Nickel-based high-temperature alloy material for laser additive manufacturing, alloy component and forming method

Abstract

The invention belongs to the technical field of metal additive manufacturing, and particularly relates to a nickel-based high-temperature alloy material for laser additive manufacturing, an alloy component and a forming method. According to the nickel-based high-temperature alloy material for laser additive manufacturing provided by the invention, the forming performance and the microstructure of a formed component are regulated and controlled by designing the types and the contents of the element components, so that the cracking sensitivity of the nickel-based high-temperature alloy material in the laser additive manufacturing forming process can be reduced; macrocracks and microcracks caused by rapid cooling and rapid heating of the nickel-based superalloy material in laser additive manufacturing are effectively eliminated, meanwhile, the comprehensive mechanical property of a formed component is improved, and the prepared material is good in formability, free of air hole and microcrack defects, high in density and good in mechanical property. And the nickel-based high-temperature alloy component has excellent tensile strength, yield strength and ductility.

Description

Technical Field

[0001] The present application belongs to the technical field of metal additive manufacturing, and more specifically, to nickel-based high-temperature alloy materials, alloy components and forming methods for laser additive manufacturing. Background Art

[0002] High-temperature alloy materials are a type of multi-metal alloy with good high-temperature performance, which can usually work stably for a long time at temperatures above 650 °C. High-temperature alloys are mainly composed of various elements such as Ni, Co, Fe, Al, Mo, Cr, Ti, etc. According to the different matrix materials, they are mainly divided into nickel-based, iron-based and cobalt-based high-temperature alloys. Compared with iron-based and cobalt-based high-temperature alloys, nickel-based alloys have better comprehensive performance. Their stable crystal structure, good oxidation resistance and excellent mechanical properties at high temperatures have led to the rapid development and application of nickel-based high-temperature alloys.

[0003] With the continuous improvement of the thrust-to-weight ratio of the new generation of aerospace engines, the hot end components of the engines have more stringent manufacturing requirements and are showing trends such as becoming more complex, thin-walled, composite, and integrated. Traditional manufacturing methods such as casting, forging, and powder metallurgy are difficult to meet their manufacturing needs. Additive manufacturing technology, as an advanced integrated forming and manufacturing technology, provides new possibilities for the preparation of complex components of nickel-based high-temperature alloys. Laser powder bed fusion (LPBF) is one of the most widely used metal additive manufacturing technologies. It uses a laser to melt / solidify powder raw materials layer by layer to achieve the purpose of forming parts.

[0004] However, the existing nickel-based high-temperature alloys have poor weldability and are prone to forming defects such as cracks and holes during the LPBF process. Currently, process optimization is mainly used, such as comprehensive control of laser scanning speed, laser power and other parameters to reduce holes, but it is difficult to completely eliminate cracks. Summary of the invention

[0005] In view of the defects of the prior art, the purpose of this application is to provide a nickel-based high-temperature alloy material, alloy component and forming method for laser additive manufacturing, aiming to solve the problems of poor weldability, cracks and holes in existing nickel-based high-temperature alloys.

[0006] To achieve the above objectives, in a first aspect, the present application provides a nickel-based high-temperature alloy material, comprising the following components, by mass percentage: 2% to 3% Al, 1% to 2.5% Ti, 0.6% to 1.1% Nb, 1.7% to 2.0% Ta, 2.0% to 2.8% W, 1.5% to 2.0% Mo, 15.7% to 16.3% Cr, 8.0% to 9.0% Co, 0.09% to 0.13% C, 0.007% to 0.012% B, 0.05% to 0.15% Zr; the rest is Ni and unavoidable impurities; The sum of the mass percentages of Al and Ti is ≤4.5%.

[0007] Preferably, the nickel-based high-temperature alloy material comprises the following components, in percentage by mass: 2.4% to 2.8% Al, 1% to 2% Ti, 0.6% to 1.1% Nb, 1.7% to 2.0% Ta, 2.0% to 2.8% W, 1.5% to 2.0% Mo, 15.7% to 16.3% Cr, 8.0% to 9.0% Co, 0.09% to 0.13% C, 0.007% to 0.012% B, 0.05% to 0.15% Zr; the rest is Ni and unavoidable impurities; The sum of the mass percentages of Al and Ti is ≤4.5%.

[0008] In a second aspect, the present application also provides a crack-free nickel-based high-temperature alloy component, which is manufactured by laser additive manufacturing of the above-mentioned nickel-based high-temperature alloy material.

[0009] In a third aspect, the present application provides a forming method of the above-mentioned nickel-based high-temperature alloy component, comprising the following steps: S1. Mixing the ingredients according to the composition of the above-mentioned nickel-based high-temperature alloy material, and then vacuum melting and atomizing the above-mentioned raw materials to obtain nickel-based high-temperature alloy material powder; S2, establishing a three-dimensional model of the nickel-based high-temperature alloy component, and cutting it into a two-dimensional scanning path using a slicing software; S3. Put the above-mentioned nickel-based high-temperature alloy material powder into the powder feeder of the laser additive manufacturing equipment, and melt the above-mentioned nickel-based high-temperature alloy material powder layer by layer on the substrate under a protective atmosphere according to the process parameters set by the laser additive manufacturing equipment and the above-mentioned two-dimensional scanning path, so as to prepare a nickel-based high-temperature alloy component.

[0010] Preferably, step S1 specifically comprises: preparing ingredients according to the composition of the above-mentioned nickel-based high-temperature alloy material, and vacuum melting the above-mentioned raw materials to obtain a master alloy ingot, and then heating the above-mentioned master alloy ingot until it is completely melted, introducing an atomizing gas for atomization and powdering, and obtaining the nickel-based high-temperature alloy material powder after cooling.

[0011] Preferably, in step S1, the atomizing gas is any one of inert gases with a purity of 99.99% or above, and the pressure of the atomizing gas is 2-3.5 MPa.

[0012] Preferably, the inert gas is one or more of helium, argon, neon and krypton.

[0013] Preferably, in step S1, the particle size of the nickel-based high-temperature alloy material powder is 15-70 μm.

[0014] Preferably, in step S3, the process parameters are: laser power of 200-260 W, scanning speed of 700-1100 mm / s, scanning spacing of 50-150 μm, and layer thickness of 30-50 μm.

[0015] Preferably, in step S3, before setting the process parameters of the laser additive manufacturing equipment, the substrate is first cleaned and preheated to 100° C. to 150° C.

[0016] Preferably, in step S3, the protective atmosphere is selected from one or more of argon, nitrogen and helium.

[0017] Preferably, in step S3, the oxygen content in the protective atmosphere is ≤500 ppm.

[0018] In general, the above technical solutions conceived by this application have the following technical advantages compared with the prior art: (1) The nickel-based high-temperature alloy material for laser additive manufacturing provided in this application can reduce the cracking sensitivity of the nickel-based high-temperature alloy material during the laser additive manufacturing process by designing the type and content of its elemental composition, and then regulating the forming performance and microstructure of the formed component. It can effectively eliminate the macro cracks and micro cracks caused by rapid cooling and heating of the nickel-based high-temperature alloy material during laser additive manufacturing, and at the same time improve the comprehensive mechanical properties of the formed component, so as to prepare a nickel-based high-temperature alloy component with good formability, no pores and micro cracks, high density, and excellent tensile strength, yield strength and ductility.

[0019] (2) This application can adjust and control the process parameters of laser additive manufacturing technology, including laser power, scanning speed, single-pass spacing, powder layer thickness, etc., to achieve adjustable and controllable comprehensive mechanical properties of nickel-based high-temperature alloy components, and can obtain formed components with excellent comprehensive mechanical properties under a wide range of process parameters. The nickel-based high-temperature alloy components provided in this application have a tensile strength of ≥966 MPa, a yield strength of ≥719 MPa, and an engineering strain of ≥19.4%, and have broad prospects for industrial application. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a flow chart of a forming method of a nickel-based high-temperature alloy component provided in an embodiment of the present application; Figure 2 The figure is a morphology and particle size distribution diagram of the nickel-based high-temperature alloy powder prepared in Example 1 of the present application, wherein content A is a SEM image and content B is a particle size distribution diagram; Figure 3 is a schematic diagram of the printing strategy of Example 1 of the present application; Figure 4 1 is a metallographic diagram of the nickel-based high-temperature alloy components prepared in Example 1 and Comparative Example 1 of the present application, wherein content (a) is the nickel-based high-temperature alloy component prepared in Example 1, and content (b) is the IN738LC alloy component prepared in Comparative Example 1; Figure 5 The density of the nickel-based high-temperature alloy components prepared in this application at different scanning speeds with laser power densities of 200 W, 230 W, and 260 W respectively; Figure 6 These are optical microscope images of nickel-based high-temperature alloy components prepared by the present application at laser power densities of 200 W, 230 W, and 260 W at different scanning speeds; Figure 7 The room temperature tensile mechanical properties of the nickel-based high temperature alloy component prepared in Example 5 of the present application, wherein content (a) is the room temperature tensile performance curve of the nickel-based high temperature alloy component, and content (b) is the tensile strength, yield strength and engineering strain of the nickel-based high temperature alloy component; Figure 8 These are the high-temperature tensile mechanical properties of the nickel-based high-temperature alloy component prepared in Example 5 of the present application, wherein content (a) is the high-temperature tensile performance curve of the nickel-based high-temperature alloy component, and content (b) is the tensile strength, yield strength and engineering strain of the nickel-based high-temperature alloy component. DETAILED DESCRIPTION

[0021] In order to make the purpose, technical solution and advantages of the present application more clearly understood, the present application is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and are not used to limit the present application.

[0022] In the specification and claims of the present application, the terms "first" and "second" etc. are used to distinguish different objects rather than to describe the specific order of the objects and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features.

[0023] In the description of this application, the term "and / or" is a description of the association relationship of associated objects, indicating that there can be three relationships. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. The symbol " / " in this article indicates that the associated objects are in an or relationship, for example, A / B means A or B.

[0024] In the description of this application, words such as "exemplary" or "for example" are used to indicate examples, illustrations or explanations. Any embodiment or design described as "exemplary" or "for example" in the embodiments of this application should not be interpreted as being more preferred or more advantageous than other embodiments or designs. Specifically, the use of words such as "exemplary" or "for example" is intended to present related concepts in a specific way.

[0025] In the description of this application, unless otherwise specified, "plurality" means two or more.

[0026] Traditional IN738LC alloy material has great crack sensitivity during the laser powder bed melting process and will form a large number of crack defects after forming. Even after optimizing the process parameters of laser powder bed melting technology, it is still impossible to completely avoid the cracks generated during forming.

[0027] For nickel-based high-temperature alloy materials, Al and Ti elements are the forming elements of the main strengthening phase γ′ phase [Ni3(Al,Ti)] in nickel-based high-temperature alloys. With the increase of Al+Ti element content, the dissolution temperature and stability of the γ′ phase will also increase, and the volume fraction of the γ′ phase in the alloy can be increased, thereby improving the high-temperature mechanical properties of the alloy. Among them, the Al element can also form a continuous aluminum oxide layer on the surface of the alloy to protect the alloy matrix and thus improve the alloy's oxidation resistance and corrosion resistance. However, excessive Al and Ti content will promote the formation of low-melting point γ / γ′ eutectic between dendrites, which is not conducive to the forming of the alloy during laser additive manufacturing. How to improve the weldability of nickel-based high-temperature alloy materials (that is, during the laser additive manufacturing process, no defects such as cracks and holes are formed) while improving the high-temperature mechanical properties of the formed components is a key technical problem to be solved in this application. Based on this, the present application provides a nickel-based high-temperature alloy material, which includes the following components, by mass percentage: 2% to 3% Al, 1% to 2.5% Ti, 0.6% to 1.1% Nb, 1.7% to 2.0% Ta, 2.0% to 2.8% W, 1.5% to 2.0% Mo, 15.7% to 16.3% Cr, 8.0% to 9.0% Co, 0.09% to 0.13% C, 0.007% to 0.012% B, 0.05% to 0.15% Zr; the rest is Ni and unavoidable impurities; The sum of the mass percentages of Al and Ti is ≤4.5%.

[0028] In some embodiments, the nickel-based high-temperature alloy material includes the following components by mass percentage: 2.4% to 2.8% Al, 1% to 2% Ti, 0.6% to 1.1% Nb, 1.7% to 2.0% Ta, 2.0% to 2.8% W, 1.5% to 2.0% Mo, 15.7% to 16.3% Cr, 8.0% to 9.0% Co, 0.09% to 0.13% C, 0.007% to 0.012% B, 0.05% to 0.15% Zr; the rest is Ni and unavoidable impurities; The sum of the mass percentages of Al and Ti is ≤4.5%.

[0029] The present application also provides a crack-free nickel-based high-temperature alloy component, which is manufactured by laser additive manufacturing of the above-mentioned nickel-based high-temperature alloy material.

[0030] On the other hand, Figure 1 As shown, the present application also provides a forming method of the above-mentioned nickel-based high-temperature alloy component, that is, a preparation method of the nickel-based high-temperature alloy component, comprising the following steps: S1. Mixing the ingredients according to the composition of the above-mentioned nickel-based high-temperature alloy material, and then vacuum melting and atomizing the above-mentioned raw materials to obtain nickel-based high-temperature alloy material powder; S2, establishing a three-dimensional model of the nickel-based high-temperature alloy component, and cutting it into a two-dimensional scanning path through a slicing software; S3. Put the above-mentioned nickel-based high-temperature alloy material powder into the powder feeder of the laser additive manufacturing equipment, and melt the above-mentioned nickel-based high-temperature alloy material powder layer by layer on the substrate under a protective atmosphere according to the process parameters set by the laser additive manufacturing equipment and the above-mentioned two-dimensional scanning path, so as to prepare a nickel-based high-temperature alloy component.

[0031] The present application does not limit the process for preparing nickel-based high-temperature alloy material powder. In some embodiments, the process for preparing nickel-based high-temperature alloy material powder can be: preparing ingredients according to the composition of the above-mentioned nickel-based high-temperature alloy material, and vacuum melting the prepared raw materials into a master alloy ingot, and then heating the above-mentioned master alloy ingot until it is completely melted, introducing an atomizing gas for atomization and powdering to obtain nickel-based high-temperature alloy material powder.

[0032] In some embodiments, the process for preparing the nickel-based high-temperature alloy material powder can also be: preparing the ingredients according to the composition of the above-mentioned nickel-based high-temperature alloy material, and vacuum melting the prepared raw materials into alloy liquid, and then introducing an atomizing gas for atomization and powdering to obtain the nickel-based high-temperature alloy material powder.

[0033] In a specific embodiment of the present application, the process for preparing the nickel-based high-temperature alloy material powder is as follows: the ingredients are prepared according to the composition of the nickel-based high-temperature alloy material, the prepared raw materials are placed in a vacuum melting furnace, vacuumized and a protective gas is introduced, and vacuum melting is performed to prepare a master alloy ingot. The prepared master alloy ingot is then placed in a melting crucible, and then vacuumized and a protective gas is introduced to perform induction heating on the master alloy ingot until it is completely melted, and then an atomizing gas is introduced to perform atomization powdering to obtain a spherical or nearly spherical nickel-based high-temperature alloy material powder to be dried.

[0034] The present invention does not limit the vacuum melting method. In some embodiments, the vacuum melting is vacuum induction melting.

[0035] In some embodiments, the induction heating temperature is between 1200°C and 1700°C.

[0036] In some embodiments, during the atomization process, the atomizing gas is any one of the inert gases with a purity of 99.99% or above, and the pressure of the atomizing gas is 2-3.5 MPa.

[0037] In some embodiments, the inert gas is one or more of helium (He), argon (Ar), neon (Ne), and krypton (Kr).

[0038] In some embodiments, step S1 further includes vacuum drying the nickel-based high-temperature alloy material powder, which can remove moisture from the powder and reduce the oxygen content in the powder. It is understandable that the present application does not limit the process of vacuum drying the nickel-based high-temperature alloy material powder. In some embodiments, the vacuum drying temperature can be 100°C to 200°C, and the vacuum drying time can be 1 to 3 hours.

[0039] In some embodiments, in step S1, the particle size of the nickel-based high-temperature alloy material powder is 10-75 μm.

[0040] The present application does not limit the two-dimensional scanning path in step S2. In practical applications, the two-dimensional scanning path can be set according to the structure of the high-temperature alloy component. In some embodiments, the two-dimensional scanning path is: one-piece molding, layer-by-layer scanning, and the inter-layer rotation angle is set to 65°~70° to release residual stress.

[0041] In some embodiments, step S3 is specifically as follows: placing the nickel-based high-temperature alloy material powder into a powder feeder of a laser melting system, starting the laser melting system, and melting and depositing the nickel-based high-temperature alloy material powder layer by layer on a substrate under a protective atmosphere to prepare a nickel-based high-temperature alloy component.

[0042] In some embodiments, in step S3, the process parameters are: laser power of 200-260 W, scanning speed of 700-1100 mm / s, scanning spacing of 50-150 μm, and layer thickness of 30-50 μm.

[0043] In some embodiments, in step S3, before setting the process parameters of the laser additive manufacturing equipment, the substrate is cleaned. In some embodiments, the cleaning includes but is not limited to surface cleaning, grinding, sandblasting, ultrasonic cleaning, and alcohol cleaning.

[0044] In some embodiments, after the substrate is cleaned and dried, the substrate is placed in a forming chamber under a protective atmosphere and fixed on a workbench of a laser additive manufacturing device for leveling and standby.

[0045] In some embodiments, in step S3, before preparing the nickel-based high-temperature alloy component, the substrate is preheated to 100° C. to 150° C.

[0046] In some embodiments, in step S3, the protective atmosphere is selected from at least one of argon (Ar), nitrogen (N2), and helium (He).

[0047] In some embodiments, in step S3, the oxygen content in the protective atmosphere is ≤500 ppm. In a preferred embodiment, the oxygen content in the protective atmosphere is ≤1000 ppm.

[0048] It should be understood that materials of the same or similar type, model, quality, nature or function as the reagents and instruments used in the following examples can be used to implement the present application. The experimental methods used in the following examples are conventional methods unless otherwise specified. The materials, reagents, etc. used in the following examples can be obtained from commercial sources unless otherwise specified.

[0049] The following are examples and comparative examples: Example 1 The method for forming a crack-free nickel-based high-temperature alloy component provided in this embodiment comprises the following steps: (1) Preparation of nickel-based high-temperature alloy material: In terms of mass percentage, the composition of the nickel-based high-temperature alloy material designed in this embodiment is as follows: 2.56% Al, 1.47% Ti, 0.94% Nb, 1.70% Ta, 2.19% W, 1.51% Mo, 16.00% Cr, 8.81% Co, 0.11% C, 0.0041% B, 0.06% Zr, and the rest is Ni. According to the composition of the designed nickel-based high-temperature alloy material, raw materials Al, Ti, Nb, Ta, W, Mo, Cr, Co, C, B, Zr, and Ni are prepared, wherein the purity of each raw material is above 99.9%, and the above-mentioned single raw materials are placed in a vacuum induction furnace for vacuum induction melting to prepare a master alloy ingot, i.e., a nickel-based high-temperature alloy material.

[0050] (2) Preparation of powdered nickel-based high-temperature alloy material: The master alloy ingot prepared as described above is placed in a melting crucible, and after evacuation, high-purity argon gas with a purity of more than 99.99% is filled in until the pressure of the melting chamber returns to the standard atmospheric pressure, and then induction heating is performed until the master alloy ingot is completely melted. The induction heating temperature is 1700°C. The molten metal liquid is poured into a middle drain bag, and argon gas with a purity of 99.99% at a pressure of 2.6 MPa is introduced for impact crushing, so that the metal liquid is atomized into fine metal droplets, which are cooled and solidified into nickel-based high-temperature alloy material powder. The nickel-based high-temperature alloy material powder is collected and sieved through a two-pass cyclone separation system to obtain a dry spherical or nearly spherical nickel-based high-temperature alloy material powder suitable for laser additive manufacturing, and the particle size is 10~75 μm (such as Figure 2 Content (a), Figure 2 Content (b) as shown), for backup.

[0051] (3) Laser additive manufacturing of nickel-based high-temperature alloy components: Establish a three-dimensional model of the component, and use the slicing software to process the model to form a laser scanning trajectory. The forming substrate is installed on the forming workbench of the printing equipment. The preheating temperature is set to 100 °C before forming to preheat the substrate to prevent part cracking during laser additive manufacturing printing and reduce the thermal residual stress of the component. The scanning path of the laser additive manufacturing nickel-based high-temperature alloy component is as follows: Figure 3As shown in the figure, the process parameters such as laser power, scanning speed, scanning spacing, and powder layer thickness are set. Specifically, a certain flow of high-purity argon gas with a purity of more than 99.99% is introduced in advance, and then the first layer of nickel-based high-temperature alloy material powder is spread on the forming substrate through the powder spreading device. The first layer is printed according to the two-dimensional scanning trajectory using a high-energy laser beam. The powder at the scanning position is completely melted and quickly solidified into an alloy. Then the forming substrate is lowered to a height and the powder is spread again. The laser scanning direction is rotated 67° to print the second layer. The laser beam melts the powder and repeats this process until the component is finally formed. Among them, the process parameters of laser additive manufacturing are: laser power of 230 W, scanning rate of 700 mm / s, scanning spacing of 100 μm, and layer thickness of 40 μm.

[0052] Figure 4 Content (a) is a metallographic image of the nickel-based high-temperature alloy component prepared in this embodiment. It can be seen that the nickel-based high-temperature alloy component has no pores and microcracks, has good formability and high forming quality.

[0053] Comparative Example 1 The nickel-based high-temperature alloy material provided in this comparative example is a traditional IN738LC alloy, and the composition of the traditional IN738LC alloy is as follows by mass percentage: 3.68% Al, 3.53% Ti, 0.92% Nb, 1.84% Ta, 2.65% W, 1.86% Mo, 15.8% Cr, 8.24% Co, 0.13% C, 0.01% B, 0.16% Zr, 0.11% Fe, 0.01% Si, 0.004% Mn, 0.01% P, 0.003% S, 0.007% O, 0.005% N, and the rest is Ni. Then, IN738LC alloy material and IN738LC alloy material powder are prepared according to the method provided in Example 1, and IN738LC alloy components are manufactured by laser additive manufacturing.

[0054] Figure 4 Content (b) is the metallographic image of the IN738LC alloy component prepared in this comparative example. It can be seen that the IN738LC alloy component has a large number of obvious cracks and the forming quality is low. The possible reason is that the traditional IN738LC alloy material powder has a large crack sensitivity during the laser powder bed melting forming process, and is very prone to alloy defects such as thermal cracks and strain aging cracks, resulting in poor formability of the alloy component.

[0055] Example 2 The preparation of nickel-based high-temperature alloy material powder in this embodiment is the same as that in Example 1.

[0056] Laser additive manufacturing was used to manufacture nickel-based high-temperature alloy components, wherein the process parameters of laser additive manufacturing were: laser power was 200 W, powder was spread using different scanning rates, and other parameters and operations were the same as in Example 1. The optical microscope image of the prepared nickel-based high-temperature alloy component was as follows: Figure 5 As shown, the density of nickel-based high-temperature alloy components was tested by drainage method and metallographic method. The results are shown in Figure 6 shown.

[0057] Example 3 The preparation of nickel-based high-temperature alloy material powder in this embodiment is the same as that in Example 1.

[0058] Laser additive manufacturing was used to manufacture nickel-based high-temperature alloy components, wherein the process parameters of laser additive manufacturing were: laser power was 230 W, different scanning rates were used for powder spreading, and other parameters and operations were the same as in Example 1. The optical microscope image of the prepared nickel-based high-temperature alloy component was as follows: Figure 5 As shown, the density of nickel-based high-temperature alloy components was tested by drainage method and metallographic method. The results are shown in Figure 6 shown.

[0059] Example 4 The preparation of nickel-based high-temperature alloy material powder in this embodiment is the same as that in Example 1.

[0060] Laser additive manufacturing of nickel-based high-temperature alloy components, wherein the process parameters of laser additive manufacturing are: laser power of 230W, powder spreading using different scanning rates, other parameters and operations are the same as in Example 1, and the optical microscope image of the prepared nickel-based high-temperature alloy component is as follows Figure 5 As shown, the density of nickel-based high-temperature alloy components was tested by drainage method and metallographic method. The results are shown in Figure 6 shown.

[0061] Depend on Figure 5 It can be seen that when the laser power is 200 W and the scanning speed is 700, 800, 900, and 1000 mm / s, the prepared nickel-based high-temperature alloy components have no cracks and holes (the density is greater than 98.0%, such as Figure 6 When the laser power is 230W and the scanning speed is 700, 800, 900, 1000, 1100 mm / s, the prepared nickel-based high-temperature alloy components have no cracks and holes (the density is greater than 98.1%, as shown in Figure 6 When the laser power is 260 W and the scanning speed is 700, 800, 900, 1000, 1100 mm / s, the prepared nickel-based high-temperature alloy components have no cracks and holes (the density is greater than 98.1%, as shown in Figure 6 as shown).

[0062] Example 5 The preparation of nickel-based high-temperature alloy material powder in this embodiment is the same as that in Example 1.

[0063] A nickel-based high-temperature alloy component was manufactured by laser additive manufacturing, wherein the process parameters of laser additive manufacturing were as follows: laser power of 230 W, scanning speed of 500 mm / s, and other parameters and operations were the same as in Example 1, and a nickel-based high-temperature alloy component P1 was prepared. The laser power was 230 W, the scanning speed was 700 mm / s, and other parameters and operations were the same as in Example 1, and a nickel-based high-temperature alloy component P2 was prepared. The laser power was 230 W, the scanning speed was 900 mm / s, and other parameters and operations were the same as in Example 1, and a nickel-based high-temperature alloy component P3 was prepared.

[0064] The room temperature tensile properties of the nickel-based high temperature alloy components P1, P2, and P3 were tested. The test results are shown in Figure 7 Content (a), Figure 7 Content (b) and Table 1. Then the nickel-based high-temperature alloy component P2 was subjected to a high-temperature tensile performance test. The specific test method was as follows: the nickel-based high-temperature alloy component P2 was placed in an atmospheric environment and tested for its high-temperature tensile performance at 700°C, 800°C, and 900°C using a material high-temperature durability tester (model AG-IC100kN). The tensile rate was 1 mm / min. The test results are shown in Figure 8 Content (a), Figure 8 Contents (b) and Table 2.

[0065] Table 1 Room temperature tensile properties of nickel-based high temperature alloy components prepared in Example 5

[0066] Table 2 High temperature tensile properties of nickel-based superalloy component P2

[0067] It can be seen from Table 1 that the nickel-based high-temperature alloy component prepared in Example 5 has excellent tensile properties at room temperature, good ductility, tensile strength ≥ 966 MPa, yield strength ≥ 719 MPa, and engineering strain ≥ 19.4%. Furthermore, the nickel-based high-temperature alloy component prepared in Example 5 still has excellent tensile properties at 700 ℃, 800 ℃, and 900 ℃ (Table 2).

[0068] Comparative Example 2 The nickel-based high-temperature alloy material provided in this comparative example has the following composition, in terms of mass percentage: 3.45% Al, 3.53% Ti, 0.89% Nb, 1.90% Ta, 2.68% W, 1.87% Mo, 16.02% Cr, 8.70% Co, 0.10% C, 0.004% B, 0.067% Zr, and the rest is Ni. Based on comparative example 1, this comparative example optimizes the content of grain boundary strengthening elements C, B, and Zr in the alloy, and removes elements such as Fe, Si, Mn, P, and S. Raw materials Al, Ti, Nb, Ta, W, Mo, Cr, Co, C, B, Zr, and Ni are prepared according to the designed composition of the nickel-based high-temperature alloy material, wherein the purity of each raw material is above 99.9%, and then the nickel-based high-temperature alloy material and nickel-based high-temperature alloy material powder are prepared according to the method provided in Example 1.

[0069] Nickel-based high-temperature alloy components were manufactured by laser additive manufacturing, wherein the process parameters of laser additive manufacturing were as follows: laser powers were 200 W, 230 W, and 260 W, respectively; scanning speeds were 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, and 1400 mm / s, respectively; other parameters and operations were the same as in Example 1, and a series of nickel-based high-temperature alloy components were prepared. Then, the density of the series of nickel-based high-temperature alloy components was measured by metallographic method and drainage method, and the alloy components prepared by 3 optimized process parameters were selected for tensile property testing. Among them, the laser power is 260 W, the scanning speed is 600 mm / s, and the other parameters and operations are the same as in Example 1, and the nickel-based high-temperature alloy component D1 is prepared; the laser power is 260 W, the scanning speed is 800 mm / s, and the other parameters and operations are the same as in Example 1, and the nickel-based high-temperature alloy component D2 is prepared; the laser power is 260 W, the scanning speed is 1000 mm / s, and the other parameters and operations are the same as in Example 1, and the nickel-based high-temperature alloy component D3 is prepared. The test method of tensile properties is the same as in Example 5, and the room temperature tensile properties of nickel-based high-temperature alloy components D1, D2, and D3 are shown in Table 3. Then, the high-temperature tensile property test of the nickel-based high-temperature alloy component D2 is carried out, and the test method is the same as in Example 5, and the high-temperature tensile properties are shown in Table 4.

[0070] Table 3 Room temperature tensile properties of nickel-based high temperature alloy components prepared in Comparative Example 2

[0071] Table 4 High temperature tensile properties of nickel-based high temperature alloy component D2

[0072] It can be seen from Table 3 that when only the content of C, B, and Zr elements is optimized, the mechanical properties of the prepared alloy components at room temperature are poor, the tensile strength and yield strength are both lower than 700 MPa, and the engineering strain is low, both less than 3%, and the ductility is poor. The above alloy components were subjected to high-temperature tensile tests (Table 4). The results show that the tensile strength at 900 °C is only 213.1 MPa, the yield strength is only 171.5 MPa, and the engineering strain is only 1.6%. The high-temperature tensile performance is poor and does not meet the requirements of the application scenario.

[0073] Comparative Example 3 The nickel-based high-temperature alloy material provided in this comparative example has the following composition, in percentage by mass: 2.5% Al, 2.5% Ti, 0.94% Nb, 1.70% Ta, 2.19% W, 1.51% Mo, 16.00% Cr, 8.81% Co, 0.11% C, 0.0041% B, 0.06% Zr, and the rest is Ni. Based on Example 1, this comparative example optimizes the content of grain boundary strengthening elements Al and Ti in the alloy. According to the designed composition of the nickel-based high-temperature alloy material, raw materials Al, Ti, Nb, Ta, W, Mo, Cr, Co, C, B, Zr, and Ni are prepared, wherein the purity of each raw material is above 99.9%, and then the nickel-based high-temperature alloy material and nickel-based high-temperature alloy material powder are prepared according to the method provided in Example 1.

[0074] The nickel-based high-temperature alloy component D4 was prepared by laser additive manufacturing. The process parameters of laser additive manufacturing were as follows: laser power of 230 W, scanning rate of 700 mm / s, scanning interval of 100 μm, and layer thickness of 40 μm.

[0075] The microstructural characterization of the nickel-based high-temperature alloy component D4 was tested and it was found that there were a small number of cracks and holes on the surface of the nickel-based high-temperature alloy component D4, which did not meet the requirements of the application scenario.

[0076] It will be easily understood by those skilled in the art that the above description is only a preferred embodiment of the present application and is not intended to limit the present application. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application shall be included in the scope of protection of the present application.

Claims

1. A nickel-based high-temperature alloy material, characterized in that: In terms of mass percentage, it includes the following components: 2%~3% Al, 1%~2.5% Ti, 0.6%~1.1% Nb, 1.7%~2.0% Ta, 2.0%~2.8% W, 1.5%~2.0% Mo, 15.7%~16.3% Cr, 8.0%~9.0% Co, 0.09%~0.13% C, 0.007%~0.012% B, 0.05%~0.15% Zr; the rest is Ni and unavoidable impurities; The sum of the mass percentages of Al and Ti is ≤4.5%.

2. The nickel-based high-temperature alloy material according to claim 1, characterized in that: In terms of mass percentage, it includes the following components: 2.4% to 2.8% Al, 1% to 2% Ti, 0.6% to 1.1% Nb, 1.7% to 2.0% Ta, 2.0% to 2.8% W, 1.5% to 2.0% Mo, 15.7% to 16.3% Cr, 8.0% to 9.0% Co, 0.09% to 0.13% C, 0.007% to 0.012% B, 0.05% to 0.15% Zr; the rest is Ni and unavoidable impurities; The sum of the mass percentages of Al and Ti is ≤4.5%.

3. A crack-free nickel-based high-temperature alloy component, characterized in that: The nickel-based high-temperature alloy material according to claim 1 or 2 is manufactured by laser additive manufacturing.

4. The forming method of the nickel-based high-temperature alloy component according to claim 3, characterized in that: The steps include: S1. preparing ingredients according to the composition of the nickel-based high-temperature alloy material, and then performing vacuum melting and atomization treatment on the raw materials to obtain nickel-based high-temperature alloy material powder; S2, establishing a three-dimensional model of the nickel-based high-temperature alloy component, and cutting it into a two-dimensional scanning path by slicing software; S3. Put the nickel-based high-temperature alloy material powder into the powder feeder of the laser additive manufacturing equipment, and melt the nickel-based high-temperature alloy material powder layer by layer on the substrate under a protective atmosphere according to the process parameters set by the laser additive manufacturing equipment and the two-dimensional scanning path, so as to prepare a nickel-based high-temperature alloy component.

5. The forming method according to claim 4, characterized in that: Step S1 specifically comprises: preparing ingredients according to the composition of the nickel-based high-temperature alloy material, and vacuum melting the raw materials to obtain a master alloy ingot, then heating the master alloy ingot until it is completely melted, introducing an atomizing gas to perform atomization and powdering, and obtaining nickel-based high-temperature alloy material powder after cooling.

6. The forming method according to claim 5, characterized in that: In step S1, the atomizing gas is any one of the inert gases with a purity of 99.99% or above, and the pressure of the atomizing gas is 2-3.5 MPa.

7. The forming method according to claim 4, characterized in that: In step S1, the particle size of the nickel-based high-temperature alloy material powder is 10-75 μm.

8. The forming method according to claim 4, characterized in that: In step S3, the process parameters are: laser power of 200-260 W, scanning speed of 700-1100 mm / s, scanning spacing of 50-150 μm, and layer thickness of 30-50 μm.

9. The forming method according to claim 4, characterized in that: In step S3, before setting the process parameters of the laser additive manufacturing equipment, the substrate is first cleaned and preheated to 100° C. to 150° C.

10. The forming method according to claim 4, characterized in that: In step S3, the protective atmosphere is selected from one or more of argon, nitrogen, and helium; and the oxygen content in the protective atmosphere is ≤500 ppm.

Images