CN111074268A - 一种用于超高速激光熔覆的铁基金属粉末、其制备方法及其应用 - Google Patents

一种用于超高速激光熔覆的铁基金属粉末、其制备方法及其应用 Download PDF

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CN111074268A
CN111074268A CN202010000985.3A CN202010000985A CN111074268A CN 111074268 A CN111074268 A CN 111074268A CN 202010000985 A CN202010000985 A CN 202010000985A CN 111074268 A CN111074268 A CN 111074268A
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metal powder
powder
iron
laser cladding
based metal
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王淼辉
葛学元
杜博睿
申博文
徐一斐
肖宁
郝胜
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China Machinery New Material Research Institute (Zhengzhou) Co.,Ltd.
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Beijing Jike Guochuang Lightweight Science Research Institute Co Ltd
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Abstract

本发明提供的一种用于超高速激光熔覆的铁基金属粉末、其制备方法及其应用，其中所述铁基金属粉末的化学成分及其质量百分比为：C 0.6～1.0％，Cr 17.0～20.0％，Ni 5.0～6.5％，Mn 2.0～4.0％，Mo 1.0～1.5％，Ti 4.0～6.0％，B 1.0～1.5％，N 0.08～0.15％，Si≤0.5％，P≤0.030％，S≤0.030％，余量为Fe和不可避免的杂质。该金属粉末粒径为：15～65μm，流动性：16～20s/50g。本发明还提供应用上述金属粉末的方法，采用超高速激光熔覆技术，搭配不同工艺，对轴类件基体表面进行强化与修复。

Description

一种用于超高速激光熔覆的铁基金属粉末、其制备方法及其 应用
技术领域
本发明属于金属材料领域，具体涉及一种用于超高速激光熔覆的铁基金属粉末、其制备方法及其应用。
背景技术
激光熔覆技术是一种表面强化工艺技术，指在基材表面通过不同的填料方式添加被选择的涂层材料，利用高功率密度的激光束使之与基材表面极薄层同时熔凝，并迅速凝固后形成稀释度极低、与基体成冶金结合的表面涂层，从而显著改善基层表面的耐磨、耐蚀、耐热、抗氧化等特性的工艺方法。传统的激光熔覆技术由于激光能量主要作用于基材表面，粉末温度低于熔点，热量散失大、能量利用率低，熔覆速率慢，且热影响区较大，严重制约了激光熔覆技术的推广应用。
铁基金属合金，是一种能耐各种类型腐蚀并兼具一定强度与韧性的合金，是在潮湿且具有腐蚀性工况条件下的良好涂层材料。
发明内容
本发明涉及一种超高速率激光熔覆专用铁基金属粉末及应用其进行熔覆的工艺。超高速率激光熔覆是一种表面加工技术，通过同步送粉添料方式，利用高能密度的束流使添加材料与高速率运动的基体材料表面同时熔化，并快速凝固后形成稀释率极低，与基体呈冶金结合的熔覆层，极大提高熔覆速率，显著改善基体材料表面的耐磨、耐蚀、耐热、抗氧化等工艺特性的工艺方法。
发明的超高速激光熔覆铁基金属耐蚀粉末的化学组成及其质量分数为：C 0.6～1.0％，Cr 17.0～20.0％，Ni 5.0～6.5％，Mn 2.0～4.0％，Mo 1.0～1.5％，Ti 4.0～6.0％，B 1.0～1.5％，N 0.08～0.15％，Si≤0.5％，P≤0.030％，S≤0.030％，余量为Fe和不可避免的杂质。
其中，Cr元素的增加能够显著提高材料的耐腐蚀性能，但过多的Cr会缩小γ相区，不利于获得稳定的奥氏体，加入Ni和Mn元素可稳定奥氏体。不锈钢通常硬度和耐磨性能较差，因此在铁基不锈钢材料基础上通过添加Ti、B等元素，原位生成TiC、TiB2硬质相进行强化，钛和碳原位合成TiC是放热反应，只要提供较少的能量就能生成TiC硬质相，生成的TiC颗粒细小均匀，相界面洁净，结合很好。TiC、TiB2硬质相与其他如WC、VC等对比，其润湿效果更好，不易出现微观裂纹。同时配合添加其他元素，共同起到提高强度、细化组织等作用，获得无裂纹、气孔等缺陷的具有良好耐磨性能的熔覆层。
由于超高速率激光熔覆技术的激光能量主要作用于粉末，熔覆过程中所使用的金属粉末对于熔覆效果有着至关重要的影响，粒度范围、流动性、球形度等参数直接影响熔覆层的质量。主要采用以下指标：(1)粒度范围，金属粉末颗粒的大小，通常用颗粒的直径来表征；(2)流动性，是指以一定量粉末流过规定孔径的标准漏斗所需要的时间来表示，通常采用的单位为s/50g，其数值越小说明该粉末的流动性愈好；(3)球形度，颗粒的形状与球体相似的程度；(5)D50，描述粉末粒度分布的指标，指一个样品的累计粒度分布百分数达到50％时所对应的粒径。
优选的，该粉末的球形度≥90％，流动性为16～20s/50g。
优选的，粒度分布为：15～65μm。
优选的，粉末的D50为25～40μm。
优选的，含氧量≦200ppm。
根据本发明另一方面，提供了上述粉末的制备方法，其特征在于，该方法为：原材料成分合金化配比，而后进行真空熔炼，应用中频感应加热熔化原料，熔炼室真空度10-1～10-2Pa，采用气雾化方法制粉，喷粉气体氩气压力1.2～3.8MPa，收得粉末后进行粒度筛分，筛选15～65μm粒度范围的金属粉末，即可制得用于超高速激光熔覆的铁基金属粉末。
其中，真空度的控制对于粉末含氧量等指标有重大影响，喷粉气体氩气的压力控制是控制粉末粒度、球形度和成粉率的核心参数，需要全面根据液流情况及各个喷粉时期做出精确调整。
根据本发明另一方面，应用上述铁基合金粉末，采用超高速激光熔覆技术，搭配不同工艺，对基体表面进行强化与修复，具体步骤为：
(1)对基体表面进行机加工；
(2)用丙酮擦拭基体表面，去除表面油脂；
(3)根据基体表面几何形状进行激光熔覆路径规划，制定工艺参数；
(4)采用半导体激光熔覆系统对基体表面进行熔覆修复，采用下述工艺参数：激光功率1500～2500W，光斑直径0.8～1.2mm，送粉速率2～5kg/h，激光扫描速率330～830m/min，搭接率40％～70％，单层熔覆厚度250～500μm，激光熔覆头具有氩气保护功能，氩气流量8～20L/min。
(5)采用数控机床对修复后的基体表面进行机加工，获得所需尺寸。
与现有技术相比，本发明的优点在于：
1.该金属粉末具有优选的合金含量搭配，能够通过激光熔覆工艺形成与基体结合致密紧实的修复涂层，合金元素分布更均匀，提升基体表面耐腐蚀性能，降低腐蚀速率，提高使用寿命，经济性好。
2.超高速激光熔覆技术可极大提高激光熔覆表面加工速率，得到表面平整光滑、无气孔、无裂纹的熔覆层，该技术对金属粉末粒度、流动性等指标有特殊要求，本发明所涉及的超高速率激光熔覆用铁基不锈钢粉末适用于该加工技术。
3.与传统激光熔覆技术相比，超高速激光熔覆的激光束能量密度更高，粉末汇聚性更好，因此可以在330mm/s以上的激光扫描速率条件下实现高速熔覆。同时，由于更高的扫描速度，超高速激光熔覆的稀释率＜2％。
具体实施方式
结合实施例和对比例对本发明作进一步描述。实施例和对比例中各元素的质量分数如表1所示，性能参数如表2所示，实施例和对比例所使用的主要工艺参数和熔覆质量见表3。
表1超高速激光熔覆用铁基金属粉末成分(质量分数，％)
Figure BDA0002353461840000031
Figure BDA0002353461840000041
表2超高速激光熔覆铁基金属粉末性能参数(质量分数，％)
实施例 粒度μm 流动性s/50g 球形度％ D<sub>50</sub>/μm
实施例1 15～65 18 91 32
实施例2 15～65 16 95 34
对比例1 50～150 13 89 95
对比例2 15～65 18 91 32
表3超高速激光熔覆与传统激光熔覆工艺对比
Figure BDA0002353461840000042
实施例1
优选地，提供了粉末的制备方法，其特征在于，该方法为：原材料成分合金化配比，而后进行真空熔炼，熔炼室真空度10-1～10-2Pa，采用气雾化方法制粉，喷粉气体氩气压力1.2～3.8MPa，收得粉末后进行粒度筛分，筛选15～65μm粒度范围的金属粉末，得到超高速激光熔覆用铁基金属粉末。
优选地，提供了一种铁基金属粉末，各元素的质量分数为：C 0.8％，Cr 19.0％，Ni5.65％，Mn 3.2％，Mo 1.2％，Ti 5.0％，B 1.2％，N 0.09％,Si≤0.5％，P≤0.030％，S≤0.030％，余量为Fe和不可避免的杂质。
该金属粉末粒径为：15～65μm，流动性：18s/50g，球形度≥91％，D50＝32μm。
优选地，粉末含氧量160ppm。空心粉率＜1％。
应用筛分后的粉末，采用超高速激光熔覆技术，搭配相应工艺，对基体表面进行修复。
优选地，修复方法为：对基体表面机加工。
用丙酮擦拭模具待修复表面，去除表面油脂。
根据基体表面几何形状进行超高速激光熔覆路径规划，制定工艺参数。
用半导体激光熔覆系统对基体表面进行熔覆修复，采用上述工艺参数：激光功率1700W，光斑直径1mm，送粉速率2.4kg/h，激光扫描速率500mm/s，搭接率55％，单层熔覆厚度320μm，激光熔覆头具有氩气保护功能，氩气流量10L/min。
采用数控机床对修复后的基体表面进行机加工，获得所需尺寸及良好的表面性能。
实施例2
优选地，提供了粉末的制备方法，其特征在于，该方法为：原材料成分合金化配比，而后进行真空熔炼，熔炼室真空度10-1～10-2Pa，采用气雾化方法制粉，喷粉气体氩气压力1.2～3.8MPa，收得粉末后进行粒度筛分，筛选15～65μm粒度范围的金属粉末，得到超高速激光熔覆用铁基金属粉末。
优选地，提供了一种铁基金属粉末，各元素的质量分数为：C 0.7％，Cr 18.0％，Ni5.8％，Mn 3.1％，Mo 1.4％，Ti 5.5％，B 1.2％，N 0.09％,Si≤0.5％，P≤0.030％，S≤0.030％，余量为Fe和不可避免的杂质。
该金属粉末粒径为：15～65μm，流动性：18s/50g，球形度≥95％，D50＝34μm。
优选地，粉末含氧量160ppm。空心粉率＜1％。
应用筛分后的粉末，采用超高速激光熔覆技术，搭配不同工艺，对基体表面进行修复。
优选地，修复方法为：对基体表面机加工。
用丙酮擦拭模具待修复表面，去除表面油脂。
根据基体表面几何形状进行超高速激光熔覆路径规划，制定工艺参数。
用半导体激光熔覆系统对基体表面进行熔覆修复，采用上述工艺参数：激光功率1550W，光斑直径1mm，送粉速率2.2kg/h，激光扫描速率417mm/s，搭接率60％，单层熔覆厚度300μm，激光熔覆头具有氩气保护功能，氩气流量10L/min。
采用数控机床对修复后的基体表面进行机加工，获得所需尺寸及良好的表面性能。
对比例1
优选地，提供了粉末的制备方法，其特征在于，该方法为：原材料成分合金化配比，而后进行真空熔炼，熔炼室真空度10-1～10-2Pa，采用气雾化方法制粉，喷粉气体氩气压力1.2～3.8MPa，收得粉末后进行粒度筛分，筛选50～150μm粒度范围的金属粉末，得到超高速激光熔覆用铁基金属粉末。
优选地，提供了一种和实施例1中成分及含量相同的铁基金属粉末，各元素的质量分数为：C 0.8％，Cr 19.0％，Ni 5.65％，Mn 3.2％，Mo 1.2％，Ti 5.0％，B 1.2％，N0.09％,Si≤0.5％，P≤0.030％，S≤0.030％，余量为Fe和不可避免的杂质。
该金属粉末粒径为：50～150μm，流动性：13s/50g，球形度≥89％，D50＝95μm。
优选地，粉末含氧量190ppm。空心粉率＜1％。
应用筛分后的粉末，采用传统激光熔覆技术，搭配相应工艺，对基体表面进行修复。
优选地，修复方法为：对基体表面机加工。
用丙酮擦拭模具待修复表面，去除表面油脂。
根据基体表面几何形状进行传统激光熔覆路径规划，制定工艺参数。
用光纤激光熔覆系统对基体表面进行熔覆修复，采用上述工艺参数：激光功率2250W，光斑直径3mm，送粉速率2.4kg/h，激光扫描速率12mm/s，搭接率55％，单层熔覆厚度980μm，激光熔覆头具有氩气保护功能，氩气流量10L/min。
采用数控机床对修复后的基体表面进行机加工，获得所需尺寸及良好的表面性能但熔覆层稀释率高，熔覆层合金元素含量显著低于实施例1和粉末成分。
对比例2
优选地，提供了粉末的制备方法，其特征在于，该方法为：原材料成分合金化配比，而后进行真空熔炼，熔炼室真空度10-1～10-2Pa，采用气雾化方法制粉，喷粉气体氩气压力1.2～3.8MPa，收得粉末后进行粒度筛分，筛选15～65μm粒度范围的金属粉末，得到超高速激光熔覆用铁基金属粉末。
优选地，提供了一种和实施例1中完全相同的铁基金属粉末，各元素的质量分数为：C 0.8％，Cr 19.0％，Ni 5.65％，Mn 3.2％，Mo 1.2％，Ti 5.0％，B 1.2％，N 0.09％,Si≤0.5％，P≤0.030％，S≤0.030％，余量为Fe和不可避免的杂质。
该金属粉末粒径为：15～65μm，流动性：18s/50g，球形度≥91％，D50＝32μm。
优选地，粉末含氧量160ppm。空心粉率＜1％。
应用筛分后的粉末，采用传统激光熔覆技术，搭配相应工艺，对基体表面进行修复。
优选地，修复方法为：对基体表面机加工。
用丙酮擦拭模具待修复表面，去除表面油脂。
根据基体表面几何形状进行传统激光熔覆路径规划，制定工艺参数。
用光纤激光熔覆系统对基体表面进行熔覆修复，采用表3所述工艺参数：激光功率5000W，光斑直径3mm，送粉速率2.4kg/h，激光扫描速率417mm/s，搭接率55％，激光熔覆头具有氩气保护功能，氩气流量10L/min。
采用传统激光熔覆技术，激光扫描速率为417mm/s时，激光功率从2250W提升至5000W，均未实现表面成型良好的熔覆层，粉末与基体未形成良好的冶金结合。
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到的变化或替换，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应以所述权利要求的保护范围为准。

Claims (7)

1.一种用于超高速激光熔覆的铁基金属粉末，其特征在于，金属粉末的化学成分及其质量百分比为：C 0.6～1.0％，Cr 17.0～20.0％，Ni 5.0～6.5％，Mn 2.0～4.0％，Mo 1.0～1.5％，Ti 4.0～6.0％，B 1.0～1.5％，N 0.08～0.15％，Si≤0.5％，P≤0.030％，S≤0.030％，余量为Fe和不可避免的杂质。
2.根据权利要求1所述的铁基金属粉末，其特征在于，所述粉末的球形度≥90％。
3.根据权利要求1所述的铁基金属粉末，其特征在于，所述粉末的粒度分布为：15-65μm。
4.根据权利要求1所述的铁基金属粉末，其特征在于，粉末的D50为25-40μm。
5.根据权利要求1所述的铁基金属粉末，其特征在于，所述粉末的流动性16～20s/50g，含氧量≦200ppm。
6.根据权利要求1～5所述的金属粉末的制备方法，其特征在于，所述方法为：原材料成分合金化配比，而后进行真空熔炼，应用中频感应加热熔化，熔炼室真空度10-1-10-2Pa，采用气雾化方法制粉，喷粉气体氩气压力1.2～3.8MPa，收得粉末后进行粒度筛分，筛选15-65μm粒度范围的金属粉末，即可制得超高速激光熔覆用铁基金属粉末。
7.应用如权利要求1～5所述的金属粉末进行超高速激光熔覆的工艺，其特征在于：
(1)对基体表面进行机加工；
(2)用丙酮擦拭基体表面，去除表面油脂；
(3)根据基体表面几何形状进行激光熔覆路径规划，制定工艺参数；
(4)采用半导体激光熔覆系统对基体表面进行熔覆修复，采用下述工艺参数：激光功率1500～2500W，光斑直径0.8～1.2mm，送粉速率2～5kg/h，激光扫描速率330～830m/min，搭接率40％～70％，单层熔覆厚度250～500μm，激光熔覆头具有氩气保护功能，氩气流量8～20L/min。
(5)采用数控机床对修复后的基体表面进行机加工，获得所需尺寸。
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