Deformation inhibition method for nickel-based superalloy component in different-angle suspension area

Abstract

A deformation restraining method for nickel-based superalloy components in different-angle suspension areas comprises the steps that a component model is obtained and sliced to obtain a plurality of slice models; dividing each slice model into an unsupported overhang area and an entity area; selective laser melting forming parameters of the support-free overhanging area and selective laser melting forming parameters of the entity area are set; the nickel-based alloy powder is laid layer by layer, solid area forming is conducted on the nickel-based alloy powder of each layer through a selective laser melting device, then discontinuous forming of a support-free overhanging area is conducted, and the steps are repeated in sequence till the selective laser melting device completes laser melting forming of the nickel-based alloy powder of all layers; thus, the nickel-based alloy unsupported member is obtained. According to the method, the nickel-based alloy support-free component which is almost fully dense and has the single-layer buckling deformation not exceeding 80 microns, the lower breadth roughness Sa smaller than 30 microns and the density higher than 99% in the forming process is obtained.

Description

Technical Field

[0001] This application relates to the field of laser additive manufacturing technology, specifically to a method for suppressing deformation of nickel-based superalloy components with different angles of overhang. Background Technology

[0002] In today's society, with the advancement of industrial technology and the iterative upgrading of products, the complexity of component structures is increasing year by year, and the number of customized components is also gradually rising. The current traditional industrial manufacturing and processing capabilities can no longer meet the increasingly complex component production needs. Laser powder bed melting (LPBF) technology, with its advantages of high precision and high design freedom, provides a brand-new possibility for the integrated manufacturing of complex geometries, becoming a key technology for the rapid iteration and customized production of precision parts.

[0003] However, when forming overhanging structures with an angle of less than 45° using laser powder bed molding, a support structure is usually required to ensure the forming quality. For some components with conformal internal channels or complex internal cavities, due to the special nature of the structure, it is impossible to add a support structure, resulting in warping and deformation problems during the forming process. Summary of the Invention

[0004] In view of the above, it is necessary to propose a deformation suppression method for nickel-based superalloy components with different angle overhangs, so as to suppress the warping deformation that occurs during the forming process of unsupported nickel-based alloy components, and achieve the control of the surface roughness of unsupported nickel-based alloy components without reducing the forming density of unsupported nickel-based alloy components and being applicable to current equipment on the market.

[0005] This application provides a method for suppressing deformation of nickel-based superalloy components in overhanging regions at different angles, comprising the following steps: Obtain the component model and slice the component model to obtain multiple slice models; Based on multiple slice models, each slice model is divided into an unsupported overhang region and a solid region, wherein the overhang angle of the unsupported overhang region of the component model is 20° to 45°. The laser selective melting forming parameters for the unsupported overhanging region and the laser selective melting forming parameters for the solid region are set, wherein the heat input of the unsupported overhanging region is lower than the heat input of the solid region; Based on the forming parameters of the unsupported overhanging region and the forming parameters of the solid region, nickel-based alloy powder is laid layer by layer. The solid region of each layer of nickel-based alloy powder is first formed by a laser selective melting device, and then the unsupported overhanging region is intermittently formed. This process is repeated until the laser selective melting device completes the laser melting and forming of all layers of nickel-based alloy powder, thereby obtaining a nickel-based alloy unsupported component.

[0006] In some embodiments, the step of first forming the solid region of each layer of nickel-based alloy powder using a laser selective melting device, and then performing discontinuous forming of the unsupported overhanging region, includes: The nickel-based alloy powder corresponding to the solid region of each layer is scanned by the laser selective melting device to form the solid region of that layer; The nickel-based alloy powder corresponding to the unsupported overhanging area of ​​each layer is scanned multiple times by the laser selective melting device to intermittently form the unsupported overhanging area of ​​the layer, wherein the interval between two adjacent scans in the multiple scans is a preset time.

[0007] In some embodiments, the preset time ranges from 5ms to 150ms.

[0008] In some embodiments, the scanning directions of two adjacent scans in the multiple scans are opposite.

[0009] In some embodiments, the nickel-based alloy powder is composed of the following by mass percentage: Cr content of 20%-24%, W content of 13%-15%, Mo content of 1%-3%, C content of 0.05%-0.2%, Si content of 0.2%-0.5%, Mn content of 0.2%-1%, Co content of 2%-4%, La content of 0.01-0.1%, Fe content of 1%-3%, Al content of less than 1%, Ti content of less than 0.1%, Cu content of less than 0.5%, B content of less than 0.01%, and the balance being Ni element and unavoidable impurities.

[0010] In some embodiments, prior to the step of obtaining the component model and slicing the component model, the method further includes: Nickel-based alloy powder with a particle size of 15μm~53μm was dried in a vacuum-protected drying oven and stored safely for later use. Design a component model in 3D software, wherein the overhang angle of the unsupported overhanging area of ​​the component model is 20°. 45°.

[0011] In some embodiments, the step of dividing each slice model into an unsupported overhang region and a solid region based on a plurality of slice models specifically includes: Based on multiple slice models, determine the protrusion length and overhang angle of each slice model relative to the adjacent slice models; Based on the protrusion length and the overhang angle, each slice model is divided into the unsupported overhang area and the solid area.

[0012] In some embodiments, the steps preceding the layer-by-layer deposition of nickel-based alloy powder include: The dried nickel-based alloy powder is pre-formed in the powder feeding chamber. After the cleaned substrate is placed on the lifting platform of the forming chamber, all the doors are closed. Argon gas is introduced into the forming chamber until the oxygen content is below 100 ppm, and the substrate is preheated to 90°C to 110°C.

[0013] In some embodiments, the laser selective melting forming parameters for the unsupported overhanging region include overhanging laser power, overhanging scanning speed, and overhanging scanning spacing. The overhanging laser power ranges from 160W to 210W, the overhanging scanning speed ranges from 700mm / s to 1200mm / s, and the overhanging scanning spacing ranges from 0.07mm to 0.12mm. The laser scanning strategy for the unsupported overhanging region is overall scanning. The laser selective melting forming parameters for the solid region include solid laser power, solid scanning speed, and solid scanning spacing. The solid laser power ranges from 185W to 235W, the solid scanning speed ranges from 600mm / s to 1000mm / s, and the solid scanning spacing ranges from 0.07mm to 0.12mm. The laser scanning strategy for the solid region is cross-strip scanning. The thickness of each layer of nickel-based alloy powder ranges from 0.02mm to 0.05mm.

[0014] In some embodiments, the steps following the setting of the laser selective melting forming parameters for the unsupported overhang region and the laser selective melting forming parameters for the solid region include: The laser selective melting forming parameters of the multiple slice models, the laser selective melting forming parameters of the unsupported overhanging region, the laser selective melting forming parameters of the solid region, and the number of laser remelting times of the unsupported overhanging region are input into the laser selective melting device to obtain a pre-demonstration nickel-based alloy unsupported component model. Based on the fact that the pre-demonstration nickel-based alloy unsupported component model conforms to the standard, it is confirmed that the laser selective melting forming parameters and the slicing model are correct.

[0015] The aforementioned deformation suppression method divides each slice model into an unsupported overhang region and a solid region. The heat input of the unsupported overhang region is lower than that of the solid region. By using a laser selective melting device to first form the solid region of each layer of nickel-based alloy powder, and then performing intermittent forming of the unsupported overhang region, the overheating phenomenon in the unsupported overhang region is reduced by changing the scanning strategy of the unsupported overhang region. This avoids the large temperature gradient and large thermal stress in the unsupported overhang region, effectively suppressing the warping deformation problem in the low-angle unsupported laser selective melting forming process. Nearly fully dense nickel-based alloy unsupported components with a single-layer warping deformation of no more than 80 μm, a lower surface roughness Sa of less than 30 μm, and a density of more than 99% are obtained during the forming process. This enables the unsupported low-angle manufacturing of complex components with complex internal cavities or conformal internal flow channels, thereby promoting the application of laser selective melting technology in the integrated forming of complex components. Because it requires no equipment modification or real-time monitoring and correction, it can be applied to most current equipment, and the forming process does not deviate from the compact forming process. Therefore, it ensures the forming density of unsupported nickel-based alloy components, achieving warpage control while maintaining the reliability of the unsupported nickel-based alloy components. Furthermore, since no support structure is needed, it avoids the time and material waste associated with forming support structures during the forming process, as well as the time waste and decreased yield caused by removing support structures during post-processing, thus improving production efficiency. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of a laser selective melting device adapted for laser additive manufacturing of metal components.

[0017] Figure 2 This is a flowchart of a method for suppressing deformation of nickel-based superalloy components with different angles of overhang, as proposed in an embodiment of this application.

[0018] Figure 3 This is a schematic diagram showing the division between the unsupported overhanging region and the solid region of an unsupported nickel-based alloy component.

[0019] Figure 4 yes Figure 2 The flowchart of step S40, "forming the solid region of each layer of nickel-based alloy powder first by means of a laser selective melting device, and then forming the discontinuous region of the unsupported overhanging region".

[0020] Figure 5 yes Figure 4 A schematic diagram of discontinuous forming in the image.

[0021] Figure 6 yes Figure 2 The flowchart of the method before step S10.

[0022] Figure 7 yes Figure 2 The flowchart of the specific method for step S20 in the process.

[0023] Figure 8 yes Figure 2 The flowchart of the method after step S30.

[0024] Figure 9 This is a comparison diagram of the degree of warping deformation in the unsupported overhanging area of ​​Example 1, Comparative Example 1, and Comparative Example 2.

[0025] Figure 10 These are comparative diagrams showing the forming density of the unsupported overhanging regions in Example 1, Comparative Example 1, and Comparative Example 2.

[0026] Figure 11 This is a density comparison diagram of the unsupported overhanging regions in Example 1, Comparative Example 1, and Comparative Example 2.

[0027] Figure 12 This is a comparison diagram of the forming density and warping deformation of the unsupported overhanging region in Example 2 and Comparative Example 3. Detailed Implementation

[0028] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0029] The following disclosure provides many different embodiments or examples for implementing different structures of this application. To simplify the disclosure, specific examples of components and arrangements are described below. Of course, these are merely examples and are not intended to limit the scope of this application. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, various specific examples of processes and materials are provided in this application, but those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0030] The embodiments of this application will be further described below with reference to the accompanying drawings.

[0031] When manufacturing metal components using laser additive manufacturing, please refer to [link / reference]. Figure 1Before forming, the dried metal powder needs to be pre-formed in the powder hopper 10 of the forming chamber 100; then, the substrate 20 is placed on the preheating platform 40 connected to the lifting platform 30 of the forming chamber 100, and all the doors of the forming chamber 100 are closed to ensure the airtightness of the forming chamber 100. 99.99% argon gas is introduced into the forming chamber 100 until the oxygen content is below 100ppm; the upper surface of the substrate 20 is adjusted to be flush with the lower surface of the scraper 50; and the substrate 20 is preheated. During forming, the powder hopper 10 lays metal powder layer by layer on the substrate 20 through the powder feeding channel 60, and the laser 70 shines the laser on the metal powder on the forming plane through the galvanometer 80 to perform laser melting and forming until the laser melting and forming of all layers of metal powder is completed, thereby obtaining a metal component.

[0032] Please see Figure 2 This application proposes a method for suppressing deformation of nickel-based superalloy components in overhanging zones at different angles, comprising the following steps: S10: Obtain the component model and slice the component model to obtain multiple slice models.

[0033] S20, based on multiple slice models, each slice model is divided into an unsupported overhanging region 101 and a solid region 102 (e.g., Figure 3 As shown in the figure, the overhang angle of the unsupported overhang area of ​​the component model is 20° to 45°.

[0034] S30, set the laser selective melting forming parameters for the unsupported overhanging area and the solid area, wherein the heat input of the unsupported overhanging area is lower than the heat input of the solid area.

[0035] S40, based on the forming parameters of the unsupported overhanging region and the forming parameters of the solid region, nickel-based alloy powder is laid layer by layer, and the solid region of each layer of nickel-based alloy powder is first formed by a laser selective melting device, and then the unsupported overhanging region is intermittently formed, and this process is repeated until the laser selective melting device completes the laser melting and forming of all layers of nickel-based alloy powder, thereby obtaining a nickel-based alloy unsupported component.

[0036] The process involves designing the component model to be formed in Solidworks software; importing the component model into MaterialiseMagics software to perform layer slicing processing on the designed component model, with the layer thickness consistent with the thickness of the nickel-based alloy powder layer.

[0037] To address the issues of surface roughness and warping caused by heat accumulation in the unsupported overhanging area during the forming process, the first step is to identify the regions of the unsupported nickel-based alloy component and divide it into unsupported overhanging areas and solid areas. By intermittently scanning the unsupported overhanging area during forming, heat dissipation is increased, reducing heat accumulation in the unsupported overhanging area, thereby achieving good forming of the low-angle unsupported component.

[0038] In particular, since the unsupported overhanging area of ​​the nickel-based alloy unsupported component is powder rather than solid, its heat dissipation capacity is poor, and it is easy to accumulate heat, leading to defects such as melt-through and warping. Therefore, the intermittent scanning forming method is used to increase the heat dissipation time of the unsupported overhanging area during the additive manufacturing process, thereby reducing the heat accumulation in the unsupported overhanging area and avoiding warping deformation caused by large thermal stress.

[0039] The laser selective melting device includes a fiber laser, a beam expander, a laser galvanometer, a flat focusing lens, a servo system, and a heating platform; its specific structure will not be described in detail here.

[0040] The aforementioned deformation suppression method divides each slice model into an unsupported overhang region and a solid region. The heat input of the unsupported overhang region is lower than that of the solid region. By using a laser selective melting device to first form the solid region of each layer of nickel-based alloy powder, and then performing intermittent forming of the unsupported overhang region, the overheating phenomenon in the unsupported overhang region is reduced by changing the scanning strategy of the unsupported overhang region. This avoids the large temperature gradient and large thermal stress in the unsupported overhang region, effectively suppressing the warping deformation problem in the low-angle unsupported laser selective melting forming process. Nearly fully dense nickel-based alloy unsupported components with a single-layer warping deformation of no more than 80 μm, a lower surface roughness Sa of less than 30 μm, and a density of more than 99% are obtained during the forming process. This enables the unsupported low-angle manufacturing of complex components with complex internal cavities or conformal internal flow channels, thereby promoting the application of laser selective melting technology in the integrated forming of complex components. Because it requires no equipment modification or real-time monitoring and correction, it can be applied to most current equipment, and the forming process does not deviate from the compact forming process. Therefore, it ensures the forming density of unsupported nickel-based alloy components, achieving warpage control while maintaining the reliability of the unsupported nickel-based alloy components. Furthermore, since no support structure is needed, it avoids the time and material waste associated with forming support structures during the forming process, as well as the time waste and decreased yield caused by removing support structures during post-processing, thus improving production efficiency.

[0041] Please see Figure 4 In some embodiments, the steps of first forming solid regions of each layer of nickel-based alloy powder using a laser selective melting device, and then performing discontinuous forming of unsupported overhanging regions, include: S401 uses a laser selective melting device to scan the nickel-based alloy powder corresponding to the solid area of ​​each layer to form the solid area of ​​that layer.

[0042] S402, the unsupported overhanging area of ​​each layer is scanned multiple times by a laser selective melting device to intermittently form the unsupported overhanging area of ​​that layer. The interval between two adjacent scans in the multiple scans is preset to a time, which is 5ms-150ms.

[0043] Please see below. Figure 5 When forming the unsupported overhanging areas of each layer, an intermittent scanning method is mainly adopted. This means that the interval between two adjacent scans in multiple scans is 5ms-150ms, thus intermittently forming the unsupported overhanging areas of that layer. The main purpose of intermittent scanning is to reduce the temperature of the previous pass by increasing the heat dissipation time after each pass, avoiding overheating during the subsequent forming process. For example, when the laser selective melting device scans the nickel-based alloy powder to form the first weld pass, printing pauses for 5ms-150ms to increase heat dissipation. Then, the laser selective melting device continues to scan the nickel-based alloy powder to form the second weld pass, and printing pauses again for 5ms-150ms, and so on, until the laser selective melting device has completed the laser melting and forming of all layers of nickel-based alloy powder. Because the intermittent scanning scheme increases the forming time, the average heat input is reduced indirectly, thus achieving heat input control.

[0044] In some embodiments, the scanning directions of two adjacent scans in a multi-scan sequence are opposite.

[0045] In some embodiments, the nickel-based alloy powder is composed of the following by mass percentage: 20%-24% Cr, 13%-15% W, 1%-3% Mo, 0.05%-0.2% C, 0.2%-0.5% Si, 0.2%-1% Mn, 2%-4% Co, 0.01-0.1% La, 1%-3% Fe, less than 1% Al, less than 0.1% Ti, less than 0.5% Cu, less than 0.01% B, with the balance being Ni and unavoidable impurities.

[0046] Preferably, the nickel-based alloy powder has the following composition by mass percentage: 22.13% Cr, 14.55% W, 2.8% Mo, 0.12% C, 0.38% Si, 0.5% Mn, 1.89% Fe, 2.4% Co, 0.43% Al, 0.08% Ti, 0.47% Cu, 0.02% La, 0.015% B, with the balance being Ni and unavoidable impurities.

[0047] Please see Figure 6 In some embodiments, prior to the step of obtaining the component model and slicing the component model, the method further includes: S11, nickel-based alloy powder with a particle size of 15μm~53μm is dried in a vacuum-protected drying oven and stored safely for later use.

[0048] S12, Design a component model in 3D software, where the overhang angle of the unsupported overhang area of ​​the component model is 20° to 45°.

[0049] Please see Figure 7 In some embodiments, the step of dividing each slice model into unsupported overhanging regions and solid regions based on multiple slice models specifically includes: S21, based on multiple slice models, determine the protrusion length and overhang angle of each slice model relative to the adjacent slice models.

[0050] S22, based on the protrusion length and the angle of the overhang area, divides each slice model into an unsupported overhang area and a solid area.

[0051] The length of the unsupported overhang area is 1.25-2.5 times the length of each layer of protrusion, gradually increasing as the angle decreases. Specifically, at 45°, the length of the unsupported overhang area is 1.25 times the length of each layer of protrusion, and at 25°, the length of the unsupported overhang area is 2.5 times the length of each layer of protrusion.

[0052] In some embodiments, the laser selective melting forming parameters for the unsupported overhang region include overhang laser power, overhang scanning speed, and overhang scanning spacing. The overhang laser power ranges from 160W to 210W, the overhang scanning speed ranges from 700mm / s to 1200mm / s, and the overhang scanning spacing ranges from 0.07mm to 0.12mm. The laser scanning strategy for the unsupported overhang region is overall scanning. The laser output beam diameter is 50μm to 120μm.

[0053] In some embodiments, the laser selective melting forming parameters for the solid region include solid laser power, solid scanning speed, and solid scanning spacing. The solid laser power ranges from 185W to 235W, the solid scanning speed ranges from 600mm / s to 1000mm / s, and the solid scanning spacing ranges from 0.07mm to 0.12mm. In some embodiments, the laser scanning strategy for the solid region is a 67° cross-strip scanning. In some embodiments, the thickness of each layer of nickel-based alloy powder ranges from 20μm to 60μm.

[0054] Please see Figure 8 In some embodiments, the steps following the setting of laser selective melting parameters for unsupported overhanging regions and laser selective melting parameters for solid regions include: S41, input multiple slice models, laser selective melting forming parameters of unsupported overhanging areas and laser selective melting forming parameters of solid areas into the laser selective melting device to obtain a pre-demonstration nickel-based alloy unsupported component model; S42, based on the pre-demonstration of a nickel-based alloy unsupported component model conforming to the standard, confirms that the laser selective melting forming parameters and the slice model are correct.

[0055] In some embodiments, the laser scanning strategy for unsupported overhang areas is overall scanning, while the laser scanning strategy for solid areas is 67° cross-strip scanning, and the thickness of each layer of nickel-based alloy powder ranges from 0.02 mm to 0.05 mm.

[0056] In some embodiments, the steps prior to layering nickel-based alloy powder include: The dried nickel-based alloy powder is pre-formed in the powder feeding chamber. After the cleaned substrate is placed on the lifting platform of the forming chamber, all the doors are closed. Argon gas is introduced into the forming chamber until the oxygen content is below 100 ppm, and the substrate is preheated to 90°C to 110°C.

[0057] Specifically, the surface of the 316L stainless steel substrate is cleaned before forming; the dried nickel-based alloy powder is pre-formed in the powder feeding chamber; the cleaned 316L stainless steel substrate is placed on the lifting platform and all doors are closed to ensure the equipment is airtight; 99.99% argon gas is introduced into the forming chamber until the oxygen content is below 100ppm; the upper surface of the 316L stainless steel substrate is adjusted to be flush with the lower surface of the equipment scraper; the 316L stainless steel substrate is preheated to 90℃~110℃ by resistance heating.

[0058] Preheating the substrate can reduce the temperature gradient in the unsupported overhanging area during the forming process, thereby reducing the thermal stress and warping deformation in the unsupported overhanging area.

[0059] The technical solutions of this application are not limited to the specific embodiments exemplified below, but also include any combination of the specific embodiments.

[0060] Example 1 This embodiment provides a method for suppressing deformation of nickel-based superalloy components in overhanging regions at different angles, including the following steps: Step 1: Dry the nickel-based alloy powder with a particle size of 15μm~53μm in a vacuum-protected drying oven and store it safely for later use. The nickel-based alloy powder has the following composition by mass percentage: Cr 22.13%, W 14.55%, Mo 2.8%, C 0.12%, Si 0.38%, Mn 0.5%, Fe 1.89%, Co 2.4%, Al 0.43%, Ti 0.08%, Cu 0.47%, La 0.02%, B 0.015%, with the balance being Ni and unavoidable impurities.

[0061] Step 2: Design the component model to be formed in Solidworks software and slice it to obtain multiple slice models. The overhang angle of the unsupported overhang area of ​​the component model is 25°, the length of the unsupported overhang area is 20mm, the thickness of the unsupported overhang area is 0.5mm, and the thickness of the solid area is 0.5mm.

[0062] Step 3: Based on multiple slice models, determine the unsupported overhang area of ​​each slice model.

[0063] Step 4: Laser selective melting and forming parameters for unsupported overhanging areas include overhanging laser power, overhanging scanning speed, and overhanging scanning spacing. The overhanging laser power is 210W, the overhanging scanning speed is 1000mm / s, the overhanging scanning spacing is 0.09mm, and the laser scanning strategy for unsupported overhanging areas is 67° overall cross scanning, with an interval of 30ms between adjacent weld passes.

[0064] Step 5: Clean the surface of the 316L stainless steel substrate; pre-form the dried nickel-based alloy powder into the powder feeding chamber; place the cleaned 316L stainless steel substrate on the lifting platform and close all doors to ensure equipment sealing; introduce 99.99% argon gas into the forming chamber until the oxygen content is below 100ppm; adjust the upper surface of the 316L stainless steel substrate to be flush with the lower surface of the equipment scraper; preheat the 316L stainless steel substrate to 100℃ using resistance heating.

[0065] Step 6: Based on the forming parameters of the unsupported overhanging region, nickel-based alloy powder with a thickness of 0.04 mm is laid layer by layer. The solid region of each layer of nickel-based alloy powder is first formed by laser selective melting device, and then the unsupported overhanging region is formed by intermittent scanning. The interval between two adjacent scans in multiple scans is 30 ms, and this process is repeated until the laser selective melting device completes the laser melting and forming of all layers of nickel-based alloy powder, thereby obtaining the unsupported nickel-based alloy component.

[0066] Please see also Figure 9 , Figure 10 and Figure 11 The GH3230 unsupported component prepared in Example 1 has a density of 99.31%, and the overall warpage height does not exceed 50 μm, indicating no obvious warpage. The overall forming quality is high, and no large-sized pores or defects are observed under a light microscope. Regarding forming accuracy, the nickel-based alloy unsupported component prepared using this method exhibits high surface quality, with a surface roughness Sa = 25.31 μm and an actual overhang width of 996.4 μm, resulting in an error of only 0.36%.

[0067] Comparative Example 1 This embodiment provides a method for suppressing deformation of nickel-based superalloy components in overhanging regions at different angles, including the following steps: Step 1: Dry the nickel-based alloy powder with a particle size of 15μm~53μm in a vacuum-protected drying oven and store it safely for later use. The nickel-based alloy powder has the following composition by mass percentage: Cr 22.13%, W 14.55%, Mo 2.8%, C 0.12%, Si 0.38%, Mn 0.5%, Fe 1.89%, Co 2.4%, Al 0.43%, Ti 0.08%, Cu 0.47%, La 0.02%, B 0.015%, with the balance being Ni and unavoidable impurities.

[0068] Step 2: Design the component model to be formed in Solidworks software and slice it. The overhang angle of the unsupported overhang area of ​​the component model is 25°, the thickness of the unsupported overhang area is 0.5mm, and the thickness of the solid area is 0.5mm.

[0069] Step 3: Based on multiple slice models, determine the unsupported overhang area of ​​each slice model.

[0070] Step 4: Laser selective melting and forming parameters for the unsupported overhanging area include overhanging laser power, overhanging scanning speed, and overhanging scanning spacing. The overhanging laser power is 210W, the overhanging scanning speed is 900mm / s, the overhanging scanning spacing is 0.09mm, the laser scanning strategy for the unsupported overhanging area is 67° cross-strip scanning, and the scanning interval of the overhanging area is [not specified].

[0071] Step 5: Clean the surface of the 316L stainless steel substrate; pre-form the dried nickel-based alloy powder into the powder feeding chamber; place the cleaned 316L stainless steel substrate on the lifting platform and close all doors to ensure equipment sealing; introduce 99.99% argon gas into the forming chamber until the oxygen content is below 100ppm; adjust the upper surface of the 316L stainless steel substrate to be flush with the lower surface of the equipment scraper; preheat the 316L stainless steel substrate to 100℃ using resistance heating.

[0072] Step 6: Based on the forming parameters of the unsupported overhanging area, nickel-based alloy powder with a thickness of 0.04 mm is laid layer by layer, and the solid area and unsupported overhanging area of ​​each layer of nickel-based alloy powder are formed by laser selective melting device. This process is repeated until the laser selective melting device completes the laser melting and forming of all layers of nickel-based alloy powder, thereby obtaining the unsupported nickel-based alloy component.

[0073] Please see also Figure 9 , Figure 10 and Figure 11 The unsupported GH3230 component prepared in Comparative Example 1 had a density of 99.44% and a warpage of 293 μm, with noticeable warpage at the tip. Overall, the forming quality was high, and no large-sized pores or defects were observed under a light microscope. Regarding forming accuracy, the unsupported nickel-based alloy component prepared using this method exhibited significant melt-through on the lower surface, resulting in poor surface roughness (Sa reaching 43.21 μm). Due to the melt collapse and melt-through phenomena caused by high laser power and high heat input, the actual overhang width increased significantly, reaching 1178.5 μm, with a dimensional error as high as 17.85%.

[0074] Comparative Example 2 This embodiment provides a method for suppressing deformation of nickel-based superalloy components in overhanging regions at different angles, including the following steps: Step 1: Dry the nickel-based alloy powder with a particle size of 15μm~53μm in a vacuum-protected drying oven and store it safely for later use. The nickel-based alloy powder has the following composition by mass percentage: Cr 22.13%, W 14.55%, Mo 2.8%, C 0.12%, Si 0.38%, Mn 0.5%, Fe 1.89%, Co 2.4%, Al 0.43%, Ti 0.08%, Cu 0.47%, La 0.02%, B 0.015%, with the balance being Ni and unavoidable impurities.

[0075] Step 2: Design the component model to be formed in Solidworks software and slice it. The overhang angle of the unsupported overhang area of ​​the component model is 25°, the thickness of the unsupported overhang area is 0.5mm, and the thickness of the solid area is 0.5mm.

[0076] Step 3: Based on multiple slice models, determine the unsupported overhang area of ​​each slice model.

[0077] Step 4: Laser selective melting and forming parameters for the unsupported overhanging area include overhanging laser power, overhanging scanning speed, and overhanging scanning spacing. The overhanging laser power is 160W, the overhanging scanning speed is 1200mm / s, the overhanging scanning spacing is 0.105mm, and the laser scanning strategy for the unsupported overhanging area is 67° cross-over overall scanning.

[0078] Step 5: Clean the surface of the 316L stainless steel substrate; pre-form the dried nickel-based alloy powder into the powder feeding chamber; place the cleaned 316L stainless steel substrate on the lifting platform and close all doors to ensure equipment sealing; introduce 99.99% argon gas into the forming chamber until the oxygen content is below 100ppm; adjust the upper surface of the 316L stainless steel substrate to be flush with the lower surface of the equipment scraper; preheat the 316L stainless steel substrate to 100℃ using resistance heating.

[0079] Step 6: Based on the forming parameters of the unsupported overhanging area, nickel-based alloy powder with a thickness of 0.04 mm is laid layer by layer, and the solid area and unsupported overhanging area of ​​each layer of nickel-based alloy powder are formed by laser selective melting device. This process is repeated until the laser selective melting device completes the laser melting and forming of all layers of nickel-based alloy powder, thereby obtaining the unsupported nickel-based alloy component.

[0080] Please see also Figure 9 , Figure 10 and Figure 11The unsupported GH3230 component prepared in Comparative Example 2 had a density of 74.13% and contained numerous discontinuous sections and unfused pores. Due to insufficient heat input and poor component continuity, no significant warping deformation occurred. Regarding forming accuracy, the lower surface roughness Sa = 27.43 μm, with no obvious slag adhesion or melt-through areas, but relatively obvious discontinuities in the weld lines were present. Simultaneously, due to the significant decrease in heat input, warping in the unsupported overhang areas was suppressed, and no significant warping deformation was observed.

[0081] Example 2 This embodiment provides a method for suppressing deformation of nickel-based superalloy components in overhanging regions at different angles, including the following steps: Step 1: Dry the nickel-based alloy powder with a particle size of 15μm~53μm in a vacuum-protected drying oven and store it safely for later use. The nickel-based alloy powder has the following composition by mass percentage: Cr 22.13%, W 14.55%, Mo 2.8%, C 0.12%, Si 0.38%, Mn 0.5%, Fe 1.89%, Co 2.4%, Al 0.43%, Ti 0.08%, Cu 0.47%, La 0.02%, B 0.015%, with the balance being Ni and unavoidable impurities.

[0082] Step 2: Design the component model to be formed in Solidworks software and slice it to obtain multiple slice models. The overhang angle of the unsupported overhang area of ​​the component model is 25°, the thickness of the unsupported overhang area is 3mm, the width of the solid area is 2.6mm, the width of the unsupported overhang area is 0.5mm, and the overlap area between the two is 0.1mm.

[0083] Step 3: Based on multiple slice models, determine the protrusion length and overhang angle of each slice model relative to the adjacent slice models; based on the protrusion length and overhang angle, divide each slice model into an unsupported overhang area and a solid area.

[0084] Step 4: Laser selective melting and forming parameters for the solid area include solid laser power, solid scanning speed, and solid scanning spacing. The solid laser power is 210W, the solid scanning speed is 900mm / s, and the solid scanning spacing is 0.09mm. The laser scanning strategy for the solid area is a 67° cross-strip scanning. Laser selective melting and forming parameters for the unsupported overhanging area include overhang laser power, overhang scanning speed, and overhang scanning spacing. The overhang laser power is 200W, the overhang scanning speed is 1000mm / s, and the overhang scanning spacing is 0.1mm. The laser scanning strategy for the unsupported overhanging area is a 67° overall cross scanning.

[0085] Step 5: Clean the surface of the 316L stainless steel substrate; pre-form the dried nickel-based alloy powder into the powder feeding chamber; place the cleaned 316L stainless steel substrate on the lifting platform and close all doors to ensure equipment sealing; introduce 99.99% argon gas into the forming chamber until the oxygen content is below 100ppm; adjust the upper surface of the 316L stainless steel substrate to be flush with the lower surface of the equipment scraper; preheat the 316L stainless steel substrate to 100℃ using resistance heating.

[0086] Step 6: Based on the forming parameters of the unsupported overhanging region, nickel-based alloy powder with a thickness of 0.04 mm is laid layer by layer. The solid region of each layer of nickel-based alloy powder is first formed by laser selective melting device, and then the unsupported overhanging region is formed by intermittent scanning in sequence. The interval between two adjacent scans in multiple scans is 30 ms, and this process is repeated until the laser selective melting device completes the laser melting and forming of all layers of nickel-based alloy powder, thereby obtaining the unsupported nickel-based alloy component.

[0087] Please see also Figure 11 and Figure 12 The density of the GH3230 unsupported component prepared in Example 2 was 99.36%, the surface roughness Sa=17.67μm, and there were no obvious slag, pits or melt-through areas. The overall shape of the lower surface was relatively uniform.

[0088] Comparative Example 3 This embodiment provides a method for suppressing deformation of nickel-based superalloy components in overhanging regions at different angles, including the following steps: Step 1: Dry the nickel-based alloy powder with a particle size of 15μm~53μm in a vacuum-protected drying oven and store it safely for later use. The nickel-based alloy powder has the following composition by mass percentage: Cr 22.13%, W 14.55%, Mo 2.8%, C 0.12%, Si 0.38%, Mn 0.5%, Fe 1.89%, Co 2.4%, Al 0.43%, Ti 0.08%, Cu 0.47%, La 0.02%, B 0.015%, with the balance being Ni and unavoidable impurities.

[0089] Step 2: Design the component model to be formed in Solidworks software and slice it to obtain multiple slice models. The overhang angle of the unsupported overhang area of ​​the component model is 25°, the thickness of the unsupported overhang area is 3mm, the width of the solid area is 2.6mm, the width of the unsupported overhang area is 0.5mm, and the overlap area between the two is 0.1mm.

[0090] Step 3: Based on multiple slice models, determine the protrusion length and overhang angle of each slice model relative to the adjacent slice models; based on the protrusion length and overhang angle, divide each slice model into an unsupported overhang area and a solid area.

[0091] Step 4: Laser selective melting and forming parameters for the solid area include solid laser power, solid scanning speed, and solid scanning spacing. The solid laser power ranges from 210W, the solid scanning speed ranges from 900mm / s, and the solid scanning spacing ranges from 0.09mm. The laser scanning strategy for the solid area is a 67° cross-strip scanning. Laser selective melting and forming parameters for the unsupported overhanging area include overhang laser power, overhang scanning speed, and overhang scanning spacing. The overhang laser power is 180W, the overhang scanning speed is 1000mm / s, and the overhang scanning spacing is 0.105mm. The laser scanning strategy for the unsupported overhanging area is a 67° overall cross-scan.

[0092] Step 5: Clean the surface of the 316L stainless steel substrate; pre-form the dried nickel-based alloy powder into the powder feeding chamber; place the cleaned 316L stainless steel substrate on the lifting platform and close all doors to ensure equipment sealing; introduce 99.99% argon gas into the forming chamber until the oxygen content is below 100ppm; adjust the upper surface of the 316L stainless steel substrate to be flush with the lower surface of the equipment scraper; preheat the 316L stainless steel substrate to 100℃ using resistance heating.

[0093] Step 6: Based on the forming parameters of the unsupported overhanging region and the solid region, nickel-based alloy powder with a thickness of 0.04 mm is laid layer by layer. The solid region of each layer of nickel-based alloy powder is formed first by a laser selective melting device, and then the unsupported overhanging region is formed. This process is repeated until the laser selective melting device completes the laser melting and forming of all layers of nickel-based alloy powder, thereby obtaining a nickel-based alloy unsupported component.

[0094] Please see also Figure 11 and Figure 12 The density of the GH3230 unsupported component prepared in Comparative Example 3 was 95.93%, with a slightly higher warpage of 153 μm. However, due to the non-optimal forming parameters, dense forming at the tip could not be achieved during the forming process, resulting in collapse at the tip. Because the forming parameters were lowered in the unsupported overhang region, dense forming was not possible, especially at the boundary between the solid region and the unsupported overhang region, where obvious porosity and incomplete fusion were observed, severely affecting the forming quality of the GH3230 unsupported component.

[0095] It will be apparent to those skilled in the art that this application is not limited to the details of the exemplary embodiments described above, and that this application can be implemented in other specific forms without departing from the spirit or essential characteristics of this application. Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects, and the scope of this application is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be embraced within this application.

[0096] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application and are not intended to limit it. Although this application has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this application without departing from the spirit and scope of the technical solutions of this application.

Claims

1. A method for suppressing deformation in nickel-based superalloy components with different angled overhangs, characterized in that, Includes the following steps: Obtain the component model and slice the component model to obtain multiple slice models; Based on multiple slice models, each slice model is divided into an unsupported overhang region and a solid region, wherein the overhang angle of the unsupported overhang region of the component model is 20° to 45°. The laser selective melting forming parameters for the unsupported overhanging region and the laser selective melting forming parameters for the solid region are set, wherein the heat input of the unsupported overhanging region is lower than the heat input of the solid region; Based on the forming parameters of the unsupported overhanging region and the forming parameters of the solid region, nickel-based alloy powder is laid layer by layer. The solid region of each layer of nickel-based alloy powder is first formed by a laser selective melting device, and then the unsupported overhanging region is intermittently formed. This process is repeated until the laser selective melting device completes the laser melting and forming of all layers of nickel-based alloy powder, thereby obtaining a nickel-based alloy unsupported component.

2. The method for suppressing deformation of nickel-based superalloy components in overhanging zones at different angles as described in claim 1, characterized in that, The steps of first forming the solid region of each layer of nickel-based alloy powder using a laser selective melting device, and then performing intermittent forming of the unsupported overhanging region, include: The nickel-based alloy powder corresponding to the solid region of each layer is scanned by the laser selective melting device to form the solid region of that layer; The nickel-based alloy powder corresponding to the unsupported overhanging area of ​​each layer is scanned multiple times by the laser selective melting device to intermittently form the unsupported overhanging area of ​​the layer, wherein the interval between two adjacent scans in the multiple scans is a preset time.

3. The method for suppressing deformation of nickel-based superalloy components in overhanging zones at different angles as described in claim 2, characterized in that, The preset time ranges from 5ms to 150ms.

4. The method for suppressing deformation of nickel-based superalloy components in overhanging zones at different angles as described in claim 2, characterized in that, The scanning directions of two adjacent scans in the multiple scans are opposite.

5. The method for suppressing deformation of nickel-based superalloy components in overhanging zones at different angles as described in claim 1, characterized in that, The nickel-based alloy powder is composed of the following components by mass percentage: Cr 20%-24%, W 13%-15%, Mo 1%-3%, C 0.05%-0.2%, Si 0.2%-0.5%, Mn 0.2%-1%, Co 2%-4%, La 0.01-0.1%, Fe 1%-3%, Al less than 1%, Ti less than 0.1%, Cu less than 0.5%, B less than 0.01%, with the balance being Ni and unavoidable impurities.

6. The method for suppressing deformation of nickel-based superalloy components in overhanging zones at different angles as described in claim 1, characterized in that, Before the step of obtaining the component model and slicing the component model, the method further includes: Nickel-based alloy powder with a particle size of 15μm~53μm was dried in a vacuum-protected drying oven and stored safely for later use. Design a component model in 3D software, wherein the overhang angle of the unsupported overhanging area of ​​the component model is 20°. 45°.

7. The method for suppressing deformation of nickel-based superalloy components with different angled overhangs as described in claim 1, characterized in that, The step of dividing each slice model into an unsupported overhang region and a solid region based on multiple slice models specifically includes: Based on multiple slice models, determine the protrusion length and overhang angle of each slice model relative to the adjacent slice models; Based on the protrusion length and the overhang angle, each slice model is divided into the unsupported overhang area and the solid area.

8. The method for suppressing deformation of nickel-based superalloy components in overhanging zones at different angles as described in claim 1, characterized in that, The steps preceding the layer-by-layer laying of nickel-based alloy powder include: The dried nickel-based alloy powder is pre-formed in the powder feeding chamber. After the cleaned substrate is placed on the lifting platform of the forming chamber, all the doors are closed. Argon gas is introduced into the forming chamber until the oxygen content is below 100 ppm, and the substrate is preheated to 90°C to 110°C.

9. The method for suppressing deformation of nickel-based superalloy components in overhanging zones at different angles as described in claim 1, characterized in that, The laser selective melting and forming parameters for the unsupported overhanging region include overhanging laser power, overhanging scanning speed, and overhanging scanning spacing. The overhanging laser power ranges from 160W to 210W, the overhanging scanning speed ranges from 700mm / s to 1200mm / s, and the overhanging scanning spacing ranges from 0.07mm to 0.12mm. The laser scanning strategy for the unsupported overhanging region is overall scanning. The laser selective melting and forming parameters for the solid region include solid laser power, solid scanning speed, and solid scanning spacing. The solid laser power ranges from 185W to 235W, the solid scanning speed ranges from 600mm / s to 1000mm / s, and the solid scanning spacing ranges from 0.07mm to 0.12mm. The laser scanning strategy for the solid region is cross-strip scanning. The thickness of each layer of nickel-based alloy powder ranges from 0.02mm to 0.05mm.

10. The method for suppressing deformation of nickel-based superalloy components with different angled overhangs as described in claim 1, characterized in that, The steps following the setting of the laser selective melting forming parameters for the unsupported overhanging region and the laser selective melting forming parameters for the solid region include: The laser selective melting forming parameters of the multiple slice models, the unsupported overhanging region, and the solid region are input into the laser selective melting device to obtain a pre-demonstration nickel-based alloy unsupported component model. Based on the fact that the pre-demonstration nickel-based alloy unsupported component model conforms to the standard, it is confirmed that the laser selective melting forming parameters and the slicing model are correct.

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