Anti-cracking metal powder for additive manufacturing and preparation method thereof

Abstract

The invention relates to the technical field of additive manufacturing, and provides anti-cracking metal powder for additive manufacturing and a preparation method thereof.The anti-cracking metal powder for additive manufacturing is composed of, by weight, 0.05%-0.1% of C, 0.15%-0.2% of Al, 0.46%-0.6% of Mn, 2.6%-3.5% of Ni, 0.1%-0.23% of Cu, 0.1%-0.2% of Mo, 0.03%-0.28% of W, 0.005%-0.025% of Ce, 0%-0.03% of Nb and the balance iron and inevitable impurities. By means of the technical scheme, the problems that in the related technology, parts obtained through additive manufacturing are poor in cracking resistance and mechanical property are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of additive manufacturing, and in particular to an anti-cracking metal powder for additive manufacturing and a preparation method thereof. Background Art

[0002] Metal powder for additive manufacturing is the raw material of metal used in additive manufacturing technology. It is composed of tiny metal particles, the size of which is usually between a few microns and a few hundred microns. For example, in the laser powder bed fusion process, the metal powder is spread into a thin layer and then selectively melted by a high-energy laser beam, and then stacked layer by layer to form a three-dimensional part.

[0003] Metal powders for additive manufacturing can be used in the aerospace field to manufacture complex structural parts and engine parts. For example, compared with traditional manufacturing methods, aircraft engine blades made of titanium alloy powders through additive manufacturing technology can reduce the weight of parts, improve the performance and reliability of parts, and shorten the manufacturing cycle. For the manufacture of automotive parts, such as aluminum alloy powders, can be used to manufacture lightweight parts such as automobile engine blocks, which helps to improve the fuel economy of automobiles. Moreover, additive manufacturing technology can realize complex part design and optimize the performance of automotive parts. In addition, metal powders are mainly used in the medical field to manufacture implants. For example, artificial joints made using 3D printing technology and titanium alloy powders with good biocompatibility can be customized according to the individual differences of patients, better fit the patient's body structure, and improve the treatment effect after implantation.

[0004] The metal powder used in additive manufacturing directly determines the crack resistance and mechanical properties of the manufactured parts. Cracking will cause the mechanical properties of the manufactured parts to deteriorate and fail to meet the use requirements. Therefore, developing an anti-cracking metal powder for additive manufacturing so that the manufactured parts have good crack resistance and mechanical properties is of great significance for improving the reliability and stability of the parts and extending the service life of the parts. Summary of the invention

[0005] The present invention provides an anti-cracking metal powder for additive manufacturing and a preparation method thereof, which solves the problem of poor anti-cracking performance and poor mechanical properties of parts obtained by additive manufacturing in the related art.

[0006] The technical solution of the present invention is as follows: The present invention provides an anti-cracking metal powder for additive manufacturing, which is composed of the following components in weight percentage: C 0.05%~0.1%, Al 0.15%~0.2%, Mn 0.46%~0.6%, Ni 2.6%~3.5%, Cu 0.1%~0.23%, Mo 0.1%~0.2%, W 0.03%~0.28%, Ce 0.005%~0.025%, Nb 0%~0.03%, and the rest are iron and its inevitable impurities.

[0007] As a further technical solution, the raw material also includes Nb 0.005%~0.025%.

[0008] As a further technical solution, the weight ratio of the sum of the weight percentages of Ce and Nb to the weight percentage of W is 1:2-5.

[0009] When the weight ratio of the sum of the weight percentages of Ce and Nb to W is 1:2~5, the mechanical properties of the parts obtained by additive manufacturing can be further improved.

[0010] As a further technical solution, the weight ratio of the Ce to the Nb is 1:1.

[0011] As a further technical solution, the particle size distribution of the metal powder is 25~80μm.

[0012] As a further technical solution, the metal powder with a particle size distribution of 25-35 μm accounts for at least 35 wt %.

[0013] The present invention also proposes a method for preparing a crack-resistant metal powder for additive manufacturing, comprising the following steps: S1. Weighing scrap steel, aluminum-iron alloy, manganese-iron alloy, nickel-iron alloy, copper-iron alloy, molybdenum-iron alloy, tungsten-iron alloy, cerium-iron alloy and niobium-iron alloy, and smelting them to obtain a melt; S2, atomizing and molding the melt to obtain the anti-cracking metal powder.

[0014] As a further technical solution, in step S1, during the smelting, the ferro-tungsten alloy, ferro-cerium alloy and ferro-niobium alloy are added in a first addition and a second addition.

[0015] As a further technical solution, during the first addition, 3 / 5 of the ferrotungsten alloy, 1 / 2 of the ferrocerium alloy and 3 / 5 of the ferroniobium alloy are added, and the remaining ferrotungsten alloy, ferrocerium alloy and ferroniobium alloy are added for the second time.

[0016] Adding ferrotungsten, ferrocerium and ferroniobium in two batches can ensure that they are evenly distributed in the metal system, further achieving synergistic effects, thereby preparing a metal powder with a denser and more stable structure, and further improving the mechanical properties of parts obtained by additive manufacturing. By adjusting the content of ferrotungsten, ferrocerium and ferroniobium added twice, when 3 / 5 ferrotungsten, 1 / 2 ferrocerium and 3 / 5 ferroniobium are added for the first time, and the remaining ferrotungsten, ferrocerium and ferroniobium are added for the second time, the mechanical properties of parts obtained by additive manufacturing can be further improved.

[0017] The present invention also proposes the use of the anti-cracking metal powder for additive manufacturing or the anti-cracking metal powder prepared by the preparation method in additive manufacturing.

[0018] The working principle and beneficial effects of the present invention are: The present invention prepares metal powder for additive manufacturing by rationally regulating the weight percentage of each component. Among them, after the introduction of W, Ce and Nb, the three have a synergistic effect, which can purify the interface while reducing defects, avoiding large internal stresses in the additive manufacturing process, improving the mechanical properties of parts obtained by additive manufacturing, and effectively inhibiting cracking caused by thermal stress, thereby significantly reducing the risk of cracks. DETAILED DESCRIPTION

[0019] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] In the following examples and comparative examples, the Al content in the aluminum-iron alloy is 90wt%; the Mn content in the manganese-iron alloy is 65%; the Ni content in the nickel-iron alloy is 50wt%; the Cu content in the copper-iron alloy is 90wt%; the Mo content in the molybdenum-iron alloy is 70wt%; the W content in the tungsten-iron alloy is 80wt%; the Ce content in the cerium-iron alloy is 70wt%; the Nb content in the niobium-iron alloy is 65wt%; The atomization molding adopts the gas atomization powder making process with the gas pressure of 3.8MPa. The particle size distribution of the anti-cracking metal powder is 25~80μm, and the metal powder with a particle size distribution of 25~35μm accounts for 50wt%.

[0021] Example 1 A crack-resistant metal powder for additive manufacturing, comprising the following components in weight percentage: C 0.05%, Al 0.15%, Mn 0.46%, Ni 2.6%, Cu 0.1%, Mo 0.1%, W 0.03%, Ce 0.005%, the rest is iron and its inevitable impurities; The preparation method comprises the following steps: S1. Weighing scrap steel, aluminum-iron alloy, manganese-iron alloy, nickel-iron alloy, copper-iron alloy, molybdenum-iron alloy, tungsten-iron alloy and cerium-iron alloy, and smelting them to obtain a melt; S2, atomizing and molding the melt to obtain crack-resistant metal powder.

[0022] Example 2 A crack-resistant metal powder for additive manufacturing, comprising the following components in weight percentage: C 0.08%, Al 0.18%, Mn 0.52%, Ni 3.0%, Cu 0.17%, Mo 0.15%, W 0.06%, Ce0.005%, Nb 0.005%, the rest is iron and its inevitable impurities; The preparation method comprises the following steps: S1. Weighing scrap steel, aluminum-iron alloy, manganese-iron alloy, nickel-iron alloy, copper-iron alloy, molybdenum-iron alloy, tungsten-iron alloy, cerium-iron alloy and niobium-iron alloy, and smelting them to obtain a melt; S2, atomizing and molding the melt to obtain crack-resistant metal powder.

[0023] Example 3 A crack-resistant metal powder for additive manufacturing, comprising the following components in weight percentage: C 0.1%, Al 0.2%, Mn 0.6%, Ni 3.5%, Cu 0.23%, Mo 0.2%, W 0.28%, Ce 0.025%, Nb0.03%, the rest is iron and its inevitable impurities; The preparation method comprises the following steps: S1. Weighing scrap steel, aluminum-iron alloy, manganese-iron alloy, nickel-iron alloy, copper-iron alloy, molybdenum-iron alloy, tungsten-iron alloy, cerium-iron alloy and niobium-iron alloy, and smelting them to obtain a melt; S2, atomizing and molding the melt to obtain crack-resistant metal powder.

[0024] Example 4 The only difference between this embodiment and embodiment 3 is that, in this embodiment, the weight percentage of W is 0.28%, the weight percentage of Ce is 0.025%, and the weight percentage of Nb is 0.025%.

[0025] Example 5 The only difference between this embodiment and embodiment 3 is that, in this embodiment, the weight percentage of W is 0.072%, the weight percentage of Ce is 0.024%, and the weight percentage of Nb is 0.024%.

[0026] Example 6 The only difference between this embodiment and Embodiment 5 is that, in this embodiment, the weight percentage of W is 0.108%, the weight percentage of Ce is 0.006%, and the weight percentage of Nb is 0.006%.

[0027] Example 7 The only difference between this embodiment and Embodiment 5 is that, in this embodiment, the weight percentage of W is 0.08%, the weight percentage of Ce is 0.02%, and the weight percentage of Nb is 0.02%.

[0028] Example 8 The only difference between this embodiment and Embodiment 5 is that, in this embodiment, the weight percentage of W is 0.1%, the weight percentage of Ce is 0.01%, and the weight percentage of Nb is 0.01%.

[0029] Example 9 The only difference between this embodiment and embodiment 8 is that, in this embodiment, the method for preparing anti-cracking metal powder for additive manufacturing includes the following steps: S1. Firstly, scrap steel, aluminum-iron alloy, manganese-iron alloy, nickel-iron alloy, copper-iron alloy, molybdenum-iron alloy, 1 / 2 tungsten-iron alloy, 1 / 2 cerium-iron alloy, and 1 / 2 niobium-iron alloy are weighed, and after smelting for 2.5 hours, the remaining tungsten-iron alloy, cerium-iron alloy, and niobium-iron alloy are added, and smelting is continued for 1.5 hours to obtain a melt; S2, atomizing and molding the melt to obtain crack-resistant metal powder.

[0030] Example 10 The only difference between this embodiment and embodiment 8 is that, in this embodiment, the method for preparing anti-cracking metal powder for additive manufacturing includes the following steps: S1. Firstly, scrap steel, aluminum-iron alloy, manganese-iron alloy, nickel-iron alloy, copper-iron alloy, molybdenum-iron alloy, 7 / 10 tungsten-iron alloy, 1 / 2 cerium-iron alloy, and 7 / 10 niobium-iron alloy are weighed, and after smelting for 2.5 hours, the remaining tungsten-iron alloy, cerium-iron alloy, and niobium-iron alloy are added, and smelting is carried out for 1.5 hours to obtain a melt; S2, atomizing and molding the melt to obtain crack-resistant metal powder.

[0031] Embodiment 11 The only difference between this embodiment and embodiment 8 is that, in this embodiment, the method for preparing anti-cracking metal powder for additive manufacturing includes the following steps: S1. Firstly, scrap steel, aluminum-iron alloy, manganese-iron alloy, nickel-iron alloy, copper-iron alloy, molybdenum-iron alloy, 1 / 2 tungsten-iron alloy, 1 / 2 cerium-iron alloy, and 7 / 10 niobium-iron alloy are weighed, and after smelting for 2.5 hours, the remaining tungsten-iron alloy, cerium-iron alloy and niobium-iron alloy are added, and smelting is continued for 1.5 hours to obtain a melt; S2, atomizing and molding the melt to obtain crack-resistant metal powder.

[0032] Example 12 The only difference between this embodiment and embodiment 8 is that, in this embodiment, the method for preparing anti-cracking metal powder for additive manufacturing includes the following steps: S1. Firstly, scrap steel, aluminum-iron alloy, manganese-iron alloy, nickel-iron alloy, copper-iron alloy, molybdenum-iron alloy, 7 / 10 tungsten-iron alloy, 1 / 2 cerium-iron alloy, and 1 / 2 niobium-iron alloy are weighed, and after smelting for 2.5 hours, the remaining tungsten-iron alloy, cerium-iron alloy, and niobium-iron alloy are added, and smelting is carried out for 1.5 hours to obtain a melt; S2, atomizing and molding the melt to obtain crack-resistant metal powder.

[0033] Example 13 The only difference between this embodiment and embodiment 8 is that, in this embodiment, the method for preparing anti-cracking metal powder for additive manufacturing includes the following steps: S1. Firstly, scrap steel, aluminum-iron alloy, manganese-iron alloy, nickel-iron alloy, copper-iron alloy, molybdenum-iron alloy, 3 / 5 tungsten-iron alloy, 1 / 2 cerium-iron alloy, and 3 / 5 niobium-iron alloy are weighed, and after smelting for 2.5 hours, the remaining tungsten-iron alloy, cerium-iron alloy, and niobium-iron alloy are added, and smelting is carried out for 1.5 hours to obtain a melt; S2, atomizing and molding the melt to obtain crack-resistant metal powder.

[0034] Comparative Example 1 The only difference between this comparative example and Example 2 is that, in this comparative example, the weight percentage of W is 0.06%, the weight percentage of Ce is 0%, and the weight percentage of Nb is 0.01%.

[0035] Comparative Example 2 The only difference between this comparative example and Example 2 is that, in this comparative example, the weight percentage of W is 0.06%, the weight percentage of Ce is 0.01%, and the weight percentage of Nb is 0%.

[0036] Comparative Example 3 The only difference between this comparative example and Example 2 is that, in this comparative example, the weight percentage of W is 0.07%, the weight percentage of Ce is 0%, and the weight percentage of Nb is 0%.

[0037] Comparative Example 4 The only difference between this comparative example and Example 2 is that, in this comparative example, the weight percentage of W is 0%, the weight percentage of Ce is 0.035%, and the weight percentage of Nb is 0.035%.

[0038] Comparative Example 5 The only difference between this comparative example and Example 2 is that in this comparative example, the weight percentages of W, Ce and Nb are all 0%.

[0039] The anti-cracking metal powders prepared in Examples 1 to 13 and Comparative Examples 1 to 5 were subjected to laser additive manufacturing, and the process parameters were: laser power 2100 W, scanning speed 6 mm / s, and scanning spacing 50 μm. After manufacturing, the surface of the parts was observed for cracks, and the tensile strength test was performed in accordance with GB / T 228.1-2021 "Metallic Materials Tensile Test Part 1: Room Temperature Test Method", and the test results are shown in Table 1 below.

[0040] Table 1 Performance test results of Examples 1 to 13 and Comparative Examples 1 to 5

[0041] Compared with Comparative Examples 1 to 5, the room temperature tensile strength of Example 2 is significantly improved, and there are no obvious cracks on the surface, indicating that after the introduction of W, Ce and Nb into the anti-cracking metal powder, the three have a synergistic effect and can significantly improve the anti-cracking performance and mechanical properties of the parts obtained by additive manufacturing.

[0042] Compared with Examples 5-6, the room temperature tensile strength of Examples 7-8 is significantly improved, indicating that when the weight ratio of the sum of the weight percentages of Ce and Nb to W is 1:2-5, the crack resistance and mechanical properties of the parts obtained by additive manufacturing can be further improved.

[0043] Compared with Example 8, the room temperature tensile strength of Examples 9 to 13 is significantly improved, indicating that adding ferrotungsten alloy, ferrocerium alloy and ferroniobium alloy twice can further improve the crack resistance and mechanical properties of the parts obtained by additive manufacturing.

[0044] Compared with Examples 9 to 12, the room temperature tensile strength of Example 13 is significantly improved, indicating that by adjusting the content of tungsten-iron alloy, cerium-iron alloy and niobium-iron alloy added twice, when 3 / 5 tungsten-iron alloy, 1 / 2 cerium-iron alloy and 3 / 5 niobium-iron alloy are added for the first time, and the remaining tungsten-iron alloy, cerium-iron alloy and niobium-iron alloy are added for the second time, the crack resistance and mechanical properties of the parts obtained by additive manufacturing can be further improved.

[0045] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A crack-resistant metal powder for additive manufacturing, characterized in that: It is composed of the following components in weight percentage: C 0.05%~0.1%, Al 0.15%~0.2%, Mn 0.46%~0.6%, Ni 2.6%~3.5%, Cu 0.1%~0.23%, Mo0.1%~0.2%, W 0.03%~0.28%, Ce 0.005%~0.025%, Nb 0%~0.03%, and the rest are iron and its inevitable impurities.

2. The anti-cracking metal powder for additive manufacturing according to 1, characterized in that: The weight percentage of Nb is 0.005% to 0.025%.

3. The anti-cracking metal powder for additive manufacturing according to claim 2, characterized in that: The weight ratio of the sum of the weight percentages of the Ce and the Nb to the W is 1:2-5.

4. The anti-cracking metal powder for additive manufacturing according to claim 3, characterized in that: The weight ratio of the Ce to the Nb is 1:

1.

5. The anti-cracking metal powder for additive manufacturing according to claim 1, characterized in that: The particle size distribution of the metal powder is 25-80 μm.

6. The anti-cracking metal powder for additive manufacturing according to claim 5, characterized in that: The metal powder with a particle size distribution of 25-35 μm accounts for at least 35 wt %.

7. The method for preparing a crack-resistant metal powder for additive manufacturing according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1. Weighing scrap steel, aluminum-iron alloy, manganese-iron alloy, nickel-iron alloy, copper-iron alloy, molybdenum-iron alloy, tungsten-iron alloy, cerium-iron alloy and niobium-iron alloy, and smelting them to obtain a melt; S2, atomizing and molding the melt to obtain the anti-cracking metal powder.

8. The method for preparing crack-resistant metal powder for additive manufacturing according to claim 7, characterized in that: In step S1, during the smelting, the ferrotungsten alloy, ferrocerium alloy and ferroniobium alloy are added in a first addition and a second addition.

9. The method for preparing crack-resistant metal powder for additive manufacturing according to claim 8, characterized in that: During the first addition, 3 / 5 of the ferrotungsten alloy, 1 / 2 of the ferrocerium alloy and 3 / 5 of the ferroniobium alloy are added, and the remaining ferrotungsten alloy, ferrocerium alloy and ferroniobium alloy are added for the second addition.

10. Use of the anti-cracking metal powder for additive manufacturing according to any one of claims 1 to 6 or the anti-cracking metal powder prepared by the preparation method according to any one of claims 7 to 9 in additive manufacturing.

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