CN108326285B - 激光增材制造内韧外刚耐磨铁基合金所用粉料 - Google Patents
激光增材制造内韧外刚耐磨铁基合金所用粉料 Download PDFInfo
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Abstract
本发明提供了激光增材制造内韧外刚耐磨铁基合金所用粉料,所用内部合金粉料为低合金钢粉体材料,外部合金粉料为耐磨铁基合金复合粉体材料。采用激光熔化沉积技术,利用光纤激光加工系统进行激光增材制造内韧外刚耐磨铁基合金构件,所制得的铁基合金组织均匀,兼具表面强度、硬度高,心部韧性优异的特点,用于制造形状复杂、尺寸较大、对韧性和耐磨性能要求较高的轴类零部件,可为激光增材制造内韧外刚耐磨铁基合金轴类零部件提供合金粉体材料。
Description
技术领域
本发明涉及激光增材制造新材料技术领域,特别是涉及激光增材制造内韧外刚耐磨铁基合金所用粉料及其构件的成形的方法。
背景技术
铁基合金因其来源广、价格低廉及综合性能良好等优点被广泛应用于国民经济的各个领域,并随着社会的发展对铁基合金材料性能的要求日益提高。凸轮轴是以铁基合金为主要制备原料的高耐磨高韧性合金构件,被广泛应用于柴油发动机中。由于节能减排的需要,新型发动机的重量在逐渐减轻,体积逐渐减小,凸轮轴所承受载荷逐渐增大,如常规车用凸轮轴载荷一般为100~120 MPa,但对于新型高功率柴油机凸轮轴承载会达到180MPa。常规的渗碳淬火工艺已无法满足其使用需要,短周期内会出现渗碳层粘着磨损、疲劳点蚀与表面剥落等失效形式,从而影响发动机的使用寿命。因此,大幅度提高凸轮轴承载凸轮表面耐磨损性能是亟待解决的问题。
近年来激光增材制造技术生产大型金属零件已经成为研究热点。增材制造技术是采用材料逐渐累加的方法制造实体零件的技术,相对于传统的材料去除-切削加工技术,是一种“自下而上”的制造方法。与传统加工技术相比,激光增材制造技术具有制造过程柔性化程度高、产品生产周期短、加工速度快、能够生产复杂结构的零件等优势,同时可实现零部件的功能化设计。这对传统的加工制造业产生深刻的影响。故根据合金元素V和Cr在铁基合金中形成碳化物增强相强化铁基合金基体的规律及合金元素V和Cr对铁基合金组织结构和性能的影响规律,设计和研制不同V和Cr含量的新型合金粉料,用于激光增材制造内韧外刚耐磨铁基合金大功率承载轴类部件具有重要意义。激光增材制造内韧外刚耐磨铁基合金具有低成本、高硬度和良好的磨损性能等优点,可以代替传统的凸轮轴的大量机加工及后续的渗碳淬火工艺,可用于形状复杂、尺寸较大、对韧性和耐磨性要求较高的轴类零部件,如发动机凸轮轴、曲轴、核电应急柴油机凸轮轴等部件的制造。
发明内容
发明目的
本发明的目的是提供激光增材制造内韧外刚耐磨铁基合金所用粉料,采用激光熔化沉积技术,利用光纤激光加工系统进行激光增材制造内韧外刚耐磨铁基合金轴类部件,熔化沉积法制得的表层铁基合金显微组织均匀,并与心部激光增材制造低合金钢结合良好,且具备表面强度、硬度高,心部韧性优异的特点,为激光增材制造内韧外刚耐磨铁基合金轴类部件提供可用的铁基合金粉料。
技术方案
激光增材制造内韧外刚耐磨铁基合金所用粉料,内部低合金钢所用粉料组成质量百分比为C:0.05-0.15%,Cr:1.40-1.60%,Ni:1.70-2.0%,Si:1.00-1.20%,Mo:0.50-0.60%,Mn:0.10-0.50%,B:0.40-0.70%, V:0.50-0.60%,其余为Fe;
外部耐磨铁基合金所用粉料的组成质量百分比为C:0.78-2.19%,Cr:18.83-24.39%,Ni:1.17-1.54%,Si:1.11-1.14%,Mo:0.69-0.91%,Mn:0.35-0.45%,B:0.86-1.13%,Al:0.08-0.24%,V:2.0-8%,其余为Fe。
所述内部低合金钢所用粉料和外部耐磨铁基合金所用粉料的粒径为53~140微米。
一种使用如所述的激光增材制造内韧外刚耐磨铁基合金所用粉料制造内韧外刚耐磨铁基合金的方法,制造方法步骤如下:
1) 将所述成分的内部低合金钢所用粉料和外部耐磨铁基合金所用粉料分别经过真空熔炼、气雾化和筛分工序,制得球形粉末a和球形粉末b;
2) 将步骤1所得的球形粉末a和球形粉末b分别在烘箱中80-120℃烘干3小时以上,制得球形粉末a’和球形粉末b’;
3) 将低合金钢基板表面用60#-600#砂纸打磨、清洗干燥后备用,将步骤2所得的球形粉末a’采用同轴送粉的方式通过光纤激光加工系统辐照后在低合金钢基板上熔化沉积合金材料;
4) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为1.8-2.5kW,扫描速度为6-8mm/s,送粉率为13-18g/min,光斑直径为3.5-4.5mm,搭接率为45-55%,保护气氩气流量为400-500L/h,获得以α-Fe为基体的激光增材制造高韧性低合金钢心部材料;
5) 将步骤2所得所得的球形粉末b’采用同轴送粉的方式通过光纤激光加工系统辐照,在步骤4所获得的以α-Fe为基体的激光增材制造高韧性低合金钢心部材料表面熔化沉积外部耐磨合金材料;
6) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为1.8-2.5kW,扫描速度为6-8mm/s,送粉率度为13-18g/min,光斑直径为3.5-4.5mm,搭接率为45-55%,保护气氩气流量为400-500L/h,获得激光增材制造内韧外刚耐磨铁基合金。
所述步骤1中制得的球形粉末a和球形粉末b,其开心球率≤2%,含氧量≤250ppm,杂质含量<0.5%。
所述步骤1中制得的球形粉末a和球形粉末b,其流动性≤16s/50g。
所述步骤1中球形粉末a和球形粉末b的松装密度≥4.35g /cm3。
所述步骤4和步骤6中激光器扫描的方法为光纤激光器连续扫描一层回到XY平面原点坐标处,然后进行下一层扫描,每层Z轴移动距离0.6mm;经过多层扫描形成3维立体的内韧外刚耐磨铁基合金。
优点及效果
本发明的粉料通过激光熔化沉积技术增材制造内韧外刚耐磨铁基合金成形性良好、硬度较高、耐磨损性能优异,外部耐磨铁基合金与心部低合金钢材料结合良好、无缺陷,可以应用于同时对零件耐磨性和韧性有较高要求的工况条件下,具有良好的工程应用前景。激光增材制造技术大大缩短了生产周期,提高大尺寸、复杂结构零部件的制造效率和精度,同时激光增材制造过程也是快速凝固的过程,抑制晶粒长大,细化晶粒,使制备出的铁基合金组织均匀致密,机械性能良好,特别适用于对磨损性能要求较高的特定工况的使用需要,可以大大延长增材制造铁基合金转动部件的使用寿命。
钢中加Cr可以提高材料力学性能,还可改善钢的抗氧化性能和抗腐蚀性能。Cr可无限固溶于α-Fe,缩小γ-Fe相区,增加材料的抗腐蚀性能,还可以溶入渗碳体形成合金渗碳体增加材料的硬度。另外,钒(V)具有众多优异的物理性能和化学性能,因而钒在发展现代工业、现代国防和现代科学技术中用途十分广泛,有金属“维生素”之称,是不可缺少的重要工业原材料之一。在钢中加入百分之几的钒,细化钢的组织和晶粒,提高晶粒粗化温度,从而起到增加钢的强度、韧性和耐磨性。再者,钒与碳原子具有更强的结合能力,可形成更加稳定的高硬度碳化物(如V8C7),进而起到增加材料硬度的作用。另一方面,钒与碳原子的结合使得Cr原子更多的固溶于α-Fe中,增加材料的抗腐蚀性能。
附图说明
图1为激光增材制造心部低合金钢X-射线衍射图谱;
图2为激光增材制造内韧外刚耐磨铁基合金(V = 2.0,4.0,6.0,8.0 wt.%)的X-射线衍射图谱;
图3为激光增材制造内韧外刚耐磨铁基合金V = 2.0wt.%韧性-刚性材料结合区组织形貌的扫描电镜照片;
图4为激光增材制造内韧外刚耐磨铁基合金V = 4.0wt.%韧性-刚性材料结合区组织形貌的扫描电镜照片;
图5为激光增材制造内韧外刚耐磨铁基合金V = 6.0wt.%韧性-刚性材料结合区组织形貌的扫描电镜照片;
图6为激光增材制造内韧外刚耐磨铁基合金V = 8.0wt.%韧性-刚性材料结合区组织形貌的扫描电镜照片;
图7为激光增材制造内韧外刚耐磨铁基合金V = 2.0wt.%刚性材料组织形貌的扫描电镜照片;
图8为激光增材制造内韧外刚耐磨铁基合金V = 4.0wt.%刚性材料组织形貌的扫描电镜照片;
图9为激光增材制造内韧外刚耐磨铁基合金V = 6.0wt.%刚性材料组织形貌的扫描电镜照片;
图10为激光增材制造内韧外刚耐磨铁基合金V = 8.0wt.%刚性材料组织形貌的扫描电镜照片;
图11为激光增材制造内韧外刚耐磨铁基合金(V = 2.0,4.0,6.0,8.0 wt.%)界面附近显微硬度分布曲线;
图12为激光增材制造内韧外刚耐磨铁基合金V = 2.0wt.%刚性材料表面磨痕形貌的扫描电镜照片;
图13为激光增材制造内韧外刚耐磨铁基合金V = 4.0wt.%刚性材料表面磨痕形貌的扫描电镜照片;
图14为激光增材制造内韧外刚耐磨铁基合金V = 6.0wt.%刚性材料表面磨痕形貌的扫描电镜照片;
图15为激光增材制造内韧外刚耐磨铁基合金V = 8.0 wt.%刚性材料表面磨痕形貌的扫描电镜照片。
具体实施方式
本发明提供激光增材制造内韧外刚耐磨铁基合金所用粉料及制造内韧外刚耐磨铁基合金的方法,利用光纤激光加工系统在低合金钢基板表面同轴送粉,高能束激光辐照下低合金钢粉末材料与耐磨铁基合金粉末迅速熔化并沉积,在快速冷凝条件下,激光增材制造耐磨铁基合金与低合金钢相互结合形成内韧外刚耐磨铁基合金。
激光增材制造内韧外刚耐磨铁基合金所用粉料,内部低合金钢所用粉料组成质量百分比为C:0.05-0.15%,Cr:1.40-1.60%,Ni:1.70-2.0%,Si:1.0-1.20%,Mo:0.50-0.60%,Mn:0.10-0.50%,B:0.40-0.70%, V:0.50-0.60%,其余为Fe;外部耐磨铁基合金所用粉料的组成质量百分比为C:0.78-2.19%,Cr:18.83-24.39%,Ni:1.17-1.54%,Si:1.11-1.14%,Mo:0.69-0.91%,Mn:0.35-0.45%,B:0.86-1.13%,Al:0.08-0.24%,V:2.0-8%,其余为Fe。内部低合金钢所用粉料和外部耐磨铁基合金所用粉料的粒径为53~140微米。
使用上述的激光增材制造内韧外刚耐磨铁基合金所用粉料制造内韧外刚耐磨铁基合金的方法,制造方法步骤如下:
1) 将所述成分的内部低合金钢所用粉料和外部耐磨铁基合金所用粉料分别经过真空熔炼、气雾化和筛分工序,制得球形粉末a和球形粉末b;其开心球率≤2%,含氧量≤250ppm,杂质含量<0.5%,流动性≤16s/50g,松装密度≥4.35g /cm3;
2) 将步骤1所得的球形粉末a和球形粉末b分别在烘箱中80-120℃烘干3小时以上,制得球形粉末a’和球形粉末b’;
3) 将低合金钢基板表面用60#-600#砂纸打磨、清洗干燥后备用,将步骤2所得的球形粉末a’采用同轴送粉的方式通过光纤激光加工系统辐照后在低合金钢基板上熔化沉积合金材料;
4) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为1.8-2.5kW,扫描速度为6-8mm/s,送粉率为13-18g/min,光斑直径为3.5-4.5mm,搭接率为45-55%,保护气氩气流量为400-500L/h,获得以α-Fe为基体的激光增材制造高韧性低合金钢心部材料;
5) 将步骤2所得所得的球形粉末b’采用同轴送粉的方式通过光纤激光加工系统辐照,在步骤4所获得的以α-Fe为基体的激光增材制造高韧性低合金钢心部材料表面熔化沉积外部耐磨合金材料;
6) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为1.8-2.5kW,扫描速度为6-8mm/s,送粉率度为13-18g/min,光斑直径为3.5-4.5mm,搭接率为45-55%,保护气氩气流量为400-500L/h,获得激光增材制造内韧外刚耐磨铁基合金。
上述步骤4和步骤6中激光器扫描的方法为光纤激光器连续扫描一层回到XY平面原点坐标处,然后进行下一层扫描,每层Z轴移动距离0.6mm;经过多层扫描形成3维立体的内韧外刚耐磨铁基合金。
利用MFT-4000型多功能材料表面性能测试仪,采用球-盘点接触方式评价内韧外刚耐磨铁基合金的磨损性能。线切割试块尺寸为10mm×10mm×10mm。样块依次经过600、1000、1400、2000号砂纸打磨,经机械抛光获得镜面表面,以排除增材制造铁基合金表面粗糙度对摩擦磨损性能的影响。摩擦磨损试验法向载荷15N;磨损时间60min;往复速度120mm/min;位移幅值7mm,上摩擦副为直径5mm的Si3N4球,下摩擦副为沉积耐磨态铁基合金试块,试验温度为20℃。通过白光干涉实验测试试块的磨损体积。
以下结合实施例详述本发明,但本发明不局限于下述实施例。
实施例1
粉料组成质量百分比为C:0.05%,Cr:1.40%,Ni:1.70%,Si:1.00%,Mo:0.50%,Mn:0.10%,B:0.40%,V:0.50%,其余为Fe。粉料的粒径为53~140微米。
采用激光熔化沉积技术制备心部高韧性低合金钢,具体制备工艺步骤是:
1) 将上述成分的合金原料经过真空熔炼、气雾化和筛选工序,制得球形粉末;制得的球形粉末,其开心球率≤2%,含氧量≤ 250ppm,杂质含量< 0.5%,流动性≤16s/50g;球形粉末的松装密度≥4.35g /cm3;
2) 将步骤1所得粉料在烘箱中80℃烘干3小时以上;
3) 将低合金钢基板表面用60#-600#砂纸打磨、清洗干燥后备用,将步骤2所得低合金钢粉料采用同轴送粉的方式通过光纤激光加工系统辐照后在合金钢基板表面进行熔化沉积韧性合金材料;
4) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为2.2kW,扫描速度为8mm/s,送粉率为18g/min,光斑直径为4mm,搭接率为50%,保护气氩气流量为400L/h,获得以α-Fe为基体的激光增材制造低合金钢韧性材料;
上述步骤4中激光器扫描的方法为光纤激光器连续扫描一层回到XY平面原点坐标处,然后进行下一层扫描,每层Z轴移动距离0.6mm;经过多层打印形成3维立体的低合金钢材料。
实施例2
低合金钢粉料组成质量百分比为C:0.05%,Cr:1.40%,Ni:1.70%,Si:1.00%,Mo:0.50%,Mn:0.10%,B:0.40%,V:0.50%其余为Fe。耐磨铁基合金粉料组成质量百分比为C:0.78%,Cr:18.83%,Ni:1.54%,Si:1.14%,Mo:0.91%,Mn:0.45%,B:1.13%,Al:0.08%,V:2.00%,其余为Fe。粉料的粒径为53~140微米。
采用激光熔化沉积技术制备内韧外刚耐磨铁基合金,具体制备工艺步骤是:
1) 将上述成分的合金原料分别经过真空熔炼、气雾化和筛分工序,制得球形粉末;制得的球形粉末,其开心球率≤2%,含氧量≤ 250ppm,杂质含量< 0.5%,流动性≤16s/50g;球形粉末的松装密度≥4.35g /cm3;
2) 将步骤1所得粉料在烘箱中80℃烘干3小时以上;
3) 将低合金钢基板表面用60#-600#砂纸打磨、清洗干燥后备用,将步骤2所得低合金钢粉料采用同轴送粉的方式通过光纤激光加工系统辐照后在合金钢基板表面进行熔化沉积;
4) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为1.8kW,扫描速度为6mm/s,送粉率为13g/min,光斑直径为3.5mm,搭接率为45%,保护气氩气流量为400L/h,获得以α-Fe为基体的激光增材制造低合金钢材料;
5) 将步骤2所得耐磨铁基合金粉料采用同轴送粉的方式通过光纤激光加工系统辐照后在步骤4所获得的以α-Fe为基体的激光增材制造低合金钢构件表面熔化沉积外部耐磨合金材料;
6) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为1.8kW,扫描速度为6mm/s,送粉率为13g/min,光斑直径为3.5mm,搭接率为45%,保护气氩气流量为400L/h,获得主要由α-Fe和Cr23C6相结构组成的激光增材制造内韧外刚耐磨铁基合金。
上述步骤4和步骤6中激光器扫描的方法为光纤激光器连续扫描一层回到XY平面原点坐标处,然后进行下一层扫描,每层Z轴移动距离0.6mm;经过多层打印形成3维立体的内韧外刚耐磨铁基合金。
实施例3
低合金钢粉料组成质量百分比为C:0.10%,Cr:1.50%,Ni:1.85%,Si:1.15%,Mo:0.55%,Mn:0.30%,B:0.55%,V:0.55%,其余为Fe。耐磨铁基合金粉料组成质量百分比为C:1.18%,Cr:20.44%,Ni:1.44%,Si:1.13%,Mo:0.85%,Mn:0.42%,B:1.06%,Al:0.12%,V:4.00%,其余为Fe。粉料的粒径为53~140微米。
采用激光熔化沉积技术制备内韧外刚耐磨铁基合金,具体制备工艺步骤是:
1) 将上述成分的合金原料分别经过真空熔炼、气雾化和筛分工序,制得球形粉末;制得的球形粉末,其开心球率≤2%,含氧量≤ 250ppm,杂质含量< 0.5%,流动性≤16s/50g;球形粉末的松装密度≥4.35g /cm3;
2) 将步骤1所得粉料在烘箱中80℃烘干3小时以上;
3) 将低合金钢基板表面用60#-600#砂纸打磨、清洗干燥后备用,将步骤2所得低合金钢粉料采用同轴送粉的方式通过光纤激光加工系统辐照后在合金钢基板表面熔化沉积;
4) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为2kW,扫描速度为7mm/s,送粉率为15g/min,光斑直径为4mm,搭接率为50%,保护气氩气流量为425L/h,获得以α-Fe为基体的激光增材制造低合金钢心部材料。
5) 将步骤2所得耐磨铁基合金粉料采用同轴送粉的方式通过光纤激光加工系统辐照后在步骤4所获得的以α-Fe为基体的激光增材制造低合金钢构件表面熔化沉积外部耐磨合金材料;
6) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为2kW,扫描速度为7mm/s,送粉率为15g/min,光斑直径为4mm,搭接率为50%,保护气氩气流量为425L/h,获得主要由α-Fe、Cr23C6和V2C相结构组成的激光增材制造内韧外刚耐磨铁基合金构件。
上述步骤4和步骤6中激光器扫描的方法为光纤激光器连续扫描一层回到XY平面原点坐标处,然后进行下一层扫描,每层Z轴移动距离0.6mm;经过多层打印形成3维立体的内韧外刚耐磨铁基合金。
实施例4
低合金钢粉料组成质量百分比为C:0.15%,Cr:1.55%,Ni:1.90%,Si:1.55%,Mo:0.55%,Mn:0.45%,B:0.60%,V:0.60%,其余为Fe。耐磨铁基合金粉料组成质量百分比为C:1.65%,Cr:22.24%,Ni:1.31%,Si:1.12%,Mo:0.77%,Mn:0.39%,B:0.96%,Al:0.18%,V:6.00%,其余为Fe。粉料的粒径为53~140微米。
采用激光熔化沉积技术制备内韧外刚耐磨铁基合金,具体制备工艺步骤是:
1) 将上述成分的合金原料分别经过真空熔炼、气雾化和筛分工序,制得球形粉末;制得的球形粉末,其开心球率≤2%,含氧量≤ 250ppm,杂质含量< 0.5%,流动性≤16s/50g;球形粉末的松装密度≥4.35g /cm3;
2) 将步骤1所得粉料在烘箱中80℃烘干3小时以上;
3) 将低合金钢基板表面用60#-600#砂纸打磨、清洗干燥后备用,将步骤2所得低合金钢粉料采用同轴送粉的方式通过光纤激光加工系统辐照后在合金钢基板表面熔化沉积合金材料;
4) 采用光纤激光加工系统进行多次激光辐照处理,激光功率为2.3kW,扫描速度为7.5mm/s,送粉率为16g/min,光斑直径为4.2mm,搭接率为50%,保护气氩气流量为450L/h,获得以α-Fe为基体的激光增材制造高韧性低合金钢心部材料。
5) 将步骤2所得耐磨铁基合金粉料采用同轴送粉的方式通过光纤激光加工系统辐照后在步骤4所获得的以α-Fe为基体的激光增材制造低合金钢构件表面熔化沉积外部耐磨合金材料;
6) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为2.3kW,扫描速度为7.5mm/s,送粉率为16g/min,光斑直径为4.2mm,搭接率为50%,保护气氩气流量为450L/h,获得主要由α-Fe、Cr23C6和V2C相结构组成的激光增材制造内韧外刚耐磨铁基合金构件。
上述步骤4和步骤6中激光器扫描的方法为光纤激光器连续扫描一层回到XY平面原点坐标处,然后进行下一层扫描,每层Z轴移动距离0.6mm;经过多层打印形成3维立体的内韧外刚耐磨铁基合金。
实施例5
低合金钢粉料组成质量百分比为C:0.15%,Cr:1.60%,Ni:2.0%,Si:1.20%,Mo:0.60%,Mn:0.50%,B:0.70%,V:0.60%,其余为Fe。耐磨铁基合金粉料组成质量百分比为C:2.19%,Cr:24.39%,Ni:1.17%,Si:1.11%,Mo:0.69%,Mn:0.35%,B:0.86%,Al:0.24%,V:8.00%,其余为Fe。粉料的粒径为53~140微米。
采用激光熔化沉积技术制备内韧外刚耐磨铁基合金,具体制备工艺步骤是:
1) 将上述成分的合金原料分别经过真空熔炼、气雾化和筛分工序,制得球形粉末;制得的球形粉末,其开心球率≤2%,含氧量≤250ppm,杂质含量< 0.5%,流动性≤16s/50g;球形粉末的松装密度≥4.35g /cm3;
2) 将步骤1所得粉料在烘箱中80℃烘干3小时以上;
3) 将低合金钢基板表面用60#-600#砂纸打磨、清洗干燥后备用,将步骤2所得低合金钢粉料采用同轴送粉的方式通过光纤激光加工系统辐照后在合金钢基板表面熔化沉积合金材料;
4) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为2.5kW,扫描速度为8mm/s,送粉率为18g/min,光斑直径为4.5mm,搭接率为55%,保护气氩气流量为500L/h,获得以α-Fe为基体的激光增材制造高韧性低合金钢心部材料。
5) 将步骤2所得耐磨铁基合金粉料采用同轴送粉的方式通过光纤激光加工系统辐照,在步骤4所获得的以α-Fe为基体的激光增材制造高韧性低合金钢构件表面熔化沉积外部耐磨合金材料;
6) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为2.5kW,扫描速度为8mm/s,送粉率为18g/min,光斑直径为4.5mm,搭接率为55%,保护气氩气流量为500L/h,获得主要由α-Fe、Cr23C6和V8C7相结构组成的激光增材制造内韧外刚耐磨铁基合金构件。
上述步骤4和步骤6中激光器扫描的方法为光纤激光器连续扫描一层回到XY平面原点坐标处,然后进行下一层扫描,每层Z轴移动距离0.6mm;经过多层打印形成3维立体的内韧外刚耐磨铁基合金。
通过实施例说明,耐磨铁基合金与激光增材制造低合金钢结合良好,结合区无气孔裂纹等缺陷,避免了不同成分合金结合区的缺陷问题。V元素可以细化铁基合金的组织和晶粒,提高晶粒粗化温度,从而增加钢的强度、韧性和耐磨性;Cr元素和C元素则可以增加铁基合金的硬度。随合金粉料中C、V和Cr元素含量的增加,耐磨铁基合金的组织得到明显的细化,铁基合金中Cr23C6、V2C及V8C7等硬质相生成,有利于提高耐磨铁基合金的硬度和耐磨性。内韧外刚耐磨铁基合金用于对硬度、耐磨性和韧性要求较高的轴类零部件的激光增材制造。
以下结合附图对本发明做进一步的说明:
图1为实施例1所述心部激光增材制造低合金钢X射线衍射图谱,可以看见心部激光增材制造低合金钢由α-Fe相组成,其硬度较低约为310HV,延伸率为18%。
图2为采用相同的激光辐照工艺参数,激光增材制造耐磨不锈钢内韧外刚耐磨铁基合金(V = 2.0,4.0,6.0,8.0 wt.%)X射线衍射图谱。合金粉末中C、Cr和V含量的增加,导致耐磨铁基合金相结构的改变。当V=2.0 wt.%时,铁基合金粉末中对应的C、Cr元素分别为0.78 wt.%和18.83 wt.%,粉末中C、Cr和V元素含量相对较少,沉积态耐磨铁基合金由α-Fe基体相和Cr23C6硬质相组成,随着合金粉末中C、Cr和V的增加,V2C和V8C7衍射峰相继出现。V和Cr是强碳化物形成元素,C和V元素的增加使钒的碳化物形成驱动力增强,致使粉末中形成V2C和相对稳定的V8C7相。以α-Fe相结构为基体的心部低合金钢与外部含有碳化物硬质相的α-Fe相耐磨合金钢共同构成内韧外刚性耐磨铁基合金,与传统渗碳淬火工艺相比,原位自生硬质相的形成对合金材料耐磨性的提高效果更优。
图3、图4、图5和图6为激光增材制造内韧外刚耐磨铁基合金(V = 2.0,4.0,6.0,8.0 wt.%)结合区微观组织形貌照片,从图中可以看出耐磨铁基合金与心部激光增材制造低合金钢结合良好,结合处均匀致密,无气孔裂纹等缺陷。
图7、图8、图9和图10为激光增材制造内韧外刚耐磨铁基合金(V = 2.0,4.0,6.0,8.0 wt.%)微观组织形貌照片;从图中可以看出,随着C、Cr和V含量的升高,胞状树枝晶晶粒尺寸先减小后增大,组织内分布着的细小的白色和黑色碳化物颗粒则逐渐增多。这是因为V元素在铁基合金内可以起到细化晶粒的作用,而随着C和V含量的增加,钒的碳化物形成驱动力增强,大部分C和V元素得以结合,生成V2C和V8C7,使分布在晶间组织内的元素含量减少,V元素对晶粒的细化效果减弱。Cr含量的升高使其与C元素结合率增加,促进了铁基合金中Cr23C6的生成。激光增材制造过程是快速熔凝过程,在该过程中凝固界面的温度梯度大,凝固速度高,导致晶粒不能正常长大,使铁基合金组织进一步细化,均匀致密的显微组织有利于提高铁基合金材料的硬度,从而进一步改善铁基合金材料的耐磨损性能。
图11为激光增材制造内韧外刚耐磨铁基合金(V = 2.0,4.0,6.0,8.0 wt.%)的显微硬度分布曲线;构件外部耐磨铁基合金(V = 2.0,4.0,6.0,8.0 wt.%)的显微硬度分别为815HV、831HV、781HV和667HV。随着合金粉末中C、Cr和V元素含量的增加,耐磨铁基合金的显微硬度先增后减。这是由于沉积试样中C、Cr和V含量的增加加重铁基合金组织内晶格畸变,促进了固溶强化效果,从而使铁基合金硬度升高。碳化物的形成也在一定程度上提高了铁基合金的硬度,但逐渐增多的碳化物减少了晶粒内和晶间组织中固溶的合金元素含量,使铁基合金组织晶格畸变减弱,使固溶强化的效果降低,使硬度降低。激光增材制造内韧外刚耐磨铁基合金的表层硬度普遍高于传统渗碳淬火工艺制备的凸轮轴表面硬度。
图12、图13、图14和图15为激光增材制造内韧外刚耐磨铁基合金(V = 2.0,4.0,6.0,8.0 wt.%)磨损试块表面磨痕形貌的扫描电镜照片。在摩擦磨损过程中,低V粉料激光增材制造内韧外刚耐磨铁基合金表面发生明显的剥落,从扫描形貌中可以看到明显的落坑。随着外部耐磨合金粉末中V元素和Cr元素含量的增加,激光增材制造内韧外刚耐磨铁基合金的磨损表面落坑明显变少,表面磨损剥落情况减弱,耐磨性增强。但在V=8.0 wt.%粉末中,因为激光增材制造内韧外刚外部耐磨铁基合金的表面硬度降低,耐磨性减弱,表面磨损剥落情况再次加重。经实验检测分析,激光增材制造内韧外刚耐磨铁基合金(V = 2.0,4.0,6.0,8.0 wt.%)的相对耐磨性(心部韧性低合金钢磨损体积/外部耐磨铁基合金磨损体积)分别为19.6、20.1、21.7和17.8。
Claims (5)
1.一种使用激光增材制造内韧外刚耐磨铁基合金所用粉料制造内韧外刚耐磨铁基合金的方法,其特征在于:
内部低合金钢所用粉料组成质量百分比为C:0.05-0.15%,Cr:1.40-1.60%,Ni:1.70-2.0%,Si:1.00-1.20%,Mo:0.50-0.60%,Mn:0.10-0.50%,B:0.40-0.70%, V:0.50-0.60%,其余为Fe;
外部耐磨铁基合金所用粉料的组成质量百分比为C:0.78-2.19%,Cr:18.83-24.39%,Ni:1.17-1.54%,Si:1.11-1.14%,Mo:0.69-0.91%,Mn:0.35-0.45%,B:0.86-1.13%,Al:0.08-0.24%,V:2.0-8%,其余为Fe;
所述内部低合金钢所用粉料和外部耐磨铁基合金所用粉料的粒径为53~140微米;
制造方法步骤如下:
1) 将所述成分的内部低合金钢所用粉料和外部耐磨铁基合金所用粉料分别经过真空熔炼、气雾化和筛分工序,制得球形粉末a和球形粉末b;
2) 将步骤1所得的球形粉末a和球形粉末b分别在烘箱中80-120℃烘干3小时以上,制得球形粉末a’和球形粉末b’;
3) 将低合金钢基板表面用60#-600#砂纸打磨、清洗干燥后备用,将步骤2所得的球形粉末a’采用同轴送粉的方式通过光纤激光加工系统辐照后在低合金钢基板上熔化沉积合金材料;
4) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为1.8-2.5kW,扫描速度为6-8mm/s,送粉率为13-18g/min,光斑直径为3.5-4.5mm,搭接率为45-55%,保护气氩气流量为400-500L/h,获得以α-Fe为基体的激光增材制造高韧性低合金钢心部材料;
5) 将步骤2所得的球形粉末b’采用同轴送粉的方式通过光纤激光加工系统辐照,在步骤4所获得的以α-Fe为基体的激光增材制造高韧性低合金钢心部材料表面熔化沉积外部耐磨合金材料;
6) 采用光纤激光加工系统进行多次激光辐照处理,激光器输出功率为1.8-2.5kW,扫描速度为6-8mm/s,送粉率度为13-18g/min,光斑直径为3.5-4.5mm,搭接率为45-55%,保护气氩气流量为400-500L/h,获得激光增材制造内韧外刚耐磨铁基合金。
2.根据权利要求1所述的激光增材制造内韧外刚耐磨铁基合金所用粉料制造内韧外刚耐磨铁基合金的方法,其特征在于:所述步骤1中制得的球形粉末a和球形粉末b,其开心球率≤2%,含氧量≤250ppm,杂质含量<0.5%。
3.根据权利要求1所述的激光增材制造内韧外刚耐磨铁基合金所用粉料制造内韧外刚耐磨铁基合金的方法,其特征在于:所述步骤1中制得的球形粉末a和球形粉末b,其流动性≤16s/50g。
4.根据权利要求1所述的激光增材制造内韧外刚耐磨铁基合金所用粉料制造内韧外刚耐磨铁基合金的方法,其特征在于:所述步骤1中球形粉末a和球形粉末b的松装密度≥4.35g /cm3。
5.根据权利要求1所述的激光增材制造内韧外刚耐磨铁基合金所用粉料制造内韧外刚耐磨铁基合金的方法,其特征在于:所述步骤4和步骤6中激光器扫描的方法为光纤激光器连续扫描一层回到XY平面原点坐标处,然后进行下一层扫描,每层Z轴移动距离0.6mm;经过多层扫描形成3维立体的内韧外刚耐磨铁基合金。
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