CN105026075B - 针对高温延展性和应力断裂寿命的增材制造 - Google Patents

针对高温延展性和应力断裂寿命的增材制造 Download PDF

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CN105026075B
CN105026075B CN201380072059.5A CN201380072059A CN105026075B CN 105026075 B CN105026075 B CN 105026075B CN 201380072059 A CN201380072059 A CN 201380072059A CN 105026075 B CN105026075 B CN 105026075B
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D.E.马特茨克
C.L.斯文格勒
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Aerojet Rocketdyne of DE Inc
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Abstract

一种制造过程，包括对部件进行增材制造；以及在所述部件的晶界处析出碳化物。

Description

针对高温延展性和应力断裂寿命的增材制造
背景技术
本公开要求2013年2月1日提交的美国临时专利公开序号61/759,886的优先权。
本公开一般涉及增材制造（additive manufacturing）的系统和过程。
增材制造过程使用3D CAD数据作为数字信息源并使用例如高功率激光束的能量源以通过熔合微细金属粉末来形成三维金属零部件。与锻造合金相比，当增材制造时一些合金可具有不同的特性。
附图说明
通过对公开的非限制性实施例的以下详细描述，对于本领域技术人员来说，各种特征将变得明显。伴随详细描述的附图能够简要描述如下：
图1是根据一个公开的非限制性实施例的增材制造系统的一般示意图；
图2是针对经由图3的过程制造的SLM-625和锻造合金625部件的容许拉伸延伸率的图示；
图3是根据一个公开的非限制性实施例的针对高温延展性和应力断裂寿命的增材制造过程；
图4是根据另一个公开的非限制性实施例的针对高温延展性和应力断裂寿命的增材制造过程；
图5是根据另一个公开的非限制性实施例的针对高温延展性和应力断裂寿命的增材制造过程；以及
图6是用于与图5的过程一起使用的增材制造系统的一般示意图。
具体实施方式
图1示意性地图示了增材制造系统20。系统20一般包括具有粉末床（powder bed）24的构建室22、例如激光器的一个或多个能量源26以及控制装置28（全部示意性地图示）。应当理解的是，如本文所限定的，“增材制造”系统包括但不限于选择性激光熔化（SLM）、粉末床电子束熔化（EBM）、电子束自由形式制造（EBF3）、激光近净成形（LENS）等。还应当理解的是，可附加地或替代性地提供各种部件和子系统。
增材制造系统20通过连续地熔化雾化合金粉末材料的2D层来构建部件，以创建CAD文件所限定的3D固体。可使用各种金属粉末，包括铁、镍、钴、钛或铝基的合金。合金625、合金718和合金230可被用于在高温环境中操作的部件，例如典型的航空航天部件和燃气涡轮发动机部件。
然而，已发现由特定合金构成的增材制造部件，例如由合金625增材制造的那些部件（本文中称为“SLM-625”），与相对应的锻造合金625相比固有地带有具有相对低的高温延展性的产出材料属性，即使当在其上执行例如应力消除、热等静压和固溶热处理（solutionheat treat）的传统热处理过程时也是如此。例如，与在1400F下高于~50%以及在1700F下高于~70%的锻造合金625的拉伸延展率对比，测试的SLM-625样品具有如下拉伸延伸率，即：在1400F下≤15%以及在1700F下≤10%（图2）。与锻造合金625相比应力断裂寿命也是相对低的。申请人已确定，一个潜在的根本原因是由于与当前的增材处理和热处理有关的独特特征引起的相对于锻造合金625的SLM-625中较弱的晶界（grain boundaries）。如当前所处理的，SLM-625的晶界不具有加强锻造合金625的晶界的碳化物。
参照图3，在一个公开的非限制性实施例中，通过过程100来增加增材制造的部件（步骤102）的高温延展性和应力断裂寿命，所述过程100经由在完成用于增材制造的部件的当前的常规热处理步骤（步骤104、106和108）之后执行的附加的热处理步骤110，来在晶界处析出（precipitate）碳化物。通常，后构建热处理是增材制造过程的组成部分。需要应力消除（步骤104）以最小化由构建周期期间产生的残余应力引起的变形，从而维持尺寸完整性。热等静压（步骤106）封闭制造的部分中的残余孔隙，并且固溶处理（步骤108）为大部分后续的制造和处理步骤提供理想的微结构。
在附加的热处理步骤（步骤110）的一个示例中，将合金625的常规处理的增材制造的部件加热至1450F并保持在1450F持续大约10小时会在晶界处析出期望的碳化物。
参照图4，在另一个公开的非限制性实施例中，可以替代性地或附加地通过过程200来增加增材制造的部件的高温延展性和应力断裂寿命，所述过程200在增材制造过程（步骤202）期间使用碳含量增加的合金粉末，例如具有超过大约0.02%的碳的合金粉末，并且在一个公开的非限制性实施例中，合金粉末具有在大约0.03%至大约0.04%之间的碳。就是说，部件的特定构建层或整体可使用碳含量增加的雾化合金粉末材料。然后，可在先前经过应力消除、热等静压和固溶热处理的部件（步骤204-208）上可选地执行图2的进一步的后处理热处理过程（步骤210）。
参照图5，在另一个公开的非限制性实施例中，可以替代性地或附加地经由通过在含有富碳物种（例如，烃类气体）的环境中熔化而使构建材料就地渗碳，来增加增材制造的部件的高温延展性和应力断裂寿命（步骤302）。就是说，注入系统30（示意性地图示；图6）操作来在增材制造过程期间维持构建室22中的渗碳环境。渗碳气体可在特定层或所有层的构建期间注入。此外，渗碳气体的注入可以可选地单独使用或与图2的后处理热处理过程（步骤310）和/或碳含量增加的合金粉末（图3）结合使用。
在描述的语境下（尤其是在以下权利要求的语境下）用语“一”、“一个”、“一种”和“所述”的使用以及类似引用应被解释为覆盖单数和复数两者，除非本文另有指示或者明确与上下文矛盾。与数量一起使用的修饰语“大约”包括陈述的值并且具有上下文指定的含义（例如，它包括与特定数量的测量相关联的误差的程度）。本文公开的所有范围都包括端点，并且这些端点可独立地彼此结合。应当理解的是，相对位置用语，例如“前”、“后”、“上”、“下”、“上方”、“下方”等，都参考设备的正常操作姿态，并且不应被认为在其他方面是限制性的。
尽管不同的非限制性实施例具有特定的图示部件，但本发明的实施例不限于那些特定组合。来自非限制性实施例中的任何实施例的部件或特征中的一些可与来自其他非限制性实施例中的任何实施例的特征或部件结合使用。
应当理解的是，贯穿这几个附图，相同的附图标记标识相对应或相似的元件。还应当理解的是，尽管图示实施例中公开了特定的部件布置，但其他布置将获益于此。
尽管示出、描述和要求了特定的步骤序列，但应理解的是，步骤可单独地或结合地按任何顺序执行，除非另有指示，并且仍将获益于本公开。
前述描述是示例性的而非受其中的限制限定。本文公开了各种非限制性实施例，但是，本领域技术人员将认识到，鉴于以上教导的各种修改和变型将落入所附权利要求的范围内。因此，应当理解的是，在所附权利要求的范围内，可按不同于具体描述的方式实践本公开。因此，应当研究所附权利要求以确定真实的范围和内容。

Claims (5)

1.一种热处理过程，包括：
给利用增材制造过程产生的部件提供应力消除、热等静压和固溶热处理，其中增材制造过程是选择性激光熔化；以及
利用附加的热处理过程在固溶热处理之后在已热处理的部件的晶界处析出碳化物。
2.如权利要求1所述的过程，还包括：
在所述部件的增材制造过程期间，将渗碳气体注入到构建室中。
3.如权利要求1或2所述的过程，还包括：
在所述增材制造过程期间，利用碳含量超过0.02%的合金粉末来增材制造所述部件。
4.一种增材制造系统，包括：
构建室；以及
渗碳气体注入系统，其在增材制造过程期间将渗碳气体注入到所述构建室中，其中所述增材制造系统适于将应力消除、热等静压和固溶热处理提供给由作为选择性激光熔化的增材制造过程产生的部件并且适于利用附加的热处理过程在固溶热处理之后在已热处理的部件的晶界处析出碳化物。
5.如权利要求4所述的系统，其特征在于，所述构建室包括具有碳含量超过0.02%的合金粉末的粉末床。
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