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

Abstract

This application belongs to the field of metal additive manufacturing technology, and more specifically, relates to nickel-based superalloy materials, alloy components, and forming methods for laser additive manufacturing. The nickel-based superalloy material for laser additive manufacturing provided in this application, by designing the types and contents of its elemental composition, can control the forming performance and microstructure of the formed component. This reduces the cracking sensitivity of the nickel-based superalloy material during the laser additive manufacturing process, effectively eliminates macroscopic and microcracks caused by rapid cooling and heating in the laser additive manufacturing process, and simultaneously improves the comprehensive mechanical properties of the formed component. The result is a nickel-based superalloy component with good formability, no porosity or microcrack defects, high density, and excellent tensile strength, yield strength, and ductility.

Description

Technical Field

[0001] This application belongs to the field of metal additive manufacturing technology, and more specifically, relates to nickel-based high-temperature alloy materials, alloy components and forming methods for laser additive manufacturing. Background Technology

[0002] High-temperature alloys are a class of multi-metal alloys with excellent high-temperature performance, typically capable of long-term stable operation above 650 °C. High-temperature alloys are mainly composed of various elements such as Ni, Co, Fe, Al, Mo, Cr, and Ti. Based on the different matrix materials, they are mainly divided into nickel-based, iron-based, and cobalt-based high-temperature alloys. Compared to iron-based and cobalt-based high-temperature alloys, nickel-based alloys have superior overall 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 new-generation aerospace engines, the manufacturing requirements for their hot-end components are becoming increasingly stringent, exhibiting trends of greater complexity, thinner walls, composite structures, and integration. Traditional manufacturing methods such as casting, forging, and powder metallurgy are insufficient to meet these demands. Additive manufacturing technology, as an advanced integrated forming manufacturing technology, offers new possibilities for the fabrication of complex nickel-based superalloy components. Laser powder bed fusion (LPBF) is one of the most widely used metal additive manufacturing technologies, utilizing a laser to melt / solidify powder raw materials layer by layer to achieve the purpose of forming parts.

[0004] However, existing nickel-based superalloys have poor weldability, and are prone to defects such as cracks and voids during the LPBF process. Currently, the main approach is to optimize the process, such as comprehensively controlling parameters like laser scanning speed and laser power, to reduce voids, but it is difficult to completely eliminate cracks. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the purpose of this application is to provide nickel-based superalloy materials, alloy components and forming methods for laser additive manufacturing, aiming to solve the problems of poor weldability, cracks and pores in existing nickel-based superalloys.

[0006] To achieve the above objectives, in a first aspect, this application provides a nickel-based superalloy material comprising, by mass percentage: 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, and 0.05%~0.15% Zr; the remainder being Ni and unavoidable impurities.

[0007] The total mass percentage of Al and Ti is ≤4.5%.

[0008] Preferably, the above-mentioned nickel-based superalloy material comprises, by mass percentage, the following components: 2.4%~2.8% Al, 1%~2% 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, and 0.05%~0.15% Zr; the remainder being Ni and unavoidable impurities.

[0009] The total mass percentage of Al and Ti is ≤4.5%.

[0010] Secondly, this application also provides a crack-free nickel-based superalloy component, which is obtained by laser additive manufacturing of the aforementioned nickel-based superalloy material.

[0011] Thirdly, this application provides a method for forming the above-mentioned nickel-based high-temperature alloy component, comprising the following steps:

[0012] S1. Prepare the raw materials according to the above-mentioned composition of nickel-based high-temperature alloy material, and then perform vacuum melting and atomization treatment on the above-mentioned raw materials to obtain nickel-based high-temperature alloy material powder.

[0013] S2. Establish a three-dimensional model of the above-mentioned nickel-based superalloy component and cut it into a two-dimensional scanning path using slicing software;

[0014] S3. The above-mentioned nickel-based high-temperature alloy material powder is placed into the powder feeder of the laser additive manufacturing equipment. According to the process parameters set by the laser additive manufacturing equipment and the above-mentioned two-dimensional scanning path, the above-mentioned nickel-based high-temperature alloy material powder is melted layer by layer on the substrate under a protective atmosphere to prepare a nickel-based high-temperature alloy component.

[0015] Preferably, step S1 specifically involves: preparing the raw materials according to the composition of the nickel-based high-temperature alloy material, and then vacuum melting the raw materials to obtain a master alloy ingot. After heating the master alloy ingot to complete melting, atomizing gas is introduced to atomize and pulverize the powder. After cooling, nickel-based high-temperature alloy material powder is obtained.

[0016] Preferably, in step S1, the atomizing gas is any one of inert gases with a purity of 99.99% or higher, and the pressure of the atomizing gas is 2~3.5 MPa.

[0017] Preferably, the inert gas is one or more of helium, argon, neon, and krypton.

[0018] Preferably, in step S1, the particle size of the nickel-based high-temperature alloy material powder is 15~70 μm.

[0019] Preferably, in step S3, the above 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.

[0020] Preferably, in step S3, before setting the process parameters of the laser additive manufacturing equipment, the substrate is first cleaned and preheated to 100 ℃~150 ℃.

[0021] Preferably, in step S3, the protective atmosphere is selected from one or more of argon, nitrogen, and helium.

[0022] Preferably, in step S3, the oxygen content in the protective atmosphere is ≤500 ppm.

[0023] In summary, the technical solutions conceived in this application have the following main technical advantages compared with the prior art:

[0024] (1) The nickel-based superalloy material for laser additive manufacturing provided in this application can reduce the cracking sensitivity of nickel-based superalloy material in the laser additive manufacturing process by designing the types and contents of its elemental composition and thereby controlling the forming performance and microstructure of the formed component. It can effectively eliminate macroscopic cracks and microcracks caused by rapid cooling and heating of nickel-based superalloy material in laser additive manufacturing, while improving the comprehensive mechanical properties of the formed component. It can also prepare nickel-based superalloy components with good formability, no pores and microcracks, high density, and excellent tensile strength, yield strength and ductility.

[0025] (2) By adjusting the process parameters of laser additive manufacturing technology, including laser power, scanning speed, single-pass spacing, and powder layer thickness, this application can achieve adjustable and controllable comprehensive mechanical properties of nickel-based superalloy components. Excellent shaped components with comprehensive mechanical properties can be obtained under a wide range of process parameters. The nickel-based superalloy components provided by this application have a tensile strength ≥966 MPa, a yield strength ≥719 MPa, and an engineering strain ≥19.4%, showing broad prospects for industrial application. Attached Figure Description

[0026] Figure 1 This is a flowchart of the forming method of the nickel-based superalloy component provided in the embodiments of this application;

[0027] Figure 2 These are morphology and particle size distribution diagrams of the nickel-based superalloy powder prepared in Example 1 of this application, wherein content A is a SEM image and content B is a particle size distribution diagram;

[0028] Figure 3 This is a schematic diagram of the printing strategy in Embodiment 1 of this application;

[0029] Figure 4 These are metallographic images of nickel-based superalloy components prepared in Example 1 and Comparative Example 1 of this application, wherein content (a) is the nickel-based superalloy component prepared in Example 1, and content (b) is the IN738LC alloy component prepared in Comparative Example 1.

[0030] Figure 5 This is the density of nickel-based superalloy components prepared by this application at different scanning speeds with laser power densities of 200 W, 230 W, and 260 W;

[0031] Figure 6 This is an optical microscope image of nickel-based superalloy components prepared by this application at different scanning speeds with laser power densities of 200 W, 230 W, and 260 W.

[0032] Figure 7 The table shows the room temperature tensile mechanical properties of the nickel-based superalloy component prepared in Example 5 of this application, wherein (a) is the room temperature tensile property curve of the nickel-based superalloy component, and (b) is the tensile strength, yield strength and engineering strain of the nickel-based superalloy component.

[0033] Figure 8 This document describes the high-temperature tensile mechanical properties of the nickel-based superalloy component prepared in Example 5 of this application. Content (a) shows the high-temperature tensile performance curve of the nickel-based superalloy component, and content (b) shows the tensile strength, yield strength, and engineering strain of the nickel-based superalloy component. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0035] In the specification and claims of this application, the terms “first” and “second” are used to distinguish different objects, rather than to describe a specific order of objects, and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated.

[0036] In this application description, the term "and / or" describes a relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. The symbol " / " in this document indicates that the related objects are in an "or" relationship; for example, A / B means A or B.

[0037] In this description, the words "exemplary" or "for example" are used to indicate that something is an example, illustration, or illustration. Any embodiment or design that is described as "exemplary" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of the words "exemplary" or "for example" is intended to present the relevant concepts in a specific manner.

[0038] In this application description, unless otherwise stated, "multiple" means two or more.

[0039] Traditional IN738LC alloy materials are highly susceptible to cracking during laser powder bed melting, resulting in numerous crack defects after forming. Even with optimization of the process parameters for laser powder bed melting technology, it is still impossible to completely avoid cracks generated during forming.

[0040] For nickel-based superalloys, Al and Ti are the main reinforcing phase γ′ [Ni3(Al,Ti)] forming elements. With increasing Al+Ti content, the dissolution temperature and stability of the γ′ phase increase, and the volume fraction of the γ′ phase in the alloy is also increased, thereby improving the alloy's high-temperature mechanical properties. Furthermore, Al can form a continuous alumina layer on the alloy surface, protecting the alloy matrix and improving its oxidation and corrosion resistance. However, excessively high Al and Ti contents can promote the formation of low-melting-point γ / γ′ eutectic between dendrites, which is detrimental to the alloy's forming process during laser additive manufacturing. The key technical problem this application aims to solve is how to improve the weldability of nickel-based superalloys (i.e., prevent the formation of defects such as cracks and voids during laser additive manufacturing) while simultaneously enhancing the high-temperature mechanical properties of the formed components. Based on this, this application provides a nickel-based superalloy material comprising, by mass percentage: 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, and 0.05%~0.15% Zr; the remainder being Ni and unavoidable impurities.

[0041] The total mass percentage of Al and Ti is ≤4.5%.

[0042] In some embodiments, the above-mentioned nickel-based superalloy material comprises, by mass percentage, the following components: 2.4%~2.8% Al, 1%~2% 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, and 0.05%~0.15% Zr; the remainder being Ni and unavoidable impurities.

[0043] The total mass percentage of Al and Ti is ≤4.5%.

[0044] This application also provides a crack-free nickel-based superalloy component, which is obtained by laser additive manufacturing from the aforementioned nickel-based superalloy material.

[0045] On the other hand, such as Figure 1 As shown, this application also provides a forming method for the above-mentioned nickel-based superalloy component, i.e., a method for preparing a nickel-based superalloy component, comprising the following steps:

[0046] S1. Prepare the raw materials according to the above-mentioned composition of nickel-based high-temperature alloy material, and then perform vacuum melting and atomization treatment on the above-mentioned raw materials to obtain nickel-based high-temperature alloy material powder.

[0047] S2. Establish a three-dimensional model of the above-mentioned nickel-based superalloy component and cut it into a two-dimensional scanning path using slicing software;

[0048] S3. The above-mentioned nickel-based high-temperature alloy material powder is placed into the powder feeder of the laser additive manufacturing equipment. According to the process parameters set by the laser additive manufacturing equipment and the above-mentioned two-dimensional scanning path, the above-mentioned nickel-based high-temperature alloy material powder is melted layer by layer on the substrate under a protective atmosphere to prepare a nickel-based high-temperature alloy component.

[0049] This 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 as follows: the raw materials are prepared according to the composition of the nickel-based high-temperature alloy material, and the prepared raw materials are vacuum melted into a master alloy ingot. Then, the master alloy ingot is heated to complete melting, and atomizing gas is introduced to atomize and powder the material to obtain nickel-based high-temperature alloy material powder.

[0050] In some embodiments, the process for preparing nickel-based high-temperature alloy material powder may further be as follows: the raw materials are prepared according to the composition of the nickel-based high-temperature alloy material, and the prepared raw materials are vacuum melted into alloy liquid, and then atomized by passing in atomizing gas to obtain nickel-based high-temperature alloy material powder.

[0051] In a specific embodiment of this application, the process for preparing nickel-based superalloy material powder is as follows: The raw materials are prepared according to the composition of the nickel-based superalloy material. The prepared raw materials are placed in a vacuum melting furnace, a vacuum is drawn, and a protective gas is introduced to perform vacuum melting to prepare a master alloy ingot. Then, the prepared master alloy ingot is placed in a melting crucible, and a vacuum is drawn while a protective gas is introduced to induction heat the master alloy ingot until it is completely melted. Finally, an atomizing gas is introduced to perform atomization powder preparation, obtaining spherical or nearly spherical nickel-based superalloy material powder to be dried.

[0052] This invention does not limit the above-described vacuum melting method; in some embodiments, the above-described vacuum melting is vacuum induction melting.

[0053] In some embodiments, the temperature of the induction heating is between 1200 ℃ and 1700 ℃.

[0054] In some embodiments, during the atomization process described above, the atomizing gas is any one of inert gases with a purity of 99.99% or higher, and the pressure of the atomizing gas is 2 to 3.5 MPa.

[0055] In some embodiments, the inert gas is one or more of helium (He), argon (Ar), neon (Ne), and krypton (Kr).

[0056] In some embodiments, step S1 further includes vacuum drying of the nickel-based superalloy powder, which can remove moisture from the powder and reduce the oxygen content in the powder. It is understood that this application does not limit the process of vacuum drying the nickel-based superalloy powder described above. In some embodiments, the vacuum drying temperature can be 100 ℃~200 ℃, and the vacuum drying time is 1~3 h.

[0057] In some embodiments, in step S1, the particle size of the nickel-based superalloy material powder is 10~75 μm.

[0058] This 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 above-mentioned two-dimensional scanning path is: integral molding, layer-by-layer scanning, and the interlayer rotation angle is set to 65°~70° to release residual stress.

[0059] In some embodiments, step S3 specifically involves: placing the above-mentioned nickel-based high-temperature alloy material powder into the powder feeder of the laser melting system, starting the laser melting system, and under a protective atmosphere, melting and depositing the above-mentioned nickel-based high-temperature alloy material powder layer by layer onto the substrate to prepare a nickel-based high-temperature alloy component.

[0060] In some embodiments, in step S3, the above 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.

[0061] In some embodiments, in step S3, before setting the process parameters of the laser additive manufacturing equipment, the substrate is cleaned first. In some embodiments, the cleaning includes, but is not limited to, surface cleaning, polishing, sandblasting, ultrasonic cleaning, and alcohol cleaning.

[0062] In some embodiments, after the substrate is cleaned and dried, it is placed in the forming chamber under a protective atmosphere and fixed on the worktable of the laser additive manufacturing equipment for leveling, ready for use.

[0063] In some embodiments, in step S3, before preparing the nickel-based high-temperature alloy component, the substrate is preheated to 100 ℃~150 ℃.

[0064] In some embodiments, in step S3, the protective atmosphere is selected from at least one of argon (Ar), nitrogen (N2), and helium (He).

[0065] 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.

[0066] It should be understood that materials of the same or similar type, model, quality, properties, or function as the reagents and instruments used in the following embodiments can be used to implement this application. Unless otherwise specified, the experimental methods used in the following embodiments are conventional methods. Unless otherwise specified, the materials and reagents used in the following embodiments are commercially available.

[0067] The following are examples and comparative examples:

[0068] Example 1

[0069] The method for forming a crack-free nickel-based superalloy component provided in this embodiment includes the following steps:

[0070] (1) Preparation of nickel-based superalloy material: The composition of the nickel-based superalloy material designed in this embodiment is as follows by mass percentage: 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, with the remainder being Ni. The raw materials Al, Ti, Nb, Ta, W, Mo, Cr, Co, C, B, Zr, and Ni were prepared according to the designed composition of the nickel-based superalloy material, wherein the purity of each raw material was above 99.9%. The above-mentioned elemental raw materials were placed in a vacuum induction furnace and vacuum induction melting was performed to prepare the master alloy ingot, i.e., the nickel-based superalloy material.

[0071] (2) Preparation of powdered nickel-based superalloy material: The master alloy ingot prepared above is placed in a melting crucible. After evacuation, high-purity argon gas with a purity of 99.99% or higher is introduced until the pressure in the melting chamber is restored to standard atmospheric pressure. Then, induction heating is performed until the master alloy ingot is completely melted. The induction heating temperature is 1700 °C. The molten metal is poured into an intermediate auger, and argon gas with a purity of 99.99% and a pressure of 2.6 MPa is introduced to impact and break it, so that it is atomized into fine metal droplets. After cooling and solidification, it becomes nickel-based superalloy material powder. The nickel-based superalloy material powder is collected and sieved by a two-stage cyclone separation system to obtain dry spherical or near-spherical nickel-based superalloy material powder suitable for laser additive manufacturing. Its particle size is 10~75 μm (e.g., Figure 2 Content (a), Figure 2 (See content (b) for reference).

[0072] (3) Laser additive manufacturing of nickel-based superalloy components: A three-dimensional model of the component is established, and the model is processed by slicing software to form a laser scanning trajectory. The forming substrate is mounted on the forming table of the printing equipment. Before forming, the preheating temperature is set to 100 ℃ to preheat the substrate to prevent cracking of the part during laser additive manufacturing and to reduce thermal residual stress in the component. The scanning path of the laser additive manufacturing of nickel-based superalloy components is as follows: Figure 3 As shown, process parameters such as laser power, scanning speed, scanning spacing, and powder layer thickness are set. Specifically, a certain flow rate of high-purity argon gas with a purity of over 99.99% is introduced beforehand. Then, a first layer of nickel-based superalloy material powder is spread evenly on the forming substrate using a powder spreading device. A high-energy laser beam is used to print the first layer according to a two-dimensional scanning trajectory. The powder at the scanning position is completely melted and rapidly solidified into an alloy. Then, the forming substrate is lowered to a certain height and powder is spread again. The laser scanning direction is rotated 67° to print the second layer. The laser beam melts the powder and this process is repeated until the component is finally formed. The process parameters for laser additive manufacturing are: laser power of 230 W, scanning speed of 700 mm / s, scanning spacing of 100 μm, and layer thickness of 40 μm.

[0073] Figure 4 Content (a) is a metallographic image of the nickel-based superalloy component prepared in this embodiment. It can be seen that the nickel-based superalloy component is free of pores and microcracks, has good formability, and high forming quality.

[0074] Comparative Example 1

[0075] The nickel-based superalloy material provided in this comparative example is the conventional IN738LC alloy. The composition of the conventional IN738LC alloy, by mass percentage, is as follows: 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, with the remainder being Ni. Then, the IN738LC alloy material and IN738LC alloy powder were prepared according to the method provided in Example 1, and IN738LC alloy components were manufactured using laser additive manufacturing.

[0076] Figure 4Content (b) is a 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 low forming quality. The reason may be that the traditional IN738LC alloy material powder has a large crack sensitivity during the laser powder bed melting process, and is very easy to generate alloy defects such as hot cracks and strain aging cracks, resulting in poor formability of the alloy component.

[0077] Example 2

[0078] In this embodiment, the preparation of nickel-based superalloy material powder is the same as in Example 1.

[0079] A nickel-based superalloy component was fabricated using laser additive manufacturing. The laser additive manufacturing process parameters were as follows: laser power of 200 W, powder spreading 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 superalloy component is shown below. Figure 5 As shown, the density of the nickel-based superalloy components was tested using the water displacement method and metallographic method, and the results are as follows. Figure 6 As shown.

[0080] Example 3

[0081] In this embodiment, the preparation of nickel-based superalloy material powder is the same as in Example 1.

[0082] A nickel-based superalloy component was fabricated using laser additive manufacturing. The laser additive manufacturing process parameters were as follows: laser power of 230 W, powder spreading 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 superalloy component is shown below. Figure 5 As shown, the density of the nickel-based superalloy components was tested using the water displacement method and metallographic method, and the results are as follows. Figure 6 As shown.

[0083] Example 4

[0084] In this embodiment, the preparation of nickel-based superalloy material powder is the same as in Example 1.

[0085] A nickel-based superalloy component was fabricated using laser additive manufacturing. The laser additive manufacturing process parameters were as follows: laser power of 230W, powder spreading 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 superalloy component is shown below. Figure 5 As shown, the density of the nickel-based superalloy components was tested using the water displacement method and metallographic method, and the results are as follows. Figure 6 As shown.

[0086] Depend on Figure 5It can be seen that the nickel-based superalloy components prepared when the laser power is 200 W and the scanning speed is 700, 800, 900, and 1000 mm / s have no cracks or pores (the density is greater than 98.0%). Figure 6 As shown); when the laser power was 230W and the scanning speed was 700, 800, 900, 1000, and 1100 mm / s, the nickel-based superalloy components prepared showed no cracks or pores (the density was greater than 98.1%). Figure 6 As shown); when the laser power was 260 W and the scanning speed was 700, 800, 900, 1000, and 1100 mm / s, the nickel-based superalloy components prepared showed no cracks or pores (the density was greater than 98.1%). Figure 6 (As shown).

[0087] Example 5

[0088] In this embodiment, the preparation of nickel-based superalloy material powder is the same as in Example 1.

[0089] Nickel-based superalloy components were fabricated using laser additive manufacturing. The laser additive manufacturing process parameters 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, resulting in nickel-based superalloy component P1. Nickel-based superalloy component P2 was fabricated using a laser power of 230 W, scanning speed of 700 mm / s, and other parameters and operations were the same as in Example 1. Nickel-based superalloy component P3 was fabricated using a laser power of 230 W, scanning speed of 900 mm / s, and other parameters and operations were the same as in Example 1.

[0090] The room temperature tensile properties of the above-mentioned nickel-based superalloy components P1, P2, and P3 were tested, and the test results are shown in [Figure number missing]. Figure 7 Content (a), Figure 7 Content (b) and Table 1. Then, the high-temperature tensile properties of the nickel-based superalloy component P2 were tested. The specific test method was as follows: the nickel-based superalloy component P2 was placed in an atmospheric environment, and its high-temperature tensile properties at 700℃, 800℃, and 900℃ were tested using a material high-temperature creep rupture testing machine (model AG-IC100kN) at a tensile rate of 1 mm / min. The test results are shown in […]. Figure 8 Content (a), Figure 8 Contents (b) and Table 2.

[0091] Table 1. Room temperature tensile properties of the nickel-based superalloy components prepared in Example 5

[0092]

[0093] Table 2 High-temperature tensile properties of nickel-based superalloy components P2

[0094]

[0095] As shown in Table 1, the nickel-based superalloy component prepared in Example 5 exhibits excellent tensile properties and good ductility at room temperature, with a tensile strength ≥966 MPa, a yield strength ≥719 MPa, and an engineering strain ≥19.4%. Furthermore, the nickel-based superalloy component prepared in Example 5 still possesses superior tensile properties at 700 ℃, 800 ℃, and 900 ℃ (Table 2).

[0096] Comparative Example 2

[0097] The nickel-based superalloy material provided in this comparative example has the following composition by 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, with the remainder being 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 were prepared according to the designed composition of the nickel-based superalloy material, with each raw material having a purity of over 99.9%. Then, the nickel-based superalloy material and nickel-based superalloy material powder were prepared according to the method provided in Example 1.

[0098] Nickel-based superalloy components were manufactured using laser additive manufacturing. The laser additive manufacturing process parameters were as follows: laser power of 200 W, 230 W, and 260 W, and scanning speed of 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. A series of nickel-based superalloy components were prepared. The density of the above series of nickel-based superalloy components was then measured by metallographic and water displacement methods. Tensile properties were tested on alloy components prepared with three optimized process parameters. In this study, a nickel-based superalloy component D1 was prepared using a laser power of 260 W and a scanning speed of 600 mm / s, with other parameters and operations identical to those in Example 1. A nickel-based superalloy component D2 was prepared using a laser power of 260 W and a scanning speed of 800 mm / s, with other parameters and operations identical to those in Example 1. A nickel-based superalloy component D3 was prepared using a laser power of 260 W and a scanning speed of 1000 mm / s, with other parameters and operations identical to those in Example 1. The tensile properties were tested using the same method as in Example 5. The room-temperature tensile properties of nickel-based superalloy components D1, D2, and D3 are shown in Table 3. Then, the high-temperature tensile properties of nickel-based superalloy component D2 were tested using the same method as in Example 5. The high-temperature tensile properties are shown in Table 4.

[0099] Table 3. Room temperature tensile properties of the nickel-based superalloy components prepared in Comparative Example 2

[0100]

[0101] Table 4 High-temperature tensile properties of nickel-based superalloy component D2

[0102]

[0103] As shown in Table 3, when only the contents of C, B, and Zr are optimized, the resulting alloy components exhibit poor mechanical properties at room temperature. Both tensile strength and yield strength are below 700 MPa, and the engineering strain is low, less than 3%, indicating poor ductility. High-temperature tensile tests were conducted on the aforementioned alloy components (Table 4). The results show that at 900 ℃, the tensile strength is only 213.1 MPa, the yield strength is only 171.5 MPa, and the engineering strain is only 1.6%, indicating poor high-temperature tensile performance that does not meet the requirements of the application scenario.

[0104] Comparative Example 3

[0105] The nickel-based superalloy material provided in this comparative example has the following composition by mass percentage: 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, with the remainder being Ni. This comparative example optimizes the content of grain boundary strengthening elements Al and Ti in the alloy based on Example 1. Raw materials Al, Ti, Nb, Ta, W, Mo, Cr, Co, C, B, Zr, and Ni were prepared according to the designed composition of the nickel-based superalloy material, with each raw material having a purity of ≥99.9%. Then, the nickel-based superalloy material and nickel-based superalloy powder were prepared according to the method provided in Example 1.

[0106] A nickel-based superalloy component was fabricated using laser additive manufacturing. The laser additive manufacturing process parameters were: laser power of 230 W, scanning rate of 700 mm / s, scanning spacing of 100 μm, and layer thickness of 40 μm. The resulting nickel-based superalloy component D4 was fabricated.

[0107] Microstructural characterization of nickel-based superalloy component D4 revealed a small number of cracks and pores on its surface, which does not meet the requirements of the application scenario.

[0108] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A crack-free nickel-base superalloy component, characterized by, It is obtained by laser additive manufacturing of nickel-based superalloy materials; The composition of the nickel-based superalloy material, by mass percentage, 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, with the remainder being Ni; The process parameters for laser additive manufacturing 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.

2. A forming method of a nickel-based superalloy member as set forth in claim 1, characterized by, Includes the following steps: S1. Prepare the raw materials according to the composition of the nickel-based high-temperature alloy material, and then perform vacuum melting and atomization treatment on the prepared raw materials to obtain nickel-based high-temperature alloy material powder. S2. Establish a three-dimensional model of the nickel-based superalloy component and cut it into a two-dimensional scanning path using slicing software; S3. The nickel-based high-temperature alloy material powder is placed into the powder feeder of the laser additive manufacturing equipment. According to the process parameters set by the laser additive manufacturing equipment and the two-dimensional scanning path, the nickel-based high-temperature alloy material powder is melted layer by layer onto the substrate under a protective atmosphere to prepare a nickel-based high-temperature alloy component.

3. The forming method of claim 2, wherein, Step S1 specifically involves: preparing the raw materials according to the composition of the nickel-based high-temperature alloy material, and then vacuum melting the prepared raw materials to obtain a master alloy ingot. After heating the master alloy ingot to complete melting, atomizing gas is introduced to atomize and pulverize the powder. After cooling, nickel-based high-temperature alloy material powder is obtained.

4. The forming method according to claim 3, characterized in that, In step S1, the atomizing gas is any one of inert gases with a purity of not less than 99.99%, and the pressure of the atomizing gas is 2~3.5 MPa.

5. The forming method according to claim 2, characterized in that, In step S1, the particle size of the nickel-based high-temperature alloy material powder is 10~75 μm.

6. The forming method according to claim 2, 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.

7. The forming method according to claim 2, 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 ℃~150 ℃.

8. The forming method according to claim 2, characterized in that, In step S3, the protective atmosphere is selected from one or more of argon, nitrogen, and helium; the oxygen content in the protective atmosphere is ≤500 ppm.

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