200R metal additive manufacturing system. The detailed process parameters are as follows: laser power 190W, scanning speed 900mm / s, layer thickness 40μm, and scanning spacing 110μm. ICP testing of the formed part revealed that it contained approximately 0.12wt.% Mg, and the burn-off condition was significantly improved.

[0061] Comparative Example

[0062] A method for additive manufacturing of nickel-based superalloy components, comprising the following specific steps:

[0063] Ni-Cr-Co powder was formed by SLM using a Concept Laser Mlab 200R metal additive manufacturing system. The detailed process parameters are as follows: laser power 190W, scanning speed 900mm / s, layer thickness 40μm, and scanning spacing 110μm.

[0064] The formability, microstructure, and performance test results of the SLM-formed Ni-Cr-Co alloy prepared in Example 1 and the comparative SLM-formed Ni-Cr-Co(Mg) alloy are as follows: Figures 1-3 As shown.

[0065] Figure 1 Metallographic images of the SLM-formed Ni-Cr-Co alloy prepared in Example 1 and the SLM-formed Ni-Cr-Co(Mg) alloy of the comparative example are shown. It can be seen that the Ni-Cr-Co alloy has no microcracks, only a small amount of porosity; the Ni-Cr-Co(Mg) alloy also has no microcracks, only a small amount of porosity. This indicates that the trace doping of the NiMg30 intermediate alloy powder did not deteriorate the SLM formability of the original Ni-Cr-Co alloy.

[0066] Figure 2 This study compares the room-temperature microhardness of the SLM-formed Ni-Cr-Co alloy prepared in Example 1 and the comparative SLM-formed Ni-Cr-Co(Mg) alloy. Hardness tests were performed on seven random points on both the Ni-Cr-Co and Ni-Cr-Co(Mg) alloys. The results show that the hardness values ​​of the Ni-Cr-Co(Mg) alloy are consistently higher than those of the Ni-Cr-Co alloy. The average microhardness of the Ni-Cr-Co alloy is 426.9 HV, while that of the Ni-Cr-Co(Mg) alloy is 528.5 HV. The increased microhardness is mainly attributed to the improved grain boundary bonding strength due to the addition of Mg. Generally, there is a direct correlation between microhardness and strength for metallic materials, thus indirectly indicating that Mg enhances the strength of the SLM-formed Ni-Cr-Co alloy.

[0067] Figure 3 Scanning electron microscope (SEM) images of the SLM-formed Ni-Cr-Co alloy prepared in Example 1 and the comparative SLM-formed Ni-Cr-Co(Mg) alloy after heat treatment. It can be seen that after heat treatment, the Ni-Cr-Co alloy exhibits chain-like carbides with an average width of approximately 0.7 μm along the grain boundaries, while a large number of blocky carbides with an average size of approximately 3.6 μm are formed at some grain boundaries. During tensile loading, the larger carbides become stress concentration points, inducing crack initiation. However, after heat treatment, the length and width of the chain-like carbides at the grain boundaries of the Ni-Cr-Co(Mg) alloy are significantly reduced, and the blocky carbides almost disappear, which significantly improves the stress concentration phenomenon under load. Furthermore, a large number of granular carbides with an average size of approximately 0.4 μm appear at the grain boundaries. The study shows that smaller granular carbides have a more significant pinning effect on grain boundaries, significantly improving alloy performance. Therefore, by doping with NiMg30 intermediate alloy powder, Mg can be safely and efficiently introduced, and high Mg content can be used to regulate the microstructure and properties of additively manufactured nickel-based superalloys.

[0068] Example 2

[0069] A method for additive manufacturing of nickel-based superalloy components, comprising the following specific steps:

[0070] (1) Ni-Cr-Co alloy powder with an average particle size of 27.6 μm and NiMg30 master alloy powder with an average particle size of 1 μm were selected and prepared into Ni-Cr-Co(Mg) alloy powder theoretically containing 0.06 wt.% Mg by a mass ratio of 99.8:0.2. ICP analysis confirmed that the powder did indeed contain approximately 0.06 wt.% Mg.

[0071] (2) Next, the Ni-Cr-Co(Mg) alloy powder is subjected to double centrifugal high-speed mixing. The mixing speed is 1100 rpm and the time is 1 minute and 30 seconds each time. After each mixing, the powder is cooled for 15 minutes before the next mixing is carried out until the powder is mixed evenly and there is no obvious agglomeration.

[0072] (3) The Ni-Cr-Co(Mg) powder obtained in the previous step was formed using a Concept Laser Mlab 200R metal additive manufacturing system. The detailed process parameters are as follows: laser power 190W, scanning speed 900mm / s, layer thickness 40μm, and scanning spacing 110μm. ICP testing of the formed part revealed that it contained approximately 0.06wt.% Mg, and the burn-off condition was significantly improved.

[0073] Example 3

[0074] A method for additive manufacturing of nickel-based superalloy components, comprising the following specific steps:

[0075] (1) Ni-Cr-Co alloy powder with an average particle size of 27.6 μm and NiMg30 master alloy powder with an average particle size of 1 μm were selected and prepared into Ni-Cr-Co(Mg) alloy powder theoretically containing 0.21 wt.% Mg by a mass ratio of 99.3:0.7. ICP analysis confirmed that the powder did indeed contain approximately 0.21 wt.% Mg.

[0076] (2) Next, the Ni-Cr-Co(Mg) alloy powder is subjected to double centrifugal high-speed mixing. The mixing speed is 1100 rpm and the time is 1 minute and 30 seconds each time. After each mixing, the powder is cooled for 15 minutes before the next mixing is carried out until the powder is mixed evenly and there is no obvious agglomeration.

[0077] (3) The Ni-Cr-Co(Mg) powder obtained in the previous step was formed using a Concept Laser Mlab 200R metal additive manufacturing system. The detailed process parameters are as follows: laser power 190W, scanning speed 900mm / s, layer thickness 40μm, and scanning spacing 110μm. ICP testing of the formed part revealed that it contained approximately 0.208wt.% Mg, and the burn-off condition was significantly improved.

[0078] Example 4

[0079] A method for additive manufacturing of nickel-based superalloy components, comprising the following specific steps:

[0080] (1) Ni-Cr-Co alloy powder with an average particle size of 27.6 μm and NiMg20 master alloy powder with an average particle size of 1 μm were selected and prepared into Ni-Cr-Co(Mg) alloy powder theoretically containing 0.12 wt.% Mg by a mass ratio of 99.4:0.6. ICP analysis confirmed that the powder did indeed contain approximately 0.12 wt.% Mg.

[0081] (2) Next, the Ni-Cr-Co(Mg) alloy powder is subjected to double centrifugal high-speed mixing. The mixing speed is 1100 rpm and the time is 1 minute and 30 seconds each time. After each mixing, the powder is cooled for 15 minutes before the next mixing is carried out until the powder is mixed evenly and there is no obvious agglomeration.

[0082] (3) The Ni-Cr-Co(Mg) powder obtained in the previous step was formed using a Concept Laser Mlab 200R metal additive manufacturing system. The detailed process parameters are as follows: laser power 190W, scanning speed 900mm / s, layer thickness 40μm, and scanning spacing 110μm. ICP testing of the formed part revealed that it contained approximately 0.12wt.% Mg, and the burn-off condition was significantly improved.

[0083] Example 5

[0084] A method for additive manufacturing of nickel-based superalloy components, comprising the following specific steps:

[0085] (1) Ni-Cr-Co alloy powder with an average particle size of 27.6 μm and NiMg50 master alloy powder with an average particle size of 1 μm were selected and prepared into Ni-Cr-Co(Mg) alloy powder theoretically containing 0.12 wt.% Mg by a mass ratio of 99.76:0.24. ICP analysis confirmed that the powder did indeed contain approximately 0.12 wt.% Mg.

[0086] (2) Next, the Ni-Cr-Co(Mg) alloy powder is subjected to double centrifugal high-speed mixing. The mixing speed is 1100 rpm and the time is 1 minute and 30 seconds each time. After each mixing, the powder is cooled for 15 minutes before the next mixing is carried out until the powder is mixed evenly and there is no obvious agglomeration.

[0087] (3) The Ni-Cr-Co(Mg) powder obtained in the previous step was formed using a Concept Laser Mlab 200R metal additive manufacturing system. The detailed process parameters are as follows: laser power 190W, scanning speed 900mm / s, layer thickness 40μm, and scanning spacing 110μm. ICP testing of the formed part revealed that it contained approximately 0.119wt.% Mg, and the burn-off condition was significantly improved.

[0088] Example 6

[0089] A method for additive manufacturing of nickel-based superalloy components, comprising the following specific steps:

[0090] (1) Ni-Cr-W alloy powder with an average particle size of 27.6 μm and NiMg30 master alloy powder with an average particle size of 1 μm were selected and prepared into Ni-Cr-W(Mg) alloy powder theoretically containing 0.18 wt.% Mg by a mass ratio of 99.4:0.6. ICP analysis confirmed that the powder did indeed contain approximately 0.18 wt.% Mg.

[0091] (2) Next, the Ni-Cr-W(Mg) alloy powder is subjected to double centrifugal high-speed mixing. The mixing speed is 1100 rpm and the time is 1 minute and 30 seconds each time. After each mixing, the powder is cooled for 15 minutes before the next mixing is carried out until the powder is mixed evenly and there is no obvious agglomeration.

[0092] (3) The Ni-Cr-W(Mg) powder obtained in the previous step was formed using a Concept Laser Mlab 200R metal additive manufacturing system. The detailed process parameters are as follows: laser power 180W, scanning speed 900mm / s, layer thickness 40μm, and scanning spacing 110μm. ICP testing of the formed part revealed that it contained approximately 0.178wt.% Mg, and the burn-off condition was significantly improved.

[0093] Example 7

[0094] A method for additive manufacturing of nickel-based superalloy components, comprising the following specific steps:

[0095] (1) Ni-Fe-Cr alloy powder with an average particle size of 27.6 μm and NiMg30 master alloy powder with an average particle size of 1 μm were selected and prepared into Ni-Fe-Cr(Mg) alloy powder theoretically containing 0.18 wt.% Mg by a mass ratio of 99.4:0.6. ICP analysis confirmed that the powder did indeed contain approximately 0.18 wt.% Mg.

[0096] (2) Next, the Ni-Fe-Cr(Mg) alloy powder is subjected to double centrifugal high-speed mixing. The mixing speed is 1100 rpm and the time is 1 minute and 30 seconds each time. After each mixing, the powder is cooled for 15 minutes before the next mixing is carried out until the powder is mixed evenly and there is no obvious agglomeration.

[0097] (3) The Ni-Fe-Cr(Mg) powder obtained in the previous step was formed using a Concept Laser Mlab 200R metal additive manufacturing system. The detailed process parameters are as follows: laser power 190W, scanning speed 1000mm / s, layer thickness 40μm, and scanning spacing 110μm. ICP testing of the formed part revealed that it contained approximately 0.177wt.% Mg, and the burn-off condition was significantly improved.

[0098] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method of high elemental magnesium doped additive manufacturing of a nickel- based superalloy material, characterized by, The nickel-based superalloy powder and the NiMg intermediate alloy powder are used as raw materials for additive manufacturing; wherein the mass of Mg in the NiMg intermediate alloy powder is 0.06-0.21 wt.% of the total mass of the alloy powder, and the total mass of the alloy powder is the total mass of the nickel-based superalloy powder and the NiMg intermediate alloy powder; The intermediate alloy powder used is NiMg, and the average particle size is 0.5-1.5 μm; The NiMg intermediate alloy powder contains only two main alloying elements, Ni and Mg; The nickel-based superalloy powder is a Ni-Cr-Co alloy powder, a Ni-Cr-W alloy powder, or a Ni-Fe-Cr alloy powder; The additive manufacturing method is laser selective melting, and the parameters of the laser selective melting are as follows: laser power 180-200 W, scanning speed 800-1000 mm / s, layer thickness 30-50 μm, and scanning pitch 100-120 μm.

2. The method of claim 1, wherein the high-magnesium element-doped additive manufactured nickel-base superalloy material is characterized by, The nickel-based superalloy powder and the NiMg intermediate alloy powder are mixed uniformly and then subjected to additive manufacturing.

3. The method of claim 2, wherein the high-magnesium element doped additive manufactured nickel-base superalloy material is characterized by, High-speed centrifugal stirring is used, and the rotating speed of the high-speed centrifugal stirring is 900-1300 rpm.

4. The method of claim 2, wherein the high-magnesium element-doped additive manufactured nickel-base superalloy material is characterized by, During the mixing process, the mixture is cooled for 10-20 minutes after being mixed for 1-2 minutes.

5. The method of claim 1, wherein the high-magnesium element doped additive manufactured nickel-base superalloy material is characterized by, The NiMg intermediate alloy powder is one or more of NiMg20 intermediate alloy powder, NiMg30 intermediate alloy powder, and NiMg50 intermediate alloy powder.

6. The method of claim 1, wherein the high-magnesium element doped additive manufactured nickel-base superalloy material is characterized by, The particle size distribution of the nickel-based superalloy powder is 15-53 μm.

7. A nickel-base superalloy product characterized by, The method of any one of claims 1-6 is used.

8. Use of the nickel-based superalloy product of claim 7 in aerospace, medical devices, marine vessels, or petrochemicals.

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