CN105143146A - 通过使用金属或陶瓷粘结剂的瞬间液相烧结的陶瓷涡轮部件的增材制造 - Google Patents

通过使用金属或陶瓷粘结剂的瞬间液相烧结的陶瓷涡轮部件的增材制造 Download PDF

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CN105143146A
CN105143146A CN201480023387.0A CN201480023387A CN105143146A CN 105143146 A CN105143146 A CN 105143146A CN 201480023387 A CN201480023387 A CN 201480023387A CN 105143146 A CN105143146 A CN 105143146A
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powder
liquid phase
ceramic powder
ceramic
mineral binder
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S.米罗内茨
G.O.库克三世
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RTX Corp
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United Technologies Corp
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Abstract

一种陶瓷涡轮部件通过包括将陶瓷粉末与无机粘结剂粉末混合的过程形成。所述粉末混合物随后被成型为涡轮部件，所述涡轮部件随后通过瞬间液相烧结致密化。在一个实施方案中，所述涡轮部件可通过增材制造工艺如选择性激光烧结形成。

Description

通过使用金属或陶瓷粘结剂的瞬间液相烧结的陶瓷涡轮部件的增材制造
背景
本发明大体上涉及增材制造的领域。具体而言，本发明涉及通过增材制造工艺形成并通过使用金属或陶瓷粘结剂的瞬间液相粘结致密化的陶瓷涡轮部件。
增材制造指一类特征在于某一事实的制造方法，所述事实为：完成的零件是通过在形状上与所述零件的并存储在生产所述零件的设备的存储器中的精确数字模型的等效平面截面相同的多个薄片材料的逐层构造而创建。增材制造可涉及由计算机控制过程将材料应用到工作台并由热过程固化所述材料以便创建层。所述过程重复几千次以获得最终部件。
已知各种类型的增材制造。如由ASTM分类的增材制造类别包括：材料喷射，其中构建材料液滴选择性地沉积；粉末床熔融，其中热能选择性地熔融粉末床的区域；定向能量沉积，其中所集中的热能在沉积期间熔化材料；材料挤压，其中材料选择性地分散穿过喷嘴等等。用于以上的典型定向能源包括激光和电子束。
增材制造中朝向生产就绪金属和陶瓷部件的直接制造发展的最近趋势已最小化了聚合物粘结剂在成型过程中发挥的作用。
概述
一种形成部件的方法包括通过将第一陶瓷粉末与无机粘结剂粉末混合来制备起始粉末。随后通过增材制造工艺将所述粉末混合物成型为部件。通过瞬间液相粘结来使所述部件致密化。在一个优选实施方案中，可通过选择性激光烧结来形成所述部件。在另一个优选实施方案中，所述部件可以是涡轮部件。
一种方法包括通过逐层增材制造工艺来从第一陶瓷粉末和无机粘结剂粉末的混合粉末形成部件。所述部件在成型期间以及在后成型处理期间被加热以开始反应，由此形成液体并且通过瞬间液相粘结进行致密化。
附图简述
图1是基于粉末的成型过程的示意图。
图2是本发明的增材制造工艺。
详述
增材制造是其中利用逐层技术直接从数字模型生产三维(3D)物体的工艺。增材制造工艺与常规的减法制造方法明显不同，在所述减法方法中材料以一件一件的方式通过机械加工、研磨等或通过其他成型方法(如锻造、铸造、注射成型等)从坯件去除。在增材制造中，件通过材料的连续层的沉积而形成，其中每层粘附到上一层直到构建完成。单层可由计算机控制的能量束通过烧结、熔融或以其他方式固化粉末床或可聚合液体的顶部表面的特定区域，或者通过计算机控制的沉积装置将一种材料的单独液体或半固体液滴沉积在工件的特定区域上而形成。常见的能源是激光和电子束。
增材制造技术最初用于形成用于设计和原型设计的聚合物模型。当前增材制造加工现从聚合物、金属、金属聚合物复合材料和陶瓷生产产品。除了预生产设计和模型，由于显而易见的原因，当前努力现包括生产零件的直接增材制造加工。超合金涡轮部件例如像具有内部冷却通道的机翼的直接自由成型制造可消除许多昂贵的制造操作。
可应用到本发明的基于粉末的增材制造工艺包括：选择性激光烧结(SLS)、直接激光烧结(DLS)、选择性激光熔化(SLM)、直接激光熔化(DLM)、电子束熔化(EBM)、直接金属沉积以及本领域已知的其他工艺。
图1中示出本发明的基于粉末的增材制造工艺的实例。工艺10包括制造室12，所述制造室12包括通过增材制造生产固体自由成型物体的设备。工艺10的实例是选择性激光烧结(SLS)。SLS工艺10包括粉末存储室14、构建室16、激光18和扫描镜20。在SLS工艺10的操作期间，粉末22由活塞24向上馈送并由辊28散布在构建平台26上。在粉末22在构建平台26上散布成均匀层后，激光18和扫描镜20被激活来引导构建平台26上方的激光束烧结粉末22的选择性区域以便形成固体自由成型物体32的单层30，并根据存储在工艺10中的STL存储器文件中的物体32的3D计算机模型将所烧结区域附接至下方的平台26。在下一个步骤中，辊28返回至起始位置，活塞24前进以暴露粉末22的另一层并使构建平台26标记下降一层厚度。辊28随后将一层粉末22散布在包括选择性烧结区域的构建平台26的表面上。根据存储在工艺10的存储器中的部件的数字模型的横截面，激光18和扫描镜20被激活并且粉末的沉积层的选择性区域再次烧结并结合到下方的层。重复所述过程直到固体自由成型零件32完成。如所提及的，工艺10只是固体自由成型制造工艺的实例并且不意味着将本发明限制于本领域已知的任何单一工艺。
工艺10的室12提供包括惰性气体或真空的受控构建环境。层厚度取决于粉末大小并且范围可从20微米至超过1毫米。粉末22可由辊28或另一个散布装置(如刮刀)散布到构建平台26上。
其他系统如直接金属沉积用在本领域中，其中材料根据由存储在沉积设备中的存储器中的3D计算机模型驱动的控制分布过程一点一点地增加。金属和陶瓷粉末可以糊的形式沉积并且金属可以熔化或半熔化形式沉积，以及通过本领域已知的其他沉积工艺。增材制造工艺的实例包括但不限于，选择性激光烧结(SLS)、直接激光烧结(DLS)、选择性激光熔化(SLM)、直接激光熔化(DLM)、激光工程化净成形(LENS)、电子束熔化(EBM)、直接金属沉积以及本领域已知的其他工艺。
聚合物粘结剂可在增材制造之前、期间和之后帮助将粉末颗粒粘合到一起。粉末形式的粘结剂可与金属或陶瓷起始粉末混合或者所述起始粉末可涂布有聚合物粘结剂。通过其中聚合物粘结剂用于改善颗粒粘附性的增材制造生产的金属或陶瓷零件通常经受烧蚀处理，以便在零件被投入服务之前从显微结构消除粘结剂。所述聚合物还可在烧结期间干扰颗粒到颗粒的粘附。
用于本发明的烧结陶瓷零件的增材制造的合适粘结剂系统包括金属和陶瓷粘结剂。当液相存在时，烧结期间的尺寸控制和颗粒粘附得以改善。液相烧结是在液相在烧结过程中固化或以其他方式消耗时提供致密化和颗粒间结合发生的工艺。烧结产品可展示低孔隙度和可接受的结构完整性。
存在许多多组分材料系统，其中一种或多种组分在烧结期间反应以形成增强致密化和尺寸稳定性的液体。具体实例是在感兴趣的加工温度下在反应物的组成范围中存在共晶或包晶反应的情况。所述液体可在过程中由周围基质消耗，或可通过与组分组合以形成固溶体、另外的金属间或陶瓷固相、通过蒸发或通过本领域已知的其他方式而固化。这一过程称为瞬间液相粘结(TLPB)。在瞬间液相粘结中，粘结剂材料和陶瓷材料相互反应并通过粘结剂系统到第一陶瓷中的扩散或通过其他方式来形成液相。液相优选地等温固化。
本发明的目的是通过使用激光或电子束驱动的增材制造加工来使用金属、陶瓷和金属/陶瓷粘结剂系统以制造自由成型的陶瓷涡轮部件。选择所述粘结剂系统以允许烧结和致密化发生，优选地借助于通过共晶、包晶或其他组分间热反应进行的瞬间液相粘结。
候选金属粘结剂系统自然取决于陶瓷部件。通常，候选粘结剂材料可以是在烧结期间与陶瓷反应以形成低熔融相的材料，所述低熔融相湿润陶瓷。此过程可存在于材料系统中发生共晶或包晶反应的组合物处。候选陶瓷材料包括至少氧化物、氮化物、碳化物、氮氧化物、碳氮化物、镧系元素及其混合物。
符合以上标准的候选材料系统由一位发明人在J.Mater.Sci.46，5305(2011)的“OverviewofTransientLiquidPhaseandPartialTransientLiquidPhaseBonding”中报告并以引用方式整体并入本文。下表示出具有瞬间液相粘结剂添加物的示例陶瓷系统。
具有瞬间液相粘结剂成分的陶瓷系统
图2示意地示出本发明的基于粉末的增材制造工艺100。在所述工艺中，陶瓷粉末102和粘结剂粉末104混合以便形成起始组合物106。粘结剂粉末104可以是金属或陶瓷粉末或其混合物。可选择粘结剂粉末104，使得当与陶瓷粉末102混合并加热至烧结温度时，粘结剂粉末104将熔化以形成液相或将合金化或以其他方式与陶瓷粉末102反应以形成可湿润所述陶瓷粉末的低温熔融相。
在陶瓷粉末102和粘结剂粉末104混合以形成混合粉末106起始材料之后，例如，对于增材制造工艺10，所述起始材料被成型为自由成型零件30(步骤108)。用于成型的增材制造工艺10可以是直接激光烧结、直接激光熔化、选择性激光烧结、选择性激光熔化、激光工程化净成形或电子束熔化中的至少一个。也可采用本领域已知的其他方法，如直接金属沉积。在通过本发明的增材制造工艺成型期间，零件可通过瞬间液相粘结而致密化。
成型之后，所述增材制造的自由成型零件可通过空气、受控气氛或真空中的瞬间液相烧结进一步致密化(步骤110)。瞬间液相烧结的常见特征是在所述液相被基质吸收、通过陶瓷或金属间相的沉淀而固化或蒸发时的等温致密化。
在一个实施方案中，氧化铝(Al2O3)自由成型零件通过利用Al和二氧化硅(SiO2)、AlN和氧化锆(ZrO2)或B2O3粘结剂系统的瞬间液相烧结形成并致密化。
在另一个实施方案中，氮化硅(Si3N4)自由成型零件通过利用BN或氧氮化物玻璃粘结剂系统的瞬间液相烧结形成并致密化。
在又一个实施方案中，碳化硅(SiC)自由成型零件通过利用氧化铝(Al2O3)、稀土氧化物和二氧化硅(SiO2)粘结剂系统的瞬间液相烧结形成并致密化。
实施例1
如Chia等人的并整体并入本文的美国专利号5,298,470中所述，可通过瞬间液相烧结从82-99％重量比的碳化硅和约0.5-10％重量比的含氮铝化合物(如氮化铝和本领域已知的其他铝化合物)的混合物形成烧结的碳化硅体。在约1850-1900℃的烧结温度下达到理论上大于90％的密度。
实施例2
如Niimi等人的并整体并入的EP1433764中所述，可利用氧化钇(Y2O3)和氧化铝(Al2O3)的混合物、通过添加氮化铝(AlN)作为烧结助剂来将透明钇铝石榴石材料(Y3Al5O12：YAG)瞬间液相烧结至透明。烧结在还原气氛下在1600-1900℃下发生。
实施例3
Garrido等人的整体并入本文的Mat.Sci.Eng.A369(2004)250已经证明：利用氧化铝(Al2O3)、锆石(ZrSiO4)和二氧化钸(CeO2)的混合物、在1450℃至1600℃的烧结温度下通过瞬间液相烧结使莫来石氧化锆(ZrO2)复合物成型。
可能实施方案的讨论
以下是本发明的可能实施方案的非排他性描述。
一种形成部件的方法包括：通过将第一陶瓷粉末与无机粘结剂粉末混合来制备起始粉末；通过增材制造工艺将所混合粉末成型为部件；以及通过瞬间液相烧结来使所述部件致密化。
另外和/或替代地，前述段落的系统可任选地包括以下特征、配置和/或另外部件中的任何一个或多个：
所述致密化可发生在成型期间和后成型处理期间。
所述瞬间液相可通过第一陶瓷粉末与粘结剂粉末之间的反应形成，所述瞬间液相固化。
所述瞬间液相的固化可以是等温过程。
无机粘结剂粉末可包括金属、金属间化合物、陶瓷或其混合物。
所述第一陶瓷可包括氧化物、氮化物、碳化物、氮氧化物、碳氮化物、镧系元素或其混合物。
所述增材制造工艺可包括选择性激光烧结、直接激光烧结、选择性激光熔化、直接激光熔化、激光工程化净成形、电子束熔化和直接金属沉积中的至少一个。
所述部件可以是涡轮部件。
所述第一陶瓷粉末可以是SiC，并且所述无机粘结剂粉末可以是Al2O3+稀土氧化物+SiO2、AlN+稀土氧化物或Ge。
所述第一陶瓷粉末可以是Si3N4，并且所述无机粘结剂粉末可以是BN或氧氮化物玻璃。
所述第一陶瓷粉末可以是Si3N4-Y2O3-AlN，并且所述无机粘结剂粉末可以是HfO。
所述第一陶瓷粉末可以是3Y-TZP(掺杂氧化钇的多晶四方氧化锆)，并且所述无机粘结剂粉末可以是CuO。
所述第一陶瓷粉末可以是Al2O3，并且所述无机粘结剂粉末可以是Al+SiO2、AlN+ZrO2、Al或B2O3。
所述第一陶瓷粉末可以是YAG(钇铝石榴石)，并且所述无机粘结剂粉末可以是AlN。
所述第一陶瓷粉末可以是TiO2，并且所述无机粘结剂粉末可以是Bi2O3。
一种形成部件的方法包括：通过逐层增材制造工艺从第一陶瓷粉末和无机粘结剂粉末的混合粉末形成所述部件；以及加热所述部件以便开始反应，由此液体被形成，其通过瞬间液相烧结开始所述部件的致密化。
另外和/或替代地，前述段落的方法可任选地包括以下特征、配置和/或另外部件中的任何一个或多个。
所述瞬间液相可通过第一陶瓷粉末与粘结剂粉末之间的反应形成并固化。
所述液相的固化可以是等温过程。
所述粘结剂粉末材料可以是金属、金属间化合物、陶瓷或其混合物中的至少一种。
所述第一陶瓷粉末可包括氧化物、氮化物、碳化物、氮氧化物、碳氮化物、镧系元素及其混合物。
所述瞬间液相可通过直接熔化粘结剂或通过颗粒间扩散或合金化以形成共晶、包晶或其他低温熔融相来形成。
所述增材制造工艺可包括选择性激光烧结、直接激光烧结、选择性激光熔化、直接激光熔化、激光工程化净成形、电子束熔化和直接金属沉积中的至少一个。
虽然已参考优选实施方案描述本发明，但是本领域的技术人员将认识到，在不脱离本发明的精神和范围的情况下可进行形式和细节的改变。

Claims (22)

1.一种形成部件的方法，其包括：
通过将第一陶瓷粉末与无机粘结剂粉末混合来制备起始粉末；
通过增材制造工艺将所述混合粉末成型为部件；以及
通过瞬间液相烧结来使所述部件致密化。
2.如权利要求1所述的方法，其中致密化可发生在成型期间和后成型处理期间。
3.如权利要求1所述的方法，其中瞬间液相通过所述第一陶瓷粉末与所述粘结剂粉末之间的反应形成，所述瞬间液相固化。
4.如权利要求3所述的方法，其中所述瞬间液相的固化是等温过程。
5.如权利要求1所述的方法，其中所述无机粘结剂粉末材料包括金属、金属间化合物、陶瓷或其混合物中的至少一种。
6.如权利要求1所述的方法，其中第一陶瓷选自由氧化物、氮化物、碳化物、氮氧化物、碳氮化物、镧系元素及其混合物组成的组。
7.如权利要求1所述的方法，其中所述增材制造工艺包括选择性激光烧结、直接激光烧结、选择性激光熔化、直接激光熔化、激光工程化净成形、电子束熔化和直接金属沉积中的至少一种。
8.如权利要求1所述的方法，其中部件是涡轮部件。
9.如权利要求1所述的方法，其中所述第一陶瓷粉末是SiC，并且所述无机粘结剂粉末选自由Al2O3+稀土氧化物+SiO2、AlN+稀土氧化物和Ge组成的组。
10.如权利要求1所述的方法，其中所述第一陶瓷粉末是Si3N4，并且所述无机粘结剂粉末选自由BN和氧氮化物玻璃组成的组。
11.如权利要求1所述的方法，其中所述第一陶瓷粉末是Si3N4-Y2O3-AlN，并且所述无机粘结剂粉末是HfO。
12.如权利要求1所述的方法，其中所述第一陶瓷粉末是3Y-TZP(掺杂氧化钇的多晶四方氧化锆)，并且所述无机粘结剂粉末是CuO。
13.如权利要求1所述的方法，其中所述第一陶瓷粉末是Al2O3，并且所述无机粘结剂粉末选自由Al+SiO2、AlN+ZrO2、Al和B2O3组成的组。
14.如权利要求1所述的方法，其中所述第一陶瓷粉末是YAG(钇铝石榴石)，并且所述无机粘结剂粉末是AlN。
15.如权利要求1所述的方法，其中所述第一陶瓷粉末是TiO2，并且所述无机粘结剂粉末是Bi2O3。
16.一种形成部件的方法，其包括：
通过逐层增材制造工艺来从第一陶瓷粉末和无机粘结剂粉末的混合粉末形成所述部件；以及
加热所述部件以开始反应，由此形成液体，其通过瞬间液相烧结开始所述部件的致密化。
17.如权利要求16所述的方法，其中瞬间液相通过所述第一陶瓷粉末与所述粘结剂粉末之间的反应形成并固化。
18.如权利要求17所述的方法，其中所述液相的固化是等温过程。
19.如权利要求16所述的方法，其中所述粘结剂粉末材料包括金属、金属间化合物、陶瓷或其混合物中的至少一种。
20.如权利要求16所述的方法，其中第一陶瓷粉末选自由氧化物、氮化物、碳化物、氮氧化物、碳氮化物、镧系元素及其混合物组成的组。
21.如权利要求17所述的方法，其中通过直接熔化所述粘结剂或通过颗粒间扩散或合金化以形成共晶、包晶或其他低温熔融相来形成瞬间液相。
22.如权利要求16所述的方法，其中所述增材制造工艺包括选择性激光烧结、直接激光烧结、选择性激光熔化、直接激光熔化、激光工程化净成形、电子束熔化和直接金属沉积中的至少一种。
CN201480023387.0A 2013-04-25 2014-04-22 通过使用金属或陶瓷粘结剂的瞬间液相烧结的陶瓷涡轮部件的增材制造 Pending CN105143146A (zh)

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