A method of manufacturing a self-suction sweating active-cooled leading edge member

Abstract

The application relates to a manufacturing method of a self-suction sweating type active-cooling leading edge component, and belongs to the technical field of aircraft thermal protection. According to the model structure characteristics of the leading edge component, slicing processing is carried out to obtain a model of an additive manufacturing sample; then, according to the model of the leading edge component, a powder bed additive manufacturing is carried out, and process parameters and scanning strategies are controlled to obtain a blank; the blank is subjected to heat treatment to remove residual stress generated in the additive manufacturing process; a femtosecond laser is used to punch holes on the surface of the processed blank to obtain the leading edge component; the obtained leading edge component is a three-layer three-channel structure, and from inside to outside, the three-layer structure comprises an internal compact layer, an intermediate porous material layer and a surface sweating structure layer, and the three-layer structure respectively comprises a conventional fractal channel, a three-dimensional gap channel and a micro-scale sweating channel, so that self-driven thermal protection is realized, the cooling efficiency is relatively high, the high-temperature mechanical properties and the fatigue resistance are good, and the aircraft can be used back and forth.

Description

Technical Field

[0001] This invention relates to the field of aircraft thermal protection technology, and in particular to a method for manufacturing a self-suctioning active cooling leading edge component. Background Technology

[0002] During supersonic flight, hypersonic vehicles generate enormous aerodynamic heat at locations such as the nose cone and wing edges due to air friction, potentially exceeding 10 MW / m² in extreme heat flux density. This poses a significant challenge to the safe flight of hypersonic vehicles. To enable the vehicle to be used repeatedly for extended periods, non-ablative thermal protection methods must be employed to ensure the safety and reliability of the vehicle's leading edge.

[0003] Self-extraction sweating cooling is a highly efficient and promising active cooling thermal protection method for the leading edge. Its mechanism involves the cooling medium undergoing transport, heat exchange, and phase change processes through a multi-stage flow channel structure driven by capillary force, forming a protective gas film layer on the component surface to isolate the ultra-high temperature heat flow generated by friction between the air and the component. The sweating cooling thermal protection scheme has two main advantages: 1) stronger cooling capacity, primarily because liquids with high specific heat capacity (such as water) are generally chosen as the cooling medium, allowing it to absorb more heat during phase change; 2) the sweating cooling thermal protection uses a multi-stage transport channel similar to a leaf, enabling autonomous transport of the cooling medium under capillary force without the need for an additional power unit, further reducing weight. However, in practical applications, the sweating active cooling thermal protection scheme has not achieved ideal results. Related research has found that the main reason for the reduced thermal protection effect is the immaturity of the multi-stage flow channel structure design and fabrication technology, and the low controllability of the flow channel distribution and dimensions, leading to difficulties in transporting the cooling medium.

[0004] Currently, the processing methods for sweating-type active cooling multi-stage flow channel structures are powder sintering and layer etching. Powder sintering prepares porous media by sintering spherical metal powders or composite materials, but the flow channel distribution and size cannot be controlled. Layer etching etches flow channels on a thin plate and then diffuses and welds them layer by layer. The flow channels are controllable, but the design and processing of complex flow channels results in poor performance and high cost.

[0005] Therefore, there is an urgent need for a sweating-type active cooling thermal protection component with high thermal protection effect and a composite manufacturing method. Summary of the Invention

[0006] Based on the above analysis, the present invention aims to provide a manufacturing method for a self-suctioning and sweating active cooling leading edge component to solve the problem of poor thermal protection effect of existing leading edge components.

[0007] On one hand, the present invention provides a method for manufacturing a self-suctioning active cooling leading edge component, comprising the following steps:

[0008] S1: Based on the structural characteristics of the leading edge component model, slice the sample to obtain an additive manufacturing prototype model; the additive manufacturing prototype model includes an inner dense layer, a middle porous material layer and a surface sweating structure layer from the inside out, wherein the inner dense layer is provided with fractal flow channels;

[0009] S2: Based on the additive manufacturing prototype model, powder bed additive manufacturing is carried out, and process parameters and scanning strategies are controlled to produce a blank consisting of an internal dense layer, a middle porous material layer and a surface sweating structure layer from the inside out.

[0010] S3: Heat-treat the obtained blank to remove residual stress generated during additive manufacturing;

[0011] S4: Using femtosecond lasers to process the surface of the pre-processed blank.

[0012] Furthermore, before S1, there is also S0: powder pretreatment, which involves vacuum low-temperature drying of the raw materials.

[0013] Furthermore, in step S0, the flowability of the dried raw material is 5-18 s / 50g.

[0014] Further, in step S2, additive manufacturing includes the following steps:

[0015] S21: The additive manufacturing prototype model is split from the inside to the surface into an internal dense layer, an intermediate porous material layer, and a surface sweating structure layer of different thicknesses;

[0016] S22: A layer of powder raw material is evenly spread on the substrate, and different process parameters are set according to the internal dense layer, the middle porous material layer and the surface sweating structure layer.

[0017] S23: After the first layer of powder is formed, another layer of powder is spread on the basis of the first layer, and the process of S32 is repeated to obtain a blank with a three-layer structure.

[0018] Furthermore, in step S22, the additive manufacturing is electron beam selective additive manufacturing. When preparing the internal dense layer and the surface sweating structure layer, the electron beam selective melting current is 15-40mA, the scanning speed is 0.5-5mm / s, the powder thickness is 40-60μm, and the overlap spacing is 70-125μm.

[0019] When preparing the intermediate porous material layer, the electron beam selective sintering current is 10-40 mA, the scanning speed is 3-20 mm / s, the powder thickness is 40-60 μm, and the overlap spacing is 70-125 μm.

[0020] Further, in step S32, the additive manufacturing is laser selective melting. When preparing the internal dense layer and the surface sweating structure layer, the laser power is 250-350W, the scanning speed is 800-1000mm / s, the overlap distance is 40-60μm, the powder thickness is 40-60μm, and the layer is rotated 67° layer by layer.

[0021] When preparing the intermediate porous material layer, the laser power of selective laser melting is 150-200W, the scanning speed is 1000-1200mm / s, the overlap distance is 70-80μm, the powder thickness is 40-60μm, and no rotation is used.

[0022] Furthermore, the density of the inner dense layer and the surface sweat-generating structure layer is above 99%; the porosity of the intermediate porous material layer is 30-50%.

[0023] Furthermore, the thickness of the surface sweating structure layer is 500-800 μm, the thickness of the intermediate porous material layer is 5-10 mm, and the thickness of the inner dense layer is 10-15 mm.

[0024] Further, S4 includes:

[0025] T1: Fix the blank and set parameters;

[0026] T2: Femtosecond laser drilling: Using a femtosecond laser to perform laser drilling on the sweating structure layer on the surface of the blank, ensuring that the laser beam is perpendicular to the surface of the blank;

[0027] T3: Femtosecond laser surface microstructure processing: Using femtosecond laser equipment to process the surface of components to form hydrophilic microstructures, which facilitates the spread of cooling media.

[0028] Furthermore, in step T2, the femtosecond laser drilling process parameters are as follows: laser spot diameter is 10-20 μm; laser pulse width is 500-800 fs; laser wavelength is 1030 nm; single pulse energy is 20-50 μJ; repetition frequency is 500-700 kHz; and scanning rate is 200-400 mm / s.

[0029] Furthermore, in step T3, the femtosecond laser surface microstructure processing technology includes: a laser spot diameter of 50-70 μm; a laser pulse width of 100-300 fs; a laser wavelength of 1030 nm; a single pulse energy of 20-50 μJ; a repetition frequency of 1-3 kHz; and a scanning rate of 0.5-10 mm / s.

[0030] Furthermore, between S3 and S4, machining is also included, which removes sintered powder and impurities from the surface of the annealed blank before further processing.

[0031] On the other hand, the present invention also provides a self-suctioning and sweating active cooling leading edge component, which is obtained by the above-described manufacturing method.

[0032] Furthermore, the leading edge component is conical and consists of a three-layer structure, from the inside out: an inner dense layer, an intermediate porous material layer, and a surface sweating structure layer. The inner dense layer contains conventional fractal channels with a pore size ≥ 1 mm; the intermediate porous material layer contains three-dimensional void channels with a pore size of 60-200 μm; and the surface sweating structure layer contains microscale sweating channels with a pore size of 30-50 μm. The conventional fractal channels, the three-dimensional void channels, and the microscale sweating channels are interconnected.

[0033] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0034] 1. This invention provides a manufacturing method for preparing a sweating active cooling leading edge component. By combining additive manufacturing and femtosecond laser processing, a leading edge component with a surface sweating structure layer, a middle porous material layer, and an internal dense layer can be prepared. The three layers are metallurgically bonded, and conventional fractal flow channels, three-dimensional void flow channels, and microscale sweating flow channels are formed in the three layers respectively. The flow channels are interconnected and have high dimensional accuracy. In addition, the manufacturing method is relatively simple and easy to control.

[0035] 2. In this invention, by designing the model and controlling the process parameters and scanning strategy in the additive manufacturing process, it is possible to form three-dimensional void channels with a diameter of 60 to 200 μm in the middle porous material layer, and to form conventional fractal channels in the inner dense layer, such as conventional fractal channels with a pore diameter ≥ 1 mm. Finally, a femtosecond laser is used to process pores with a pore diameter of 30 to 50 μm on the surface sweating structure layer to form microscale sweating channels, resulting in high forming efficiency.

[0036] In this invention, the above-described technical solutions can be combined with each other to achieve more preferred combinations. Other features and advantages of this invention will be set forth in the following description, and some advantages may become apparent from the description or be learned by practicing the invention. The objects and other advantages of this invention can be realized and obtained from what is particularly pointed out in the description and drawings. Attached Figure Description

[0037] The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts.

[0038] Figure 1 This is a schematic diagram of the leading edge component of a certain type of aircraft.

[0039] Figure 2This is a schematic cross-sectional view of a leading-edge component of a certain type of aircraft.

[0040] Figure 3 Microscale sweating pathway diagram using femtosecond laser;

[0041] In the figure, 1. Surface sweating structure layer; 2. Middle porous material layer; 3. Internal dense layer; 4. Microscale sweating channel; 5. Three-dimensional void channel; 6. Conventional fractal channel; 7. Cooling medium. Detailed Implementation

[0042] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which constitute a part of the present invention and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not intended to limit the scope of the present invention.

[0043] Leading-edge components are critical structural parts in aircraft, facing severe thermal protection challenges during high Mach number flight. Self-suction active cooling systems can enable the leading edge to cool itself autonomously without power, allowing it to operate at higher temperatures. Currently, the main fabrication processes for leading-edge components include powder sintering, lamination etching, and additive manufacturing. However, existing processes suffer from poor stability, high control difficulty, and low forming accuracy, making it impossible to fabricate complex flow channels and potentially clogging the sweating channels, thus affecting the cooling and protection effect.

[0044] Therefore, the present invention provides a method for manufacturing a self-suctioning active cooling leading edge component, comprising the following steps:

[0045] S1: Based on the structural characteristics of the leading edge component model, slice the sample to obtain an additive manufacturing prototype model; the additive manufacturing prototype model includes an inner dense layer, a middle porous material layer and a surface sweating structure layer from the inside out, wherein the inner dense layer is provided with fractal flow channels;

[0046] S2: Based on the additive manufacturing prototype model, powder bed additive manufacturing is carried out, and process parameters and scanning strategies are controlled to produce a blank consisting of an internal dense layer, a middle porous material layer and a surface sweating structure layer from the inside out.

[0047] S3: Heat-treat the obtained blank to remove residual stress generated during additive manufacturing;

[0048] S4: A femtosecond laser is used to drill holes on the surface of the processed blank to obtain the leading edge component.

[0049] The resulting leading edge component is a three-layer, three-channel structure, consisting of an inner dense layer, an intermediate porous material layer, and a surface sweating structure layer from the inside out. The three layers contain conventional fractal channels, three-dimensional void channels, and microscale sweating channels, respectively.

[0050] Compared with existing technologies, the preparation method provided by this invention, through the combination of additive manufacturing and femtosecond laser processing, can fabricate a leading edge component with a three-layer structure, consisting of a surface sweating structure layer 1, a middle porous material layer 2, and an inner dense layer 3, from the outside to the inside. Furthermore, microscale sweating channels 4, three-dimensional void channels 5, and conventional fractal channels 6 are formed on the three-layer structure, respectively, and these channels are interconnected. Cooling medium 7 sequentially flows through the conventional fractal channels 6, the three-dimensional void channels 5, and the microscale sweating channels 4. Under capillary action, the cooling medium 7 seeps out from the microscale sweating channels 4, undergoing a phase change and absorbing heat. A gas film is formed on the leading edge surface, thereby achieving cooling and better protecting the leading edge component. The leading edge component obtained by this invention has high channel dimensional accuracy, eliminates the problem of channel blockage, and has a relatively simple and easy-to-control preparation method with high thermal protection efficiency.

[0051] Specifically, before S1, there is also S0: powder pretreatment, which involves vacuum low-temperature drying of the raw materials.

[0052] Specifically, in step S0, the flowability of the dried raw material is 5-18s / 50g.

[0053] In this invention, the raw materials are the initial step in preparing the leading edge component, and their performance directly affects the quality of the leading edge component. Therefore, it is necessary to dry the raw materials to control their flowability at 5-18s / 50g (Hall flow rate), which facilitates the subsequent preparation of the leading edge component and ensures the formation and precision of the flow channel.

[0054] Specifically, in this invention, the raw material can be a nickel-based alloy or pure tungsten.

[0055] Preferably, the nickel-based alloy can be MAR-M247 or GH4099.

[0056] Preferably, when the nickel-based alloy is MAR-M247, the powder has a D10 of 45–50 μm, a D50 of 72–78 μm, a D90 of 100–108 μm, and a loose packing density ≥5 g / cm³. 3 .

[0057] Preferably, when the nickel-based alloy is GH4099, the powder has a D10 of 15–20 μm, a D50 of 30–35 μm, a D90 of 45–50 μm, and a loose packing density ≥4.6 g / cm³. 3 .

[0058] Preferably, when the raw material is pure tungsten, the powder has a D10 of 45–50 μm, a D50 of 72–78 μm, a D90 of 100–108 μm, and a bulk density ≥10.5 g / cm³. 3 .

[0059] Specifically, in step S2, additive manufacturing includes the following steps:

[0060] S21: The additive manufacturing prototype model is split from the inside to the surface into an internal dense layer, an intermediate porous material layer, and a surface sweating structure layer of different thicknesses;

[0061] S22: A layer of powder raw material is evenly spread on the substrate, and different process parameters are set according to the internal dense layer, the middle porous material layer and the surface sweating structure layer.

[0062] S23: After the first layer of powder is formed, another layer of powder is spread on the basis of the first layer, and the process of S22 is repeated to obtain a blank with a three-layer structure.

[0063] Specifically, in step S2, the additive manufacturing includes laser selective melting or electron beam selective melting.

[0064] Raw material powder is prepared into a blank using selective laser melting or selective electron beam melting. The blank has a three-layer structure, consisting of an inner dense layer, an intermediate porous material layer, and a surface sweating structure layer from the inside out. The density of the inner dense layer and the surface sweating structure layer is above 99%. The density of the intermediate porous material layer is 30-40%. The thickness of the surface sweating structure layer is 0.3-0.4 μm. The thickness of the intermediate porous material layer is 5-10 mm. The thickness of the inner dense layer is 10-15 mm.

[0065] To ensure the density of the internal dense layer, the surface sweating structure layer, and the intermediate porous material layer, and to facilitate subsequent femtosecond laser processing and channel precision, the preparation parameters for each layer are different. Electron beam selective melting is selected to prepare the blank. When preparing the internal dense layer and the surface sweating structure layer, the electron beam selective melting beam current is 15-40 mA, the scanning speed is 0.5-5 mm / s, the powder thickness is 40-60 μm, and the overlap spacing is 70-125 μm.

[0066] Preferably, when preparing the internal dense layer and the surface sweating structure layer, the electron beam selective melting current can be 15-20mA or 30-40mA, the scanning speed can be 0.5-1mm / s or 4-5mm / s, the powder thickness is 40-50μm, and the overlap spacing is 80-100μm.

[0067] When preparing the intermediate porous material layer, the electron beam selective sintering current is 10-40 mA, the scanning speed is 3-20 mm / s, the powder thickness is 40-60 μm, and the overlap spacing is 70-125 μm.

[0068] Preferably, when preparing the intermediate porous material layer, the beam current of the electron beam selective sintering can be 10-20mA or 30-40mA, the scanning speed can be 3-6mm / s or 10-20mm / s, the powder thickness is 50-60μm, and the overlap spacing is 80-100μm.

[0069] Selective laser melting is used to prepare the blank. When preparing the internal dense layer and the surface sweating structure layer, the laser power is 250-350W, the scanning speed is 800-1000mm / s, the overlap distance is 40-60μm, the powder thickness is 40-60μm, and the layer is rotated 67° layer by layer.

[0070] Preferably, when preparing the internal dense layer and the surface sweating structure layer, the laser power of selective laser melting is 300-350W, the scanning speed is 800-960mm / s, the overlap distance is 50-60μm, and the powder thickness is 40-50μm.

[0071] When preparing the intermediate porous material layer, the laser power of selective laser melting is 150-200W, the scanning speed is 1000-1200mm / s, the overlap distance is 70-80μm, the powder thickness is 40-60μm, and no rotation is used.

[0072] Preferably, when preparing the intermediate porous material layer, the laser power of selective laser melting is 180-200W, the scanning speed is 1100-1200mm / s, the overlap distance is 70-80μm, the powder thickness is 50-60μm, and no rotation is used.

[0073] During the preparation of the blank, the raw material powder needs to be preheated at a temperature of 900-1100℃ to give the powder better thermal conductivity, electrical conductivity and mechanical stability.

[0074] Preferably, the preheating temperature is 950-1000℃.

[0075] Preferably, when the raw material powder is preheated, the preheating treatment adopts electron beam defocusing heating, the electron beam defocusing current is 30-40mA, the scanning speed is 20-30m / s, and the powder thickness is 40-50μm.

[0076] Specifically, to obtain a blank using additive manufacturing, the blank needs to be heat-treated to ensure that microscale sweating channels can be formed on the surface of the blank using a femtosecond laser.

[0077] Preferably, when the raw material is a high-temperature alloy, the heat treatment is carried out by solution treatment and aging annealing.

[0078] More preferably, when the raw material is MAR-M247, the solution temperature is 1150-1250℃, the solution time is 1-2h, the aging temperature is 800-900℃, and the aging time is 20h.

[0079] More preferably, when the raw material is GH4099, the solution temperature is 1100-1200℃, the solution time is 1-2h, the aging temperature is 700-850℃, and the aging time is 16h.

[0080] More preferably, when the raw material is GH4099, the heat treatment can also be stress relief treatment and aging treatment. The stress relief treatment is heated at 500-550℃ and held for 1.5-2.5 hours. The aging treatment is held at a higher temperature for the first holding than the second holding. The first holding temperature is 800-850℃ and held for 1-2 hours. The second holding temperature is 700-750℃ and held for 3-4 hours.

[0081] More preferably, when the raw material is pure tungsten, the annealing temperature is 1100-1300℃ and the annealing time is 1-2 hours.

[0082] The leading edge component mainly cools itself through the principle of sweating. A three-layer structure blank is obtained by additive manufacturing. The three layers are, from the inside to the outside, an inner dense layer, an intermediate porous material layer, and a surface sweating structure layer. Conventional fractal flow channels and three-dimensional void flow channels are formed in the inner dense layer and the intermediate porous material layer, respectively, and the two are interconnected. The pore size of the conventional fractal flow channel is ≥1mm; the pore size of the three-dimensional void flow channel is 60~200μm.

[0083] To achieve the above-mentioned sweating cooling, a femtosecond laser was used to prepare microscale sweating channels with a pore size of 30-50 μm on the surface sweating structure layer. The resulting channels have high precision and do not have clogging problems, thus ensuring the sweating cooling effect of the leading edge component.

[0084] Specifically, step S4, the femtosecond laser processing procedure, includes the following steps:

[0085] T1: Fix the blank and set parameters;

[0086] T2: Laser drilling: Laser drilling is performed on the surface sweating structure layer of the blank using a femtosecond laser, ensuring that the laser beam is perpendicular to the surface of the blank.

[0087] T3: Surface microstructure processing: Femtosecond laser is used to process the surface of the component to form a hydrophilic microstructure, which facilitates the spread of the cooling medium.

[0088] It should be noted that a series of regularly arranged microchannels with apertures ≤50μm are prepared on the surface of the component using femtosecond lasers; at the same time, the surface is modified using femtosecond lasers to improve the wettability of the material on the surface of the component, obtain sufficiently high capillary pressure, overcome the effect of gravity, and realize the self-suction of the cooling medium.

[0089] Specifically, in step T2, the femtosecond laser drilling process has the following characteristics: laser spot diameter of 10-20 μm; laser pulse width of 500-800 fs; laser wavelength of 1030 nm; single pulse energy of 20-50 μJ; repetition frequency of 500-700 kHz; and scanning rate of 200-400 mm / s.

[0090] Preferably, during step T2, the single-pulse energy of the femtosecond laser can be 20-30 μJ, 30-50 μJ, or 40-50 μJ; the repetition frequency can be 500-600 kHz or 600-700 kHz; and the scanning rate can be 200-300 mm / s or 300-400 mm / s.

[0091] Specifically, in step T3, the femtosecond laser surface microstructure processing technology includes: a laser spot diameter of 50-70 μm; a laser pulse width of 100-300 fs; a laser wavelength of 1030 nm; a single pulse energy of 20-50 μJ; a repetition frequency of 1-3 kHz; and a scanning rate of 0.5-10 mm / s.

[0092] Preferably, in step T3, the single pulse energy of the femtosecond laser can be 20-30 μJ, 20-40 μJ, or 40-50 μJ; the repetition frequency can be 1-2 kHz or 2-3 kHz; and the scanning rate can be 0.5-1 mm / s, 1-5 mm / s, or 5-10 mm / s.

[0093] The leading edge component obtained by the above manufacturing method is conical and consists of a three-layer structure. From the inside out, it consists of an inner dense layer, an intermediate porous material layer, and a surface sweating structure layer. The density of the inner dense layer and the surface sweating structure layer is above 99%. The thickness of the surface sweating structure layer is 500-800 μm, and the thickness of the inner dense layer is 10-15 mm. The porosity of the intermediate porous material layer is 30-50%, and the thickness is 5-10 mm. The inner dense layer contains conventional fractal channels with a pore size ≥ 1 mm. The intermediate porous material layer contains three-dimensional void channels with a pore size of 60-200 μm. The surface sweating structure layer contains microscale sweating channels with a pore size of 30-50 μm. The conventional fractal channels, the three-dimensional void channels, and the microscale sweating channels are interconnected.

[0094] To more clearly describe the present invention, the following embodiments and comparative examples are provided for further illustration.

[0095] Example 1

[0096] This embodiment provides a method for manufacturing a self-suctioning, active cooling leading edge component, including the following steps:

[0097] S0: Powder pretreatment, which involves vacuum low-temperature drying of raw materials (100-120℃, 1-2h) to improve the flowability of the raw materials;

[0098] In this embodiment, the raw material is MAR-M247 cast nickel-based superalloy powder, with the following alloying elements and mass fractions: C: 0.08 wt.%, Cr: 8.51 wt.%, Co: 9.37 wt.%, Mo: 0.52 wt.%, W: 9.58 wt.%, Ta: 3.13 wt.%, Ti: 0.60 wt.%, Al: 5.73 wt.%, B: 0.03 wt.%, Zr: 0.01 wt.%, Hf: 1.49 wt.%, V: 0.05 wt.%, Re: 0.03 wt.%, Mg: 0.007 wt.%, Mn: 0.03 wt.%, Si: 0.03 wt.%, (N+O): 300 ppm, and the remainder is Ni.

[0099] The MAR-M247 powder has a D10 of 45 μm, a D50 of 73 μm, a D90 of 105 μm, a flowability (Hall flow rate) of 6.5 s / 50 g, and a bulk density of 5 g / cm³. 3 ;

[0100] S1: Model design. Based on the structural characteristics of the leading edge component, slice the model to prepare the additive prototype model.

[0101] S2: Additive manufacturing includes:

[0102] S21: Decompose the additive prototype model from the inside to the surface into an internal dense layer, an intermediate porous material layer and a surface sweating structure layer of different thicknesses;

[0103] S22: A layer of powder raw material is evenly spread on the substrate, and different process parameters are set according to the internal dense layer, the middle porous material layer and the surface sweating structure layer.

[0104] S23: After the first layer of powder is formed, powder is spread on the basis of the first layer, and the process of S22 is repeated to obtain a blank with a three-layer structure.

[0105] Before step S22, the powder is heated to 1100℃ using electron beam defocusing heating. The process parameters for electron beam defocusing are: beam current 40mA; scanning speed 25m / s; powder thickness 50μm; and high-speed reciprocating scanning strategy.

[0106] In step S22, the powder is prepared into a blank using selective electron beam melting. When preparing the internal dense layer and the surface sweating structure layer, the electron beam current of selective electron beam melting is 30mA; the scanning speed is 4.0m / s; the overlap distance is 70μm; the powder thickness is 50μm; the density of the internal dense layer and the surface sweating structure layer is above 99%; and the internal dense layer contains conventional fractal channels with a pore size of 2mm.

[0107] When preparing the intermediate porous material layer, the electron beam selective sintering process parameters are as follows: beam current is 35mA, scanning speed is 15m / s, powder thickness is 50μm, scanning strategy is high-speed reciprocating scanning, the density of the intermediate porous material layer is 35%, and the intermediate porous material layer contains three-dimensional void channels with pore size of 60-200μm.

[0108] S3: Heat treatment, the blank is heat treated by solution treatment and aging, the solution treatment temperature is 1200℃, the holding time is 2h, and the air quenching is performed; the aging temperature is 870℃, the holding time is 20h, and the air cooling is performed.

[0109] S31: Machining, removing sintered powder and impurities from the surface of the annealed blank, and then processing it;

[0110] S4: Using a femtosecond laser, microscale sweating channels are fabricated on the surface of the processed blank (on the surface sweating structure layer), including:

[0111] T1: Fix the processed blank and then set the operating parameters of the femtosecond laser;

[0112] T2: Femtosecond laser drilling: Laser drilling is performed on the surface sweating structure layer of the blank using a femtosecond laser, ensuring that the laser beam is perpendicular to the surface of the blank. The aperture of the microscale sweating channel is 30-50μm, penetrating the surface sweating structure layer.

[0113] The laser spot diameter is 10μm, the laser pulse width is 800fs, the laser wavelength is 1030nm, the single pulse energy is 30μJ, the repetition frequency is 600kHz, and the scanning rate is 300mm / s.

[0114] T3: Femtosecond laser surface microstructure processing: The surface of the component is processed using a femtosecond laser device to form a hydrophilic microstructure, which facilitates the spread of the cooling medium. The laser spot diameter is 50μm; the pulse width is 100fs; the laser wavelength is 1030nm; the single pulse energy is 50μJ; the repetition frequency is 2kHz; and the scanning rate is 10mm / s to obtain the leading edge component.

[0115] Reference Figure 1 and Figure 2The leading edge component is conical and consists of a three-layer structure: an inner dense layer, a middle porous material layer, and a surface sweating structure layer, with thicknesses of 10 mm, 5 mm, and 0.5 mm, respectively. The inner dense layer contains conventional fractal channels with pore sizes ≥ 1 mm; the middle porous material layer contains three-dimensional void channels with pore sizes of 60-200 μm; and the surface sweating structure layer contains microscale sweating channels with pore sizes of 30-50 μm (see reference). Figure 3 ).

[0116] Example 2

[0117] The preparation process of Example 2 is largely the same as that of Example 1, except that the electron beam process parameters and alloy element content are different in Example 2.

[0118] In step S0, nickel-based superalloy powder is cast, with the following alloying elements and mass fractions: C: 0.07 wt.%, Cr: 8.23 ​​wt.%, Co: 9.31 wt.%, Mo: 0.56 wt.%, W: 9.67 wt.%, Ta: 3.23 wt.%, Ti: 0.69 wt.%, Al: 5.52 wt.%, B: 0.03 wt.%, Zr: 0.01 wt.%, Hf: 1.54 wt.%, V: 0.04 wt.%, Re: 0.03 wt.%, Mg: 0.006 wt.%, Mn: 0.03 wt.%, Si: 0.03 wt.%, (N+O): 300 ppm, and the remainder being Ni;

[0119] In step S2, the powder is prepared into a blank using selective electron beam additive manufacturing technology. When preparing the internal dense layer and the surface sweating structure layer, the electron beam current for selective melting is 40 mA; the scanning speed is 5.0 m / s; the overlap distance is 90 μm; the powder thickness is 60 μm; the density of the internal dense layer and the surface sweating structure layer is above 99%; and the internal dense layer contains conventional fractal channels with a pore size of 2 mm.

[0120] When preparing the intermediate porous material layer, the electron beam selective sintering process parameters are as follows: beam current 30mA, scanning speed 15m / s, powder thickness 45μm, scanning strategy is high-speed reciprocating scanning, the density of the intermediate porous material layer is 35%, and the intermediate porous material layer contains three-dimensional void channels with pore size of 60-200μm.

[0121] Example 3

[0122] The preparation process of Example 3 is largely the same as that of Example 1, except that the femtosecond laser processing technology and the content of alloying elements are slightly different in Example 3.

[0123] In step S0, nickel-based superalloy powder is cast, with the following alloying elements and mass fractions: C: 0.09 wt.%, Cr: 8.15 wt.%, Co: 9.24 wt.%, Mo: 0.53 wt.%, W: 9.57 wt.%, Ta: 3.13 wt.%, Ti: 0.76 wt.%, Al: 5.63 wt.%, B: 0.03 wt.%, Zr: 0.01 wt.%, Hf: 1.41 wt.%, V: 0.02 wt.%, Re: 0.05 wt.%, Mg: 0.007 wt.%, Mn: 0.05 wt.%, Si: 0.03 wt.%, (N+O): 200 ppm, and the remainder being Ni.

[0124] In step S4, microscale sweating channels are processed on the surface sweating structure layer of the blank using femtosecond laser processing, including:

[0125] T1: Fix the processed blank and then set the operating parameters of the femtosecond laser;

[0126] T2: Femtosecond laser drilling: Laser drilling is performed on the surface sweating structure layer of the blank using a femtosecond laser, ensuring that the laser beam is perpendicular to the surface of the blank. The aperture of the microscale sweating channel is 30-50μm, penetrating the surface sweating structure layer.

[0127] The laser spot diameter is 20μm, the laser pulse width is 500fs, the laser wavelength is 1030nm, the single pulse energy is 50μJ, the repetition frequency is 500kHz, and the scanning rate is 200mm / s.

[0128] T3: Femtosecond laser surface microstructure processing: The surface of the component is processed using a femtosecond laser to form a hydrophilic microstructure, which facilitates the spread of the cooling medium. The laser spot diameter is 60μm; the pulse width is 200fs; the laser wavelength is 1030nm; the single pulse energy is 50μJ; the repetition frequency is 3kHz; and the scanning rate is 5mm / s to obtain the leading edge component.

[0129] Example 4

[0130] This embodiment provides a method for manufacturing a sweating active cooling leading edge component, including the following steps:

[0131] S0: Powder pretreatment, which involves vacuum low-temperature drying of raw materials (100-120℃, 1-2h) to improve the flowability of the raw materials;

[0132] In this embodiment, the raw material is pure tungsten powder. The tungsten powder has a D10 of 49 μm, a D50 of 73 μm, a D90 of 103 μm, a flowability (Hall flow rate) of 6.5 s / 50 g, and a loose packing density of 10.5 g / cm³. 3;

[0133] S1: Model design. Based on the structural characteristics of the leading edge component, slice the model to prepare the additive prototype model.

[0134] S2: Additive manufacturing, including:

[0135] S21: Decompose the additive prototype model from the inside to the surface into an internal dense layer, an intermediate porous material layer and a surface sweating structure layer of different thicknesses;

[0136] S22: A layer of powder raw material is evenly spread on the substrate, and different process parameters are set according to the internal dense layer, the middle porous material layer and the surface sweating structure layer.

[0137] S23: After the first layer of powder is formed, powder is spread on the basis of the first layer, and the process of S32 is repeated to obtain a blank with a three-layer structure.

[0138] Before step S22, the powder is heated to 1100℃ using electron beam defocusing heating. The process parameters for electron beam defocusing are: beam current 15mA; scanning speed 5m / s; powder thickness 50μm; and scanning strategy is high-speed reciprocating scanning.

[0139] In step S22, the powder is prepared into a blank using selective electron beam melting. When preparing the internal dense layer and the surface sweating structure layer, the electron beam current of selective electron beam melting is 20mA; the scanning speed is 1.0m / s; the overlap distance is 90μm; the powder thickness is 50μm; the density of the internal dense layer and the surface sweating structure layer is above 99%; and the internal dense layer contains conventional fractal channels with a pore size of 2mm.

[0140] When preparing the intermediate porous material layer, the electron beam selective sintering process parameters are as follows: beam current 10mA, scanning speed 5m / s, powder thickness 50μm, scanning strategy is high-speed reciprocating scanning, the density of the intermediate porous material layer is 40%, and the intermediate porous material layer contains three-dimensional void channels with pore size of 60-200μm.

[0141] S3: The obtained blank is subjected to heat treatment. Under vacuum, the annealing temperature is 1200℃ and the annealing time is 2h.

[0142] S31: Machining, removing sintered powder and impurities from the surface of the annealed blank, and then processing it;

[0143] S4: Using a femtosecond laser, microscale sweating channels are fabricated on the surface of the processed blank (on the surface sweating structure layer), including:

[0144] T1: Fix the processed blank and then set the operating parameters of the femtosecond laser;

[0145] T2: Femtosecond laser drilling: Laser drilling is performed on the surface sweating structure layer of the blank using a femtosecond laser, ensuring that the laser beam is perpendicular to the surface of the blank. The aperture of the microscale sweating channel is 30-50μm and penetrates the surface sweating structure layer.

[0146] The laser spot diameter is 10μm, the laser pulse width is 500fs, the laser wavelength is 1030nm, the single pulse energy is 40μJ, the repetition frequency is 600kHz, and the scanning rate is 200mm / s.

[0147] T3: Femtosecond laser surface microstructure processing: The surface of the component is processed using a femtosecond laser device to form a hydrophilic microstructure, which facilitates the spread of the cooling medium. The laser spot diameter is 50μm; the pulse width is 300fs; the laser wavelength is 1030nm; the single pulse energy is 50μJ; the repetition frequency is 1kHz; and the scanning rate is 0.5mm / s.

[0148] Example 5

[0149] The preparation process of Example 5 is largely the same as that of Example 4, except that the electron beam additive manufacturing process is different in Example 5.

[0150] In step S2, the powder is prepared into a blank using selective electron beam additive manufacturing technology. When preparing the internal dense layer and the surface sweating structure layer, the electron beam current for selective melting is 15 mA; the scanning speed is 0.5 m / s; the overlap distance is 80 μm; the powder thickness is 50 μm; the density of the internal dense layer and the surface sweating structure layer is above 99%; and the internal dense layer contains conventional fractal channels with a pore size of 2 mm.

[0151] When preparing the intermediate porous material layer, the electron beam selective sintering process parameters are as follows: beam current 20mA, scanning speed 6m / s, powder thickness 50μm, scanning strategy is high-speed reciprocating scanning, the density of the intermediate porous material layer is 40%, and the intermediate porous material layer contains three-dimensional void channels with pore size of 60-200μm.

[0152] Example 6

[0153] The preparation process of Example 6 is largely the same as that of Example 4, except that the femtosecond laser processing technology is different in Example 6.

[0154] In step S4, a femtosecond laser is used to process the surface of the processed blank to create microscale sweat channels, including:

[0155] T1: Fix the processed blank and then set the operating parameters of the femtosecond laser;

[0156] T2: Femtosecond laser drilling: Laser drilling is performed on the surface sweating structure layer of the blank using a femtosecond laser, ensuring that the laser beam is perpendicular to the surface of the blank. The aperture of the microscale sweating channel is 30-50μm and penetrates the surface sweating structure layer.

[0157] The laser spot diameter is 10 μm; the laser pulse width is 500 fs; the laser wavelength is 1030 nm; the single pulse energy is 50 μJ; the repetition frequency is 500 kHz; and the scanning rate is 200 mm / s.

[0158] T3: Femtosecond laser surface microstructure processing: Femtosecond lasers are used to process the surface of components to form hydrophilic microstructures, which facilitate the spread of cooling media. The parameters for femtosecond laser surface microstructure processing are: laser spot diameter 60μm; pulse width 200fs; laser wavelength 1030nm; single pulse energy 50μJ; repetition frequency 3kHz; and scanning rate 1.0mm / s.

[0159] Example 7

[0160] This embodiment provides a method for manufacturing a self-suctioning, active cooling leading edge component, including the following steps:

[0161] S0: Powder pretreatment, which involves vacuum low-temperature drying of raw materials (100-120℃, 1-2h) to improve the flowability of the raw materials;

[0162] In this embodiment, the raw material is GH4099 high-temperature alloy powder, with the following mass percentages: C: 0.039 wt.%, Cr: 18.81 wt.%, W: 6.10 wt.%, Mo: 4.19 wt.%, Co: 6.56 wt.%, Al: 2.07 wt.%, Ti: 1.28 wt.%, Fe: 1.05 wt.%, B: 0.002 wt.%, Mg: 0.007 wt.%, Ce: 0.015 wt.%, Mn: 0.02 wt.%, Si: 0.31 wt.%, P: 0.004 wt.%, S: 0.005 wt.%, and the balance being Ni.

[0163] The GH4099 high-temperature alloy powder has a D10 of 15–20 μm, a D50 of 30–35 μm, a D90 of 45–50 μm, a flowability (Hall flow rate) of 17 s / 50 g, and a loose packing density of 4.6 g / cm³. 3 ;

[0164] S1: Model design. Based on the structural characteristics of the leading edge component, slice the model to prepare the additive prototype model.

[0165] S2: Additive manufacturing, including:

[0166] S21: Decompose the additive prototype model from the inside to the surface into an internal dense layer, an intermediate porous material layer and a surface sweating structure layer of different thicknesses;

[0167] S22: A layer of powder raw material is evenly spread on the substrate, and different process parameters are set according to the internal dense layer, the middle porous material layer and the surface sweating structure layer.

[0168] S23: After the first layer of powder is formed, powder is spread on the basis of the first layer, and the process of S32 is repeated to obtain a blank with a three-layer structure.

[0169] In step S22, the powder is prepared into a blank by selective laser melting. When preparing the internal dense layer and the surface sweating structure layer, the laser power of selective laser melting is 300W, the scanning speed is 960mm / s, the overlap distance is 50μm, the powder thickness is 40μm, and the layer is rotated 67° layer by layer.

[0170] The process parameters for laser selective melting in preparing the intermediate porous material layer are as follows: laser power is 200W, scanning speed is 1200mm / s, overlap distance is 80μm, powder thickness is 40μm, reciprocating scanning, no rotation;

[0171] S3: Heat treatment, the blank is heat treated by solution treatment and aging, the solution treatment temperature is 1150℃ and the holding time is 2h; the aging temperature is 750℃ and the holding time is 16h, followed by air cooling.

[0172] S31: Machining, removing sintered powder and impurities from the surface of the annealed blank, and then processing it;

[0173] S4: Using a femtosecond laser, microscale sweating channels are fabricated on the surface of the processed blank (on the surface sweating structure layer), including:

[0174] T1: Fix the processed blank and then set the operating parameters of the femtosecond laser;

[0175] T2: Femtosecond laser drilling: Laser drilling is performed on the surface sweating structure layer of the blank using a femtosecond laser, ensuring that the laser beam is perpendicular to the surface of the blank. The aperture of the microscale sweating channel is 30-50μm, penetrating the surface sweating structure layer.

[0176] The laser spot diameter is 20μm, the laser pulse width is 800fs, the laser wavelength is 1030nm, the single pulse energy is 40μJ, the repetition frequency is 600kHz, and the scanning rate is 400mm / s.

[0177] T3: Femtosecond laser surface microstructure processing: The surface of the component is processed using a femtosecond laser device to form a hydrophilic microstructure, which facilitates the spread of the cooling medium. The laser spot diameter is 70μm; the pulse width is 300fs; the laser wavelength is 1030nm; the single pulse energy is 30μJ; the repetition frequency is 3kHz; and the scanning rate is 10mm / s to obtain the leading edge component.

[0178] Example 8

[0179] The preparation process of Example 8 is largely the same as that of Example 7, except that the laser selective melting process in Example 8 is different.

[0180] In step S2, the powder is prepared into a blank by selective laser melting. When preparing the internal dense layer and the surface sweating structure layer, the laser power of selective laser melting is 350W, the scanning speed is 1000mm / s, the overlap distance is 40μm, the powder thickness is 40μm, and the layer is rotated 67° layer by layer.

[0181] The process parameters for laser selective melting in preparing the intermediate porous material layer are as follows: laser power is 150W, scanning speed is 1000mm / s, overlap distance is 90μm, powder thickness is 40μm, reciprocating scanning, no rotation.

[0182] Example 9

[0183] The preparation process of Example 9 is largely the same as that of Example 7, except that the femtosecond laser processing technology is different in Example 9.

[0184] In step S4, T2: Femtosecond laser drilling: A femtosecond laser is used to drill holes in the sweating structure layer on the surface of the blank, ensuring that the laser beam is perpendicular to the surface of the blank. The aperture of the microscale sweating channel is 30-50 μm, penetrating the surface sweating structure layer.

[0185] The laser spot diameter is 10 μm, the laser pulse width is 600 fs, the laser wavelength is 1030 nm, the single pulse energy is 40 μJ, the repetition frequency is 500 kHz, and the scanning rate is 400 mm / s.

[0186] T3: Surface microstructure processing: Femtosecond laser is used to process the surface of the component to form a hydrophilic microstructure, which facilitates the spread of the cooling medium. The laser spot diameter is 70μm; the pulse width is 200fs; the laser wavelength is 1030nm; the single pulse energy is 30μJ; the repetition frequency is 2kHz; and the scanning rate is 7mm / s.

[0187] Example 10

[0188] The preparation process of Example 10 is largely the same as that of Example 7, except that the heat treatment in Example 10 is different from that in Example 7.

[0189] In step S3, the heat treatment can also be stress relief treatment and aging treatment. The stress relief treatment is heated to 530°C and held for 1 hour, then cooled to room temperature in the furnace. The aging treatment is heated to a higher temperature for the first holding than for the second holding. The blank is heated to 830°C for the first holding and held for 1.5 hours. The second holding is heated to 730°C for 3 hours.

[0190] Example 11

[0191] The preparation process of Example 11 is largely the same as that of Example 7, except that the heat treatment in Example 11 is different from that in Example 7.

[0192] In step S3, the heat treatment can also be stress relief treatment and aging treatment. The stress relief treatment is heated to 500°C and held for 2 hours, and then cooled to room temperature in the furnace. The aging treatment is heated to a higher temperature for the first holding than for the second holding. The blank is heated to 800°C for the first holding and held for 2 hours. The second holding is heated to 700°C for 4 hours.

[0193] Example 12

[0194] The preparation process of Example 12 is largely the same as that of Example 7, except that the heat treatment in Example 12 is different from that in Example 7.

[0195] In step S3, the heat treatment can also be stress relief treatment and aging treatment. The stress relief treatment is heated to 520°C and held for 2 hours, then cooled to room temperature in the furnace. The aging treatment is heated to a higher temperature for the first holding than for the second holding. The blank is heated to 820°C for the first holding and held for 1.5 hours. The second holding is heated to 720°C for 3 hours.

[0196] Example 13

[0197] The preparation process of Example 13 is largely the same as that of Example 7, except that the heat treatment in Example 13 is different from that in Example 7.

[0198] In step S3, the heat treatment can also be stress relief treatment and aging treatment. The stress relief treatment is heated to 550°C and held for 1.5 hours, then cooled to room temperature in the furnace. The aging treatment is heated to a higher temperature for the first holding than for the second holding. The blank is heated to 850°C for the first holding and held for 1 hour. The second holding is heated to 750°C for 3 hours.

[0199] Comparative Example 1

[0200] This comparative example provides a sintering manufacturing method for a sweating active cooling leading edge component, including the following steps:

[0201] S1: Screening Process: Based on service conditions, spherical high-temperature alloy powder materials with the required particle diameter are selected using a vibrating screen. Urea (CO(NH2)2) pore-forming agent is selected, and urea is ground into powders of different particle diameters, which are then screened to obtain urea with the required particle diameter.

[0202] S2: Powder mixing treatment: The high-temperature alloy powder obtained in S1 is combined with urea in different proportions and mechanically dry-mixed in a ball mill for 4 hours to make the material evenly distributed.

[0203] S3: Compression Molding: Before molding, to improve the strength of the compact and prevent segregation of the powder mixture, an appropriate amount of liquid polyvinyl alcohol is added to the powder as a molding agent, and the powder is ground evenly. The ground powder is then introduced into the leading edge mold and pressed into a conical porous media leading edge blank under static pressure in a large hydraulic press.

[0204] S4: Sintering and Shaping: First, slowly heat from room temperature to 180℃ to fully decompose the pore-forming agent in the porous blank; then heat to 600℃ and hold for 30-60 minutes to completely reduce the surface oxides of the powder particles, forming sintering necks at the particle interfaces; next, heat to the sintering temperature of 1250℃ and hold for 100-150 minutes to allow sintering to proceed fully and near completion. Finally, reduce the temperature to 500℃ and allow it to cool naturally to room temperature.

[0205] Comparative Example 2

[0206] This comparative example provides a method for etching a layer to manufacture a sweating active cooling leading edge component, including the following steps:

[0207] S1: Plate preparation: First, use organic solvents to clean the surface of the high-temperature alloy sheet to remove surface oil and impurities;

[0208] S2: Plate fixing: Fix the high-temperature alloy sheet on the processing platform to ensure that the high-temperature alloy sheet will not move during the micro-groove processing;

[0209] S3: Parameter Settings: Set all operating parameters for the photolithography or chemical etching equipment;

[0210] S4: Flow channel processing: Using photolithography or chemical etching equipment to process at fixed positions on the surface of high-temperature alloy thin plates to obtain complex internal flow channels;

[0211] S5: Cleaning: Clean the grooves on the surface of the high-temperature alloy sheet to ensure the wettability of the groove walls and the flow performance of the cooling medium. After cleaning, perform drying.

[0212] S6: Welding: Welding metal plates processed by photolithography or chemical etching to form a layer plate leading edge structure, thereby obtaining a layer plate etching leading edge component.

[0213] Comparative Example 3

[0214] This comparative example provides a laser additive manufacturing method for a sweating-type actively cooled leading edge component, including the following steps:

[0215] S1: Powder pretreatment: Vacuum low-temperature drying treatment of raw materials (100-120℃, 1-2h) to improve the flowability of raw materials;

[0216] In this embodiment, the raw material is GH4099 high-temperature alloy powder, with the following mass percentages: C: 0.039 wt.%, Cr: 18.81 wt.%, W: 6.10 wt.%, Mo: 4.19 wt.%, Co: 6.56 wt.%, Al: 2.07 wt.%, Ti: 1.28 wt.%, Fe: 1.05 wt.%, B: 0.002 wt.%, Mg: 0.007 wt.%, Ce: 0.015 wt.%, Mn: 0.02 wt.%, Si: 0.31 wt.%, P: 0.004 wt.%, S: 0.005 wt.%, and the balance being Ni.

[0217] The GH4099 high-temperature alloy powder has a D10 of 19 μm, a D50 of 34 μm, a D90 of 49 μm, a flowability (Hall flow rate) of 15.64 s / 50 g, and a loose packing density of 4.6 g / cm³. 3 ;

[0218] S2: Model Design: Based on the structural characteristics of the leading edge component, slice the model to prepare the additive prototype model;

[0219] S3: Additive Manufacturing: Based on the sliced ​​model, the leading edge component is formed by selective laser melting. The laser power of selective laser melting additive manufacturing is 300W, the scanning speed is 960mm / s, the overlap distance is 50μm, the powder thickness is 40μm, and the layer-by-layer rotation is 67°.

[0220] S4: Heat treatment: The blank is heat treated in a vacuum environment. The annealing temperature is 1200℃ and the annealing time is 2h.

[0221] S5: Machining: Remove sintered powder and impurities from the surface of the annealed blank, and then process it; finally obtain the laser additive manufacturing sweating active cooling leading edge component.

[0222] Performance testing

[0223] The leading edge components obtained in Examples 1-13 and Comparative Examples 1-3 were tested. The leading edge components were directly injected with an oxyacetylene flame at a temperature of 1700K and a heat flux density of 0.32. The temperatures of the inner and outer surfaces of the leading edge components before and after the coolant was introduced were measured. The test results are shown in Table 1 (each group was tested three times and the average value was taken).

[0224] Table 1 Test Results

[0225]

[0226]

[0227] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for manufacturing a self-suctioning, active cooling leading edge component, characterized in that, Includes the following steps: S1: Based on the structural characteristics of the leading edge component model, slice the sample to obtain an additive manufacturing prototype model; the additive manufacturing prototype model includes an inner dense layer, a middle porous material layer and a surface sweating structure layer from the inside out, wherein the inner dense layer is provided with conventional fractal flow channels; S2: Powder bed additive manufacturing is performed based on the additive manufacturing prototype model. The process parameters and scanning strategy are controlled to produce a blank consisting of an internal dense layer, an intermediate porous material layer, and a surface sweating structure layer from the inside out. Conventional fractal flow channels and three-dimensional void flow channels are formed in the internal dense layer and the intermediate porous material layer, respectively, and the two are interconnected. The pore diameter of the conventional fractal flow channel is ≥1mm; the pore diameter of the three-dimensional void flow channel is 60~200µm. S3: Heat-treat the obtained blank to remove residual stress generated during additive manufacturing; S4: A femtosecond laser is used to drill holes on the surface of the processed blank to obtain the leading edge component; microscale sweating channels with a pore size of 30~50µm are prepared on the surface sweating structure layer; The density of the inner dense layer and the surface sweat-generating structure layer is above 99%; the porosity of the intermediate porous material layer is 30-50%.

2. The manufacturing method of the self-suctioning active cooling leading edge component according to claim 1, characterized in that, Before S1, there is also S0: powder pretreatment, which involves vacuum low-temperature drying of the raw materials.

3. The manufacturing method of the self-suctioning active cooling leading edge component according to claim 2, characterized in that, In step S0, the flowability of the dried raw material is 5~18s / 50g.

4. The manufacturing method of the self-suctioning active cooling leading edge component according to claim 1, characterized in that, In step S2, additive manufacturing includes the following steps: S21: The additive manufacturing prototype model is split from the inside to the surface into an internal dense layer, an intermediate porous material layer, and a surface sweating structure layer of different thicknesses; S22: A layer of powder raw material is evenly spread on the substrate, and different process parameters are set according to the internal dense layer, the middle porous material layer and the surface sweating structure layer. S23: After the first layer of powder is formed, another layer of powder is spread on the basis of the first layer, and the process of S22 is repeated to obtain a blank with a three-layer structure.

5. The manufacturing method of the self-suctioning active cooling leading edge component according to claim 4, characterized in that, In step S22, the additive manufacturing is electron beam selective additive manufacturing. When preparing the internal dense layer and the surface sweating structure layer, the electron beam selective melting current is 15-40mA, the scanning speed is 0.5-5mm / s, the powder thickness is 40-60μm, and the overlap spacing is 70-125μm. When preparing the intermediate porous material layer, the electron beam selective sintering current is 10-40 mA, the scanning speed is 3-20 mm / s, the powder thickness is 40-60 μm, and the overlap spacing is 70-125 μm.

6. The manufacturing method of the self-suctioning active cooling leading edge component according to claim 4, characterized in that, In step S22, the additive manufacturing is laser selective melting. When preparing the internal dense layer and the surface sweating structure layer, the laser power is 250-350W, the scanning speed is 800-1000mm / s, the overlap distance is 40-60μm, the powder thickness is 40-60μm, and the layer is rotated 67° layer by layer. When preparing the intermediate porous material layer, the laser power of selective laser melting is 150-200W, the scanning speed is 1000-1200mm / s, the overlap distance is 70-80μm, the powder thickness is 40-60μm, and no rotation is used.

7. The method for manufacturing the self-suctioning active cooling leading edge component according to claim 5 or 6, characterized in that, The thickness of the surface sweating structure layer is 500-800µm, the thickness of the intermediate porous material layer is 5-10mm, and the thickness of the inner dense layer is 10-15mm.

8. The manufacturing method of the self-suctioning active cooling leading edge component according to claim 1, characterized in that, S4 includes: T1: Fix the blank and set parameters; T2: Laser drilling: Laser drilling is performed on the surface sweating structure layer of the blank using a femtosecond laser, ensuring that the laser beam is perpendicular to the surface of the blank. T3: Surface microstructure processing: Femtosecond laser is used to process the surface of the component to form a hydrophilic microstructure, which facilitates the spread of the cooling medium.

9. A self-suctioning, sweating-type active cooling leading edge component, characterized in that, It is obtained by the manufacturing method described in any one of claims 1-8.

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