CN107755668B - Method for preparing reinforced nickel-based high-temperature alloy composite material single crystal blade - Google Patents
Method for preparing reinforced nickel-based high-temperature alloy composite material single crystal blade Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/02—Use of electric or magnetic effects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
- B22D27/045—Directionally solidified castings
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/08—Making alloys containing metallic or non-metallic fibres or filaments by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
- C22C49/02—Alloys containing metallic or non-metallic fibres or filaments characterised by the matrix material
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
- C22C49/14—Alloys containing metallic or non-metallic fibres or filaments characterised by the fibres or filaments
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B29/00—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
- C30B29/10—Inorganic compounds or compositions
- C30B29/52—Alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C2200/00—Crystalline structure
Abstract
The invention relates to a method for preparing a reinforced nickel-based high-temperature alloy composite material single crystal blade, which is characterized in that superfine single crystal nickel powder is used as a main raw material, a reinforcing material is added, other superfine refractory metal powder is added according to the formula requirement of a high-temperature alloy material, and after molding, the graphene reinforced nickel-based high-temperature alloy composite material single crystal turbine blade of an aircraft engine is prepared by a method of electromagnetic field constraint induction zone melting directional solidification recrystallization. Compared with the prior art, the invention fully utilizes the excellent mechanical property and high thermal conductivity of the reinforcing material, inhibits the generation and development of internal stress cracks when the single crystal blade works, and improves the thermal conductivity coefficient and the rapid heat dissipation performance of the single crystal blade, thereby obviously improving the high-temperature mechanical property, the working temperature and the high-temperature fatigue service life of the traditional single crystal blade, and further obviously improving the thrust-weight ratio of an aircraft engine.
Description
Technical Field
The invention belongs to the technical field of aerospace materials, and particularly relates to a method for preparing a reinforced nickel-based superalloy composite material single crystal blade based on electromagnetic field induction of superfine nickel powder.
Background
A single crystal blade is a cast blade with only one grain. The directional solidification crystallization blade eliminates transverse crystal boundaries sensitive to cavities and cracks, and all the crystal boundaries are parallel to the stress axis direction, so that the high-temperature service performance of the alloy is improved. At present, the turbine blade of an aero-engine generally adopts a composite air film cooling type single crystal hollow structure, but due to the fact that the structure shape is complex, the forming precision is low, the rejection rate is extremely high, industrialization of casting of the single crystal blade is not achieved, and the performance of the turbine blade is not improved by adding a second phase reinforcing material. Graphene is a honeycomb-structured two-dimensional material completely composed of conjugated hybridized carbon atoms, and has been proved to be the thinnest and hardest nanomaterial in the world, and is almost completely transparent. The graphene has 2630m2The theoretical specific surface area of per g can reach 125GPa in breaking strength, 130GPa in tensile strength, 1100GPa in Young's modulus, 5300W/mK in heat conductivity higher than that of carbon nanotube and diamond, 1 omega-m in resistivity lower than that of copper or silver, and has the chemical performance of being the material with the lowest resistivityIs extremely stable. Moreover, carbon is a substance with the highest melting point in nature, and the melting point is as high as 3650 ℃. Therefore, the graphene has excellent mechanical property and thermal property, and is an ideal metal solid solution second phase strengthening and reinforcing material. If the advantages of high melting point, high strength, high specific modulus and the like of graphene are combined with the characteristics of high strength, good fatigue resistance and creep resistance of the nickel-based superalloy, great influence is brought to material design and performance improvement of the nickel-based superalloy single crystal blade, and the graphene-reinforced nickel-based superalloy composite single crystal blade with excellent performance is expected to be developed.
Although the united states patents US2012070303a1, US2012034098a1 and chinese patent 200510046361.0 propose a method for preparing a nickel-based superalloy single crystal blade containing rhenium, and chinese patents 201510907051.7 and 201610214707.1 propose a method for preparing a graphene-reinforced nickel-based superalloy, which either use a conventional directional solidification technique to prepare a single crystal blade or use a conventional composite material technique to prepare a nickel-based superalloy composite material, the problem of improving the performance of a turbine blade still cannot be solved.
Disclosure of Invention
The invention aims to overcome the defects that a nickel-based high-temperature alloy single crystal blade produced by the prior art is not added with a graphene reinforced material, has low mechanical property, short high-temperature fatigue life and the like, and provides a method for preparing a reinforced nickel-based high-temperature alloy composite material single crystal blade under the induction of an electromagnetic field based on superfine single crystal nickel powder.
The purpose of the invention can be realized by the following technical scheme:
the method for preparing the reinforced nickel-based superalloy composite material single crystal blade comprises the following steps:
(1) superfine single crystal or polycrystal nickel powder particles are taken as main raw materials, and other superfine refractory metal powder is added according to the formula requirement of a high-temperature alloy material;
(2) adding graphene, carbon nanotubes or carbon fibers as reinforcing materials, and performing ball milling and mixing uniformly;
(3) uniformly mixing powder added with the reinforcing material, and performing die pressing or 3D printing on the powder to form a blade blank;
(4) the obtained blade blank is subjected to alloying treatment by zone melting and directional solidification to realize recrystallization, an electromagnetic field is applied before a melting zone by utilizing the characteristic that superfine single crystal nickel powder has superparamagnetism above the Curie temperature, the magnetic moments of micro magnetic domains of single crystal or polycrystal nickel powder particles which are not melted are forced to be directionally arranged according to the growth direction of the single crystal blade, meanwhile, the electromagnetic field is also applied after the melting zone to restrain and induce the large single crystal magnetic domain magnetic moments of the blades which are not solidified and are in the high-temperature recrystallization process to be directionally arranged according to the growth direction of the single crystal blade and to be slowly solidified and crystallized to form a single crystal with all atomic arrangements being the same, and thus the nickel-based composite material single crystal blade reinforced by graphene, carbon nano tubes or carbon fibers is manufactured.
As a preferred embodiment, in the step (1), the superfine single crystal or polycrystal nickel powder particles are spherical or spheroidal crystals, the particle size is micron, submicron or nano particles, the adding amount is more than 50 wt%, and the particle size is 20 nm-1 mm; more preferably, the particle size of the ultrafine single crystal or polycrystalline nickel powder particles is in the range of 1 to 10 μm, and the addition amount is 50 to 100 wt%, and still more preferably, 65 to 85 wt%.
In a preferred embodiment, the other ultrafine metal powder in step (1) comprises one or more of tungsten, molybdenum, chromium, cobalt, rhenium, ruthenium, aluminum or tantalum, and the powder is micron, submicron or nano-particle, spherical or spherical-like in morphology, and can be crystalline or amorphous.
As a preferred embodiment, the reinforcing material in the step (2) is added in an amount of 0.01 to 10 wt%, preferably 0.1 to 1 wt%.
As a preferenceThe added reinforcing material needs to have the characteristics of good powder dispersibility, high electrical conductivity, good thermal conductivity, less impurity elements and the like. The added graphene is a single layer or few layers, the number of the layers is less than 10, the carbon content is more than 99 percent, and the specific surface area is more than 80m2The electrical conductivity is more than 1000S/m. The added carbon nanotube is single-wall or double-wall carbon nanotube with diameter less than 4 μm, length less than 30 μm, purity greater than 95%, and specific surface area greater than 400m2The electrical conductivity is more than 150S/m. The added carbon fiber is carbon fiber powder with high heat conductivity, the diameter is less than 50 μm, the length is less than 500 μm, the carbon content is more than 99%, and the specific surface area is more than 0.4m2The electrical conductivity is more than 1000S/m, and the thermal conductivity is more than 400W/mK. And mixing by adopting dry ball milling or wet ball milling.
In a more preferred embodiment, the reinforcing material is preferably graphene. The added graphene is a single layer or few layers, the number of the layers is less than 10, the carbon content is more than 99 percent, and the specific surface area is more than 80m2The electrical conductivity is more than 1000S/m.
As a preferred embodiment, the smelting temperature of the smelting area in the step (4) is controlled to be 1000-1600 ℃, the temperature gradient is greater than 50K/cm, the traction speed is 0.5-150mm/min, and air, water or liquid metal can be adopted for cooling; applying a pretreatment external electromagnetic field before an unmelted smelting area, wherein the included angle between the magnetic moment direction of the external electromagnetic field and the axial direction of the curved surface of the blade is always controlled within the range of less than 10 degrees; and applying an after-treatment external electromagnetic field after the non-solidified smelting region, wherein the included angle between the magnetic moment direction of the external electromagnetic field and the axial direction of the curved surface of the blade is always controlled within the range of less than 10 degrees.
In a more preferred embodiment, the magnetic induction intensity of the external electromagnetic field applied before the non-melted melting zone is 0.1 to 100 Tesla, and the direction of the external magnetic field and the axial direction of the blade are controlled to be 0 to 5 °. The magnetic induction intensity of an external electromagnetic field for post-treatment is applied to an unsolidified smelting area and is 0.1-100 Tesla, and the direction of the external magnetic field and the axial direction of the blade are controlled to be 0-5 degrees.
The prepared composite material single crystal blade is a solid blade or a hollow blade, and can be a single crystal blade, a columnar crystal blade, an isometric crystal blade or a grain-refined directional solidification blade from the material viewpoint.
In addition to blades, composite casings and turbine disks can be made by the above-described method.
Compared with the prior art, the graphene and the like are introduced into the material as the reinforcing material, the superfine single crystal or polycrystalline nickel powder is used as the main raw material, the external electromagnetic field double-induction constraint directional recrystallization is introduced in the process, the excellent mechanical property and the high thermal conductivity of the reinforcing material are fully utilized, the generation and the development of internal stress cracks of the single crystal blade during working are inhibited, the thermal conductivity and the rapid heat dissipation performance of the single crystal blade are improved, the high-temperature mechanical property, the working temperature and the high-temperature fatigue service life of the traditional single crystal blade are obviously improved, the thrust-weight ratio of an aircraft engine is obviously improved, and the following beneficial effects can be obtained:
(1) the graphene is added into the raw materials, so that the generation and development of internal stress cracks of the single crystal blade during working can be inhibited, the heat conductivity coefficient of the single crystal blade is improved, the heat of the blade is rapidly diffused out during high-temperature use, the mechanical property of the turbine blade during high-temperature use is improved, particularly, the high-temperature fatigue life is prolonged, and the working temperature of the turbine blade is improved.
(2) The superfine metal powder is used as the raw material, so that the sintering and crystallization temperature can be reduced, and the crystal grains are more refined;
(3) because of using the superfine metal powder, the sintering driving force is stronger, the diffusion of alloy elements is easier, the diffusion distance is short, the alloying is easier, and simultaneously the macrosegregation can be reduced;
(4) the superfine nickel powder is used, has superparamagnetism at the nickel Curie point of more than 357.6 ℃, can easily adjust, restrict and control the arrangement direction of single crystal magnetic domains under the regulation and control of an external restriction magnetic field before melting, and restricts the melting and sintering of powder particles.
(5) Because the sintering does not destroy the magnetic domain structure of the single crystal nickel powder, the magnetic domain of the single crystal particles can be easily arranged in an oriented way in the recrystallization process, and the recrystallization process is completed.
(6) Alloying the powder, and easily adjusting and controlling the components and the proportion of the single crystal alloy by changing the formula;
(7) utilizing an electromagnetic field to restrain melting and restrain induced solidification recrystallization;
(8) the sintering process is essentially an alloying and recrystallization process, the sintering temperature can be lower than the nickel melting point of 1453 ℃, powder is not required to be completely melted, the surface melting is carried out to complete sintering, the grain boundary of single crystal particles is eliminated, alloying is completed, and finally a large alloy single crystal process is formed.
(9) The magnetic domain and atomic magnetic moment of the single crystal powder can be controlled to be arranged in the same direction by the double constraint of the rotating magnetic field, and the crystallization direction and the axial direction of the curved surface of the blade can be always controlled to be less than 5 degrees, so that the quality and the yield of the single crystal are improved;
(10) the mould shell and the mould core are not provided, so that the pollution and deformation influence of the components of the mould shell are reduced, and the cost is reduced;
(11)3D printing or die pressing preforming can accurately control the size and the shape of the blade, and a hollow blade blank is easy to prepare;
(12) powder alloying, sintering and crystallizing are completed at one time;
(13) the zone sintering can establish larger temperature gradient, easily control the longitudinal heat flow direction and the transverse temperature distribution, and rapidly sinter and solidify without a vacuum sintering furnace;
(14) and seeding, crystal selection and transition section waste materials are not generated.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that variations and modifications can be made by persons skilled in the art without departing from the spirit of the invention. All falling within the scope of the present invention.
Example 1
2 micron spherical superfine monocrystal nickel powder is added with 0.3 wt% of graphene powder, the added graphene is a single layer, the carbon content is more than 99%, and the specific surface area is more than 80m2A specific electric conductivity of more than 1000S/mAccording to the material formula, spherical superfine metal powder of tungsten, molybdenum, chromium, cobalt, rhenium, ruthenium, aluminum, tantalum and the like with the particle size of less than 5 microns is added in proportion, the ball milling and the mixing are carried out in an ethanol solvent, a blade blank is formed by utilizing a 3D printing process, then the blank is subjected to zone melting alloying, meanwhile, a large temperature gradient is formed in a melting zone for directional solidification, external electromagnetic fields are applied before and after the blank is close to the melting zone, disordered micro nickel powder single crystal magnetic domain directional arrangement is forced, the directional growth of a nickel-based alloy single crystal is restrained and induced, meanwhile, the direction of an external magnetic field is rotationally adjusted, and the directional arrangement direction of the micro magnetic domain magnetic moment of the superfine single crystal nickel powder is restrained to be always kept at an included angle of less. The prepared graphene reinforced composite material single crystal blade has the advantages of good mechanical property, long high-temperature fatigue life, high working temperature and the like.
Example 2
2 micron spherical superfine polycrystalline nickel powder is used, 0.3 wt% of carbon nanotube powder is added, the added carbon nanotube is single-walled carbon nanotube, the diameter is less than 4 microns, the length is less than 30 microns, the purity is more than 95%, and the specific surface area is more than 400m2The electric conductivity is more than 150S/m, meanwhile, according to the material formula, spherical ultrafine metal powder of tungsten, molybdenum, chromium, cobalt, rhenium, ruthenium, aluminum, tantalum and the like with the particle size of less than 5 microns is added in proportion, the ball milling and the uniform mixing are carried out in an ethanol solvent, a blade blank is formed by utilizing a powder die pressing process, then the blank is subjected to zone melting alloying, a large temperature gradient is formed in a melting zone for directional solidification, external electromagnetic fields are applied before and after the melting zone, disordered tiny nickel powder single crystal directional arrangement is forced, the directional growth of nickel base alloy single crystal is restrained and induced, the direction of an external magnetic field is adjusted in a rotating mode, and the magnetic domain magnetic moment directional arrangement direction of the tiny magnetic domain of the tiny single crystal nickel powder is restrained to be always kept at an included angle of less than 5 degrees with the. The prepared graphene reinforced composite material single crystal blade has the advantages of good mechanical property, long high-temperature fatigue life, high working temperature and the like.
Example 3
2 micron spherical superfine polycrystalline nickel powder is added with 0.3 wt% of carbon fiber powderIs carbon fiber powder with high heat conductivity, diameter less than 50 μm, length less than 500 μm, carbon content greater than 99%, and specific surface area greater than 0.4m2The method comprises the steps of performing area smelting alloying on a blank, forming a large temperature gradient in a smelting area for directional solidification, applying external electromagnetic fields before and after the blank is close to the smelting area to force disordered micro nickel powder single crystal magnetic domain directional arrangement, restraining the directional growth of nickel-based induced alloy single crystals, simultaneously performing rotary adjustment on the direction of an external magnetic field, and restraining the direction of the magnetic moment directional arrangement of the micro magnetic domain of the ultra-fine single crystal nickel powder from always keeping an included angle of less than 5 degrees with the axial direction of a turbine blade. The prepared graphene reinforced composite material single crystal blade has the advantages of good mechanical property, long high-temperature fatigue life, high working temperature and the like.
Example 4
500 nanometer spherical superfine monocrystal nickel powder is added with 0.3 wt% of graphene powder, the added graphene has 5 layers, the carbon content is more than 99%, and the specific surface area is more than 80m2The specific surface area of the nickel-based alloy is determined by the following steps of/g, the electric conductivity is more than 1000S/m, meanwhile, according to the material formula, adding spherical ultrafine metal powder of tungsten, molybdenum, chromium, cobalt, rhenium, ruthenium, aluminum, tantalum and the like which are less than 5 microns in proportion, carrying out ball milling and mixing uniformly in an ethanol solvent, forming a blade blank by using a 3D printing process, then carrying out zone melting alloying on the blank, simultaneously forming a large temperature gradient in a melting zone for directional solidification, applying external electromagnetic fields before and after the zone close to the melting zone to force disordered micro nickel powder single crystal magnetic domain directional arrangement, restraining and inducing the directional growth of a nickel-based alloy single crystal, simultaneously rotating and adjusting the direction of an external magnetic field, and restraining the micro magnetic domain magnetic moment directional arrangement direction of the ultrafine single crystal nickel powder and keeping an included angle of. The prepared graphene reinforced composite material single crystal blade has the advantages of good mechanical property, long high-temperature fatigue life, high working temperature and the like.
Example 5
50 nanometer spherical superfine monocrystal nickel powder is added with 0.3 wt% of graphene powder, the added graphene has 8 layers, the carbon content is more than 99%, and the specific surface area is more than 80m2The specific surface area of the nickel-based alloy is determined by the following steps of/g, the electric conductivity is more than 1000S/m, meanwhile, according to the material formula, adding spherical ultrafine metal powder of tungsten, molybdenum, chromium, cobalt, rhenium, ruthenium, aluminum, tantalum and the like which are less than 5 microns in proportion, carrying out ball milling and mixing uniformly in an ethanol solvent, forming a blade blank by using a 3D printing process, then carrying out zone melting alloying on the blank, simultaneously forming a large temperature gradient in a melting zone for directional solidification, applying external electromagnetic fields before and after the zone close to the melting zone to force disordered micro nickel powder single crystal magnetic domain directional arrangement, restraining and inducing the directional growth of a nickel-based alloy single crystal, simultaneously rotating and adjusting the direction of an external magnetic field, and restraining the micro magnetic domain magnetic moment directional arrangement direction of the ultrafine single crystal nickel powder and keeping an included angle of. The prepared graphene reinforced composite material single crystal blade has the advantages of good mechanical property, long high-temperature fatigue life, high working temperature and the like.
Example 6
2 micron spherical superfine monocrystal nickel powder is added with 0.1 wt% of graphene powder, the added graphene has 2 layers, the carbon content is more than 99%, and the specific surface area is more than 80m2The specific surface area of the nickel-based alloy is determined by the following steps of/g, the electric conductivity is more than 1000S/m, meanwhile, according to the material formula, adding spherical ultrafine metal powder of tungsten, molybdenum, chromium, cobalt, rhenium, ruthenium, aluminum, tantalum and the like which are less than 5 microns in proportion, carrying out ball milling and mixing uniformly in an ethanol solvent, forming a blade blank by using a 3D printing process, then carrying out zone melting alloying on the blank, simultaneously forming a large temperature gradient in a melting zone for directional solidification, applying external electromagnetic fields before and after the zone close to the melting zone to force disordered micro nickel powder single crystal magnetic domain directional arrangement, restraining and inducing the directional growth of a nickel-based alloy single crystal, simultaneously rotating and adjusting the direction of an external magnetic field, and restraining the micro magnetic domain magnetic moment directional arrangement direction of the ultrafine single crystal nickel powder and keeping an included angle of. The prepared graphene reinforced composite material single crystal blade has good mechanical property, long high-temperature fatigue life and working temperatureHigh advantage.
Example 7
2 micron spherical superfine monocrystal nickel powder is added with 1 wt% of graphene powder, the added graphene has 5 layers, the carbon content is more than 99%, and the specific surface area is more than 80m2The specific surface area of the nickel-based alloy is determined by the following steps of/g, the electric conductivity is more than 1000S/m, meanwhile, according to the material formula, adding spherical ultrafine metal powder of tungsten, molybdenum, chromium, cobalt, rhenium, ruthenium, aluminum, tantalum and the like which are less than 5 microns in proportion, carrying out ball milling and mixing uniformly in an ethanol solvent, forming a blade blank by using a 3D printing process, then carrying out zone melting alloying on the blank, simultaneously forming a large temperature gradient in a melting zone for directional solidification, applying external electromagnetic fields before and after the zone close to the melting zone to force disordered micro nickel powder single crystal magnetic domain directional arrangement, restraining and inducing the directional growth of a nickel-based alloy single crystal, simultaneously rotating and adjusting the direction of an external magnetic field, and restraining the micro magnetic domain magnetic moment directional arrangement direction of the ultrafine single crystal nickel powder and keeping an included angle of. The prepared graphene reinforced composite material single crystal blade has the advantages of good mechanical property, long high-temperature fatigue life, high working temperature and the like.
Example 8
The method for preparing the reinforced nickel-based high-temperature alloy composite material single crystal blade based on the electromagnetic field induction of the superfine nickel powder comprises the following steps:
(1) taking superfine single-crystal nickel powder particles as a main raw material, wherein the superfine single-crystal nickel powder particles adopted in the embodiment are spherical, the particle size is 20nm, the addition amount is 50 wt%, other superfine metal powder can be added according to the formula requirement of the high-temperature alloy material, the superfine metal powder added in the embodiment is tungsten and molybdenum, the powder is nano particles, the shape is spherical crystals, and then dry ball milling and mixing are carried out;
(2) adding carbon nanotube as reinforcing material, wherein the added carbon nanotube is double-wall carbon nanotube with diameter less than 4 μm, length less than 30 μm, purity greater than 95%, and specific surface area greater than 400m2The electrical conductivity is more than 150S/m, the adding amount is 0.01 wt% of the materials, and then the materials are ball-milled and mixed evenly by a dry method;
(3) molding the uniformly mixed superfine metal powder into a blade blank through a die;
(4) and the obtained blade blank is subjected to alloying treatment through a smelting region and directional solidification to realize recrystallization, the smelting temperature of the smelting region is controlled at 1100 ℃, the temperature gradient is greater than 50K/cm, the traction speed is 0.5mm/min, and air is adopted for cooling treatment during directional solidification. Applying magnetic fields before and after a smelting region to force micro magnetic domains of monocrystalline or polycrystalline nickel powder particles which are not melted to be directionally arranged according to the growth direction of a monocrystalline blade and restrain and induce monocrystalline magnetic moments in a high-temperature recrystallization process to be directionally arranged according to the growth direction of the monocrystalline blade, wherein the magnetic induction intensity of a pretreatment external electromagnetic field applied before the smelting region is 0.1 Tesla, the included angle between the magnetic moment direction and the axial direction of a curved surface of the blade is always controlled within the range of less than 10 degrees, a post-treatment external electromagnetic field is applied after the smelting region, the magnetic induction intensity of the external electromagnetic field is 0.1 Tesla, the included angle between the magnetic moment direction and the axial direction of the curved surface of the blade is always controlled within the range of less than 10 degrees, and the manufactured monocrystalline blade is solid in structure.
Example 9
The method for preparing the reinforced nickel-based high-temperature alloy composite material single crystal blade based on the electromagnetic field induction of the superfine nickel powder comprises the following steps:
(1) taking superfine monocrystalline nickel powder particles as a main raw material, wherein the superfine monocrystalline nickel powder particles adopted in the embodiment are sphere-like, the particle size is 1 mu m, the adding amount is 65 wt%, other superfine metal powder can be added according to the formula requirement of the high-temperature alloy material, the superfine metal powder added in the embodiment is tungsten and molybdenum, the powder is submicron particles, the shape is spherical crystals, and then dry ball milling and mixing are carried out;
(2) adding carbon nanotube as reinforcing material, wherein the added carbon nanotube is double-wall carbon nanotube with diameter less than 4 μm, length less than 30 μm, purity greater than 95%, and specific surface area greater than 400m2The specific conductivity is more than 150S/m, the adding amount is 0.1 wt% of the materials, and then the materials are ball-milled and mixed uniformly by a dry method;
(3) molding the uniformly mixed superfine metal powder into a blade blank through a die;
(4) and the obtained blade blank is subjected to alloying treatment through a smelting region and directional solidification to realize recrystallization, the smelting temperature of the smelting region is controlled at 1200 ℃, the temperature gradient is greater than 50K/cm, the traction speed is 10mm/min, and air is adopted for cooling treatment during directional solidification. Applying magnetic fields before and after the smelting region to force micro magnetic domains of monocrystalline or polycrystalline nickel powder particles which are not melted to be directionally arranged according to the growth direction of the monocrystalline blade and restrain and induce monocrystalline magnetic moments in the high-temperature recrystallization process to be directionally arranged according to the growth direction of the monocrystalline blade, wherein the magnetic induction intensity of a pretreatment external electromagnetic field applied before the smelting region is 1 Tesla, the included angle between the magnetic moment direction and the axial direction of the curved surface of the blade is always controlled at 5 degrees, a post-treatment external electromagnetic field is applied after the smelting region, the magnetic induction intensity of the external electromagnetic field is 1 Tesla, and the included angle between the magnetic moment direction and the axial direction of the curved surface of the blade is always controlled at 5 degrees, so that the hollow columnar crystal blade is manufactured.
Example 10
The method for preparing the reinforced nickel-based high-temperature alloy composite material single crystal blade based on the electromagnetic field induction of the superfine nickel powder comprises the following steps:
(1) taking superfine polycrystalline nickel powder particles as a main raw material, wherein the superfine polycrystalline nickel powder particles adopted in the embodiment are sphere-like, the particle size is 10 microns, the addition amount is 85 wt%, other superfine metal powder can be added according to the formula requirement of a high-temperature alloy material, the superfine metal powder added in the embodiment is cobalt, rhenium and ruthenium, the powder is micron particles, the morphology is a sphere-like amorphous body, and wet ball milling and mixing are carried out;
(2) adding carbon fiber as reinforcing material, wherein the added carbon fiber is carbon fiber powder with high thermal conductivity, the diameter is less than 50 μm, the length is less than 500 μm, the carbon content is more than 99%, and the specific surface area is more than 0.4m2The specific surface area of the material is determined by the following steps of (1)/g, the electrical conductivity is more than 1000S/m, the thermal conductivity is more than 400W/mK, the addition amount is 1 wt% of the material, and then the materials are ball-milled and mixed uniformly by a wet method;
(3) printing the uniformly mixed superfine metal powder into a blade blank through 3D;
(4) and the obtained blade blank is subjected to alloying treatment through a smelting region and directional solidification to realize recrystallization, the smelting temperature of the smelting region is controlled at 1400 ℃, the temperature gradient is greater than 50K/cm, the traction speed is 80mm/min, and air is adopted for cooling treatment during directional solidification. Applying magnetic fields before and after the smelting region to force micro magnetic domains of monocrystalline or polycrystalline nickel powder particles which are not melted to be directionally arranged according to the growth direction of the monocrystalline blade and restrain and induce monocrystalline magnetic moments in the high-temperature recrystallization process to be directionally arranged according to the growth direction of the monocrystalline blade, wherein the magnetic induction intensity of a pretreatment external electromagnetic field applied before the smelting region is 10 Tesla, the included angle between the magnetic moment direction and the axial direction of the curved surface of the blade is always controlled at 2 degrees, a post-treatment external electromagnetic field is applied after the smelting region, the magnetic induction intensity of the external electromagnetic field is 10 Tesla, and the included angle between the magnetic moment direction and the axial direction of the curved surface of the blade is always controlled at 2 degrees, so that the hollow isometric crystal blade is manufactured.
Example 11
The method for preparing the reinforced nickel-based high-temperature alloy composite material single crystal blade based on the electromagnetic field induction of the superfine nickel powder comprises the following steps:
(1) taking superfine polycrystalline nickel powder particles as a main raw material, wherein the superfine polycrystalline nickel powder particles adopted in the embodiment are sphere-like, the particle size is 1mm, the addition amount is 95 wt%, other superfine metal powder can be added according to the formula requirement of a high-temperature alloy material, the superfine metal powder added in the embodiment is cobalt, rhenium and ruthenium, the powder is micron particles, the shape is a sphere-like amorphous body, and then wet ball milling and mixing are carried out;
(2) adding carbon fiber as reinforcing material, wherein the added carbon fiber is carbon fiber powder with high thermal conductivity, the diameter is less than 50 μm, the length is less than 500 μm, the carbon content is more than 99%, and the specific surface area is more than 0.4m2The specific surface area of the material is/g, the electric conductivity is more than 1000S/m, the heat conductivity coefficient is more than 400W/mK, the adding amount is 10 wt% of the material, and then the wet ball milling is adopted for mixing uniformly;
(3) printing the uniformly mixed superfine metal powder into a blade blank through 3D;
(4) and the obtained blade blank is subjected to alloying treatment through a smelting region and directional solidification to realize recrystallization, the smelting temperature of the smelting region is controlled at 1600 ℃, the temperature gradient is greater than 50K/cm, the traction speed is 150mm/min, and air is adopted for cooling treatment during directional solidification. Applying magnetic fields before and after the smelting region to force micro magnetic domains of monocrystalline or polycrystalline nickel powder particles which are not melted to be directionally arranged according to the growth direction of the monocrystalline blade and restrain and induce monocrystalline magnetic moments in the high-temperature recrystallization process to be directionally arranged according to the growth direction of the monocrystalline blade, wherein the magnetic induction intensity of a pretreatment external electromagnetic field applied before the smelting region is 10 Tesla, the included angle between the magnetic moment direction and the axial direction of the curved surface of the blade is always controlled at 0 degree, a post-treatment external electromagnetic field is applied after the smelting region, the magnetic induction intensity of the external electromagnetic field is 10 Tesla, and the included angle between the magnetic moment direction and the axial direction of the curved surface of the blade is always controlled at 0 degree, so that the hollow isometric crystal blade is manufactured.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes and modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention.
Claims (15)
1. The method for preparing the reinforced nickel-based superalloy composite single crystal blade is characterized by comprising the following steps of:
(1) taking ultrafine single crystal or polycrystal nickel powder particles with the particle size range of 1-10 mu m as a main raw material, and adding other ultrafine refractory metal powder according to the formula requirement of the high-temperature alloy material;
(2) adding one or more of graphene, carbon nanotubes or carbon fibers as a reinforcing material, and performing ball milling and mixing uniformly;
(3) uniformly mixing powder added with the reinforcing material, and performing die pressing or 3D printing on the powder to form a blade blank;
(4) the obtained blade blank is subjected to alloying treatment by zone melting and directional solidification to realize recrystallization, an electromagnetic field is applied before a melting zone to force the micro magnetic domain magnetic moments of single crystal or polycrystal nickel powder particles which are not melted to be directionally arranged according to the growth direction of the single crystal blade, the electromagnetic field is applied after the melting zone to restrain and induce the large single crystal magnetic domain magnetic moments of the blades which are not solidified and are in the high-temperature recrystallization process to be directionally arranged according to the growth direction of the single crystal blade to grow, solidify and crystallize to form a single crystal with all atomic arrangements consistent, and the reinforced nickel-based composite material single crystal blade is manufactured;
the graphene is a single layer or few layers, the number of the layers is less than 10, the carbon content is more than 99%, and the specific surface area is more than 80m2Per g, an electrical conductivity of more than 1000S/m,
the carbon nanotube is single-wall or double-wall carbon nanotube with diameter less than 4 μm, length less than 30 μm, purity greater than 95%, and specific surface area greater than 400m2Per g, an electrical conductivity of more than 150S/m,
the carbon fiber is high heat conductive carbon fiber powder, the diameter is less than 50 μm, the length is less than 500 μm, the carbon content is more than 99%, and the specific surface area is more than 0.4m2The electrical conductivity is more than 1000S/m, and the thermal conductivity is more than 400W/mK.
2. The method for preparing a reinforced nickel-based superalloy composite single crystal blade according to claim 1, wherein the ultra-fine single crystal or polycrystalline nickel powder particles in step (1) are spherical or spheroidal crystals and are added in an amount of more than 50 wt%.
3. The method for preparing the enhanced nickel-based superalloy composite single crystal blade according to claim 1, wherein the amount of the ultrafine single crystal or polycrystalline nickel powder particles added in the step (1) is 50 to 100 wt%.
4. The method for preparing the enhanced nickel-based superalloy composite single crystal blade according to claim 1, wherein the amount of the ultrafine single crystal or polycrystalline nickel powder particles added in the step (1) is 65 to 85 wt%.
5. The method for preparing the enhanced nickel-based superalloy composite single crystal blade according to claim 1, wherein the other ultrafine refractory metal powder in step (1) comprises one or more of tungsten, molybdenum, chromium, cobalt, rhenium, ruthenium, or tantalum, the powder is micron, submicron, or nano particles, the morphology is spherical or spheroidal, and the powder is crystalline or amorphous.
6. The method for preparing the reinforced nickel-based superalloy composite single crystal blade according to claim 1, wherein the reinforcing material is added in an amount of 0.01 to 10 wt% in the step (2).
7. The method for preparing the reinforced nickel-based superalloy composite single crystal blade according to claim 1, wherein the reinforcing material is added in an amount of 0.1 to 1 wt% in the step (2).
8. The method for preparing the enhanced nickel-based superalloy composite single crystal blade according to claim 1, wherein step (2) is mixing by dry ball milling or wet ball milling.
9. The method for preparing the reinforced nickel-based superalloy composite single crystal blade according to claim 1, wherein the melting temperature of the melting zone in the step (4) is controlled to be 1000-1600 ℃, the temperature gradient is greater than 50K/cm, the traction speed is 0.5-150mm/min, and air, water or liquid metal is adopted for cooling.
10. The method for preparing the reinforced nickel-based superalloy composite single crystal blade according to claim 1, wherein step (4) is performed by applying a pre-treatment external electromagnetic field before an unmelted melting area, and an included angle between a magnetic moment direction of the external electromagnetic field and an axial direction of a curved surface of the blade is always controlled to be less than 10 degrees.
11. The method for preparing the reinforced nickel-based superalloy composite single crystal blade according to claim 10, wherein the magnetic induction intensity of an external electromagnetic field is 0.1-100 tesla, and the direction of the external magnetic field and the axial direction of the blade are controlled to be 0-5 °.
12. The method for preparing the reinforced nickel-based superalloy composite single crystal blade according to claim 1, wherein the step (4) is that after the non-solidified smelting region, an after-treatment external electromagnetic field is applied, and the included angle between the magnetic moment direction of the external electromagnetic field and the axial direction of the curved surface of the blade is always controlled to be less than 10 degrees.
13. The method for preparing the reinforced nickel-based superalloy composite single crystal blade according to claim 12, wherein the magnetic induction intensity of an external electromagnetic field is 0.1-100 tesla, and the direction of the external magnetic field and the axial direction of the blade are controlled to be 0-5 °.
14. The method for preparing the reinforced nickel-based superalloy composite single crystal blade according to claim 1, wherein the composite single crystal blade is a solid blade or a hollow blade.
15. The method for preparing the reinforced nickel-based superalloy composite single crystal blade according to claim 1, wherein the manufactured composite blade is a single crystal blade, a columnar crystal blade, or an isometric crystal blade.
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