CN114799211A - In-situ metal ceramic multi-material preparation method based on powder bed melting - Google Patents
In-situ metal ceramic multi-material preparation method based on powder bed melting Download PDFInfo
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- 239000000463 material Substances 0.000 title claims abstract description 53
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- 238000002844 melting Methods 0.000 title claims abstract description 20
- 230000008018 melting Effects 0.000 title claims abstract description 20
- 238000002360 preparation method Methods 0.000 title claims abstract description 17
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims abstract description 50
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 38
- 239000001301 oxygen Substances 0.000 claims abstract description 38
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 38
- 229910001092 metal group alloy Inorganic materials 0.000 claims abstract description 29
- 238000007639 printing Methods 0.000 claims abstract description 28
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- 238000000034 method Methods 0.000 claims description 23
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 16
- 239000000758 substrate Substances 0.000 claims description 13
- 239000011195 cermet Substances 0.000 claims description 12
- 229910000838 Al alloy Inorganic materials 0.000 claims description 8
- 229910052786 argon Inorganic materials 0.000 claims description 8
- 229910001069 Ti alloy Inorganic materials 0.000 claims description 7
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 4
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- 238000005488 sandblasting Methods 0.000 description 3
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
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- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Automation & Control Theory (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Powder Metallurgy (AREA)
Abstract
The invention discloses an in-situ metal ceramic multi-material preparation method based on powder bed melting, which is characterized by comprising the following steps of: (1) dividing a three-dimensional structure of a part into a metal area and a ceramic area; (2) judging whether the part to be printed is a metal area or a ceramic area along the printing direction, if so, adopting relatively low laser energy density, and printing the metal area of the part according to the three-dimensional structure by adopting an additive manufacturing technology under a protective atmosphere; if the ceramic area is the ceramic area, printing the ceramic area of the part according to the three-dimensional structure by adopting a relatively high laser energy density and adopting an additive manufacturing technology under the atmosphere of oxygen or nitrogen; (3) repeating the step (2) until the printing of the part is finished; the metal area and the ceramic area are printed by using metal alloy powder with the same composition as the raw material. The invention realizes the in-situ formation of the metal ceramic multi-material part under the condition of using the same metal powder by changing the gas atmosphere in the forming cavity.
Description
Technical Field
The invention belongs to the technical field of multi-material additive manufacturing, and particularly relates to an in-situ metal ceramic multi-material preparation method based on powder bed melting.
Background
The ceramic material has excellent performances of high temperature resistance, high strength, high hardness, wear resistance, corrosion resistance and the like, and is suitable for the fields of aerospace, power electronics, energy traffic and the like. However, the material itself is very brittle and difficult to machine into large-sized complex-shaped parts. The metal material has good electrical conductivity, ductility and thermal conductivity, and has a complementary relationship with the ceramic in performance. The metallurgical combination of metal and ceramic materials can fully utilize the respective excellent performances of the two materials, realize the conduction-dielectric property, high extensibility-high strength and hardness and the like in the same component, and meet the requirements of complex components.
However, due to the problems of excessive residual stress caused by difference between the ceramic covalent bond and the metal bond, poor wettability of the ceramic interface, and large difference between the thermal expansion coefficients of the ceramic covalent bond and the metal bond, the metal and the ceramic interface are often difficult to realize good metallurgical bonding. Although the traditional means such as brazing, solid-phase diffusion bonding, fusion welding, friction welding, ultrasonic bonding and the like can realize the combination of metal and ceramic to a certain extent, the traditional means can only process parts with simple shapes such as rod-shaped, plate-shaped, block-shaped and the like, and cannot process complex parts. The additive manufacturing technology is an effective multi-material part processing mode, and can realize the customized forming of multi-material parts with complex shapes. For the existing powder bed melting additive manufacturing technology, certain difficulties exist in processing metal and ceramic multi-materials. Powder mixing waste is easily caused in the forming process, the powder replacement operation is complicated, the efficiency is low, only multi-material parts in the deposition direction can be formed, and multi-material components in the horizontal plane are difficult to realize. In addition, because of the great difference between the properties of metal and ceramic, parts formed by the existing powder bed melting technology are easy to crack and delaminate, and the parts are scrapped.
In summary, the existing powder bed melting technology lacks an in-situ preparation method capable of efficiently realizing the metal ceramic multi-material parts.
Disclosure of Invention
Aiming at the defects or improvement requirements of the prior art, the invention provides an in-situ metal ceramic multi-material preparation method based on powder bed melting, and aims to perform printing by adjusting the cavity atmosphere in the additive manufacturing process, so that the technical problems that the existing powder replacement operation is complicated, the efficiency is low, the difference between the properties of metal and ceramic is large, and a formed part is easy to crack and delaminate are solved.
To achieve the above objects, according to one aspect of the present invention, there is provided an in-situ cermet multi-material preparation method based on powder bed melting. An in-situ cermet multi-material preparation method based on powder bed melting, the method comprising:
(1) dividing a three-dimensional structure of a part into a metal area and a ceramic area;
(2) judging whether the part to be printed is a metal area or a ceramic area along the printing direction, if so, adopting relatively low laser energy density, and printing the metal area of the part according to the three-dimensional structure by adopting an additive manufacturing technology under a protective atmosphere; if the ceramic area is the ceramic area, printing the ceramic area of the part according to the three-dimensional structure by adopting a relatively high laser energy density and adopting an additive manufacturing technology under the atmosphere of oxygen or nitrogen; wherein, the laser energy density E is P/Vht, where P is the laser power, V is the scanning speed, h is the filling pitch (constant in the present invention), and t is the layer thickness (constant in the present invention), the value of h in the ceramic region is the same as the value of h in the metal region, and the value of t in the ceramic region is the same as the value of t in the metal region.
(3) Repeating the step (2) until the printing of the part is finished; wherein, the metal area and the ceramic area adopt metal alloy powder with the same components as raw materials to be printed.
Preferably, the relatively low laser energy density is achieved by a laser power of 50W to 150W and a scanning speed of 800mm/s to 1400 mm/s.
Preferably, the relatively high laser energy density is achieved by a laser power of 200W to 400W and a scanning speed of 300mm/s to 700 mm/s.
Preferably, the gas atmosphere containing oxygen or nitrogen comprises oxygen or nitrogen in a protective atmosphere, and the volume ratio of the nitrogen or the oxygen is 10-30%.
Preferably, the metal alloy powder is an alloy powder capable of forming a ceramic phase with an oxygen or nitrogen element, and preferably, the metal alloy powder is an aluminum alloy, a titanium alloy, or a magnesium alloy.
Preferably, the metal alloy powder has an average particle diameter of 20 to 60 μm and a sphericity of 99.9%.
Preferably, before the step (2), the method further comprises the following steps: the substrate is sand blasted and then a layer of metal alloy powder is pre-laid on the substrate, wherein the thickness of the layer of metal alloy powder is 30-60 mu m.
Preferably, in the step (2), the metal area of the part is printed according to the three-dimensional structure by using an additive manufacturing technology under a protective atmosphere, specifically under the protection of argon, and the oxygen content is lower than 40 ppm.
In accordance with another aspect of the present invention, an in-situ cermet multi-material is provided.
In general, at least the following advantages can be obtained by the above technical solution contemplated by the present invention compared to the prior art.
(1) The invention realizes the in-situ formation of the metal ceramic multi-material part under the condition of using the same metal powder by changing the gas atmosphere in the forming cavity, introducing or not introducing nitrogen/oxygen and combining high laser energy density and low laser energy density. Compared with the traditional powder bed melting, the method avoids the complex operation of powder replacement in the multi-material forming process, does not need to improve the forming system of the equipment and reduces the cost. The problem of only can form the multi-material part of direction of deposit, be difficult to realize the multi-material component in the horizontal plane is solved.
The principle of forming the metal ceramic multi-material part in situ under the condition of using the same metal powder is as follows: when the laser energy density is relatively low (for example, the laser power is 50W-150W, and the scanning speed is 800mm/s-1400 mm/s), the metal powder can be melted without being oxidized by oxygen or nitrided by nitrogen in the chamber, because the molten pool has short existence time, the liquid metal is cooled to be solid before being oxidized or nitrided, and the formed part is a metal alloy. At relatively high laser energy densities (e.g., laser powers of 200W-400W and scanning speeds of 300mm/s-700mm/s), the molten metal powder is readily oxidized or nitridized by oxygen in the chamber to form an oxide or nitride ceramic, due to the longer molten pool time, and the liquid metal at high temperature is oxidized or nitridized to form an oxide or nitride ceramic phase.
(2) In the invention, because the metal and the ceramic which are formed in situ are fundamentally derived from the same powder, when the formation of the metal and the ceramic is respectively adjusted by a laser process, a certain transition region can be formed at the interface, and because the high laser power density parameter can partially re-melt the formed region before scanning, such as the transition region from aluminum alloy to aluminum oxide, compared with the existing powder bed melting formation, the rapid change of the interface is avoided, and the interface combination effect is better.
(3) The invention can design and produce any customized metal ceramic multi-material part only according to the designed three-dimensional model and by matching with the laser process parameters provided by the invention. Can conveniently realize special combination properties such as conductivity-dielectric property, high extensibility-high hardness and the like.
Drawings
FIG. 1 is a schematic view of a magnesium alloy and magnesia ceramic multi-material member in example 1 of the present invention;
FIG. 2 is a schematic view of a titanium alloy and titanium nitride ceramic multi-material member according to example 2 of the present invention;
FIG. 3 is a schematic view of an aluminum alloy and alumina ceramic multi-material member in example 3 of the present invention.
The reference signs are: 1. metal region, 2, ceramic region.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
Example 1
The embodiment provides an in-situ metal ceramic multi-material preparation method based on powder bed melting, which comprises the following steps:
(1) and modeling and designing the metal ceramic multi-material part to be formed by utilizing three-dimensional modeling software, exporting the metal ceramic multi-material part into stl format, and inputting the metal ceramic multi-material part into a powder bed melting system.
The three-dimensional model of the part is shown in figure 1, and the metal area 1 and the ceramic area 2 integrally belong to the same part.
(2) The powder used for multi-material printing is metal alloy powder, then the substrate is subjected to sand blasting treatment, and then a layer of metal alloy powder is pre-laid on the substrate. The metal alloy powder is magnesium alloy powder, the average grain diameter of the metal alloy powder is 40 mu m, and the sphericity ratio is 99.9%. The thickness of the layer of metal alloy powder is 50 μm.
(3) Judging whether the part to be printed is a metal area or a ceramic area along the printing direction, if so, adopting relatively low laser energy density, and printing the metal area of the part according to the three-dimensional structure by adopting an additive manufacturing technology under a protective atmosphere; if the ceramic area is the ceramic area, the ceramic area of the part is printed according to the three-dimensional structure by adopting relatively high laser energy density and adopting an additive manufacturing technology under the atmosphere of gas containing oxygen or nitrogen.
The control of the printing gas atmosphere is specifically as follows: and closing the hatch door of the forming chamber, and controlling the gas atmosphere in the chamber through the gas inlet. The protective atmosphere is: and opening a protective gas inlet valve and a pressure release valve, and introducing argon to remove oxygen in the chamber, wherein the oxygen content is lower than 40 ppm. The atmosphere containing oxygen or nitrogen is: and opening the second air inlet valve, and controlling the relative flow of the oxygen or the nitrogen to ensure that the proportion of the oxygen or the nitrogen in the cavity is within a preset range. And after the gas proportion in the cavity meets the machining requirements, forming the metal ceramic multi-material part by adopting an optimized forming process.
In the embodiment, the laser power of the metal area forming process is 50W, the scanning speed is 800mm/s, the laser energy density is low, the protective gas is argon, and the oxygen content is lower than 40 ppm; the laser power of the ceramic area forming process is 200W, the scanning speed is 300mm/s, the laser energy density is high, and the proportion of oxygen in the cavity is 10-20%, wherein the proportion refers to the volume percentage.
(4) And (4) repeating the step (3) until printing is finished.
(5) And after the part is processed, separating the part from the substrate by wire cutting.
Example 2
The embodiment provides an in-situ metal ceramic multi-material preparation method based on powder bed melting, which comprises the following steps:
(1) and modeling and designing the metal ceramic multi-material part to be formed by utilizing three-dimensional modeling software, exporting the metal ceramic multi-material part into stl format, and inputting the metal ceramic multi-material part into a powder bed melting system.
The three-dimensional model of the part is shown in figure 1, and the metal area 1 and the ceramic area 2 integrally belong to the same part.
(2) The powder used for multi-material printing is metal alloy powder, then the substrate is subjected to sand blasting treatment, and then a layer of metal alloy powder is pre-laid on the substrate. The metal alloy powder is titanium alloy powder, the average grain diameter of the metal alloy powder is 53 mu m, and the sphericity ratio is 99.9%. The thickness of the layer of metal alloy powder is 50 μm.
(3) Judging whether the part to be printed is a metal area or a ceramic area along the printing direction, if so, adopting relatively low laser energy density, and printing the metal area of the part according to the three-dimensional structure by adopting an additive manufacturing technology under a protective atmosphere; if the ceramic area is the ceramic area, the ceramic area of the part is printed according to the three-dimensional structure by adopting relatively high laser energy density and adopting an additive manufacturing technology under the atmosphere of gas containing oxygen or nitrogen.
The control of the printing gas atmosphere is specifically as follows: and closing the hatch door of the forming chamber, and controlling the gas atmosphere in the chamber through the gas inlet. The protective atmosphere is as follows: and opening a protective gas inlet valve and a pressure release valve, and introducing argon to remove oxygen in the cavity, wherein the oxygen content of the protective gas is lower than 40 ppm. The atmosphere containing oxygen or nitrogen is: and opening the second air inlet valve, and controlling the relative flow of the oxygen or the nitrogen to ensure that the proportion of the oxygen or the nitrogen in the cavity is within a preset range. And after the gas proportion in the cavity meets the machining requirements, forming the metal ceramic multi-material part by adopting an optimized forming process.
In the embodiment, the laser power of the metal area forming process is 150W, the scanning speed is 900mm/s, the laser energy density is low, the protective gas is argon, and the oxygen content is lower than 40 ppm; the laser power of the ceramic area forming process is 300W, the scanning speed is 500mm/s, the laser energy density is high, and the proportion of nitrogen in the cavity is 20-30%, wherein the proportion refers to the volume percentage.
(4) And (4) repeating the step (3) until printing is finished.
(5) And after the part is processed, separating the part from the substrate by wire cutting.
Referring to fig. 2, the part prepared in this embodiment includes an internal titanium alloy molding and a magnesium nitride ceramic connected to the external titanium alloy molding, and combines the high wear resistance and high melting point of the peripheral magnesium nitride ceramic to form a combination of hard outside and tough inside based on the strength and toughness of the internal titanium alloy.
Example 3
The embodiment provides an in-situ cermet multi-material preparation method based on powder bed melting, which comprises the following steps of:
(1) and modeling and designing the metal ceramic multi-material part to be formed by utilizing three-dimensional modeling software, exporting the metal ceramic multi-material part to be formed into stl format, and inputting the metal ceramic multi-material part to a powder bed melting system.
The three-dimensional model of the part is shown in figure 1, and the metal area 1 and the ceramic area 2 integrally belong to the same part.
(2) The powder used for multi-material printing is metal alloy powder, then the substrate is subjected to sand blasting treatment, and then a layer of metal alloy powder is pre-laid on the substrate. The metal alloy powder is aluminum alloy powder, the average grain diameter of the metal alloy powder is 30 mu m, and the sphericity ratio is 99.9%. The thickness of the layer of metal alloy powder is 30 μm.
(3) Judging whether the part to be printed is a metal area or a ceramic area along the printing direction, if so, adopting relatively low laser energy density, and printing the metal area of the part according to the three-dimensional structure by adopting an additive manufacturing technology under a protective atmosphere; if the ceramic area is the ceramic area, the ceramic area of the part is printed according to the three-dimensional structure by adopting relatively high laser energy density and adopting an additive manufacturing technology under the atmosphere of gas containing oxygen or nitrogen.
The control of the printing gas atmosphere is specifically as follows: and closing a hatch door of the forming chamber, and controlling the gas atmosphere in the chamber through the gas inlet. The protective atmosphere is: and opening a protective gas inlet valve and a pressure release valve, and introducing argon to remove oxygen in the chamber, wherein the oxygen content is lower than 40 ppm. The atmosphere containing oxygen or nitrogen is: and opening a second air inlet valve, and controlling the relative flow of the oxygen or the nitrogen to ensure that the proportion of the oxygen or the nitrogen in the cavity is within a preset range. And after the gas proportion in the cavity meets the machining requirements, forming the metal ceramic multi-material part by adopting an optimized forming process.
In the embodiment, the laser power of the metal area forming process is 100W, the scanning speed is 1000mm/s, the laser energy density is low, the protective gas is argon, and the oxygen content is lower than 40 ppm; the laser power of the ceramic area forming process is 250W, the scanning speed is 600mm/s, the laser energy density is high, and the proportion of oxygen in the cavity is 10-30%, wherein the proportion refers to the volume percentage.
(4) And (4) repeating the step (3) until printing is finished.
(5) And after the part is processed, separating the part from the substrate by wire cutting.
Referring to fig. 3, the part prepared in this embodiment includes an array of columnar aluminum alloy formed parts and aluminum oxide ceramic parts connected to the aluminum alloy formed parts at two sides thereof, and the dielectric properties of the aluminum oxide ceramic at two sides are combined to form a plurality of conductive-dielectric combination properties based on the conductivity of the aluminum alloy.
It will be understood by those skilled in the art that the foregoing is only an exemplary embodiment of the present invention, and is not intended to limit the invention to the particular forms disclosed, since various modifications, substitutions and improvements within the spirit and scope of the invention are possible and within the scope of the appended claims.
Claims (9)
1. An in-situ cermet multi-material preparation method based on powder bed melting, characterized in that the method comprises:
(1) dividing a three-dimensional structure of a part into a metal area and a ceramic area;
(2) judging whether the part to be printed is a metal area or a ceramic area along the printing direction, if so, adopting relatively low laser energy density, and printing the metal area of the part according to the three-dimensional structure by adopting an additive manufacturing technology under a protective atmosphere; if the ceramic area is the ceramic area, printing the ceramic area of the part according to the three-dimensional structure by adopting a relatively high laser energy density and adopting an additive manufacturing technology under the atmosphere of oxygen or nitrogen;
(3) repeating the step (2) until the printing of the part is finished; wherein, the metal area and the ceramic area are printed by adopting metal alloy powder with the same components as the raw material.
2. The in-situ cermet multi-material preparation method of claim 1, wherein the relatively low laser energy density is achieved by a laser power of 50W-150W and a scanning speed of 800mm/s-1400 mm/s.
3. The in-situ cermet multi-material preparation method according to claim 1 or 2, characterised in that the relatively high laser energy density is achieved by a laser power of 200W-400W and a scanning speed of 300mm/s-700 mm/s.
4. The method for preparing the in-situ cermet multi-material according to claim 1, wherein the atmosphere containing oxygen or nitrogen is a protective atmosphere containing oxygen or nitrogen, and the volume ratio of nitrogen or oxygen is 10-30%.
5. The in-situ cermet multi-material preparation method according to claim 1, wherein the metal alloy powder is an alloy powder capable of forming a ceramic phase with oxygen or nitrogen element, preferably the metal alloy powder is an aluminum alloy, a titanium alloy or a magnesium alloy.
6. The method of claim 5, wherein the metal alloy powder has an average particle size of 20-60 μm and a sphericity of 99.9%.
7. The in-situ cermet multi-material preparation method of claim 1, further comprising, before step (2): the substrate is sandblasted and then a layer of metal alloy powder is pre-laid on the substrate, the thickness of the layer of metal alloy powder being 30-60 μm.
8. The in-situ cermet multi-material preparation method according to claim 1, characterized in that in step (2), the metal area of the part is printed according to a three-dimensional structure using additive manufacturing technique under protective atmosphere, in particular under argon protection, and the oxygen content is made to be less than 40 ppm.
9. The in-situ cermet multi-material prepared by the method of any one of claims 1-8.
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