CN105088119B - 由γ’强化超合金制成的增材制造组件的构建后热处理方法 - Google Patents
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Abstract
本发明涉及增材制造的高强度组件的构建后热处理方法，所述高强度组件由基于Ni或Co或Fe或它们的组合的γ'强化超合金制成。在增材制造后的第一构建后热处理期间在特定温度范围内施加20‑60℃/min的快速加热速率避免或至少最小化在加热期间组件中的γ'沉淀。相较于常规热处理组件中出现的显著裂纹，这产生无裂纹组件/制品。
Description
技术领域
本发明涉及超合金技术。它涉及组件的构建后(post-built)热处理方法，所述组件由γ'强化超合金制成并通过增材制造(additive manufacturing)技术(例如通过选择性激光熔融(SLM))构建。使用本公开内容的方法可避免组件中(例如涡轮部件中)显著的裂纹例如应变老化裂化。
背景技术
已知高强度镍、钴或铁基超合金(例如具有另外元素如铝和钛的镍基超合金)因为材料中高度的γ'相的沉淀硬化效应而具有其高强度特征。还已知这些超合金很难成功焊接。
SLM-产生的制品相较于相同合金的常规浇铸材料具有不同的微结构。这些过程中的高能束材料相互作用导致在SLM期间的高冷却速率和很快固化。
作为结果，合金元素的分离与沉淀的形成降低。因此，由于增材制造过程固有的快速冷却，很少至没有γ'沉淀存在于构建后的组件(由含有γ'的合金制成)中。
需要构建后热处理以调整部件的微结构和减少/消除剩余应力。在这些构建后热处理期间，γ'相在第一加热期间沉淀。但与该沉淀相关联的体积改变可导致部件中显著的裂纹(例如应变老化裂化)。当前施加的应用于SLM-加工的γ'强化超合金的热处理顺序导致显著的裂化和因此导致部件报废(rejection)。
已知使用不同的焊接前和焊接后热处理用于通过焊接连接由γ'强化超合金制成的浇铸组件或组件的部件。
US7854064 B2公开了修复涡轮部件的方法，该方法包括使用加热速率介于16-23℃/min，温度范围介于593-871℃的焊接前固溶(solutioning)热处理。在一个实施方案中提及从固溶温度到低于677℃的0.2-5℃/min的缓慢冷却速率。此外，除上述焊接前热处理之外，还描述了使用与焊接前热处理相同的加热速率的焊接后热处理。根据该文献的方法可应用于多种浇铸和锻造镍基合金，例如Waspaloy、IN738、IN792或IN939。提及电子束和钨电弧焊接作为实例方法。
虽然公开于US7854064 B2的方法具有可修复(例如实质上不存在微裂纹地焊接)由镍基超合金制成的涡轮组件的优点，但它就所述焊接前与焊接后热处理的多个步骤而言具有耗费时间和成本的缺点。
最近，申请人提交了有关不带焊接填充物的γ'强化超合金(例如IN738LC、MarM247、CM247LC、CMSX-4、MK4HC、MD2)的电子束焊接的新的专利申请(未公布)。对比US7854064，该方法不取决于特定的焊接前热处理并因此可用于修复以及用于连接新部件。为了使该方法更有效，在接近于γ'可沉淀的最终保持温度的整个温度范围内(1100℃，而非871℃)使用快速加热速率。仅在不存在其它避免裂纹的方式时，即不带焊接填装物的焊接过程，时结合使用该方法。使用可延展的焊接填充物也可有助于避免裂纹形成，但是，使用这些焊接填装物削弱了焊缝。
然而，上述文献仅涵盖连接方法(例如焊接)，因此并没有涵盖整个通过增材制造(例如通过选择性激光熔融(SLM))制成的组件。
发明内容
本发明的目的为提供用于热处理组件的有效方法，所述组件由含有γ'的超合金制成并通过增材制造技术(优选SLM)构建。相比存在于常规热处理的增材制造组件中显著的裂纹，本方法将保证可生产无裂缝的组件/制品。
附图说明
增材制造组件(由基于Ni或Co或Fe或其组合的γ'强化超合金制成)的构建后热处理方法包括以下步骤：
a)提供刚构建状态下的增材制造组件，随后
b)将所述组件从室温(RT)加热至温度T1，其中T1比热膨胀系数开始下降的温度Ts低50-100℃，随后
c)保持所述组件在T1下经时间t1以实现均匀的组件温度，随后
d)通过施加加热速率v2为至少25℃/min的快速加热将所述组件从T1加热至T2≥850℃以避免或至少降低γ'相的沉淀，随后
e)根据热处理的目的向所述组件施加进一步的时间/温度步骤。
本发明的核心是在增材制造之后的第一构建后热处理期间在特定温度范围内施加快速加热速率以最小化/避免在加热期间组件中的γ'沉淀。本方法相较于呈现显著裂纹的常规热处理的组件，有利地产生无裂纹的组件/制品。
在一个实施方案中，在步骤e)中，实施两小时的等温停留时间t2以减少剩余应力。
优选地，加热速率v2为25-60℃/min。该范围内更高的速率可通过诱导加热实现。加热速率v1(步骤b中)可优选为1-10℃/min。
在本发明的另一实施方案中，在步骤e)中，在温度T3＞T2下施加不同或另外的保持时间以进一步减少剩余应力和/或使微结构再结晶。
在压力下(例如在高温等静压(HIP)期间)实施热处理是有利的。
在一个实施方案中，将以下构建后热处理参数应用于增材制造且由IN738LC制成的组件(例如定子热屏蔽)：
T1 = 400℃
v1 = 5℃/min
t1 = 60 min
v2 = 35℃/min
T2 = 1050℃
t2 = 2h
T3 = 1200℃
t3 = 4h。
以下描述另外的实施方案。
现在使用不同的实施方案并参照附图更紧密地阐明本发明。
图1显示SLM加工的IN738LC的热膨胀系数，其取决于温度、构建方向和第一或第二加热；
图2显示SLM加工的IN738LC的热容量，其取决于温度、构建方向和第一或第二加热；
图3显示(除图1与图2之外)SLM加工的IN738LC在刚构建状态下的拉伸机械结果；
图4显示用于SLM加工的IN738LC的根据现有技术的标准热处理程序的时间-温度-图表；
图5显示用于SLM加工的IN738LC的根据本发明实施方案的时间-温度-图表。
具体实施方式
图1显示SLM加工的IN738LC的热膨胀系数，其取决于温度、构建方向和第一或第二加热。可以看到，在第一加热期间，曲线中出现了异常(起始于超过400℃)，其特征在于热膨胀系数的下降。该异常在第二加热期间不再出现并可归因于第一加热期间的γ'沉淀。热膨胀系数的异常指征了由于γ'沉淀所导致的体积收缩。
同样可见于图2，图2显示SLM加工的IN738LC的热容量，其取决于温度、构建方向和第一或第二加热。
除热-物理性质外还列出了刚构建状态下(例如没有任何热处理)的拉伸机械结果(见于图3)。
可以看到，在室温下，在刚构建状态下，IN738LC的延性相当高(～20-24%)。然而，通过在2h内将试样加热(加热速率为～7℃/min)至850℃并在15min保持时间后对其进行测试，观察到延性显著降低(从～20%到～0.2%！)。
在第一加热期间在升高的温度下固有的低延性和由于SLM加工而存在的显著量的剩余应力是显著裂化的原因。
值得一提的是，对于另一个γ'强化超合金CM247LC(于850℃在刚构建状态下测试)观察到可比的低延性。
图4显示现有技术已知的用于组件(由浇铸或锻造的IN738LC制成)的标准热处理程序(例如应力解除热处理)。将这一标准热处理施加在SLM-制造的IN738LC组件。遗憾的是，在这一热处理之后，该组件具有显著的裂纹，因此为缺陷产品。
对于通常施加在γ'强化超合金上的其它标准热处理程序获得了类似的结果。
相比之下，施加根据本发明的热处理分别导致相应的无裂纹组件。
图5显示IN738LC的根据本发明实施方案的时间-温度-图表。以相当低的加热速率v1=5℃/min和足够长以保证均匀的组件/部件温度的保持时间t1=60min将组件加热至～400℃(=T1)。随后，关键点是此时快速加热(以v2=35℃/min从400到～1050℃)穿过临界温度区域以避免/降低γ'的沉淀。
一旦超过了临界温度区域，可取决于热处理目的附加另外不同的时间/温度步骤。在根据图5的实例中，在T3=1050℃实施2小时(t3)的等温停留以减少剩余应力。可于更高的温度下增加不同或另外的保持时间以例如进一步减少剩余应力和/或使微结构再结晶。例如，以1250℃/3h或1200℃/4h处理导致再结晶。
甚至更高的加热速率可有利于比IN738LC含更高量γ'的合金(例如CM247LC和CMSX-4)。此外，也可取决于对应合金的固溶温度提高等温停留温度。
所述根据本发明的热处理必须为SLM构建之后施加的第一热处理。可将其施加在已从基盘移除的SLM组件(其构建于已有的部件上(混合构建))或仍在基盘上的SLM组件上。在后两种情况中，热处理另外通过避免由γ'的沉淀导致的延性降低而有助于避免由不同的热膨胀系数所导致的裂纹(其可在热处理期间产生另外的应力)。
此外，值得一提的是也可在压力下(例如在具有另外益处的高温等静压(HIP)期间)实施上述热处理。
加热速率v2优选为25-60℃/min。更高的速率可通过诱导加热实现。
一旦根据本发明实施了第一热处理，可施加其它标准热处理。
当然，本发明不受限于所述实施方案。它可用于所有通过SLM加工γ'超合金的组件，例如用于服务的燃气涡轮/模块化部件中的混合部件。
Claims (6)
1.增材制造组件的构建后热处理方法，所述增材制造组件由基于Ni或Co或Fe或它们的组合的γ'强化超合金制成，所述方法包括以下步骤：
a)提供刚构建状态下的增材制造组件，随后
b)将所述组件以加热速率v1从室温(RT)加热至温度T1，其中T1比热膨胀系数开始下降的温度Ts低50-100℃，随后
c)保持所述组件在T1下经时间t1以实现均匀的组件温度，随后
d)通过施加加热速率v2为至少25℃/min的快速加热将所述组件从T1加热至T2≥850℃以避免或至少降低γ'相的沉淀，随后
e)根据热处理的目的向所述组件施加进一步的时间t2/温度T3步骤。
2.根据权利要求1所述的方法，其特征在于在步骤d)中，所述加热速率为v2=25-60℃/min。
3.根据权利要求1所述的方法，其特征在于在步骤e)中，实施2小时的等温停留时间t2以减少剩余应力。
4.根据权利要求3所述的方法，其特征在于在步骤e)中，在温度T3＞T2下施加不同或另外的保持时间以进一步减少剩余应力和/或使微结构再结晶。
5.根据权利要求1所述的方法，其特征在于在高温等静压条件下在压力下实施步骤b)-e)中的热处理。
6.根据权利要求1-2或5中任一项所述的方法，其特征在于用于增材制造且由IN738LC制成的组件的以下构建后热处理参数：
T1 = 400℃
v1 = 5℃/min
v2 = 35℃/min
T2 = 1050℃
T3 = 1120℃且t2 =2h，或T3 = 1200℃且t2 =4h，或T3 = 1250℃且t2 =3h。
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| EP2944402B1 (en) | 2014-05-12 | 2019-04-03 | Ansaldo Energia IP UK Limited | Method for post-built heat treatment of additively manufactured components made of gamma-prime strengthened superalloys |
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| DE102016203901A1 (de) | 2016-03-10 | 2017-09-14 | MTU Aero Engines AG | Verfahren und Vorrichtung zum Herstellen zumindest eines Bauteilbereichs eines Bauteils |
| JP6826821B2 (ja) * | 2016-05-12 | 2021-02-10 | 三菱重工業株式会社 | 金属部材の製造方法 |
| JP2020506090A (ja) * | 2017-02-02 | 2020-02-27 | アイメリーズ タルク アメリカ，インコーポレーテッド | ３ｄプリンティングで造形されたプラスチック部品におけるロード間の接着及び合体の改善 |
| WO2018216067A1 (ja) | 2017-05-22 | 2018-11-29 | 川崎重工業株式会社 | 高温部品及びその製造方法 |
| EP3406371A1 (en) * | 2017-05-22 | 2018-11-28 | Siemens Aktiengesellschaft | Method of relieving mechanical stress in additive manufacturing |
| CN108914029A (zh) * | 2017-06-13 | 2018-11-30 | 刘红宾 | 一种防止异种金属材料锯齿状界面开裂的方法 |
| GB201709540D0 (en) * | 2017-06-15 | 2017-08-02 | Rolls Royce Plc | Processing method |
| GB2565063B (en) | 2017-07-28 | 2020-05-27 | Oxmet Tech Limited | A nickel-based alloy |
| US10889872B2 (en) | 2017-08-02 | 2021-01-12 | Kennametal Inc. | Tool steel articles from additive manufacturing |
| WO2019099000A1 (en) * | 2017-11-15 | 2019-05-23 | Siemens Energy, Inc. | Method of repairing gamma prime strengthened superalloys |
| US11097348B2 (en) | 2017-12-08 | 2021-08-24 | General Electric Company | Structures and components having composite unit cell matrix construction |
| EP3521804A1 (en) * | 2018-02-02 | 2019-08-07 | CL Schutzrechtsverwaltungs GmbH | Device for determining at least one component parameter of a plurality of, particularly additively manufactured, components |
| GB201808824D0 (en) * | 2018-05-30 | 2018-07-11 | Rolls Royce Plc | Crack reduction for additive layer manufacturing |
| DE102018210397A1 (de) * | 2018-06-26 | 2020-01-02 | Siemens Aktiengesellschaft | Verfahren zur additiven Herstellung einer Struktur mit Kühlmittelführung, Bauteil und Vorrichtung |
| CN108994304B (zh) * | 2018-07-27 | 2019-07-26 | 中南大学 | 一种消除金属材料增材制造裂纹提高力学性能的方法 |
| US10577679B1 (en) | 2018-12-04 | 2020-03-03 | General Electric Company | Gamma prime strengthened nickel superalloy for additive manufacturing |
| US11077512B2 (en) * | 2019-02-07 | 2021-08-03 | General Electric Company | Manufactured article and method |
| US11807929B2 (en) | 2019-03-14 | 2023-11-07 | Unison Industries, Llc | Thermally stabilized nickel-cobalt materials and methods of thermally stabilizing the same |
| US11235405B2 (en) * | 2019-05-02 | 2022-02-01 | General Electric Company | Method of repairing superalloy components using phase agglomeration |
| GB2584654B (en) | 2019-06-07 | 2022-10-12 | Alloyed Ltd | A nickel-based alloy |
| GB2587635B (en) * | 2019-10-02 | 2022-11-02 | Alloyed Ltd | A Nickel-based alloy |
| CN110964992B (zh) * | 2019-11-28 | 2021-06-01 | 西安航天发动机有限公司 | 一种低温环境工作的增材制造高温合金的热处理方法 |
| CN111390180A (zh) * | 2020-04-27 | 2020-07-10 | 南京国重新金属材料研究院有限公司 | 一种提高由激光选区熔化技术制造的gh3536合金的持久性能的方法 |
| CN112828310B (zh) * | 2020-12-31 | 2023-01-24 | 湖北三江航天红阳机电有限公司 | 一种提高3d打印镍基高温合金件韧性的方法 |
| CN113584294B (zh) * | 2021-06-25 | 2023-03-14 | 西安热工研究院有限公司 | 一种沉淀强化高温合金焊后去应力处理方法 |
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| EP2944402B1 (en) | 2019-04-03 |
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