CN112548103B - 一种钛合金激光增材修复与表面渗氮复合处理工艺 - Google Patents

一种钛合金激光增材修复与表面渗氮复合处理工艺 Download PDF

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CN112548103B
CN112548103B CN202011536999.3A CN202011536999A CN112548103B CN 112548103 B CN112548103 B CN 112548103B CN 202011536999 A CN202011536999 A CN 202011536999A CN 112548103 B CN112548103 B CN 112548103B
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titanium alloy
nitriding
repair
powder
laser additive
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CN112548103A (zh
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李聪
肖斌
谢盼
陈荐
邱玮
李微
何建军
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Qingyuan Yuebo Technology Co ltd
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Changsha University of Science and Technology
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Abstract

本发明公开了一种钛合金激光增材修复与表面渗氮复合处理工艺。首先，对钛合金零件表面进行前处理，采用激光增材修复工艺参数如下：激光功率为1300‑1500W，扫描速度为13mm/s，光斑直径为3.5～4mm，送粉量为25‑30g/min，搭接量50%，高度方向增量Z为0.3毫米/层；对修复钛合金表面进行后处理，恢复钛合金尺寸及精度，再将钛合金进行渗氮处理：氮气压力200‑500Pa，温度540‑650℃，时间3‑8小时，占空比为80；电压为‑500V。最后在450℃退火1h。获得高质量的钛合金修复与表面改性试样，修复试样表面改性层硬度高达1100HV‑1200HV，耐磨性较基材提升3‑5倍。

Description

一种钛合金激光增材修复与表面渗氮复合处理工艺
技术领域
本发明涉及激光金属材料加工领域，尤其涉及一种钛合金激光增材修复与表面渗氮复合处理工艺。
背景技术
钛及钛合金具有密度低、比强度高、抗蚀性能和耐高温性能优越等特点，被广泛应用于航空航天、核工业及生物医疗等领域关键部件的制造。然而，钛合金部件表面硬度较低、耐磨性能较差，对粘着磨损和微动磨损非常敏感。钛合金部件在服役过程中易产生磨损、裂纹、疲劳等，导致零件失效，造成经济损失。激光增材修复技术以高能束激光为热源，具有热量输入低、稀释小、热影响区小及变形小等特点，可实现钛合金部件的快速再制造。
通常，在相同的服役环境下，钛合金修复件在后期服役过程中极可能再次出现磨损等失效情况。因此，有必要对钛合金零件修复区进行表面改性处理。钛的氮化物具有高熔点、高硬度、以及耐磨性和高温稳定性能优异等优点。在钛合金部件表面制备钛的氮化物改性层是提高其表面硬度，改善其耐磨性，延长其使用寿命，扩大其使用范围的有效方法。目前，主要采用离子渗氮、激光气体氮化及气体渗氮方法在钛合金钢表面制备氮化物改性层。离子渗氮难以对形状复杂的零件进行处理，且成本较高；激光渗氮容易产生缺陷，如气孔和裂纹等。气体渗氮简单易行，成本低廉，可以在钛合金钢表面形成氮化物硬质相，显著提高耐磨性能和腐蚀性能，因此，受到了越来越广泛的应用。
本发明提供一种钛合金激光修复与表面渗氮的复合处理工艺，该方法能在保证钛合金修复质量的情况下，同时提高修复区的表面性能。
发明内容
本发明的目的是提供一种钛合金激光增材修复与表面渗氮复合处理工艺。
步骤一：对钛合金零件表面进行前处理，包括待修复区机械加工、清洁、喷砂及烘干；
步骤二：采用热成像仪对激光增材制造过程中熔池进行监测，获得熔池形貌及温度变化信息，计算出熔池长轴平均值a与短轴平均值b，并计算出熔池边界的平均冷却速率ξ。
步骤三：根据1.5≤a/b≤2.2，且7.0×103℃/s≤ξ≤8.3×104℃/s原则对工艺参数进行优化，获得优化的增材修复工艺窗口：激光功率为1300-1500W，扫描速度为13mm/s，光斑直径为3.5～4mm，送粉量为25-30g/min，搭接量50%，高度方向增量Z为0.3毫米/层。
步骤四：采用优化工艺参数对钛合金进行修复，并对修复后钛合金表面进行机械加工、抛光、喷砂及清洗，恢复钛合金尺寸及精度。
步骤五：将修复钛合金放在氮化炉中进行渗氮处理：氮气压力为200-500Pa，氮化温度为540-650℃，氮化时间为3-8小时，占空比为80%；电压为-500V。
步骤六：钛合金修复与改性的后续处理：退火温度450℃，退火时间1h。
在步骤二中，热成像仪发射率设置为1.0，单个数据采集时间为1.5ms。
在步骤四中，修复材料为钛合金粉末、纯锆粉及纯铝粉的混合粉末，其中包括质量分数为98%的钛合金粉末，1.5%的纯锆粉与0.5%的纯铝粉；填充路径为交叉扫描路径；
在步骤五中，加热的条件为：当氮化炉内真空室的真空度小于1×10-4 Pa时，通入氮气；
所述的钛合金，包括α钛合金、α+β钛合金及β钛合金。
本发明通过对激光增材修复工艺的严格筛选与优化，获得优化的修复工艺参数如下：激光功率为1300-1500W，扫描速度为13mm/s，光斑直径为3.5～4mm，送粉量为25-30g/min，搭接量50%，高度方向增量Z为0.3毫米/层；按上述工艺参数及方法进行激光增材修复，一方面，可保证修复过程中足够的激光能量输入与熔池冷却速率，避免冶金缺陷与细化枝晶组织；另一方面，在修复粉末材料中加少量的纯锆粉和纯铝粉，增材修复过程中纯锆粉和纯铝粉通过与熔池中的氧气发生原位反应生成高熔点的氧化锆与氧化铝陶瓷颗粒，这些高熔点的颗粒在熔池凝固过程中为晶粒或枝晶的形核提供异质形核点，进而细化晶粒。此外，通过对渗氮工艺的优化，获得优化的氮化工艺参数如下：氮气压力为200-500Pa，氮化温度为540-650℃，氮化时间为3-8小时，占空比为80%；电压为-500V；然后将修复与渗氮试样进行后续处理，退火温度450℃，退火时间1h。按上述工艺参数及方法对修复件进行渗氮处理，可在修复零件表面获得可控高性能氮化层。值得一提的是，通过本发明方法获得的钛合金修复零件具有细化的晶粒组织，可为后续氮化处理提供更多的扩散通道(晶界)，促进氮化反应的进行，在钛合金修复件表面形成厚度均匀、高硬度、高耐磨性的氮化层。采用本发明方法可获得高质量的修复与表面改性试样，钛合金修复零件内部无冶金缺陷、微观组织细密，修复件表面改性层硬度高达1100HV-1200HV，耐磨性较基材提升3-5倍。
附图说明
图1为现有方法得到的钛合金修复试样金相图；
图2为本发明得到的钛合金增材修复与改性试样金相图。
具体实施方式
实施例1
以TC4(α+β双相)合金为例。
步骤一：对TC4合金零件表面进行前处理，包括待修复区机械加工、清洁、喷砂及烘干；步骤二：采用热成像仪对激光增材制造过程中熔池进行监测，获得熔池形貌及温度变化信息，计算出熔池长轴平均值a与短轴平均值b，并计算出熔池边界的平均冷却速率ξ；步骤三：根据1.5≤a/b≤2.2，且7.0×103℃/s≤ξ≤8.3×104℃/s原则对工艺参数进行优化，获得优化的增材修复工艺窗口：激光功率为1350W，扫描速度为13mm/s，光斑直径为3.8mm，送粉量为26g/min，搭接量50%，高度方向增量Z为0.3毫米/层，修复材料为TC4钛合金粉末、纯锆粉及纯铝粉的混合粉末，其中包括质量分数为98%的TC4钛合金粉末，1.5%的纯锆粉与0.5%的纯铝粉，填充路径为交叉扫描路径；步骤四：采用优化工艺参数对钛合金进行修复，并对修复后钛合金表面进行机械加工、抛光、喷砂及清洗，恢复钛合金尺寸及精度；步骤五：将修复钛合金零件放在氮化炉中进行渗氮处理：当氮化炉内真空室的真空度小于1×10-4Pa时，通入氮气，氮化温度为540-650℃，氮化时间为3-8小时，占空比为80%；步骤六：钛合金零件修复与改性的后续处理：退火温度450℃，退火时间1h。获得高质量的修复与表面改性试样，TC4钛合金修复零件内部无冶金缺陷、微观组织细密，修复件表面改性层硬度高达1120HV，耐磨性较基材提升4.5倍。
图1为采用已有方法所获得的钛合金修复试样金相图。钛合金修复试样内部结构较为致密，无明显裂纹及气孔等冶金缺陷，修复区的平均硬度约为356HV。上述结果表明，在本发明方法外，很难获得高硬度的钛合金修复试样。
图2为采用本发明实施例1所获得的钛合金修复与改性试样金相图。钛合金修复试样结构致密，无气孔及裂纹等冶金缺陷，修复区的平均硬度为403HV；修复试样表面具有明显的氮化层，表层硬度高达1120HV。由此可见，采用本发明方法可有效提高钛合金修复试样表面的耐磨性能。采用本发明提出方法不仅对熔池的温度进行严格的控制，确保高致密的钛合金修复试样，同时通过严格控制渗氮工艺参数，确保在低氮势条件下进行渗氮，提高渗氮层质量与硬度。上述结果表明，采用本发明方法可以有效提高钛合金修复试样的表面性能。
实施例2
以TB1(β型)合金为例。
步骤一：对TB1钛合金零件表面进行前处理，包括待修复区机械加工、清洁、喷砂及烘干；步骤二：采用热成像仪对激光增材制造过程中熔池进行监测，获得熔池形貌及温度变化信息，计算出熔池长轴平均值a与短轴平均值b，并计算出熔池边界的平均冷却速率ξ；步骤三：根据1.5≤a/b≤2.2，且7.0×103℃/s≤ξ≤8.3×104℃/s原则对工艺参数进行优化，获得优化的增材修复工艺窗口：激光功率为1450W，扫描速度为13mm/s，光斑直径为3.5mm，送粉量为27g/min，搭接量50%，高度方向增量Z为0.3毫米/层，修复材料为TB1钛合金粉末、纯锆粉及纯铝粉的混合粉末，其中包括质量分数为98%的TB1钛合金粉末，1.5%的纯锆粉与0.5%的纯铝粉，填充路径为交叉扫描路径；步骤四：采用上述优化工艺参数对TB1钛合金零件进行修复，并对修复后钛合金表面进行机械加工、抛光、喷砂及清洗，恢复钛合金尺寸及精度；步骤五：将修复钛合金零件放在氮化炉中进行渗氮处理：当氮化炉内真空室的真空度小于1×10-4 Pa时，通入氮气,氮气压力为200-500Pa，氮化温度为540-650℃，氮化时间为3-8小时，占空比为80%；电压为-500V；步骤六：钛合金修复与改性的后续处理：退火温度450℃，退火时间1h，获得高质量的修复与表面改性试样，TB1钛合金修复零件内部无冶金缺陷、微观组织细密，修复件表面改性层硬度高达1180HV，耐磨性较基材提升4倍。

Claims (4)

1.一种钛合金激光增材修复与表面渗氮复合处理工艺，其特征在于包括以下步骤：
步骤一：对钛合金零件表面进行前处理，包括待修复区机械加工、清洁、喷砂及烘干；
步骤二：采用热成像仪对激光增材制造过程中熔池进行监测，获得熔池形貌及温度变化信息，计算出熔池长轴平均值a与短轴平均值b，并计算出熔池边界的平均冷却速率ξ；
步骤三：根据1.5≤a/b≤2.2，且7.0×103℃/s≤ξ≤8.3×104℃/s原则对工艺参数进行优化，获得优化的增材修复工艺窗口：激光功率为1300-1500W，扫描速度为13mm/s，光斑直径为3.5～4mm，送粉量为25-30g/min，搭接量50%，高度方向增量Z为0.3毫米/层；
步骤四：采用优化工艺参数对钛合金进行修复，并对修复后钛合金表面进行机械加工、抛光、喷砂及清洗，恢复钛合金尺寸及精度；修复材料为钛合金粉末、纯锆粉及纯铝粉的混合粉末，混合粉末的质量分数为98%的钛合金粉末，1.5%的纯铬粉与0.5%的纯铝粉；
步骤五：将修复钛合金放在氮化炉中进行渗氮处理：氮气压力为200-500Pa，氮化温度为540-650℃，氮化时间为3-8小时，占空比为80；电压为-500V；
步骤六：钛合金修复与改性的后续处理：退火温度450℃，退火时间1h。
2.根据权利要求1所述的一种钛合金激光增材修复与表面渗氮复合处理工艺，其特征在于：在步骤二中，热成像仪发射率设置为1.0，单个数据采集时间为1.5ms。
3.根据权利要求1所述的一种钛合金激光增材修复与表面渗氮复合处理工艺，其特征在于：在步骤五中，加热的条件为：当氮化炉内真空室的真空度小于1×10-4 Pa时，通入氮气。
4.根据权利要求1所述的一种钛合金激光增材修复与表面渗氮复合处理工艺，其特征在于：所述的钛合金，包括α钛合金、α+β钛合金及β钛合金。
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