Adaptive zoned heat treatment method and system for additively manufactured high temperature alloy components

Abstract

This invention discloses an adaptive zoned heat treatment method and system for additive manufacturing high-temperature alloy components. The method discretizes the embedded space, targets and fills it with temperature-controlled phase-change composite powder whose Curie temperature matches the target heat treatment temperature, and constructs a static solid-phase heat transfer interface. An alternating magnetic field is applied to generate hysteresis loss heating. The heating path is cut off by utilizing the mechanism of the powder's paramagnetic phase transition and increased electromagnetic skin depth when the magnetic medium senses the Curie temperature, achieving multi-temperature zone adaptive isothermal residence. After heat preservation, the magnetic field is cut off and an inert gas is introduced, driving the powder bed to transform into a dynamic fluidized bed. In-situ conformal rapid cooling is achieved through gas-solid two-phase convective heat transfer. Combined with a sealed docking and purging fixture to block external bypasses, and with mechanical vibration waves to force-inject pulsed airflow, the powder trapped in the flow channels is stripped and emptied. This invention achieves passive temperature control, in-situ rapid cooling, and structural separation of complex components.

Description

Technical Field

[0001] This invention relates to the field of heat treatment technology for metallic materials, specifically to an adaptive partitioned heat treatment method and system for additive manufacturing of high-temperature alloy components. Background Technology

[0002] Additive manufacturing technology can form high-temperature alloy components with complex internal topological pores and conformal cooling channels by melting and stacking layers one after another. After additive manufacturing, high-temperature alloy components usually have residual stress and uneven micro-grain size distribution. In order to eliminate residual stress and control the microstructure, the formed high-temperature alloy components must undergo heat treatment.

[0003] Existing conventional heat treatment processes typically involve placing the additively manufactured high-temperature alloy component as a whole into a vacuum heating furnace or atmosphere-protected furnace. The component is heated to the target temperature by thermal radiation from the furnace wall and convection of the gas inside the furnace, and then held at a constant temperature before cooling. This traditional monolithic heat treatment equipment places the entire component in a single temperature field for uniform heating and holding.

[0004] Existing monolithic heating methods cannot meet the differentiated heat treatment requirements of different geometric parts of additively manufactured components. Because additively manufactured components include both thick-walled solid structures and thin-walled complex features, the initial residual stress state and grain structure vary in different regions. A uniform heating temperature can lead to excessive grain growth in thin-walled areas or incomplete stress relief in thick-walled areas. If conventional multi-zone furnaces are used for zonal temperature control, for components with complex topological pores, external macroscopic temperature sensing elements cannot penetrate deep into the component to obtain accurate temperature feedback, and there is spatial attenuation and time lag when external heat is conducted inward. This makes it difficult for conventional zonal temperature control methods to achieve a smooth transition at the boundaries of different temperature zones in complex components, easily causing abrupt temperature changes internally, which in turn induces secondary thermal stress within the component, leading to thermal stress cracking in high-temperature alloy components during heat treatment. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an adaptive zoned heat treatment method and system for additively manufactured high-temperature alloy components. This solves the problem that existing integral heating or conventional zoned temperature control equipment is unable to provide spatially adaptive differentiated temperature control for the initial residual stress and grain size differences in different geometric parts of complex additively manufactured high-temperature alloy components. Furthermore, it is prone to secondary thermal stress caused by temperature feedback lag and internal step temperature differences, which can lead to abnormal grain growth, plastic deformation, or thermal stress cracking during the heat treatment process.

[0006] To achieve the above objectives, the present invention provides the following technical solution: The first aspect of the present invention provides an adaptive partitioned heat treatment method for additive manufacturing high-temperature alloy components, comprising the following steps: Geometric model parameters and initial microstructure distribution data of additively manufactured high-temperature alloy components are obtained, target heat treatment temperature fields for each geometric part are set, and the embedded space outside the additively manufactured high-temperature alloy components is discretized into multiple filling regions. For each filling region, magnetic medium induction powder with a Curie temperature equal to the corresponding target heat treatment temperature is selected and mixed with thermally conductive and insulating ceramic powder to prepare multiple sets of temperature-controlled phase change composite powders. Multiple sets of temperature-controlled phase change composite powders are filled into the corresponding spatial positions around the additive manufacturing high-temperature alloy component placed in the fluidized confinement mold module, completely adhering to the outer surface contour of the additive manufacturing high-temperature alloy component and penetrating into the inner cavity channel to form a dense static solid phase heat transfer contact interface. The alternating magnetic field generating module is activated to apply a globally distributed alternating magnetic field. Multiple sets of temperature-controlled phase change composite powders are kept in a static fixed bed state under the action of gravity. The magnetic medium induction powder generates hysteresis loss heat inside. When the local temperature rises to the Curie temperature of the magnetic medium induction powder, the ferromagnetic alloy particles in the corresponding filling area undergo an intrinsic physical transformation from ferromagnetic phase to paramagnetic phase. The relative permeability decreases abruptly, the heating behavior is physically blocked, and the heat preservation and residence stage begins. After a preset heat preservation and residence time, the power output of the alternating magnetic field generating module is cut off, and the inert gas fluidization control module is turned on simultaneously to introduce inert gas. By adjusting the apparent flow rate of the gas entering the temperature-controlled phase change composite powder to be greater than the critical fluidization rate, the temperature-controlled phase change composite powder changes from a static fixed bed to a dynamic fluidized bed of particle mixing. The heat transfer mechanism at the medium interface is transformed into gas-solid two-phase convective heat transfer, realizing in-situ conformal rapid cooling. After the temperature drops to the furnace exit temperature range, the inert gas fluidization control module is turned off, and the temperature-controlled phase change composite powder is redeposited into a static state. The temperature-controlled phase change composite powder is then released, and the additively manufactured high-temperature alloy component is removed from the fluidization constraint mold module.

[0007] Furthermore, in the stage of establishing the target heat treatment temperature field, temperature nodes are set according to a mapping database containing the correspondence between residual stress values, grain size values ​​and target heat treatment temperature values; a spatial volume transition zone is inserted between adjacent discrete filling regions where the temperature difference exceeds the safety threshold, and the transition temperature node is calculated using a linear interpolation algorithm according to the spatial distance ratio. A transition state temperature-controlled phase change composite powder for filling the spatial volume transition zone is prepared by combining magnetic medium induction powder with thermally conductive and insulating ceramic powder with a Curie temperature value equal to the transition temperature node.

[0008] Furthermore, when configuring the temperature-controlled phase change composite powder, the volume percentage of the thermally conductive and insulating ceramic powder is configured to be in the range of 65% to 85%, and the volume percentage of the magnetic medium induction powder is configured to be in the range of 15% to 35%. The median particle size parameter of the thermally conductive and insulating ceramic powder and the median particle size parameter of the magnetic medium induction powder are configured to be on the same order of magnitude, and both are defined in the range of 20μm to 150μm.

[0009] Furthermore, in the static magnetic induction adaptive heating stage, the frequency of the alternating magnetic field output by the alternating magnetic field generation module is set to make the electromagnetic skin depth of the alternating magnetic field greater than the median particle size of the magnetic medium induction powder; when the temperature crosses the Curie temperature node and causes the relative permeability to decay, the electromagnetic skin depth increases instantaneously and completely penetrates the magnetic medium induction powder particles, cutting off the eddy current loss heating path; when the temperature falls back below the Curie temperature, the magnetic medium induction powder restores its ferromagnetic phase physical properties and resumes heating, forming a dynamic thermal balance network of induction heating power and dissipation power.

[0010] Furthermore, during the rapid cooling stage of gas-solid fluidized phase change, after the apparent velocity of the injected inert gas reaches the critical fluidization velocity and breaks through the mechanical equilibrium state, the temperature-controlled phase change composite powder bed enters a suspended remixing state under the drag force of the inert gas; the time length for the apparent velocity of the injected inert gas to jump from zero to the critical fluidization velocity is strictly less than the incubation time threshold corresponding to the nose temperature of the strengthening phase precipitation in additive manufacturing high-temperature alloy components.

[0011] Furthermore, during the powder separation stage, the high-temperature unloading valve located below the inlet pressure stabilizing chamber is opened to discharge the temperature-controlled phase change composite powder; the operating equipment presses the sealing and purging fixture onto the air inlet port of the conformal cooling channel of the additive manufacturing high-temperature alloy component; the system controls the mechanical vibration platform to activate the low-frequency sweep frequency excitation mode to apply mechanical vibration waves, and simultaneously activates the auxiliary high-pressure air source to force the injection of pulse airflow through the sealing and purging fixture. The pulse airflow blocks the external bypass airflow and, in conjunction with the mechanical vibration waves, blows the temperature-controlled phase change composite powder retained in the channel downwards and collects it.

[0012] A second aspect of the present invention provides an adaptive partitioned heat treatment system for additive manufacturing of high-temperature alloy components, used to perform the aforementioned adaptive partitioned heat treatment method, the system comprising: The system comprises a fluidized bed mold module, an alternating magnetic field generating module, an inert gas fluidization control module, external auxiliary separation components, and a system processing terminal. The fluidized bed mold module forms a sealed cavity; the alternating magnetic field generating module includes a high-frequency induction coil and a programmable power supply; the inert gas fluidization control module is connected to the inlet pressure stabilizing chamber below the porous gas distribution plate, and the pipeline integrates a gas preheater, heat exchange components, and a gas compressor; the external auxiliary separation components include a mechanical vibration platform, a vacuum pump, a sealed purging fixture, and an auxiliary high-pressure gas source; and the system processing terminal is electrically connected to each actuator.

[0013] This invention provides an adaptive zoned heat treatment method and system for additively manufactured high-temperature alloy components. It offers the following advantages: 1. This invention discretizes and targets the embedded space with temperature-controlled phase change composite powder corresponding to the Curie temperature. It utilizes the mechanism that when the magnetic medium induction powder reaches the Curie temperature under an alternating magnetic field, it transforms from a ferromagnetic phase to a paramagnetic phase, causing a decrease in relative permeability and an increase in electromagnetic skin depth, thereby cutting off the heating path. Under the condition of no external temperature measurement circuit intervention, a microscopic heating and heat dissipation dynamic thermal balance network is spontaneously formed, realizing the passive adaptive isothermal residence of high-temperature alloy components with complex topology in multiple temperature zones and the local temperature control effect of eliminating thermal stress cracking.

[0014] 2. After the heat preservation period ends, the alternating magnetic field output is cut off and high-pressure inert gas is injected simultaneously to make the apparent gas velocity inside the powder bed greater than the critical fluidization velocity. This drives the temperature-controlled phase change composite powder to change from a static fixed bed to a dynamic fluidized bed with suspended particles and back mixing. By relying on the fluidized solid powder particles to penetrate the gas thermal boundary layer on the surface of the component for microscopic heat capacity carrier replacement, the heat transfer mechanism is rapidly switched from solid phase heat conduction to gas-solid two-phase convective heat transfer, as well as the in-situ conformal rapid cooling and anti-plastic deformation effect of the complex conformal flow channel of the component.

[0015] 3. This invention presses a sealing and purging fixture onto the air inlet port of the conformal cooling channel of an additively manufactured high-temperature alloy component and controls a mechanical vibration platform to input a low-frequency sweep vibration mechanical vibration wave. Simultaneously, an auxiliary high-pressure air source is turned on to force a pulsed airflow into the channel. The sealing and purging fixture blocks the external bypass airflow and, in conjunction with the mechanical vibration wave, destroys the mechanical self-locking structure of the powder particles in the channel. This achieves the physical stripping and downward discharge of powder trapped in complex topological pores and curved conformal channels, while preventing internal channel blockage. Attached Figure Description

[0016] Figure 1 This is a flowchart of the present invention; Figure 2 This is a system architecture diagram of the present invention. Detailed Implementation

[0017] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Please see the appendix Figure 2 This invention provides an adaptive zoned heat treatment system for additive manufacturing of high-temperature alloy components. The system includes an alternating magnetic field generating module, a fluidized bed confinement mold module, a temperature-controlled phase change composite powder bed, and an inert gas fluidization control module. The alternating magnetic field generating module is used to establish an alternating magnetic field within a specific working space. In one specific embodiment, the alternating magnetic field generating module includes a high-frequency induction coil and a programmable power supply electrically connected to the high-frequency induction coil. The programmable power supply is configured to output an alternating current with a preset frequency and a preset current intensity to the high-frequency induction coil, thereby generating a globally distributed alternating magnetic field. The high-frequency induction coil is arranged around the outside of the fluidized bed confinement mold module to ensure that the alternating magnetic field can penetrate and cover the working area inside the fluidized bed confinement mold module.

[0019] The fluidized bed mold module is located within the operating area of ​​the alternating magnetic field generating module and is used to contain the heat transfer medium and the additive manufacturing high-temperature alloy components to be processed. The fluidized bed mold module includes a mold body and a porous gas distribution plate located at the bottom of the mold body, with a gas exhaust port at the top of the mold body. The mold body is made of a non-magnetic and non-conductive high-temperature resistant material, such as quartz glass, high-purity alumina ceramic, or silicon nitride ceramic, to prevent electromagnetic induction heating of the mold body in the alternating magnetic field and to ensure the penetration rate of high-frequency electromagnetic waves. The porous gas distribution plate has an array of micropores, the pore size of which is configured to be smaller than the minimum particle size of the powder particles loaded inside, to prevent solid powder from leaking downwards under gravity and to provide an upwardly uniformly distributed airflow channel during the fluidization stage.

[0020] A temperature-controlled phase change composite powder bed fills the cavity inside the mold body and covers the outer surface and inner cavity channels of the additively manufactured high-temperature alloy component. To clearly illustrate the technical solution of this application, the temperature-controlled phase change composite powder bed is a powdered physical medium, a solid particle aggregate formed by mechanically mixing thermally conductive and insulating ceramic powder and magnetically inductive powder in a preset volume fraction. Specific examples of the thermally conductive and insulating ceramic powder include alumina powder, aluminum nitride powder, or boron nitride powder, which play a role in three-dimensional thermal conduction and structural support in the temperature-controlled phase change composite powder bed. Specific examples of the magnetically inductive powder are ferromagnetic alloy particles with a specific Curie temperature. To meet the material microstructure requirements of different discrete regions on the surface of the additively manufactured high-temperature alloy component, the Curie temperature of the magnetically inductive powder filling the corresponding region is matched with the target solution treatment temperature.

[0021] The inert gas fluidization control module is located outside the mold body and is in gas path communication with the inlet pressure stabilizing chamber below the porous gas distribution plate. The inert gas fluidization control module consists of a high-pressure inert gas source, gas supply pipeline, pressure regulating valve, and mass flow controller. The high-pressure inert gas source can specifically be a high-pressure argon cylinder group or a nitrogen storage tank. The mass flow controller measures and regulates the gas flow rate to control the apparent flow rate of the gas entering the inner cavity of the mold body.

[0022] Furthermore, the adaptive partitioned heat treatment system also includes a system processing terminal electrically connected to each module, as well as temperature sensors. To achieve conformal powder filling and deep stripping in complex internal cavities, the fluidized bed mold module is externally configured with a mechanical vibration platform, vacuum pump equipment, sealing and purging fixtures, and an auxiliary high-pressure gas source. To construct a closed-loop quenching circuit, the inert gas fluidization control module further integrates a gas preheater, heat exchange components, and a gas compressor on its pipeline.

[0023] Based on the above hardware system architecture, please refer to the appendix. Figure 1 The adaptive zoned heat treatment workflow for additive manufacturing of high-temperature alloy components is divided into the following steps: Step S100: Initial state assessment and partitioned powder configuration.

[0024] Geometric model parameters and initial microstructure distribution data of additively manufactured high-temperature alloy components were obtained, and target heat treatment temperature fields were set for each geometric part of the component. The embedded space outside the additively manufactured high-temperature alloy component was discretized into multiple filling regions. For each filling region, the corresponding target heat treatment temperature was extracted. Magnetic medium induction powder with a Curie temperature equal to the target heat treatment temperature was selected, and the selected magnetic medium induction powder was mixed with thermally conductive and insulating ceramic powder to prepare multiple sets of temperature-controlled phase change composite powders corresponding to multiple filling regions.

[0025] Step S200: The component is embedded in the solid phase and the interface between the solid phase and the solid phase is constructed.

[0026] The additively manufactured high-temperature alloy component is placed inside the mold body of the fluidized bed mold module. Based on the embedding space positions defined in step S100, multiple sets of pre-configured temperature-controlled phase change composite powders are filled into the corresponding spatial positions around the additively manufactured high-temperature alloy component. During the actual physical filling process, a thin-walled metal baffle can be used to temporarily divide the inner cavity of the mold body into multiple sub-chambers corresponding to the filling area. After pouring the corresponding temperature-controlled phase change composite powder into each sub-chamber, the thin-walled metal baffle is slowly pulled upwards to achieve a partitioned spatial arrangement of powders of different components. Due to the discrete flowability of the powder medium, the temperature-controlled phase change composite powder completely adheres to the outer surface contour of the additively manufactured high-temperature alloy component and penetrates into the conformal cooling channels or topological pore structures inside the component, displacing internal gas and forming a dense static solid-phase heat transfer contact interface.

[0027] Step S300: Static magnetic induction adaptive heating and zone dwell.

[0028] The alternating magnetic field generation module is activated. During this stage, the inert gas fluidization control module is off, and each group of temperature-controlled phase change composite powders remains in a static fixed bed state under the influence of gravity. Under the action of the alternating magnetic field, the magnetic medium induction powder undergoes magnetic domain friction and induced eddy currents, resulting in energy loss and heat generation. The heat generated in local areas is conducted to the surface of the encapsulated additive manufacturing high-temperature alloy component through the solid-phase contact surfaces between powder particles and the thermally conductive and insulating ceramic powder. When the local temperature of a certain filling area rises to the Curie temperature of the corresponding magnetic medium induction powder, the ferromagnetic alloy particles in that filling area undergo an intrinsic physical transformation from a ferromagnetic phase to a paramagnetic phase, and the relative permeability decreases significantly. At this time, the internal heat source generation rate caused by the alternating magnetic field attenuates synchronously, and the heating behavior is physically blocked. Following this pattern, each local filling area in the mold body spontaneously stops heating after reaching its preset Curie temperature and enters a heat preservation and residence stage without external control source.

[0029] Step S400: Gas-solid fluidization phase transition and in-situ conformal rapid cooling.

[0030] After the additively manufactured high-temperature alloy component has undergone a preset heat preservation and residence time, the power output of the alternating magnetic field generating module is cut off, and the global induction heating physical termination occurs. Simultaneously, the inert gas fluidization control module is activated, injecting high-pressure inert gas into the inlet pressure stabilizing chamber below the porous gas distribution plate. By adjusting the mass flow controller, the apparent flow velocity of the gas passing through the porous gas distribution plate and entering the temperature-controlled phase change composite powder is made greater than the critical fluidization velocity of the temperature-controlled phase change composite powder. At this point, the temperature-controlled phase change composite powder overcomes gravity, transforming from a static fixed bed to a dynamic fluidized bed of particle mixing. The fluidized powder particles undergo continuous collision and displacement motion on the surface of the additively manufactured high-temperature alloy component and the surface of the internal flow channels, and the heat transfer mechanism at the medium interface changes from solid-phase heat conduction to gas-solid two-phase convective heat transfer. The heat inside the additively manufactured high-temperature alloy component is stripped away by the fluidized powder and carried out from the exhaust port of the mold body with the discharged high-temperature inert gas. After being cooled by external heat exchange components, it circulates and fluidizes, achieving in-situ conformal rapid cooling.

[0031] Step S500: Fluidization terminates and component is separated.

[0032] After the temperature of the additively manufactured high-temperature alloy component drops to the set furnace exit temperature range, the inert gas fluidization control module is shut down. Once the gas flow rate is zero, the powder particles are redeposited into a static state under gravity. The discharge mechanism at the bottom of the mold body is then activated to release the temperature-controlled phase-change composite powder, allowing the heat-treated additively manufactured high-temperature alloy component to be removed from the fluidization-constrained mold module.

[0033] The fluidized bed mold module has an overall vertical cylindrical structure, forming a sealed cavity inside to accommodate the heat transfer medium and the high-temperature alloy component to be processed in additive manufacturing. To meet the penetration requirements of the alternating magnetic field and prevent eddy current heating within the mold body itself, the mold body is made of a non-conductive and non-magnetic high-temperature resistant material. Specific examples of non-conductive and non-magnetic high-temperature resistant materials include quartz glass, high-purity alumina ceramic, or silicon nitride ceramic. The selection of these materials reduces the absorption of electromagnetic energy by the mold body, ensuring that the energy of the alternating magnetic field is concentrated on the internal temperature-controlled phase-change composite powder.

[0034] A sealed top cover is provided on the top of the mold body. To withstand the back pressure of the gas inside the mold during the gas-solid fluidization rapid cooling stage, the sealed top cover is locked and fixed to the end face of the mold body by a flange structure, and a high-temperature resistant sealing ring is pressed between the sealing top cover and the mold body mating surface. An exhaust port is provided on the sealed top cover. A gas-solid separation assembly is connected to the external pipeline of the exhaust port. The gas-solid separation assembly is specifically in the form of a cyclone separator or a sintered metal filter. The gas-solid separation assembly is used to separate the discharged high-pressure inert gas from the powder particles carried by the airflow during the gas-solid fluidization rapid cooling stage, intercepting the powder particles and discharging the separated inert gas into a gas volume storage tank.

[0035] The porous gas distribution plate divides the interior of the mold body into an upper powder loading area and a lower air inlet and pressure regulating chamber. The side wall of the air inlet and pressure regulating chamber has an air inlet port, which is connected to a high-pressure inert gas source. The porous gas distribution plate serves to support the temperature-controlled phase change composite powder and to uniformly distribute the airflow. The porous gas distribution plate is made of non-magnetic high-temperature resistant alloy material or porous ceramic sintered parts.

[0036] The porous gas distribution plate has arrayed flow-guiding micropores that extend through the thickness direction. The pore size of the flow-guiding micropores is smaller than the diameter of the smallest powder particle in the temperature-controlled phase change composite powder, which is used to prevent powder particles from falling into the inlet pressure-stabilizing chamber due to gravity.

[0037] Pressure drop across the porous gas distribution plate caused by inert gas passing through it Determined based on the following formula: In the formula, The dimensionless local drag coefficient representing the porous gas distribution plate. The physical density representing an inert gas. This represents the apparent gas velocity of the inert gas passing through the guide micropores.

[0038] By changing the overall porosity of the porous gas distribution plate and the cross-sectional shape of the guiding micropores, the local resistance coefficient can be adjusted. The value. Adjusting the local drag coefficient. The aim is to establish a stable fluid back pressure at the bottom of the bed, eliminate gas channeling in the powder loading area, and enable the temperature-controlled phase change composite powder around the additive manufacturing high-temperature alloy components to enter the fluidized state simultaneously.

[0039] The mold body contains a discharge channel that runs through the air intake and pressure stabilizing chamber and directly connects to the powder loading area. The top of the discharge channel is flush with the surface of the porous gas distribution plate, and the bottom of the discharge channel extends to the outside of the mold body. A high-temperature resistant unloading valve is installed on the external pipeline of the discharge channel. After the heat treatment step is completed, the high-temperature resistant unloading valve is opened, and the temperature-controlled phase change composite powder in the powder loading area is discharged downwards along the discharge channel by gravity to the external collection container, thereby releasing the embedding constraint on the additive manufacturing high-temperature alloy component.

[0040] Temperature-controlled phase change composite powder bed is the space heat transfer medium inside an adaptive zoned heat treatment system. It is prepared by mechanically mixing thermally conductive and insulating ceramic powder with magnetically inductive powder.

[0041] The thermally conductive and insulating ceramic powder is made of high-purity alumina powder or high-purity boron nitride powder. It possesses high thermal conductivity and high resistivity. To meet the material stability requirements under high-temperature heat treatment conditions, the thermally conductive and insulating ceramic powder has a melting point higher than the highest targeted heat treatment temperature of the additively manufactured high-temperature alloy components. The surface of the thermally conductive and insulating ceramic powder is chemically inert and will not chemically react with the additively manufactured high-temperature alloy components at high temperatures. In the microstructure of the temperature-controlled phase change composite powder bed, the thermally conductive and insulating ceramic powder acts as a structural support framework and provides physical isolation barriers between magnetically inductive powder particles and between magnetically inductive powder particles and the surface of the additively manufactured high-temperature alloy components. The function of the physical isolation barrier is to prevent high-temperature sintering and adhesion during the high-temperature residence stage, ensuring that the temperature-controlled phase change composite powder bed maintains a discrete particle state after high-temperature heat treatment, providing the basic physical conditions for gas-solid fluidized phase change.

[0042] Magnetic induction powder is the active component that provides the internal heat source. The magnetic induction powder is selected from iron-nickel alloy powder or iron-cobalt alloy powder. Magnetic induction powder possesses intrinsic physical phase transition properties, specifically manifested as a step-like abrupt decrease in relative permeability when the local temperature reaches a specific Curie temperature.

[0043] To prevent the accumulation of alternating magnetic field energy on the outer surface of the temperature-controlled phase change composite powder bed, which would generate a macroscopic skin effect, it is necessary to block the macroscopic conductive pathways within the bed. In the formulation design, to completely block the three-dimensional overlapping network of conductive particles based on percolation theory, the volume percentage of thermally conductive insulating ceramic powder is configured between 65% and 85%, while the corresponding volume percentage of magnetic media induction powder is configured between 15% and 35%. By setting these volume percentage differences, the predominantly numerous thermally conductive insulating ceramic powder particles encapsulate the fewer magnetic media induction powder particles, constructing a continuous insulating and thermally conductive framework network within the temperature-controlled phase change composite powder bed. This insulating and thermally conductive framework network spatially isolates the individual magnetic media induction powder particles, preventing them from contacting each other and forming a continuous conductor. This ensures that the alternating magnetic field can penetrate deep into the temperature-controlled phase change composite powder bed, achieving globally uniform volumetric induced heating.

[0044] In the preparation of the temperature-controlled phase change composite powder bed, to ensure the macroscopic uniformity of the two powders with different densities during the gas-solid fluidization rapid cooling stage and to prevent particle stratification and segregation, the median particle size parameters of the thermally conductive and insulating ceramic powder and the magnetically inductive powder were configured to be on the same order of magnitude, and both were defined within the range of 20 to 150 micrometers. Defining the median particle size within this range serves two purposes: firstly, it prevents powder particles from agglomerating and caking due to excessive microscopic van der Waals forces, ensuring the temperature-controlled phase change composite powder bed is in a fluidizable gas-solid operation state; secondly, the matching design of the median particle size ensures the consistency of the mixed powders in fluidization kinetics, preventing the sedimentation or segregation of a single component within the mold body and maintaining the spatial stability of localized heating power.

[0045] Step S100 includes the physical state assessment of the additively manufactured high-temperature alloy component and the preparation and distribution of the corresponding heat transfer medium, which is specifically subdivided into the following execution steps: Step S101: Obtain the three-dimensional geometric model and initial microstructure distribution data of the additively manufactured high-temperature alloy component. The three-dimensional geometric model is imported into the system processing terminal in a three-dimensional solid format. The initial microstructure distribution data characterizes the three-dimensional spatial distribution of the residual stress field and micrograin size inside the additively manufactured high-temperature alloy component. The initial microstructure distribution data can be obtained by scanning and exporting it through non-destructive testing equipment, or by inputting the printing process parameters of the additive manufacturing equipment into thermo-coupled finite element simulation software for numerical calculation.

[0046] Step S102: Establish a target heat treatment temperature mapping field. The system processing terminal receives initial microstructure distribution data and sets corresponding targeted solution treatment temperatures for different geometric parts of the additively manufactured high-temperature alloy component. The system processing terminal internally stores a mapping database containing the corresponding mapping relationships between residual stress values, grain size values, and target heat treatment temperature values. Based on the mapping database, the system processing terminal sets a first target heat treatment temperature for geometric parts with grain size greater than a preset grain threshold and residual stress greater than a preset stress threshold, and sets a second target heat treatment temperature for geometric parts with grain size less than the preset grain threshold and residual stress less than the preset stress threshold, wherein the first target heat treatment temperature value is greater than the second target heat treatment temperature value.

[0047] Step S103: Discretize the embedded space. Using the three-dimensional geometric model of the additively manufactured high-temperature alloy component as the center, a virtual three-dimensional embedded space is established within a set spatial coverage margin. The system processing terminal uses a voxelization algorithm to divide the three-dimensional embedded space into multiple discrete filling regions of defined sizes. The system processing terminal identifies two adjacent discrete filling regions where the difference between their corresponding target heat treatment temperatures exceeds a safety threshold, and inserts a spatial volume transition region between these two adjacent discrete filling regions. The function of the spatial volume transition region is to smooth the spatial temperature gradient and prevent thermal stress microcracks from forming in the additively manufactured high-temperature alloy component during alternating magnetic field heating.

[0048] Step S104: Targeted configuration of temperature-controlled phase change composite powder. The system processing terminal extracts the target heat treatment temperature value mapped to each discrete filling region. In a pre-established magnetic material parameter database, magnetic media induction powder with a Curie temperature value equal to the target heat treatment temperature value is retrieved and selected. The selected Curie temperature magnetic media induction powder is mechanically blended with thermally conductive and insulating ceramic powder at a preset volume percentage to prepare multiple sets of temperature-controlled phase change composite powders corresponding to the properties of each discrete filling region. For the spatial volume transition region inserted in step S103, the system processing terminal calculates the transition temperature node using a linear interpolation algorithm according to the spatial distance ratio. The system processing terminal selects magnetic media induction powder with a Curie temperature value equal to the transition temperature node and combines it with thermally conductive and insulating ceramic powder to prepare transitional temperature-controlled phase change composite powder for filling the spatial volume transition region, thereby constructing a gradient thermal medium layer with a continuously stepwise change in Curie temperature inside the temperature-controlled phase change composite powder bed.

[0049] Step S200 aims to establish a tight solid-phase thermal conductivity network between the temperature-controlled phase change composite powder bed inside the fluidized bed mold module and the surface of the additively manufactured high-temperature alloy component, specifically including the following execution steps: Step S201: Component positioning and partitioning fixture placement. The additive manufacturing high-temperature alloy component to be processed is placed in the inner cavity of the mold body of the fluidized bed mold module and supported and fixed above the porous gas distribution plate. Based on the spatial coordinate boundaries of the discrete filling regions determined in step S100, a thin-walled metal baffle fixture is inserted into the inner cavity of the mold body. The shape of the thin-walled metal baffle fixture is adapted to the three-dimensional interface contour of the discrete filling regions. The thin-walled metal baffle fixture physically divides the inner cavity of the mold body into multiple independent sub-loading chambers corresponding one-to-one with the discrete filling regions.

[0050] Step S202, Powder Partition Injection and Vibration Filling. Multiple sets of temperature-controlled phase change composite powders are injected into their respective independent sub-loading chambers. The additively manufactured high-temperature alloy components contain topology-optimized pores and conformal cooling channel structures. Gravity tilting causes powder particle bridging within the microchannels, resulting in the formation of localized air insulation layers. To ensure that the temperature-controlled phase change composite powder fills the entire internal space of the additively manufactured high-temperature alloy component, a mechanical vibration platform is externally connected to the bottom of the fluidized bed mold module. During the powder injection stage, the mechanical vibration platform is simultaneously activated, applying high-frequency, low-amplitude vertical vibration to the fluidized bed mold module. The vibration energy breaks the static friction and mechanical self-locking between powder particles, causing the temperature-controlled phase change composite powder to exhibit flow characteristics and penetrate into the conformal features inside the additively manufactured high-temperature alloy component.

[0051] Step S203: Baffle Removal and Solid-Phase Interface Construction. After all independent sub-loading chambers are filled with temperature-controlled phase change composite powder to the preset height, the mechanical vibration platform is stopped. The thin-walled metal baffle fixture is pulled out vertically upwards at a uniform speed. Under the action of gravity and residual lateral pressure, the temperature-controlled phase change composite powder in adjacent discrete filling areas undergoes microscopic interlocking, forming a continuous powder bed without macroscopic physical gaps. To improve the density of the solid-phase contact interface and eliminate residual air in the gaps between powder particles, the exhaust port of the fluidized bed mold module is connected to a vacuum pump. The vacuum pump is started to evacuate the sealed cavity of the fluidized bed mold module. The exhaust of air eliminates the interfacial gas phase thermal resistance, forcing the temperature-controlled phase change composite powder particles to adhere tightly to the outer surface and inner flow channel surface of the additive manufacturing high-temperature alloy component under the action of atmospheric pressure difference, completing the construction of a dense solid-phase heat transfer contact interface.

[0052] Step S300 aims to achieve passive and precise temperature control of multiple spatial regions in additively manufactured high-temperature alloy components by utilizing the intrinsic physical phase transformation mechanism of the material. Specifically, it includes the following execution steps: Step S301: Inject static heat transfer atmosphere. Before starting the alternating magnetic field generating module, static inert gas is injected into the sealed cavity of the fluidized bed confinement mold module via the inert gas fluidization control module. The absolute pressure inside the sealed cavity is controlled to be greater than the external standard atmospheric pressure. The injection of static inert gas aims to fill the pores formed by the contact between the temperature-controlled phase change composite powder particles with gas molecules. The gas molecules in the pores provide a gas-phase heat conduction path, improving the macroscopic effective thermal conductivity of the temperature-controlled phase change composite powder bed and promoting heat transfer to the additively manufactured high-temperature alloy component. The slightly positive pressure environment simultaneously prevents surface oxidation of the additively manufactured high-temperature alloy component under heat treatment conditions.

[0053] Step S302: Initiate alternating magnetic field and volumetric heating. The alternating magnetic field generating module is activated, applying a globally distributed alternating magnetic field to the temperature-controlled phase change composite powder bed inside the fluidized bed confinement mold module. To cut off the eddy current heating effect and ensure the effectiveness of the subsequent phase change cutoff mechanism, the frequency of the alternating magnetic field output by the alternating magnetic field generating module is configured such that the electromagnetic skin depth of the alternating magnetic field is greater than the median particle size of the magnetically induced powder. Under these limiting conditions, the alternating magnetic field completely penetrates the magnetically induced powder, and no macroscopic eddy currents are generated inside the magnetically induced powder. Hysteresis loss becomes the only heat source inside the temperature-controlled phase change composite powder bed.

[0054] Magnetic media induction powder under a slightly positive pressure static environment absorbs the electromagnetic energy of an alternating magnetic field and generates heat energy. The rate of internal heat source generation per unit volume of powder... Determined based on the formula: In the formula, Represents the vacuum permeability. Represents the effect of local temperature The relative permeability of the powder induced by the changing magnetic medium Represents the frequency of the alternating magnetic field. The magnetic field strength represents the alternating magnetic field. This represents the imaginary component of the magnetic susceptibility of the magnetically inductive powder under the action of an alternating magnetic field. Thermal energy is conducted to the additively manufactured high-temperature alloy component through the thermally conductive and insulating ceramic powder and the static inert gas within the pores, causing the local temperature of multiple discrete filling regions around the additively manufactured high-temperature alloy component to rise synchronously.

[0055] Step S303, Curie point adaptive phase transition blocking. As the volumetric heating process continues, when the local temperature of a certain discrete filling region rises to the Curie temperature of the magnetic medium induction powder disposed in the corresponding discrete filling region, the magnetic medium induction powder in the corresponding discrete filling region undergoes a physical transition from a ferromagnetic phase to a paramagnetic phase. After the physical transition, the relative permeability of the magnetic medium induction powder abruptly decreases and approaches the value of 1. According to the internal heat source generation rate formula, the internal heat source generation rate synchronously decreases to zero, and the heating behavior in the corresponding discrete filling region is physically blocked.

[0056] Step S304: Dynamic Thermal Equilibrium and Zoned Residence. After the physical interruption of the heating behavior, the discrete filling region dissipates heat to the external environment and to the lower-temperature geometric parts inside the additively manufactured high-temperature alloy component, resulting in a decrease in the local temperature of the discrete filling region. When the local temperature drops below the Curie temperature, the magnetic medium induction powder restores its ferromagnetic phase physical properties, its relative permeability increases, it reabsorbs alternating magnetic field energy, and resumes heating. Through the phase transition cycle of the magnetic medium induction powder near the Curie temperature, the induction heating power and dissipation power of the discrete filling region spontaneously form a dynamic thermal equilibrium. Multiple discrete filling regions inside the fluidized bed mold module independently enter the phase transition cycle state at different time points according to the pre-configured Curie temperature differences, completing the adaptive heat preservation residence of the additively manufactured high-temperature alloy component in multiple temperature gradient fields.

[0057] The purpose of step S400 is to cut off the heat source input inside the system and change the solid-state deposition structure of the temperature-controlled phase change composite powder bed, transforming it into a dynamic convection heat transfer medium to complete the in-situ cooling of the additively manufactured high-temperature alloy components. Specifically, it includes the following execution steps: Step S401: Heat source cutoff and variable temperature fluidization triggering. After the additively manufactured high-temperature alloy component has undergone a preset heat preservation dwell time, the system processing terminal sends a shutdown command to the alternating magnetic field generating module, cutting off the power input to the high-frequency induction coil. The system processing terminal activates the inert gas fluidization control module. The system processing terminal connects the internal heating circuit of the gas preheater, so that the inert gas output from the high-pressure inert gas source is heated to the preset initial buffer temperature when flowing through the gas preheater. The inert gas with the initial buffer temperature is injected into the powder loading area of ​​the mold body through the inlet pressure stabilizing chamber and the porous gas distribution plate.

[0058] Step S402: Phase change from solid-state fixed bed to dynamic fluidized bed. The system processing terminal adjusts the valve opening of the mass flow controller to increase the flow rate of inert gas entering the mold body. The inert gas passes through the temperature-controlled phase change composite powder bed from bottom to top in the powder loading zone. The gas pressure drop across the temperature-controlled phase change composite powder bed increases with the increase of the apparent gas velocity of the inert gas. When the apparent gas velocity of the inert gas reaches the critical fluidization velocity of the temperature-controlled phase change composite powder bed, the gas pressure drop across the temperature-controlled phase change composite powder bed and the effective gravity per unit area of ​​the temperature-controlled phase change composite powder bed reach a state of mechanical equilibrium. The mechanical equilibrium state satisfies the following equation: In the equation, This represents the gas pressure drop across the temperature-controlled phase change composite powder bed under fluidized state. This represents the bed height of the temperature-controlled phase change composite powder bed when it reaches the critical fluidization state. This represents the porosity of the powder bed under critical fluidization conditions. The effective density of microparticles representing temperature-controlled phase change composite powder. Represents the density of inert gases. It represents gravitational acceleration.

[0059] After breaking through the mechanical equilibrium state, the temperature-controlled phase change composite powder bed undergoes volume expansion, and the powder particles lose their fixed spatial geometric position constraints, entering a suspended remixing state under the drag force of the inert gas.

[0060] Step S403: In-situ conformal rapid cooling and closed-loop heat transfer control. After entering the fluidized state, the suspended and tumbling temperature-controlled phase change composite powder particles collide and displace the outer surface and internal conformal flow channel surface of the additively manufactured high-temperature alloy component. The powder particles absorb heat conducted from the interior of the additively manufactured high-temperature alloy component upon contact with its surface, and transfer the heat to the surrounding inert gas medium after detaching from the component surface. The system processing terminal reduces the output power of the gas preheater according to the preset cooling rate curve until the gas preheater is completely shut off. The inert gas fluidization control module injects room-temperature inert gas into the mold body.

[0061] After absorbing heat, the high-temperature inert gas, carrying fine powder, flows upward and enters the gas-solid separation component through the exhaust port on the sealed top cover. The gas-solid separation component intercepts the fine powder, and the separated high-temperature inert gas is introduced into the external heat exchange component. The heat exchange component cools the high-temperature inert gas to room temperature through circulating cooling water in the pipeline. The cooled room-temperature inert gas is then pumped back into the high-pressure inert gas source by a gas compressor, forming a closed-loop cooling circulation loop for the inert gas. The fluidized temperature-controlled phase change composite powder bed maintains a dynamic convective heat transfer process inside the mold body until the temperature of the additively manufactured high-temperature alloy component drops below the set furnace exit temperature boundary.

[0062] The purpose of step S500 is to safely terminate the gas-solid fluidization heat transfer process, physically separate the cooled additively manufactured high-temperature alloy component from the temperature-controlled phase change composite powder, and restore the adaptive zoned heat treatment system to standby mode. Specifically, it includes the following execution steps: Step S501, Fluidization Termination and Media Deposition. When the temperature sensor detects that the surface temperature of the additively manufactured high-temperature alloy component has dropped below the set anti-oxidation safety temperature threshold, the system processing terminal sends a shutdown command to the inert gas fluidization control module. The mass flow controller inside the inert gas fluidization control module adjusts the input flow rate of the inert gas to zero. The upward airflow drag inside the mold body disappears. The temperature-controlled phase change composite powder settles downward under the action of gravity, and is redeposited from a suspended fluidized state into a static fixed bed structure supported above the porous gas distribution plate.

[0063] Step S502: Gravity unloading and initial separation of powder. The system processing terminal sends an opening command to the high-temperature unloading valve located below the inlet pressure regulating chamber. The valve core of the high-temperature unloading valve rotates to the connected state. The temperature-controlled phase change composite powder deposited inside the powder loading area flows downward through the discharge channel under gravity and is discharged into the externally configured powder recovery container. As the powder level in the inner cavity of the mold body decreases, the outer surface of the additive manufacturing high-temperature alloy component loses its powder coating and is exposed inside the mold body.

[0064] Step S503: Powder evacuation and physical stripping from the internal flow channel. For the temperature-controlled phase change composite powder retained in the topological pores and conformal cooling channels of the additive manufacturing high-temperature alloy component, the system processing terminal controls the mechanical vibration platform to activate a low-frequency sweep vibration mode. The mechanical vibration platform inputs continuously varying mechanical vibration waves into the additive manufacturing high-temperature alloy component. The frequency of the mechanical vibration waves covers the resonant frequency range of the temperature-controlled phase change composite powder particles, and the mechanical vibration energy disrupts the mechanical self-locking structure of the powder particles inside the conformal cooling channel. Simultaneously, the operating equipment lowers and presses the sealing and purging fixture against the air inlet port of the conformal cooling channel of the additive manufacturing high-temperature alloy component. The system processing terminal activates the auxiliary high-pressure air source connected to the sealing and purging fixture. The auxiliary high-pressure air source forcibly injects pulsed airflow into the conformal cooling channel through the sealing and purging fixture. Because the sealing and purging fixture blocks the external bypass airflow, the pulsed airflow can only pass through the conformal cooling channel. Pulsed airflow, combined with mechanical vibration waves, blows the temperature-controlled phase change composite powder trapped inside the conformal cooling channel downwards. The blown-out temperature-controlled phase change composite powder falls into the discharge channel through the leakage channel on the porous gas distribution plate and is collected in the powder recovery container.

[0065] Step S504: Component Removal and System Reset. After the temperature-controlled phase change composite powder is vented, the system processing terminal shuts down the mechanical vibration platform and auxiliary high-pressure gas source. The operating equipment removes the sealing docking purging fixture. The flange locking structure between the sealing top cover and the mold body end face is released, and the sealing top cover is removed. The operating equipment enters the inner cavity of the mold body, removes the additive manufacturing high-temperature alloy component from the porous gas distribution plate, and removes it from the fluidized bed mold module. The system processing terminal controls the high-temperature unloading valve to reset to the closed state, completing the single heat treatment operation process.

[0066] The adaptive zoned heat treatment system relies on the physical coupling of electromagnetic and temperature fields to establish microscopic temperature control logic. An alternating magnetic field generating module outputs an alternating magnetic field to the working space. This alternating magnetic field penetrates the temperature-controlled phase-change composite powder bed inside the fluidized bed mold module. Within the range below the Curie temperature, the magnetically induced powder inside the temperature-controlled phase-change composite powder bed is in a ferromagnetic phase. The magnetic domains within the magnetically induced powder undergo periodic flipping under the influence of the alternating magnetic field, generating hysteresis loss. This hysteresis loss converts electromagnetic energy into heat energy.

[0067] The three-dimensional transient heat transfer process inside the temperature-controlled phase change composite powder bed follows the electromagnetic-thermal coupling control equation: In the equation, The macroscopic bulk density representing the temperature-controlled phase change composite powder bed. The equivalent specific heat capacity of the temperature-controlled phase change composite powder bed. This represents the heating time. Represents the spatial gradient operator. The effective thermal conductivity of the temperature-controlled phase change composite powder bed under static inert gas injection conditions. This represents the rate of internal heat source generation per unit volume of powder under the influence of an alternating magnetic field.

[0068] Based on the coupled control equations, the internal heat source generation rate Drive local temperature Rising. Local temperature. The increase in temperature has a reverse effect on the relative permeability of the magnetic medium-induced powder. When the local temperature... Below the preset Curie temperature, the relative permeability remains at a high value, and the internal heat source generation rate... Maintain within the heating power range.

[0069] When the local temperature Upon crossing the Curie temperature node, the crystal lattice of the magnetically inductive powder remains unchanged, but its macroscopic magnetism transforms from a ferromagnetic phase to a paramagnetic phase. Accompanying this transformation, the relative permeability undergoes a step-like decay, approaching a value of 1. The penetration depth of the alternating magnetic field within the magnetically inductive powder is controlled by the electromagnetic skin effect, and the electromagnetic skin depth is inversely proportional to the square root of the relative permeability. The step-like decay of the relative permeability causes a sudden increase in the electromagnetic skin depth of the alternating magnetic field within the magnetically inductive powder. Since the median particle size of the magnetically inductive powder is strictly defined below this increased electromagnetic skin depth, the alternating magnetic field completely penetrates the powder particles, thus cutting off the eddy current loss heating path at a physical level.

[0070] The heating path of eddy current loss is cut off, and at the same time, hysteresis loss disappears due to the paramagnetic phase transition, reducing the internal heat source generation rate. The rate of synchronous decline and approaching zero. Internal heat source generation rate. The physical blockage terminates the heat accumulation process. Due to continuous heat dissipation within the additively manufactured high-temperature alloy components and the external environment of the fluidized bed mold module, the local temperature... A decline occurred. Local temperature. After falling below the Curie temperature node, the spontaneous magnetization exchange of magnetic domains within the magnetically induced powder resumes, and the relative permeability rebounds. This rebound in relative permeability increases the rate of internal heat source generation. Increase to replenish the dissipated heat.

[0071] Internal heat source generation rate A dynamic equilibrium network is formed with the heat dissipation rate near the Curie temperature node. The dynamic equilibrium network, based on the phase transition properties of magnetically induced powder, sets the temperature control execution terminal at the microscopic powder particle level, avoiding the spatial resolution limitations and heat conduction time lag problems of macroscopic temperature sensing elements, and ensuring accurate adaptive truncation of complex topologies at the boundaries of different temperature zones.

[0072] The adaptive zoned heat treatment system achieves a physical switching of heat transfer modes by altering the aerodynamic and hydrodynamic boundary conditions of the temperature-controlled phase change composite powder bed. During the heat preservation and residence phase, the temperature-controlled phase change composite powder bed is in a static stacking state. In this static stacking state, the heat transfer mechanism is mainly through contact heat conduction between solid particles. The heat dissipated by the additively manufactured high-temperature alloy components creates a spatial temperature gradient within the static powder bed.

[0073] After introducing an inert gas to transform the temperature-controlled phase change composite powder bed into a gas-solid fluidized state, the heat transfer mechanism abruptly changes to gas-solid two-way convective heat transfer. During single-phase gas forced air cooling, a stagnant gas thermal boundary layer adheres to the surface of the additively manufactured high-temperature alloy component. This gas thermal boundary layer provides thermal resistance, hindering heat dissipation. In the gas-solid fluidized state, the solid powder particles inside the temperature-controlled phase change composite powder bed, carried by the airflow, penetrate and disrupt the gas thermal boundary layer on the surface of the additively manufactured high-temperature alloy component. The specific heat capacity and density of the solid powder particles are greater than those of the inert gas. During the contact time with the surface of the additively manufactured high-temperature alloy component, the solid powder particles absorb the sensible surface heat conducted by the surface. After absorbing heat, the solid powder particles rebound and are re-entered into the mainstream region of the powder bed, releasing the heat they carry to the inert gas. Based on the heat stripping mechanism of micro-particle group replacement, the surface heat transfer coefficient of the gas-solid fluidized state exceeds that of simple gas convection heat transfer, meeting the quenching metallurgical requirements of high-temperature alloy materials.

[0074] To meet the cooling rate requirements of the strengthening phase precipitation kinetics in high-temperature alloy materials, the transition process of the temperature-controlled phase change composite powder bed from a static insulating state to a dynamic quenching state is configured with strict time boundary parameters. The system's terminal control mass flow controller valve action ensures that the time it takes for the apparent velocity of the inert gas injected into the mold body to jump from zero to the critical fluidization velocity is less than the incubation time threshold corresponding to the nose temperature of the strengthening phase precipitation in the additively manufactured high-temperature alloy component. This time-response control constraint allows the temperature-controlled phase change composite powder bed to complete the fluidization kinetic phase transition within a limited time window, preventing unexpected microstructural transformations in the additively manufactured high-temperature alloy component during the slow cooling range.

[0075] For additively manufactured high-temperature alloy components with complex topological structures and conformal flow channels, a fluidized, temperature-controlled phase-change composite powder bed exhibits pseudo-fluid physical properties. Suspended micro-particle clusters flow into and traverse the tortuous flow channels within the additively manufactured high-temperature alloy component. The back-mixing motion of particle bubbles leads to a spatially uniform powder environment temperature within the mold cavity. This spatial uniformity of the powder environment temperature eliminates the cooling rate difference between thick-walled and thin-walled regions of the additively manufactured high-temperature alloy component. The pseudo-fluid homogenization effect avoids the quenching thermal stress induced by localized air cooling within the additively manufactured high-temperature alloy component, preventing plastic deformation during the cooling stage.

[0076] For the internal inverter control circuit topology of the programmable power supply, the underlying communication protocol configuration of the system processing terminal and the programmable logic controller, the internal flow channel structure size calculation of the gas-solid separation component, and the mechanical structure control of the high-temperature unloading valve involved in all embodiments of the present invention, those skilled in the art can consult standard industrial control manuals and chemical equipment design specifications for conventional engineering implementation. The underlying circuits, basic fluid calculation equations and standard control code logic of the above hardware are all well-known technologies in the field and will not be described in detail here.

[0077] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An adaptive zoned heat treatment system for additive manufacturing high-temperature alloy components, characterized in that, include: The fluidized bed mold module includes a mold body, a porous gas distribution plate located at the bottom of the mold body, and a sealed top cover, forming a closed cavity inside for accommodating additive manufacturing high-temperature alloy components and temperature-controlled phase change composite powder. An alternating magnetic field generating module includes a high-frequency induction coil surrounding the fluidized confinement mold module and a programmable power supply electrically connected to the high-frequency induction coil. The inert gas fluidization control module is located outside the mold body and is in gas path communication with the air inlet pressure stabilizing chamber below the porous gas distribution plate. It includes a high-pressure inert gas source, a mass flow controller, and a gas preheater, heat exchange components and gas compressor integrated on the pipeline. External auxiliary separation components include a mechanical excitation platform connected to the bottom of the fluidized confinement mold module, a vacuum pump connected to the exhaust port, and a locally configured sealing docking purging fixture and auxiliary high-pressure gas source; The system processing terminal is electrically connected to the alternating magnetic field generating module, the inert gas fluidization control module, and various external actuators.

2. An adaptive zoned heat treatment method for additively manufactured high-temperature alloy components, characterized in that, Based on the adaptive partitioned heat treatment system as described in claim 1, the following steps are included: Geometric model parameters and initial microstructure distribution data of additively manufactured high-temperature alloy components are obtained, target heat treatment temperature fields for each geometric part are set, and the embedded space outside the additively manufactured high-temperature alloy components is discretized into multiple filling regions. For each filling region, magnetic medium induction powder with a Curie temperature equal to the corresponding target heat treatment temperature is selected and mixed with thermally conductive and insulating ceramic powder to prepare multiple sets of temperature-controlled phase change composite powders. Multiple sets of temperature-controlled phase change composite powders are filled into the corresponding spatial positions around the additive manufacturing high-temperature alloy component placed in the fluidized confinement mold module, completely adhering to the outer surface contour of the additive manufacturing high-temperature alloy component and penetrating into the inner cavity channel to form a dense static solid phase heat transfer contact interface. The alternating magnetic field generating module is activated to apply a globally distributed alternating magnetic field. Multiple sets of temperature-controlled phase change composite powders are kept in a static fixed bed state under the action of gravity. The magnetic medium induction powder generates hysteresis loss heat inside. When the local temperature rises to the Curie temperature of the magnetic medium induction powder, the magnetic medium induction powder in the corresponding filling area undergoes an intrinsic physical transformation from ferromagnetic phase to paramagnetic phase. The relative permeability decreases abruptly, the heating behavior is physically blocked, and the heat preservation and residence stage begins. After a preset heat preservation and residence time, the power output of the alternating magnetic field generating module is cut off, and the inert gas fluidization control module is turned on simultaneously to introduce inert gas. By adjusting the apparent flow rate of the gas entering the temperature-controlled phase change composite powder to be greater than the critical fluidization rate, the temperature-controlled phase change composite powder changes from a static fixed bed to a dynamic fluidized bed of particle mixing. The heat transfer mechanism at the medium interface is transformed into gas-solid two-phase convective heat transfer, realizing in-situ conformal rapid cooling. After the temperature drops to the furnace exit temperature range, the inert gas fluidization control module is turned off, and the temperature-controlled phase change composite powder is redeposited into a static state. The temperature-controlled phase change composite powder is then released, and the additively manufactured high-temperature alloy component is removed from the fluidization constraint mold module.

3. The adaptive partitioned heat treatment method for additive manufacturing high-temperature alloy components according to claim 2, characterized in that, The process of setting the target heat treatment temperature field and preparing multiple sets of temperature-controlled phase change composite powders specifically includes: The system processing terminal sets a first target heat treatment temperature for geometric parts with grain size greater than a preset grain threshold and residual stress greater than a preset stress threshold, based on a mapping database containing the correspondence between residual stress value, grain size value and target heat treatment temperature value; and sets a second target heat treatment temperature for geometric parts with grain size less than a preset grain threshold and residual stress less than a preset stress threshold. Adjacent discrete filling regions where the temperature difference between two corresponding target heat treatment regions exceeds a safety threshold are identified. A spatial volume transition region is inserted between the two adjacent discrete filling regions. The transition temperature node is calculated using a linear interpolation algorithm according to the spatial distance ratio. A transition state temperature-controlled phase change composite powder for filling the spatial volume transition region is prepared by combining magnetic medium induction powder with thermally conductive and insulating ceramic powder with a Curie temperature value equal to the transition temperature node.

4. The adaptive partitioned heat treatment method for additively manufactured high-temperature alloy components according to claim 2, characterized in that, In temperature-controlled phase change composite powders: To completely block the three-dimensional overlapping network of conductive particles based on permeation theory, the volume percentage of thermally conductive insulating ceramic powder was configured in the range of 65% to 85%, and the volume percentage of magnetic medium induction powder was configured in the range of 15% to 35%. The median particle size parameters of the thermally conductive insulating ceramic powder and the magnetically inductive powder are configured to be on the same order of magnitude and both are defined in the range of 20 μm to 150 μm.

5. The adaptive partitioned heat treatment method for additive manufacturing high-temperature alloy components according to claim 2, characterized in that, The process of filling multiple sets of temperature-controlled phase change composite powders into corresponding spatial positions around additively manufactured high-temperature alloy components and forming static solid-phase heat transfer contact interfaces specifically includes: A thin-walled metal baffle tooling is inserted into the inner cavity of the fluidized confinement mold module, physically dividing it into multiple independent sub-loading chambers corresponding to the filling area; During the stage of injecting the corresponding temperature-controlled phase change composite powder into each independent sub-loading chamber, the mechanical excitation platform is simultaneously activated to apply high-frequency, low-amplitude vibration in the vertical direction. After filling to the preset height, stop the vibration and pull out the thin-walled metal baffle tooling vertically upward at a uniform speed; start the vacuum pump equipment to perform vacuuming operation, forcing the temperature-controlled phase change composite powder particles to adhere tightly to the outer surface and inner flow channel surface of the additive manufacturing high-temperature alloy component under the action of atmospheric pressure difference.

6. The adaptive partitioned heat treatment method for additive manufacturing high-temperature alloy components according to claim 2, characterized in that, Before activating the alternating magnetic field generating module and during the application of the globally distributed alternating magnetic field: Static inert gas is injected into the sealed cavity of the fluidized confinement mold module to control the absolute pressure inside the sealed cavity to be greater than the external standard atmospheric pressure, so that gas molecules fill the pores of the powder particles. The frequency of the alternating magnetic field output by the alternating magnetic field generating module is configured such that the electromagnetic skin depth of the alternating magnetic field is greater than the median particle size of the magnetic medium induction powder, so that the alternating magnetic field completely penetrates the magnetic medium induction powder and cuts off the eddy current loss heating path.

7. The adaptive partitioned heat treatment method for additive manufacturing high-temperature alloy components according to claim 2, characterized in that, The dynamic heat balance mechanism of heat generation and dissipation after entering the heat preservation and residence stage is as follows: After the physical blocking of the heating behavior, the local temperature of the discrete filling area drops slightly; when the local temperature falls below the Curie temperature, the magnetic medium induction powder restores the ferromagnetic phase physical properties, the relative permeability increases, it reabsorbs the energy of the alternating magnetic field and resumes heating; through the phase change cycle of the magnetic medium induction powder near the Curie temperature, the induction heating power and the dissipation power spontaneously form a dynamic thermal equilibrium.

8. The adaptive partitioned heat treatment method for additive manufacturing high-temperature alloy components according to claim 2, characterized in that, During the in-situ conformal rapid cooling execution phase: The gas preheater heats the inert gas output from the high-pressure inert gas source to a preset initial buffer temperature, and then injects it into the fluidized confinement mold module; When the apparent velocity of the inert gas reaches the critical fluidization velocity of the temperature-controlled phase change composite powder bed, the gas pressure drop at both ends of the temperature-controlled phase change composite powder bed and the effective gravity per unit area of ​​the temperature-controlled phase change composite powder bed reach a mechanical equilibrium state. After breaking through the mechanical equilibrium state, the temperature-controlled phase change composite powder bed undergoes volume expansion and enters a suspension and remixing state under the drag force of the inert gas. Furthermore, the time it takes for the apparent velocity of the injected inert gas to jump from zero to the critical fluidization velocity is less than the incubation time threshold corresponding to the nose temperature of the strengthening phase precipitation in additively manufactured high-temperature alloy components.

9. The adaptive partitioned heat treatment method for additive manufacturing high-temperature alloy components according to claim 8, characterized in that, The closed-loop heat transfer control process after entering the fluidized state specifically includes: The system processing terminal reduces the output power of the gas preheater until it is completely shut down according to the preset cooling rate curve, and injects room temperature inert gas into the mold body; After absorbing heat, the high-temperature inert gas carries fine powder upwards. The fine powder is intercepted by the gas-solid separation component, and the separated high-temperature inert gas is introduced into the heat exchange component to be reduced to room temperature. The cooled room-temperature inert gas is pumped back into the high-pressure inert gas source by the gas compressor, forming a closed-loop cooling cycle for the inert gas.

10. The adaptive partitioned heat treatment method for additive manufacturing high-temperature alloy components according to claim 2, characterized in that, The physical stripping and evacuation steps for releasing the temperature-controlled phase change composite powder include: Open the high-temperature discharge valve located below the air intake pressure regulating chamber, and the internally deposited temperature-controlled phase change composite powder will be discharged downward through the discharge channel under the action of gravity; The operating equipment presses the sealing and purging fixture onto the air inlet port of the conformal cooling channel of the additively manufactured high-temperature alloy component; the system processing terminal controls the mechanical excitation platform to start the low-frequency sweep frequency excitation mode and input continuously changing mechanical vibration waves, and simultaneously starts the auxiliary high-pressure air source, forcibly injecting pulse airflow into the conformal cooling channel through the sealing and purging fixture; the pulse airflow blocks the external bypass airflow and, in conjunction with the mechanical vibration waves, blows out and collects the temperature-controlled phase change composite powder trapped inside the conformal cooling channel.

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