CN114309659A - High-temperature alloy laser rapid forming system and forming method - Google Patents
High-temperature alloy laser rapid forming system and forming method Download PDFInfo
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- CN114309659A CN114309659A CN202111400986.8A CN202111400986A CN114309659A CN 114309659 A CN114309659 A CN 114309659A CN 202111400986 A CN202111400986 A CN 202111400986A CN 114309659 A CN114309659 A CN 114309659A
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- 239000000956 alloy Substances 0.000 title claims abstract description 43
- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 42
- 238000000034 method Methods 0.000 title claims abstract description 36
- 230000008021 deposition Effects 0.000 claims abstract description 37
- 229910001338 liquidmetal Inorganic materials 0.000 claims abstract description 36
- 238000010438 heat treatment Methods 0.000 claims abstract description 26
- 239000000758 substrate Substances 0.000 claims abstract description 24
- 238000002360 preparation method Methods 0.000 claims abstract description 8
- 239000000843 powder Substances 0.000 claims description 39
- 229910000601 superalloy Inorganic materials 0.000 claims description 26
- 230000006698 induction Effects 0.000 claims description 21
- 239000007789 gas Substances 0.000 claims description 15
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 10
- 230000001681 protective effect Effects 0.000 claims description 8
- 229910052786 argon Inorganic materials 0.000 claims description 6
- 229910001128 Sn alloy Inorganic materials 0.000 claims description 3
- 238000006243 chemical reaction Methods 0.000 claims description 2
- 239000013078 crystal Substances 0.000 abstract description 31
- 238000004519 manufacturing process Methods 0.000 abstract description 18
- 239000000654 additive Substances 0.000 abstract description 13
- 230000000996 additive effect Effects 0.000 abstract description 13
- 230000008569 process Effects 0.000 abstract description 13
- 230000008646 thermal stress Effects 0.000 abstract description 6
- 230000005674 electromagnetic induction Effects 0.000 abstract description 3
- 238000009825 accumulation Methods 0.000 abstract description 2
- 230000009466 transformation Effects 0.000 abstract description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 14
- 238000005516 engineering process Methods 0.000 description 9
- 229910052759 nickel Inorganic materials 0.000 description 7
- 230000008018 melting Effects 0.000 description 5
- 238000002844 melting Methods 0.000 description 5
- 230000009471 action Effects 0.000 description 3
- 238000005266 casting Methods 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000011812 mixed powder Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
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- 230000035945 sensitivity Effects 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 230000035882 stress Effects 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 208000003351 Melanosis Diseases 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005094 computer simulation Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 210000001787 dendrite Anatomy 0.000 description 1
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- 238000010586 diagram Methods 0.000 description 1
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- 238000005204 segregation Methods 0.000 description 1
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Abstract
The invention belongs to the technical field of high-temperature alloy forming, and particularly relates to a high-temperature alloy laser rapid forming system and a forming method. As laser additive manufacturing progresses, the formed region will generate a large heat accumulation, which severely affects the heat flow during additive manufacturing, resulting in the transformation of the single crystal structure of the alloy to the equiaxed structure. The invention provides a high-temperature alloy laser rapid forming system and a forming method, wherein in the forming process, an electromagnetic induction heating method is adopted, so that a laser direct deposition forming area is in a high-temperature state, the formed area is gradually immersed into a liquid metal container along with a forming substrate, heat in the forming process is rapidly led out, and directional heat flow along the forming direction is formed. The preparation period of the alloy can be greatly shortened, and the alloy has the forming potential of a complex structure; thermal stress in the additive manufacturing process is effectively and slowly released.
Description
Technical Field
The invention belongs to the technical field of high-temperature alloy forming, and particularly relates to a high-temperature alloy laser rapid forming system and a forming method.
Background
The single crystal high temperature alloy has good high temperature strength, oxidation resistance, corrosion resistance, fatigue resistance, creep resistance, fracture performance and structural stability, and is widely applied to the fields of aeroengines, industrial gas turbine blades and the like.
The existing single crystal high temperature alloy is mainly prepared by a casting method, a seed crystal is preset in the front or a crystal selector is added, a forced cooling means is adopted in the casting process to establish a specific temperature gradient, and the alloy is solidified by taking a single crystal nucleus as a crystal core to finally obtain a single crystal. However, most of the single crystal superalloy materials produced in practice have dendritic structures, and solidification defects, such as mixed crystals, freckle chains, looseness and the like, are formed, so that the yield of single crystal blades is low, and the production cost of single crystal turbine blades is greatly increased.
Advanced high performance aircraft engines require high temperature alloy materials for turbine components to withstand high operating temperatures and operating stresses. Because the working temperature and the stress state of the parts such as the wheel disc, the wheel rim, the blades and the like are different, the turbine blade disc with a single material and a single structure cannot completely meet the requirement of a high thrust ratio aero-engine. The turbine blade has higher working temperature, and the requirement of the turbine blade on high-temperature creep property and low fatigue crack propagation rate is met by adopting a blade with a single crystal or oriented structure; the working temperature of the turbine disk core is relatively low, but the turbine disk core needs to bear great working load, and the requirements on tensile strength and low cycle fatigue performance are met by adopting the powder high-temperature alloy as the disk core. A double-alloy integral turbine blade disc of directional high-temperature alloy and powder high-temperature alloy is one of ideal material combinations of advanced aeroengine turbines.
At present, the preparation process of the double-alloy integral turbine blade disc mainly adopts the following steps: the disc and the blade are respectively prepared and then connected by methods such as linear friction welding, diffusion welding and the like. The method has more process flows and great process control difficulty, and the connection process generally needs large-scale equipment and the like.
The laser additive manufacturing technology is an advanced manufacturing technology for manufacturing parts directly from a CAD model in a layer-by-layer stacking mode. In the aspect of preparing the single crystal alloy, compared with other traditional casting and forging technologies, the laser additive manufacturing technology has the following advantages:
(1) by means of the advantages of the rapid forming technology and the computer model design technology, the advanced turbine blade with a complex hollow structure can be directly prepared theoretically, and the production period of the turbine blade is greatly shortened.
(2) The additive manufacturing process keeps higher temperature gradient and solidification speed, is beneficial to reducing component segregation, the number of micropores and the primary dendrite spacing, and improves the comprehensive mechanical property of the alloy.
(3) No special die and clamp are needed, the working procedures are less, the processing period is short, and the material utilization rate is high; the structure has better structural adaptability and smaller structural limitation; has stronger material adaptability, and can manufacture a functional gradient structure combining more than two materials.
However, laser additive manufacturing to produce single crystals currently still presents the following obstacles: laser additive manufacturing involves rapid solidification and cooling processes, wherein extremely large thermal stress is formed in the forming process, and single crystal superalloy has extremely high thermal crack sensitivity and is easy to generate liquefaction cracks under the action of large thermal stress to cause cracking. As laser additive manufacturing progresses, the formed region will generate a large heat accumulation, which severely affects the heat flow during additive manufacturing, resulting in the transformation of the single crystal structure of the alloy to the equiaxed structure. On a substrate with an equiaxed structure, the directional structure is difficult to form through additive manufacturing. The additive manufacturing process has large thermal stress, so that under the condition of large thermal stress, liquefaction cracks are easily generated in the alloy.
Disclosure of Invention
In order to solve the problems, the invention provides a high-temperature alloy laser rapid forming system and a forming method, wherein in the forming process, an electromagnetic induction heating method is adopted, so that a laser direct deposition forming area is in a high-temperature state, the formed area is gradually immersed into a liquid metal container along with a forming substrate, heat in the forming process is rapidly led out, and directional heat flow along the forming direction is formed.
The invention provides a high-temperature alloy laser rapid forming system, which adopts laser direct deposition equipment to deposit on a forming substrate of high-temperature alloy, and also comprises induction heating equipment and a liquid metal container, wherein the liquid metal container is provided with liquid metal, the non-forming end of the forming substrate is positioned in the liquid metal container and can move up and down, the periphery of the forming end of the forming substrate is provided with the induction heating equipment, the upper induction heating equipment and the lower liquid metal make the forming substrate have upper and lower temperature gradients during forming, and the formed area is gradually immersed into the liquid metal container along with the forming substrate.
Advantageously or optionally, the laser direct deposition apparatus comprises a laser, a mirror and a powder feeder.
Advantageously or alternatively, the forming space is in an inert atmosphere.
Advantageously or alternatively, the lower end of the liquid metal container is fixed to a numerically controlled machine tool.
Advantageously or alternatively, the liquid metal container is a liquid metal container system that does not undergo a strong chemical reaction with the superalloy.
The invention also provides a high-temperature alloy laser rapid forming method, which utilizes the forming system and comprises the following steps:
s1, modeling the three-dimensional CAD model and introducing model information into a laser direct deposition system;
s2, loading the high-temperature alloy powder into a powder feeder of a laser direct deposition system, and taking high-purity argon gas as a powder carrying gas and a protective gas;
s3, placing the non-forming end of the forming substrate in a liquid metal container;
s4, heating the to-be-formed area by using induction heating equipment;
s5, starting the laser direct deposition equipment to perform slicing deposition after the deposition condition is met to obtain a deposition layer;
and S6, after the forming base material is downwards reduced by the thickness of the deposition layer, finishing the part preparation, or returning to S5 to continue the slice deposition.
Advantageously or alternatively, in S1, the three-dimensional CAD model is sliced hierarchically in the elevation direction and scan path filling is performed for each slice, and then the slice information and the scan path information are introduced into the laser direct deposition system.
Advantageously or alternatively, in S2, the superalloy powder has an average grain size of about 45 to 150 μm.
Advantageously or alternatively, the liquid metal In S3 is a Ga-In-Sn alloy or other liquid metal system that is non-reactive with the alloy being prepared.
Advantageously or alternatively, in S4, the coil of the induction heating device follows the shape of the prepared member, and the distance between the coil and the surface of the member is 5-10 mm.
Advantageously or alternatively, in S5, the region to be formed is heated to a suitable temperature, the laser direct deposition apparatus is activated, the laser and powder are coaxially output, and moved along the scan path.
Particularly, when the superalloy is a nickel-based single crystal superalloy, the average particle size of the nickel-based single crystal superalloy powder is about 45 to 150 μm, and the flow rate of the powder-carrying gas flow is: 10-30L/min, protective gas flow rate: 5-10L/min. The <001> crystal orientation of the nickel-based single crystal superalloy substrate is parallel to the forming direction of laser melting deposition. The coil in the induction heating device follows the shape of the prepared member, and the distance between the coil and the surface of the member is 5-10 mm. The induction heating requires the forming location to be heated to 800-. The powder feeding rate is 5-15g/min, the thickness of the deposition layer is 0.2-1mm, and the laser power is as follows: 500-: 400-2000 mm/min.
Especially for laser direct deposition of powder superalloy and directional superalloy dual alloy structures, the mean particle size of the superalloy raw material powder is about 45-150 μm, the powder-loaded gas flow velocity: 10-30L/min, protective gas flow rate: 5-10L/min. The liquid metal is Ga-In-Sn alloy or other liquid metal systems which do not react with the prepared alloy. The coil in the induction heating device follows the shape of the prepared member, the distance between the coil and the surface of the member is 5-10mm, and the induction heating device needs to be capable of heating the forming position to 800-1000 ℃. In the laser direct deposition system, only a laser channel is opened, a powder channel is closed, and the area of a region scanned by a high-energy laser beam needs to completely cover a region to be formed. The laser power is 500-: 500-1500mm/min, and the scanning times are 1-3. The powder feeding speed is 5-15g/min, the thickness of the deposition layer is 0.2-1mm, and the laser power is as follows: 500-1500W, the laser scanning speed is: 400-2000 mm/min.
Has the advantages that:
(1) the preparation method has the advantages that the laser direct deposition forming technology is adopted, the preparation period of the single crystal alloy can be greatly shortened by means of the advantages of the rapid forming technology, and the forming potential of a complex structure is realized;
(2) the forming area adopts an electromagnetic induction heating technology, so that the temperature of the forming area can be kept above 800 ℃, the thermal stress in the additive manufacturing process is effectively and slowly released, the liquefied cracks of the nickel-based single crystal high-temperature alloy with high thermal crack sensitivity can be avoided, and the metallurgical defects such as cracks and the like generated in the laser direct deposition process are avoided;
(3) in the forming process, a part of the base material and the formed area are kept to be immersed in liquid metal, and heat of the forming area is rapidly led out by utilizing the characteristics of high thermal conductivity, high specific heat capacity and the like of a liquid metal container, so that the single crystal alloy forming process is kept at a relatively fixed temperature gradient, and the tissue stability and continuous epitaxial growth of the single crystal are ensured.
The features, functions, and advantages that have been discussed can be achieved independently in various examples or may be combined in yet other examples. Further details of the examples can be seen with reference to the following description and the accompanying drawings.
Drawings
The illustrative examples, as well as a preferred mode of use, further objectives, and descriptions thereof, will best be understood by reference to the following detailed description of an example of the present invention when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic diagram of a laser rapid prototyping system for a nickel-based single crystal alloy in accordance with the present invention.
Detailed Description
The disclosed examples will be described more fully with reference to the accompanying drawings, in which some (but not all) of the disclosed examples are shown. Indeed, many different examples may be described and should not be construed as limited to the examples set forth herein. Rather, these examples are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.
The present invention is further illustrated by the following examples, but is not limited to the specific embodiments.
The first embodiment is as follows: a preparation method of an IC10 single crystal superalloy turbine blade comprises the following steps:
(1) in fig. 1, reference numeral 1 denotes a laser, reference numeral 2 denotes a mirror, reference numeral 3 denotes a powder feeder, reference numeral 4 denotes an induction heating apparatus, reference numeral 5 denotes a liquid metal container, reference numeral 6 denotes an inert atmosphere environment, reference numeral 7 denotes a numerically controlled machine tool, and reference numeral 8 denotes a forming substrate.
(2) Establishing a turbine blade three-dimensional CAD model to be prepared, then carrying out layered slicing processing on the turbine blade three-dimensional CAD model in the height direction, carrying out scanning path filling on each layer of slices, and then introducing slice information and scanning path information into a laser direct deposition system.
(3) IC10 nickel-based single crystal superalloy powder with the granularity of 45-150 mu m is loaded into a powder feeder 3 of a laser direct deposition system, high-purity argon is used as powder feeding airflow, and the powder loading airflow is set as follows: 8L/min, the powder feeding speed of the mixed powder is 8g/min, argon is used as protective gas, and the flow of the protective gas is as follows: 20L/min.
(4) The bottom of a DD5 single crystal superalloy substrate for molding was immersed In a Ga-In-Sn liquid metal vessel 5 having a melting point of 30 ℃ so that the <001> crystal orientation of the DD5 alloy was parallel to the molding direction.
(5) And (3) adopting an induction heating device 4, enabling an induction coil to follow the shape of the blade to be processed, enabling the distance between the position of the coil and the surface of the blade to be about 8mm, heating the area to be formed and heating the temperature of the area to be formed to 900 ℃.
(6) Laser and powder are coaxially output, the laser focus is at the forming base surface, and the laser power is set as follows: 800W, laser scanning speed is as follows: 1200 mm/min. And (3) moving according to the scanning path set in the step (2), under the action of the laser, melting the IC10 powder on the forming substrate to form a molten pool, solidifying the molten pool as the powder and the laser move away, and scanning the whole sliced layer by the laser to obtain a deposited layer with the thickness of about 0.5 mm.
(7) And (5) lowering the forming substrate by 0.5mm downwards, and repeating the step (6) to obtain another deposition layer. The position of the induction coil and the liquid metal 5 is kept relatively fixed during the forming process.
(8) And (5) repeating the step (7) until the part preparation is completed.
Example two: a method for preparing IC10 oriented superalloy on FGH96 alloy comprises the following steps:
(1) in fig. 1, reference numeral 1 denotes a laser, reference numeral 2 denotes a mirror, reference numeral 3 denotes a powder feeder, reference numeral 4 denotes an induction heating apparatus, reference numeral 5 denotes a liquid metal container, reference numeral 6 denotes an inert atmosphere environment, reference numeral 7 denotes a numerically controlled machine tool, and reference numeral 8 denotes a forming substrate.
(2) Establishing a three-dimensional CAD model of a part to be prepared, then carrying out layered slicing processing on the part in the height direction, carrying out scanning path filling on each layer of slices, and then introducing slice information and scanning path information into a laser direct deposition system.
(3) IC10 nickel-based single crystal superalloy powder with the granularity of 45-150 mu m is loaded into a powder feeder 3 of a laser direct deposition system, high-purity argon is used as powder feeding airflow, and the powder loading airflow is set as follows: 8L/min, the powder feeding speed of the mixed powder is 8g/min, argon is used as protective gas, and the flow of the protective gas is as follows: 20L/min.
(4) The bottom of the powder superalloy substrate for molding was immersed In a Ga-In-Sn liquid metal container 5 having a melting point of 30 ℃.
(5) The substrate 8 is heated to a temperature of 900 c in the region to be formed by using the induction heating device 4.
(6) And scanning the area to be formed by laser, wherein the area to be formed by laser scanning is 1-2mm closer to the outer side than the edge of the area to be formed. Laser power: 1000W, scanning speed: 600mm/min, and 2 times of scanning by the same laser process.
(7) Laser and powder are coaxially output, the laser focus is at the forming base surface, and the laser power is set as follows: 800W, laser scanning speed is as follows: 1200 mm/min. And (3) moving according to the scanning path set in the step (2), under the action of the laser, melting the IC10 powder on the forming substrate to form a molten pool, solidifying the molten pool as the powder and the laser move away, and scanning the whole sliced layer by the laser to obtain a deposited layer with the thickness of about 0.5 mm.
(8) And (5) lowering the forming substrate by 0.5mm downwards, and repeating the step (7) to obtain another deposition layer. The position of the induction coil and the liquid metal 5 is kept relatively fixed during the forming process.
(9) And (5) repeating the step (8) until the part is prepared.
Different examples of the systems, devices, and methods disclosed herein include various components, features, and functions. It should be understood that the various examples of the systems, devices, and methods disclosed herein may include any of the components, features, and functions of any of the other examples of the systems, devices, and methods disclosed herein in any combination or sub-combination, and all such possibilities are intended to fall within the scope of the present invention.
The description of the different advantageous arrangements has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the examples in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Additionally, the different advantageous examples may describe different advantages as compared to other advantageous examples. The example or examples selected are chosen and described in order to best explain the principles of the examples, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various examples with various modifications as are suited to the particular use contemplated.
Claims (10)
1. A rapid laser forming system for high temperature alloys, which uses a laser direct deposition apparatus to deposit on a formed substrate (8) of high temperature alloy, characterized in that: the system also comprises an induction heating device (4) and a liquid metal container (5), wherein liquid metal is contained in the liquid metal container (5), the non-forming end of the forming substrate (8) is positioned in the liquid metal container (5) and can move up and down, the induction heating device (4) is arranged at the periphery of the forming end of the forming substrate (8), the upper induction heating device (4) and the lower liquid metal enable the forming substrate (8) to have an upper temperature gradient and a lower temperature gradient during forming, and the formed area is gradually immersed into the liquid metal container (5) along with the forming substrate.
2. The superalloy laser rapid prototyping system of claim 1 wherein: the laser direct deposition equipment comprises a laser (1), a reflector (2) and a powder feeder (3).
3. The superalloy laser rapid prototyping system of claim 1 wherein: the forming space is in an inert atmosphere (6).
4. The superalloy laser rapid prototyping system of claim 1 wherein: the lower end of the liquid metal container (5) is fixed on a numerical control machine tool (7).
5. The superalloy laser rapid prototyping system of claim 1 wherein: the liquid metal container (5) is a liquid metal container system which does not have strong chemical reaction with the high-temperature alloy.
6. A high-temperature alloy laser rapid forming method is characterized in that: the method utilizes the forming system of any one of claims 1-5 and comprises the steps of:
s1, modeling the three-dimensional CAD model and introducing model information into a laser direct deposition system;
s2, loading the high-temperature alloy powder into a powder feeder of a laser direct deposition system, and taking high-purity argon gas as a powder carrying gas and a protective gas;
s3, placing the non-forming end of the forming base material (8) in a liquid metal container (5);
s4, heating the to-be-formed area by using induction heating equipment (4);
s5, starting the laser direct deposition equipment to perform slicing deposition after the deposition condition is met to obtain a deposition layer;
s6, after the forming base material (8) is downwards reduced by the thickness of the deposition layer, if the part preparation is finished, otherwise, the step returns to S5 to continue the slice deposition.
7. The superalloy laser rapid prototyping method of claim 6 wherein: in S1, the three-dimensional CAD model is sliced hierarchically in the height direction, and scan path filling is performed for each slice, and then slice information and scan path information are introduced into the laser direct deposition system.
8. The superalloy laser rapid prototyping method of claim 6 wherein: in S2, the superalloy powder has an average grain size of about 45 to 150 μm.
9. The superalloy laser rapid prototyping method of claim 6 wherein: the liquid metal In S3 is Ga-In-Sn alloy or other liquid metal system that does not react with the alloy being prepared.
10. The superalloy laser rapid prototyping method of claim 6 wherein: and S4, the coil in the induction heating device follows the shape of the prepared member, and the distance between the coil and the surface of the member is 5-10 mm.
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