CN112872355A - 一种具有多级孔结构的金属吸液芯材料及其制备方法 - Google Patents
一种具有多级孔结构的金属吸液芯材料及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种具有多级孔结构的金属吸液芯材料,所述多级孔结构由不同孔径范围的大孔、中孔和小孔构成,其中所述大孔通过粉末挤出3D打印获得,所述中孔由脱脂过程中粘结剂挥发形成,所述小孔由烧结后金属粉末颗粒之间的孔隙组成。本发明还提供一种多级孔结构的金属吸液芯材料的制备方法:通过新型粉末挤出3D打印工艺制备出具有三维构型的有序大孔;然后采用水浴加热、烧结等后续处理工艺,在大孔骨架内部形成中孔和小孔,从而构建出由大、中、小三级孔构成的多级孔材料。本发明提供的制备方法能够调控孔径大小和孔隙分布,利于多孔吸液芯材料结构设计和性能优化;并且制备工艺简单,成本较低,适用于复杂结构吸液芯材料的设计和制备。
Description
技术领域
本发明涉及增材制造领域,尤其涉及一种具有多级孔结构的金属吸液芯材料及其制备方法。
背景技术
热管是利用热传导和相变介质进行快速导热的装置,与传统的散热装置相比,它具有导热性能强、均温性能好等优点,在航空航天,能源化工以及电子工业等领域有着重要应用前景。吸液芯是热管的重要组成部分,由多孔材料构成,其孔结构与热管的传热性能密切相关。吸液芯的主要作用为:(1)提供冷凝液从冷凝段回流到蒸发段所需的通道;(2)汽-液分界面上的表面毛细孔产生的毛细力可帮助冷凝液回流;(3)提供管壳内壁与汽-液分界面之间的热流通路。因此改进吸液芯孔结构,提升吸液芯毛细能力成为提升热管性能的关键。
如何提高吸液芯的毛细作用一直是材料和工程热物理领域的研究热点。吸液芯毛细作用大小由两个性能指标共同决定:渗透率和毛细压力。渗透率是表征吸液芯开孔程度的物理量,孔径越大,渗透率越高,液体通过吸液芯所需的能量越小;毛细压力是表征吸液芯对液体吸力大小的物理量,孔径越小,毛细力越大,液体通过吸液芯的所受的驱动力越大。因此,单一增大或者减小吸液芯中的孔径,都不能同时提升吸液芯的为了同时提高吸液芯的渗透率和毛细压力,这导致多孔结构吸液芯的渗透率和毛细压力呈倒置关系。因此如何通过孔径结构设计,实现渗透率和毛细压力的同步提升,是热管用吸液芯研究面临的关键问题。
为了克服渗透率和毛细压力的矛盾,需要使吸液芯同时含有孔径不一的两级甚至多级孔。造孔剂法是制备多级孔结构的常用方法,该方法的工艺路线为:首先将造孔剂和金属粉末均匀混合,之后对混合粉末进行烧结,最后根据造孔剂的性质采用溶解或热挥发将其去除。比如,有学者将氯化钠晶体与金属粉末混合烧结,之后将烧结得到的产品浸没在水中使氯化钠溶解,最终得到具有两种孔径分布的多孔结构,氯化钠晶体作为造孔剂,溶解后形成大孔,金属粉末彼此通过扩散连接的孔隙则形成小孔。依照该工艺方法,能够得到具有双级甚至多级孔结构的吸液芯材料,也可以通过控制造孔剂颗粒的大小调控孔径大小。但是,该工艺方法最大的弊端在于得到的多级孔结构是随机分布的,这会增加毛细通道的长度和材料内部出现闭孔的几率,进而大大降低吸液芯的工作效率。
粉末挤出打印是以含有粘结剂的粉末颗粒为原料,在一定温度下将熔融的粘结剂和粉末混合物挤出成型的新兴间接3D打印技术。该技术利用三维设计零件模型数据在设备上快速而精确地制造出复杂形状的零件,无需传统的刀具、夹具及多道加工工序,展现出巨大的发展潜力和应用前景。此外,与基于熔融沉积成型的激光增材制造工艺不同的是,粉末挤出打印可以通过后续脱脂和烧结工艺的调控,制备出具有不同孔隙结构的多级孔材料。因此,结合粉末挤出打印以及打印件脱脂和烧结工艺控制,可以制造出孔径尺寸和孔隙分布可控的多级孔结构,从而突破当前工艺无法调控多级孔尺寸和分布的难题。
发明内容
有鉴于现有技术的上述缺陷,本发明所要解决的技术问题是提供一种孔径尺寸和孔隙分布可控的多级孔结构的金属吸液芯材料及其制备方法。
为实现上述目的,本发明提供了一种具有多级孔结构的金属吸液芯材料,所述多级孔结构由不同孔径范围的大孔、中孔和小孔构成,所述大孔孔径在100-800微米之间,所述中孔孔径在30-80微米之间,所述小孔孔径在1-10微米之间,其中所述大孔通过粉末挤出3D打印获得,所述中孔由脱脂过程中粘结剂挥发形成,所述小孔由烧结后金属粉末颗粒之间的孔隙组成。
进一步地,所述大孔呈三维连通网格状结构,网格横截面形状为方形、六边形或圆形中的一种,所述中孔的横截面形状为不规则多边形。
本发明还提供一种具有多级孔结构的金属吸液芯材料的制备方法,包括以下几个步骤:
步骤1:将金属粉末和粘结剂混合制得混合颗粒;
步骤2:以步骤1得到的所述混合颗粒在粉末挤出3D打印设备上按照预先设计好的模型图进行打印,得到打印胚体;
步骤3:将步骤2得到的所述打印坯体进行水浴加热,以去除生坯中的所述粘结剂,得到处理后胚体;
步骤4:将步骤3得到的所述处理后坯体进行烘干,得到烘干胚体;
步骤5:将步骤4得到的所述烘干坯体在真空或还原性气氛中进行烧结,最终得到所述具有多级孔结构的金属吸液芯材料。
进一步地,步骤1中所述混合颗粒中所述粘结剂的含量在40-60%之间。
进一步地,步骤4中,所述烘干条件为真空。
进一步地,步骤2中所述打印胚体为三维连通网格状结构。
进一步地,步骤1中所述金属粉末为镍基合金、铜、不锈钢或钛合金中的一种。
进一步地,步骤1中还包括如下步骤:所述混合颗粒为通过密炼和造粒的方法制备出近似球形的混合颗粒。
进一步地,步骤3中水浴加热的温度和时间,需要根据所选的所述粘结剂种类和添加量确定;水浴加热完成后,所述粘结剂挥发并在金属框架处留下中孔。
进一步地,步骤5中的烧结温度和时间,需要根据所选的所述金属粉末确定。
本发明提供一种具有多级孔结构的金属吸液芯材料及其制备方法,得到的金属吸液芯材料同时具有大孔、中孔和小孔,且孔隙有序分布的多级孔结构。三种孔的协同作用,能够同时提升吸液芯的渗透率和毛细率,其毛细作用明显高于单一孔径和孔径随机分布的多级孔吸液芯材料,进而大大提升热管的工作效率。所述的多级孔结构的吸液芯材料的制备方法,使用了新型粉末挤出3D打印方法,避免了传统粉末烧结和添加造孔剂造成的孔径无序分布的情况;同时充分利用了粉末挤出3D打印的工艺特点并结合后续脱脂和烧结工艺,得到三级孔结构。
以下将结合附图对本发明的构思、具体结构及产生的技术效果作进一步说明,以充分地了解本发明的目的、特征和效果。
附图说明
图1是本发明的一个较佳实施例获得的网格状结构金属吸液芯材料的低倍扫描电镜照片;
图2是本发明的一个较佳实施例获得的金属吸液芯材料金属骨架连接处的扫描电镜照片;
图3是本发明的一个较佳实施例获得的金属吸液芯材料金属骨架内部的扫描电镜照片。
具体实施方式
以下参考说明书附图介绍本发明的多个优选实施例,使其技术内容更加清楚和便于理解。本发明可以通过许多不同形式的实施例来得以体现,本发明的保护范围并非仅限于文中提到的实施例。
本实施例通过以下步骤制备具有多级孔结构的镍基合金吸液芯材料:
步骤1:分别称取一定量粘结剂(体积分数40%)和镍基合金粉末(牌号K438,粒度0-15μm)进行混合密炼和造粒,制备出粒径在1-5毫米之间的近球形颗粒;
步骤2:将制得的金属和粘结剂的混合颗粒作为原料,按照预先设计好的三维网格状结构进行粉末挤出3D打印;
步骤3:将3D打印得到的生坯进行水浴加热,其中水浴温度为50℃,保温时间为48h;
步骤4:将水浴加热后的坯体在真空干燥箱内烘干,温度为50℃,保温时间2h;
步骤5:将烘干后的坯体置于管式炉中加热烧结,其中烧结气氛为H2/Ar混合气(H2体积含量为5%),烧结温度为1200℃,保温时间为1小时。
利用扫描电镜表征本实施例得到的吸液芯宏观结构如图1所示,证实了粉末挤出3D打印得到的吸液芯材料呈现网格状结构。将吸液芯金属骨架连接处部分放大可以看到,如图2所示,连接处的表面呈现金属粉末的凹凸状,这是由于本发明的烧结工艺采用的是无压烧结,金属粉末之间仅靠扩散作用彼此连接。将金属骨架部分继续放大,如图3所示,从中可以看到金属骨架内部包含两种孔径的孔洞,即粘结剂挥发留下的中孔和依靠金属粉末之间扩散连接形成的小孔。
扫描电子显微镜分析结果显示,本实施例得到的吸液芯材料包含大孔、中孔和小孔,呈现三级孔结构的有序分布。该吸液芯材料同时具有高渗透率和高毛细力,能显著提升热管的工作效率。
以上详细描述了本发明的较佳具体实施例。应当理解,本领域的普通技术无需创造性劳动就可以根据本发明的构思作出诸多修改和变化。因此,凡本技术领域中技术人员依本发明的构思在现有技术的基础上通过逻辑分析、推理或者有限的实验可以得到的技术方案,皆应在由权利要求书所确定的保护范围内。
Claims (10)
1.一种具有多级孔结构的金属吸液芯材料,其特征在于,所述多级孔结构由不同孔径范围的大孔、中孔和小孔构成,所述大孔孔径在100-800微米之间,所述中孔孔径在30-80微米之间,所述小孔孔径在1-10微米之间,其中所述大孔通过粉末挤出3D打印获得,所述中孔由脱脂过程中粘结剂挥发形成,所述小孔由烧结后金属粉末颗粒之间的孔隙组成。
2.如权利要求1所述的具有多级孔结构的金属吸液芯材料,其特征在于,所述大孔呈三维连通网格状结构,网格横截面形状为方形、六边形或圆形中的一种,所述中孔的横截面形状为不规则多边形。
3.如权利要求1所述的具有多级孔结构的金属吸液芯材料的制备方法,其特征在于,包括以下几个步骤:
步骤1:将金属粉末和粘结剂混合制得混合颗粒;
步骤2:以步骤1得到的所述混合颗粒在粉末挤出3D打印设备上按照预先设计好的模型图进行打印,得到打印胚体;
步骤3:将步骤2得到的所述打印坯体进行水浴加热,以去除生坯中的所述粘结剂,得到处理后胚体;
步骤4:将步骤3得到的所述处理后坯体进行烘干,得到烘干胚体;
步骤5:将步骤4得到的所述烘干坯体在真空或还原性气氛中进行烧结,最终得到所述具有多级孔结构的金属吸液芯材料。
4.如权利要求3所述的具有多级孔结构的金属吸液芯材料的制备方法,其特征在于,步骤1中所述混合颗粒中所述粘结剂的含量在40-60%之间。
5.如权利要求3所述的具有多级孔结构的金属吸液芯材料的制备方法,其特征在于,步骤4中,所述烘干条件为真空。
6.如权利要求3所述的具有多级孔结构的金属吸液芯材料的制备方法,其特征在于,步骤2中所述打印胚体为三维连通网格状结构。
7.如权利要求3所述的具有多级孔结构的金属吸液芯材料的制备方法,其特征在于,步骤1中所述金属粉末为镍基合金、铜、不锈钢或钛合金中的一种。
8.如权利要求3所述的具有多级孔结构的金属吸液芯材料的制备方法,其特征在于,步骤1中还包括如下步骤:所述混合颗粒为通过密炼和造粒的方法制备出近似球形的混合颗粒。
9.如权利要求3所述的具有多级孔结构的金属吸液芯材料的制备方法,其特征在于,步骤3中水浴加热的温度和时间,需要根据所选的所述粘结剂种类和添加量确定;水浴加热完成后,所述粘结剂挥发并在金属框架处留下中孔。
10.如权利要求3所述的具有多级孔结构的金属吸液芯材料的制备方法,其特征在于,步骤5中的烧结温度和时间,需要根据所选的所述金属粉末确定。
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