CN107900341B - 一种激光选区熔化成形大尺寸高性能偏晶合金的方法 - Google Patents

一种激光选区熔化成形大尺寸高性能偏晶合金的方法 Download PDF

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CN107900341B
CN107900341B CN201711389074.9A CN201711389074A CN107900341B CN 107900341 B CN107900341 B CN 107900341B CN 201711389074 A CN201711389074 A CN 201711389074A CN 107900341 B CN107900341 B CN 107900341B
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周圣丰
戴晓琴
谢敏
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Abstract

一种激光选区熔化成形大尺寸高性能偏晶合金的方法，该方法的特点为：铜铁基合金粉末进行机械合金化处理后粒径为30μm；采用激光选区熔化的方法制备大尺寸高性能偏晶合金；其中，铜铁基合金粉末化学成分为：Cu 58.3wt.％，Fe 22.2wt.％，P 5.07wt.％，W 3.07wt.％，Mo 1.02wt.％，Cr 2.05wt.％，Ni 2.06wt.％，Si 1.02wt.％，Mn 0.34wt.％，C 0.34wt.％，Nb 1.23wt.％，HfO20.8wt.％与TiB22.5wt.％；采用该方法制备的偏晶合金尺寸可达150mm×150mm×150mm或Φ150mm×150mm，TiB2颗粒与由于液相分离而自组装生成的非晶富铁颗粒均匀分布于富铜基体内；硬度是黄铜7倍，耐磨性是黄铜的5倍，电导率为65％IACS，室温最大饱和磁化强度为150emu/g，矫顽力为15Oe。

Description

一种激光选区熔化成形大尺寸高性能偏晶合金的方法
技术领域
本发明涉及一种激光选区熔化成形大尺寸高性能偏晶合金的方法，属于激光增材制造或激光3D打印技术领域。
背景技术
当具有亚稳态难混溶区间的偏晶合金处于过冷液相区时，可自发地分离成两种熔体：L1是少量熔体，L2是主要熔体。当凝固后，球状微量相颗粒弥散分布在主体相金属基体内而形成难混溶合金，这些合金具有许多新性能，如高强度、高导电性、优异的软磁性能和巨磁电阻效应，因此被用作结晶器、电源插头、磁带、光学仪器和传感器等。尤其是Cu-Fe偏晶合金，因Fe与Cr、Nb和Ag等相比，具有成本较低的特点，在工业领域中具有巨大的发展前景。
但是，采用传统凝固技术制备的Cu-Fe偏晶合金，由于受到具有不同密度的两种液态熔体的影响，极易发生组织偏析，因而成为Cu-Fe偏晶合金在工业领域广泛应用的主要难点。为了克服这一难题，得到由弥散分布于金属基体中的少量球形颗粒组成的结构，研究者提出了诸如落管技术、无容器超过冷技术、气雾化、电磁悬浮技术等方法。但是，这些方法并不能有效解决由Marangoni运动与Stokes运动导致的颗粒之间的碰撞、合并与长大，很难获得结构尺寸较大且第二相颗粒弥散分布的偏晶合金，极大地限制了偏晶合金的大规模制备及应用领域。
激光选区熔化技术是采用精细激光束快速熔化预置粉末材料，几乎可以直接获得任意形状以及具有完全冶金结合的功能零件，致密度可达到几乎100％，尺寸精度达20～50微米，表面粗糙度达20～30微米，是一种极具发展前景的快速成形技术，尤其是其超快加热与超快冷却速度以及超高过冷度的特征，为常规方法难以生产的材料开辟了一个全新的增材制造方法，受到了研究者的广泛关注。但是，关于激光选区熔化成形大尺寸高性能偏晶合金的方法并未见文献报道。
发明内容
本发明的目的在于提供一种激光选区熔化成形大尺寸高性能偏晶合金的方法。本发明是这样来实现的，其方法与步骤为：
(1)将铜铁基合金粉末在高能球磨机内进行机械合金化处理，然后放置于自动刮粉器的装料斗内；
(2)将带有支撑结构的偏晶合金零件CAD模型分层切片，根据切片轮廓信息生成一系列激光选区熔化成形轨迹；将激光选区熔化工作室抽成真空，将表面经过除锈与喷砂处理的基材加热到200℃；根据生成的成形轨迹，采用激光选区熔化的方法逐层堆积成三维实体的偏晶合金。
本发明在进行所述的步骤(1)时，铜铁基合金粉末化学成分为：Cu 58.3wt.％，Fe22.2wt.％，P 5.07wt.％，W 3.07wt.％，Mo 1.02wt.％，Cr 2.05wt.％，Ni 2.06wt.％，Si1.02wt.％，Mn 0.34wt.％，C 0.34wt.％，Nb 1.23wt.％，HfO20.8wt.％与TiB2 2.5wt.％；机械合金化工艺参数为：高能球磨机转速为240转/分，球磨气氛为氩气，不锈钢球与铜铁基合金粉质量比为15：1，不锈钢球直径为8mm，采用球磨40分钟然后暂停10分钟的方法球磨60小时，球磨后铜铁基合金粉末粒径为30μm。
本发明在进行所述的步骤(2)时，制备支撑结构的工艺参数为：光纤激光器波长为1060nm，激光功率P＝200W，支撑结构高度为2mm，激光扫描速度为500mm/s，分层切片厚度为50μm，搭接率为50％；制备偏晶合金零件的工艺参数：激光功率P＝200W，激光扫描速度为2500mm/s，分层切片厚度为50μm，搭接率为50％，采用连续两层间激光扫描方向相互垂直的路径方式成形切片，直到完成尺寸达150mm×150mm×150mm或Φ150mm×150mm偏晶合金零件制造。
本发明在进行所述的步骤(2)时，偏晶合金的结构特征为：TiB2颗粒与由于液相分离而自组装生成的非晶富铁颗粒均匀分布于富铜基体内；偏晶合金的性能特征为：硬度是黄铜7倍，耐磨性是黄铜的5倍，电导率为65％IACS，室温最大饱和磁化强度为150emu/g，矫顽力为15Oe。
本发明的优点是：(1)可以制备形状复杂与结构尺寸大的偏晶合金；(2)非晶球状富Fe颗粒均匀分布于富铜基体内；(3)偏晶合金的力学性能得到大幅度提高，硬度是黄铜7倍，耐磨性是黄铜的5倍；(4)偏晶合金还表现出优异的软磁性能与导电性能，如电导率为65％IACS，室温最大饱和磁化强度为150emu/g，矫顽力为15Oe。
具体实施方式
在基材为A3钢表面，采用激光选区熔化的方法制备大尺寸高性能偏晶合金，制备的尺寸为150mm×150mm×150mm(长×宽×高)或Φ150mm×150mm,显微结构特征为：TiB2颗粒与由于液相分离而自组装生成的非晶富铁颗粒均匀分布于富铜基体内；检测的性能为：硬度是黄铜7倍，耐磨性是黄铜的5倍；电导率为65％IACS，室温最大饱和磁化强度为150emu/g，矫顽力为15Oe。具体实施过程如下：
(1)将铜铁基合金粉末在高能球磨机内进行机械合金化处理，然后放置于自动刮粉器的装料斗内，铜铁基合金粉末化学成分为：Cu 58.3wt.％，Fe 22.2wt.％，P5.07wt.％，W 3.07wt.％，Mo 1.02wt.％，Cr 2.05wt.％，Ni 2.06wt.％，Si 1.02wt.％，Mn0.34wt.％，C 0.34wt.％，Nb 1.23wt.％，HfO2 0.8wt.％与TiB22.5wt.％；机械合金化工艺参数为：高能球磨机转速为240转/分，球磨气氛为氩气，不锈钢球与铜铁基合金粉质量比为15：1，不锈钢球直径为8mm，采用球磨40分钟然后暂停10分钟的方法球磨60小时，球磨后铜铁基合金粉末粒径为30μm；
(2)将带有支撑结构的偏晶合金零件CAD模型分层切片，根据切片轮廓信息生成一系列激光选区熔化成形轨迹；将激光选区熔化工作室抽成真空，将表面经过除锈与喷砂处理的基材加热到200℃；根据生成的成形轨迹，采用激光选区熔化的方法逐层堆积成三维实体的偏晶合金；制备支撑结构的工艺参数为：光纤激光器波长为1060nm，激光功率P＝200W，支撑结构高度为2mm，激光扫描速度为500mm/s，分层切片厚度为50μm，搭接率为50％；制备偏晶合金零件的工艺参数：激光功率P＝200W，激光扫描速度为2500mm/s，分层切片厚度为50μm，搭接率为50％，采用连续两层间激光扫描方向相互垂直的路径方式成形切片，直到完成尺寸达150mm×150mm×150mm或Φ150mm×150mm偏晶合金零件制造。

Claims (1)

1.一种激光选区熔化成形大尺寸高性能偏晶合金的方法，其方法与步骤为：
(1)将铜铁基合金粉末在高能球磨机内进行机械合金化处理，然后放置于自动刮粉器的装料斗内，铜铁基合金粉末化学成分为：Cu 58.3wt.％，Fe 22.2wt.％，P 5.07wt.％，W3.07wt.％，Mo 1.02wt.％，Cr 2.05wt.％，Ni 2.06wt.％，Si 1.02wt.％，Mn 0.34wt.％，C0.34wt.％，Nb 1.23wt.％，HfO2 0.8wt.％与TiB2 2.5wt.％；机械合金化工艺参数为：高能球磨机转速为240转/分，球磨气氛为氩气，不锈钢球与铜铁基合金粉质量比为15：1，不锈钢球直径为8mm，采用球磨40分钟然后暂停10分钟的方法球磨60小时，球磨后铜铁基合金粉末粒径为30μm；
(2)将带有支撑结构的偏晶合金零件CAD模型分层切片，根据切片轮廓信息生成一系列激光选区熔化成形轨迹；将激光选区熔化工作室抽成真空，将表面经过除锈与喷砂处理的基材加热到200℃；根据生成的成形轨迹，采用激光选区熔化的方法逐层堆积成尺寸达150mm×150mm×150mm或Φ150mm×150mm三维实体的偏晶合金；
制备支撑结构的工艺参数为：光纤激光器波长为1060nm，激光功率P＝200W，支撑结构高度为2mm，激光扫描速度为500mm/s，分层切片厚度为50μm，搭接率为50％；制备偏晶合金零件的工艺参数：激光功率P＝200W，激光扫描速度为2500mm/s，分层切片厚度为50μm，搭接率为50％，采用连续两层间激光扫描方向相互垂直的路径方式成形切片，直到完成偏晶合金零件制造；
偏晶合金的结构特征为：TiB2颗粒与由于液相分离而自组装生成的非晶富铁颗粒均匀分布于富铜基体内；偏晶合金的性能特征为：硬度是黄铜7倍，耐磨性是黄铜的5倍，电导率为65％IACS，室温最大饱和磁化强度为150emu/g，矫顽力为15Oe。
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CN112605396B (zh) * 2020-12-09 2022-07-12 暨南大学 一种激光选区熔化成形铁基非晶增强铜基偏晶复合材料的方法
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