CN114878777B - High-throughput preparation and characterization system and method for high-temperature alloy based on additive manufacturing - Google Patents
High-throughput preparation and characterization system and method for high-temperature alloy based on additive manufacturing Download PDFInfo
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Abstract
The invention discloses a high-temperature alloy high-flux preparation and characterization system and method based on additive manufacturing, wherein the system comprises a main control console, a high-energy beam heat source processing head, a plurality of forming characterization modules, a high-flux control platform and a water cooling device; each forming representation module comprises a top opening and a hollow cylindrical body part, a water-cooling base is arranged at the bottom in the body part, a substrate for additive manufacturing forming is arranged on the water-cooling base, and an optical imaging module, an ultrasonic detection module and an X-ray detection module are arranged on the inner wall of the body part. According to the invention, the special high-temperature alloy components suitable for additive manufacturing and the corresponding screened optimal additive manufacturing process parameters are screened out through the special preparation and characterization system and method, so that the integration of forming and characterization is realized, the research and development flow is simplified to the greatest extent, and the research and development efficiency is improved.
Description
Technical Field
The invention relates to the technical field of high-throughput preparation processes of metal materials, in particular to a high-throughput preparation and characterization system of metal materials, especially high-temperature alloys based on additive manufacturing and a high-throughput preparation and characterization method using the system.
Background
The high-temperature alloy is a high-temperature metal material which works for a long time under the condition of more than 600 ℃ and certain stress, has excellent comprehensive properties such as high-temperature strength, oxidation resistance, hot corrosion resistance, fatigue performance, fracture toughness and the like, and can be mainly divided into three types of iron-based, nickel-based and cobalt-based high-temperature alloys according to matrix materials. The nickel-based high-temperature alloy can still keep good creep resistance, fatigue resistance and corrosion resistance at the temperature of 80-90% of the melting point, is suitable for the conditions of high rotating speed, high temperature, high load and high stress of a turbine engine, and therefore becomes a material of an aircraft engine blade.
The new generation of aeroengine blade has complex structure and high performance requirement, and the traditional directional solidification technology is adopted to prepare the high-temperature alloy blade, so that the defects of mixed crystals, cracks, air holes and the like are easily generated, the yield is greatly reduced, the segregation is serious in the preparation process, and the performance of the high-temperature alloy is influenced to a certain extent.
The metal additive manufacturing technology is an advanced manufacturing technology combining a rapid prototyping technology and a metal cladding technology. In the additive manufacturing process, a high-energy heat source continuously forms a tiny molten pool, and metal raw materials in the tiny molten pool perform metallurgical reaction, so that the preparation of high-performance materials and the manufacturing of complex components can be completed in one step. The high-flexibility characteristic of the additive manufacturing technology can realize the manufacturing of high-performance non-equilibrium materials and complex structures, and the formed member has a rapid solidification non-equilibrium structure without macrosegregation and compact component uniform structure, and has excellent comprehensive mechanical properties. Therefore, the manufacturing of the blade of the aircraft engine is carried out by adopting the additive manufacturing technology, the manufacturing of a complex structure is facilitated, the formed part has no macrosegregation, the yield and the performance of the blade of the aircraft engine can be greatly improved, and the additive manufacturing technology for directly manufacturing metal parts by utilizing a high-energy heat source is widely applied to the rapid manufacturing or repairing of high-performance key parts in aviation, aerospace and national defense technologies.
However, the conventional directionally solidified superalloy material system may not be suitable for additive manufacturing, and is prone to generating cracks or hole defects, so that research and development of a special new-component superalloy for additive manufacturing and a corresponding process thereof are urgently needed. The rapidity and high flexibility of the metal additive manufacturing technology are beneficial to realizing high-throughput preparation of metal materials, so that the research and development speed of high-performance new materials is remarkably improved, and therefore, the development of the special new-component high-temperature alloy for additive manufacturing based on the high-throughput preparation characterization process of the additive manufacturing technology has important significance.
Disclosure of Invention
Therefore, the invention develops a high-flux preparation and characterization system for high-temperature alloy based on metal additive manufacturing technology, screens out the high-temperature alloy components suitable for additive manufacturing by special preparation and characterization means and the optimal additive manufacturing process parameters correspondingly screened out, realizes the integration of forming and characterization, simplifies the research and development process to the greatest extent and improves the research and development efficiency.
Specifically, the invention provides a high-throughput preparation and characterization system for a high-temperature alloy based on additive manufacturing, which is characterized by comprising the following steps of:
the system comprises a main control table, a high-energy-beam heat source machining head, a plurality of forming characterization modules, a high-flux control platform and a water cooling device;
the plurality of formed characterization modules are uniformly distributed within the high-throughput control platform;
each forming representation module comprises a hollow cylindrical body part with an opening at the top, a water-cooling base is arranged at the bottom in the body part, a substrate for additive manufacturing forming is arranged on the water-cooling base, and an optical imaging module, an ultrasonic detection module and an X-ray detection module are arranged on the inner wall of the body part;
the water cooling device is communicated with the water cooling base;
and the main control console is respectively in communication connection with the high-energy beam heat source processing head, the water cooling device and the water cooling base, the optical imaging module, the ultrasonic detection module and the X-ray detection module of the forming representation module.
More preferably, the water-cooled base is a copper base having a cooling water path therein.
Further preferably, the base plate is detachably arranged on the water-cooling base.
Further preferably, the ultrasonic detection module comprises an ultrasonic transmitting device and an ultrasonic receiving device, and the ultrasonic transmitting device and the ultrasonic receiving device are superposed with a horizontal projection of a vertical connecting line of the central axis of the cylinder.
Further preferably, the X-ray detection module includes an X-ray emitting device and an X-ray receiving device, and a connecting line of the X-ray emitting device and the X-ray receiving device is a diameter of the cylinder.
Further preferably, the optical imaging module includes a plurality of optical cameras, and the plurality of optical cameras are uniformly distributed on the inner peripheral wall of the main body.
The invention also provides a high-throughput preparation and characterization method of the high-temperature alloy by using the system, which is characterized by comprising the following steps:
presetting a plurality of sets of process parameter designs on the main control console, wherein each set of process parameter design at least comprises alloy composition, laser power, scanning speed, powder feeding amount and spot diameter process parameter factors, and at least one process parameter factor is different between any two sets of process parameter designs;
according to the multiple sets of process parameter designs, the main control console drives the high-energy beam heat source machining head to respectively move to the positions above the openings of the multiple forming characterization modules to perform additive manufacturing on the high-temperature alloy samples, and the additive manufacturing performed at the multiple forming characterization modules corresponds to the multiple sets of process parameter designs one by one;
the main console controls the optical imaging module, the ultrasonic detection module and the X-ray detection module to respectively carry out photographing detection, ultrasonic detection and X-ray detection and records detection results;
and screening according to the detection result to obtain a qualified process parameter design and a corresponding high-temperature alloy sample.
Preferably, the method further comprises the steps of readjusting and presetting a plurality of sets of new process parameter designs on the master console according to the qualified process parameter designs, and repeating the additive manufacturing, detecting and screening steps at a plurality of new forming characterization modules according to the plurality of sets of new process parameter designs.
Further preferably, the photographing detection, the ultrasonic detection and the X-ray detection are performed in the following order:
firstly, photographing a sample for detection, and detecting the sample without cracks and obvious defects of holes on the surface in the next step;
then carrying out ultrasonic detection and/or X-ray detection on the sample, and carrying out next detection on the sample without cracks and obvious defects of holes inside;
and then carrying out ultrasonic detection on the sample, analyzing the grain boundary in the sample, and carrying out next detection on the sample with few grain boundaries.
Preferably, the additive manufacturing includes that in an inert gas protection atmosphere, a high-temperature alloy sample is prepared on the surface of the substrate through directional solidification in a mode of optical coaxial feeding, and the laser scanning adopts linear scanning to prepare a single-channel multi-layer high-temperature alloy sample.
The invention provides a high-flux preparation and characterization system for high-temperature alloy based on additive manufacturing technology and an application method thereof, which realize the forming and characterization of high-temperature alloy materials, realize the integration of the forming and characterization, simplify the research and development process to the greatest extent and improve the research and development efficiency of new high-temperature alloy materials.
Drawings
FIG. 1 is a schematic structural diagram of a system for high throughput preparation and characterization of a superalloy of the present invention.
FIG. 2 is a schematic structural diagram of a form characterization module of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be described below with reference to the drawings in the embodiments of the present invention.
Fig. 1 is a schematic structural diagram of a system for high-throughput preparation and characterization of a high-temperature alloy based on additive manufacturing according to the present invention, which includes a main console 1, a high-energy beam heat source processing head 2, a plurality of forming characterization modules 3, a high-throughput control platform 4, and a water cooling device 5, wherein the remaining components except for the main console 1 may be disposed in a forming chamber (not shown) protected by an inert atmosphere. A plurality of shaped characterization modules 3 are evenly distributed within the high throughput control platform 4 (up to 100 shaped characterization modules 3 may be provided).
As shown in FIG. 2, each of the shaped characterization modules 3 comprises an open-topped, hollow cylindrical body portion 6, the body portion 6 being, for example, a cylindrical structure 50mm in diameter and 80mm in height, capable of supporting a sample with a maximum width of 40mm and a maximum height of 60mm; a water-cooling base 7 is arranged at the bottom in the body part 6 (the water-cooling base 7 is preferably a copper base with a cooling water channel inside), the substrate can be cooled in the forming process, the temperature gradient in the forming process is increased, the directionality of the high-temperature alloy is improved, the performance of the high-temperature alloy is improved, and the temperature gradient can be further controlled by controlling the circulation of cooling water; the base plate 9 for manufacturing and forming the high-temperature alloy sample 8 in an additive manufacturing mode is arranged on the water-cooling base, and the base plate 9 is detachably arranged on the water-cooling base 7, so that a proper base plate can be selected according to different design components of the preformed high-temperature alloy, and the base plate is generally selected to be a high-temperature alloy plate which is prepared by directional solidification and has similar components with the designed high-temperature alloy; the inner wall of the body part 6 is provided with an optical imaging module 10, such as an optical camera, which can photograph the high-temperature alloy sample 8, and the optical imaging module can be arranged above the body part 6 and is provided with a plurality of, such as 4, high-temperature alloy samples which are uniformly distributed on the inner peripheral wall of the body part 6; the inner wall of the body part 6 is also provided with an ultrasonic detection module, the ultrasonic detection module comprises an ultrasonic transmitting device 11 and an ultrasonic receiving device 12, and can transmit ultrasonic waves to carry out nondestructive detection on the high-temperature alloy sample 8 and detect defects and crystal boundaries in the sample, the ultrasonic transmitting device 11 and the ultrasonic receiving device 12 are superposed with the horizontal projection of the vertical connecting line of the central axis of the cylinder, namely the arrangement positions of the ultrasonic transmitting device 11 and the ultrasonic receiving device 12 are the same on the longitude of the cylinder of the body part 6, so that the accurate transmission and reception of the ultrasonic waves are ensured, and the radiation range of the ultrasonic transmitting device 11 can cover the alloy sample; the inner wall of the body part 6 is also provided with an X-ray detection module which comprises an X-ray emitting device 13 and an X-ray receiving device 14 and can emit X-rays to carry out nondestructive detection on the high-temperature alloy sample 8 and detect the defects inside the sample, and the connecting line of the X-ray emitting device 13 and the X-ray receiving device 14 is the diameter of the cylinder of the body part 6 so as to ensure the accurate emission and reception of the X-rays, and the radiation range of the X-ray emitting device 13 can cover the alloy sample.
The high-energy-beam heat source processing head 2 can be driven by a three-axis numerical control machine tool or a multi-axis manipulator (not shown), the high-energy-beam heat source processing head 2 for in-light coaxial feeding is adopted, and a feeding pipeline can simultaneously convey powder and wires.
Wherein the water cooling device 5 may be in communication with a water cooled base 7 within each of the form characterization modules 3.
The main control console 1 can be respectively in communication connection with the high-energy-beam heat source processing head 2, the water cooling device 5, the water cooling base 7 of the forming representation module 3, the optical imaging module 9, the ultrasonic detection module and the X-ray detection module so as to drive and control all the components.
When the powder is used as a raw material, the powder hardly scatters, the coupling stability of the light and the powder is better than that of the light and external multi-path coaxial powder feeding, and meanwhile, the waste of the powder is greatly reduced, the surface quality is improved, and the forming precision is improved. When the wire material is adopted as a raw material, the wire material vertically enters a molten pool, so that the disturbance to the molten pool can be reduced, the quantity of mixed crystals in a repair area can be reduced, and the forming precision and the surface quality can be improved. However, some superalloy wires are difficult to produce, and for such superalloys, powder feeding is used for production.
The metal powder adopted by the additive manufacturing can be prepared by adopting a prealloying method or obtained by adopting a method of mixing a plurality of alloy powders. The mode of mixing various alloy powders is low in cost, but the components are difficult to mix uniformly and are generally used for coarse screening. The prealloying method is high in cost, but the powder components are uniform, so that the performance is improved, and the prealloying method is generally used for fine screening and forming process tests.
When the system is adopted to carry out high-throughput preparation and characterization on the high-temperature alloy, a plurality of groups of process parameter designs are preset on a main control console, each group of process parameter designs at least comprise process parameter factors such as alloy components, laser power, scanning speed, powder feeding amount, spot diameter and the like, at least one process parameter factor is different between any two groups of process parameter designs, and during actual operation, only one process parameter factor can be changed while other process parameter factors are fixed, so that the influence of the process parameter factors with different changes can be conveniently examined.
And then, according to the design of a plurality of groups of process parameters, the main control console drives the high-energy beam heat source machining head to respectively move to the upper part of the openings of the plurality of forming characterization modules to perform additive manufacturing on the high-temperature alloy sample, and the additive manufacturing performed at the plurality of forming characterization modules corresponds to the design of the plurality of groups of process parameters one by one so as to obtain the high-temperature alloy sample corresponding to the investigated process parameter design.
Then, the main console controls the optical imaging module, the ultrasonic detection module and the X-ray detection module to respectively carry out photographing detection, ultrasonic detection and X-ray detection and record detection results; the photographing detection, the ultrasonic detection and the X-ray detection are carried out according to the following sequence: firstly, photographing a sample for detection, and detecting the sample without cracks and obvious defects of holes on the surface in the next step; then carrying out ultrasonic detection and/or X-ray detection on the sample, and determining the sample without obvious cracks and hole defects inside the sample as a qualified sample (namely, no obvious wave crest is found in the set low-frequency ultrasonic detection, and no obvious defect is found in an X-ray image picture); and then continuing to perform ultrasonic detection on the sample, analyzing the grain boundary in the sample, and performing next detection on the sample with fewer grain boundaries (namely, the number of wave peaks is less in the set high-frequency ultrasonic detection).
In order to improve the research and development efficiency, the invention can further research and develop and investigate within the optimized parameter range, namely, the qualified process parameter design obtained in the previous step is fixed according to the optimized result of different process parameter factors changed in the previous step, one or more of other process parameter factors are adjusted, so as to readjust and preset multiple groups of new process parameter designs on the main control console, and the additive manufacturing, detecting and screening steps are repeated at multiple new forming characterization modules according to the multiple groups of new process parameter designs, and as the number of the forming characterization modules can reach 100, the optimized process can be repeated for multiple times.
The laser spot diameter of the invention can be 2-8mm, and when the spot diameter is determined, for example, the scanning speed, the laser power and the feeding amount are mainly adjusted to carry out a process parameter test. And the laser scanning adopts linear scanning to prepare a single-channel multilayer high-temperature alloy sample.
The qualified test sample after screening in the above steps can be further tested and screened, for example, stress relief annealing treatment is carried out at 500-600 ℃ for 5-6 hours, the test sample after stress relief annealing is processed into a high-temperature tensile test sample, and the high-temperature tensile property or high-temperature durability of the test sample is tested to finally determine the performance of the test sample.
The embodiment is as follows:
the composition improvement test is carried out on the second generation single crystal superalloy DD5, and the following compositions are adopted for the test: ni-7Cr-8Co-6.2Al-xTa-yW-2Mo-3Re-0.2Hf (x =3,5,7. The process parameters are shown in the following table, and a single-pass multilayer sheet 30mm long and 50mm high was prepared by performing the same process parameter tests on each component, and the test parameters are shown in table 1.
TABLE 1 Single-pass multilayer laser additive repair test technological parameters
And after the forming is finished, optical, X-ray and ultrasonic detection is carried out, 7 samples meeting the requirements are obtained after screening, the samples are processed into tensile samples after stress relief annealing at the temperature of 600 ℃ for 5 hours, and high-temperature endurance life test at the temperature of 900 ℃ and 400MPa is carried out, the results are shown in table 2, and the No. 5 and No. 6 components and matched process parameters in the table are optimal, so that the further research and test can be carried out.
TABLE 2 Process endurance life of different compositions and different superalloys
| Serial number | Composition of sample | Technological parameters | Long life (h) |
| 1 | x=3，y=3 | A2 | 71.3 |
| 2 | x=3，y=3 | B3 | 78.1 |
| 3 | x=3，y=5 | A1 | 87.5 |
| 4 | x=5，y=5 | A2 | 92.7 |
| 5 | x=5，y=5 | B2 | 102.4 |
| 6 | x=5，y=3 | A1 | 99.3 |
| 7 | x=5，y=3 | B2 | 92.6 |
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (7)
1. A high-throughput preparation and characterization system for a high-temperature alloy based on additive manufacturing is characterized in that:
the system comprises a main control console, a high-energy beam heat source processing head, a plurality of forming characterization modules, a high-flux control platform and a water cooling device;
the plurality of formed characterization modules are uniformly distributed within the high-throughput control platform;
each forming representation module comprises a hollow cylindrical body part with an opening at the top, a water-cooling base is arranged at the bottom in the body part, a substrate for additive manufacturing forming is arranged on the water-cooling base, and an optical imaging module, an ultrasonic detection module and an X-ray detection module are arranged on the inner wall of the body part;
the ultrasonic detection module comprises an ultrasonic transmitting device and an ultrasonic receiving device, and the ultrasonic transmitting device and the ultrasonic receiving device are superposed with the horizontal projection of the vertical connecting line of the central axis of the cylinder;
the X-ray detection module comprises an X-ray transmitting device and an X-ray receiving device, and the connecting line of the X-ray transmitting device and the X-ray receiving device is the diameter of the cylinder;
the optical imaging module comprises a plurality of optical cameras which are uniformly distributed on the inner peripheral wall of the body part;
the water cooling device is communicated with the water cooling base;
and the main control console is in communication connection with the high-energy-beam heat source processing head, the water cooling device, the water cooling base of the forming characterization module, the optical imaging module, the ultrasonic detection module and the X-ray detection module respectively.
2. The system of claim 1, wherein: the water-cooling base is a copper base with a cooling water path inside.
3. The system of claim 1, wherein: the base plate is detachably arranged on the water-cooling base.
4. A high-throughput superalloy manufacturing and characterization method using the system of any of claims 1-3, wherein:
presetting a plurality of sets of process parameter designs on the main control console, wherein each set of process parameter design at least comprises alloy composition, laser power, scanning speed, powder feeding amount and spot diameter process parameter factors, and at least one process parameter factor is different between any two sets of process parameter designs;
according to the multiple sets of process parameter designs, the main control console drives the high-energy beam heat source machining head to respectively move to the positions above the openings of the multiple forming characterization modules to perform additive manufacturing on the high-temperature alloy samples, and the additive manufacturing performed at the multiple forming characterization modules corresponds to the multiple sets of process parameter designs one by one;
the main console controls the optical imaging module, the ultrasonic detection module and the X-ray detection module to respectively carry out photographing detection, ultrasonic detection and X-ray detection and records detection results;
and screening according to the detection result to obtain a qualified process parameter design and a corresponding high-temperature alloy sample.
5. The high-throughput superalloy preparation and characterization method of claim 4, wherein:
and further comprising readjusting and presetting a plurality of groups of new process parameter designs on the main control console according to the qualified process parameter designs, and repeating the additive manufacturing, detecting and screening steps at a plurality of new forming characterization modules according to the plurality of groups of new process parameter designs.
6. The high-throughput preparation and characterization method for a superalloy according to claim 4, wherein: the photographing detection, the ultrasonic detection and the X-ray detection are carried out according to the following sequence:
firstly, photographing a sample for detection, and carrying out next detection on the sample without cracks and obvious defects of holes on the surface;
then carrying out ultrasonic detection and/or X-ray detection on the sample, and carrying out next detection on the sample without cracks and obvious defects of holes inside;
and then carrying out ultrasonic detection on the sample, analyzing the grain boundary in the sample, and carrying out next detection on the sample with less grain boundaries.
7. The high-throughput preparation and characterization method for a superalloy according to claim 4, wherein: the additive manufacturing specifically comprises the steps of preparing a high-temperature alloy sample on the surface of the substrate by directional solidification in a mode of optical inner coaxial feeding in an inert gas protection atmosphere, and preparing a single-channel multilayer high-temperature alloy sample by linear scanning in laser scanning.
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