WO2022041255A1 - 采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法 - Google Patents

采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法 Download PDF

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WO2022041255A1
WO2022041255A1 PCT/CN2020/112696 CN2020112696W WO2022041255A1 WO 2022041255 A1 WO2022041255 A1 WO 2022041255A1 CN 2020112696 W CN2020112696 W CN 2020112696W WO 2022041255 A1 WO2022041255 A1 WO 2022041255A1
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ceramic particles
nickel
based superalloy
powder
nano
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PCT/CN2020/112696
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English (en)
French (fr)
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刘祖铭
魏冰
农必重
吕学谦
任亚科
曹镔
艾永康
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中南大学
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Priority to US18/023,731 priority Critical patent/US20240060156A1/en
Publication of WO2022041255A1 publication Critical patent/WO2022041255A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/05—Mixtures of metal powder with non-metallic powder
    • C—CHEMISTRY; METALLURGY
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    • C22C—ALLOYS
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    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/05—Mixtures of metal powder with non-metallic powder
    • C22C1/059—Making alloys comprising less than 5% by weight of dispersed reinforcing phases
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    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
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    • B33Y10/00—Processes of additive manufacturing
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    • 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/10—Pre-treatment
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    • 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
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
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    • B82—NANOTECHNOLOGY
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    • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
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    • B82—NANOTECHNOLOGY
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    • B82Y40/00—Manufacture or treatment of nanostructures
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    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0433—Nickel- or cobalt-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1084—Alloys containing non-metals by mechanical alloying (blending, milling)
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/056—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C30/00—Alloys containing less than 50% by weight of each constituent
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • B22F1/065—Spherical particles
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    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
    • B22F2009/043—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by ball milling
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
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    • B22F2304/10—Micron size particles, i.e. above 1 micrometer up to 500 micrometer
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    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the invention provides a method for preparing a nano-phase reinforced nickel-based superalloy by using micron ceramic particles, and belongs to the field of nickel-based alloy preparation.
  • Nickel-based superalloys have high high temperature strength, high temperature creep strength, good fatigue properties, fracture toughness, good oxidation and corrosion resistance, etc., and have good microstructure stability and reliability at high temperatures, and are widely used. It is widely used in the manufacture of hot-end components of aviation jet engines and various industrial gas turbines. The development of high thrust-to-weight ratio aero-engines has put forward higher requirements for the comprehensive properties (strength, service temperature, durability, etc.) of nickel-based superalloys.
  • Ceramic particle-reinforced metal matrix composites have the advantages of high specific strength, specific modulus, high temperature resistance, small thermal expansion coefficient, wear resistance, corrosion resistance, and good dimensional stability. Among them, the nanoparticle-reinforced nickel-based superalloy composite material can maintain good toughness, high temperature creep strength and fatigue strength while improving mechanical properties such as strength and hardness.
  • Chinese patent discloses a method for in-situ reaction synthesis of TiCx particle reinforced nickel-based composite materials.
  • the preparation process includes (1) preparation of mixed powder: the powder material is composed of Ti, C, Al, Fe, and Mo, among which Al powder 8 -12wt.%, Fe powder 12-15wt.%, Mo powder 3-5wt.%, graphite C powder 8-12wt.%, the balance is Ti powder, the ratio of the weight of Ti powder to the weight of C powder in the powder must satisfy ( 5-6.7): 1 relationship; (2) Preparation of powder chips: roll Ni foil into a cylinder with a diameter of 16-25mm, and pour the mixed powder after ball milling into the cylinder; (3) Smelting and casting Process: TiCx/Ni composites were prepared by vacuum intermediate frequency induction melting furnace.
  • the TiCx/Ni composite material with a TiCx volume fraction of 20-40% was prepared, the density was close to 100%, and the high temperature strength and hardness were significantly higher than those of conventional nickel-based superalloys.
  • Chinese patent (CN107116217A) discloses a method for preparing TiC-reinforced nickel-based composite material by selective laser melting forming method. The nickel-based alloy and the reinforcing-based alloy are respectively weighed according to the proportions, and the diameter of the added TiC reinforcing phase particles is 5-8 microns.
  • the weighed powder is placed in a low-temperature planetary ball mill to prepare nickel-based mixed powder, and the prepared nickel-based mixed powder is prepared on a selective laser melting forming machine to prepare a nickel-based composite material.
  • the yield strength and tensile strength of the prepared alloy material are The strengths are 599.6 ⁇ 649.6MPa and 998.5 ⁇ 1079.5MPa respectively.
  • Chinese patent (CN104745887A) discloses a nano-ceramic particle reinforced nickel-based superalloy composite material and its laser 3D printing forming method. CrC is the reinforcing phase, and the weight percentage of CrC added is 2.0-8.0% of the composite matrix.
  • the nano-CrC particle hybrid reinforced nickel-based superalloy composite parts are prepared.
  • the present invention proposes for the first time a method of using micro-ceramic particles as raw materials, preparing nickel-based superalloy composite powder with uniformly distributed nano-ceramic particles through a specific ball milling process, and preparing nano-ceramic phase-reinforced nickel-based superalloy through 3D printing technology.
  • the uniform distribution of the phase in the matrix solves the problem of nano-ceramic phase agglomeration and the problem of interface defects caused by poor wettability between the ceramic reinforcing phase and the metal matrix; the use of micron-scale ceramic particles is low in cost; the invention can be integrally formed arbitrarily Parts with complex shapes improve material utilization.
  • the present invention provides a method for preparing nano-phase reinforced nickel-based superalloy by using micro-ceramic particles.
  • the composite powder with uniform distribution of nano-ceramic particles is prepared; the nano-ceramic phase reinforced nickel-based superalloy is prepared by 3D printing technology, and the uniform distribution of nano-ceramic phase in the alloy matrix is realized.
  • the use of Marangoni convection to stir the melt promote the rearrangement of ceramic particles in the melt, solve the problem of nano-ceramic phase agglomeration, and realize the uniform distribution of nano-ceramic phase in the melt; by laser or electron beam High-temperature melting and rapid solidification, solving the problem of segregation of nano-ceramic phase and interface defect caused by poor wettability between ceramic reinforcing phase and metal matrix; using micron-sized ceramic particles, the cost is low; the invention can integrally form any complex shape parts to improve material utilization.
  • the present invention is a method for preparing nano-phase reinforced nickel-based superalloy by using micron ceramic particles.
  • the micron-level ceramic particles are used as raw material A, and the nickel-based superalloy powder is used as raw material B; After dry grinding treatment, a composite powder with uniform distribution of nano-ceramic particles is obtained; then the composite powder and the remaining raw material B are mixed uniformly to obtain a mixed powder; the mixed powder is 3D printed to obtain a finished product; the mass ratio of the raw material A to the raw material B is (1-5): (99-95).
  • the present invention is a method for preparing nano-phase reinforced nickel-based superalloy by using micron ceramic particles, wherein the particle size of the nickel-based superalloy is 15-53 ⁇ m or 53-106 ⁇ m; the micron ceramic particles are selected from TiC, TiB 2 , At least one of WC and A1 2 O 3 ; the particle size of the micron-scale ceramic particles is 1-5 ⁇ m.
  • the 3D printing is selected from one of selective laser melting (SLM) technology, electron beam melting (EBM) technology, and coaxial powder feeding laser forming (LENS) technology.
  • SLM selective laser melting
  • EBM electron beam melting
  • LENS coaxial powder feeding laser forming
  • the present invention is a method for preparing a nano-phase reinforced nickel-based superalloy by using micro-ceramic particles, comprising the following steps.
  • step (2) Load the composite powder prepared in step (1) and the prepared remaining raw material B into a V-type mixer, and mix uniformly to obtain a mixed powder; when mixing, use an inert atmosphere for protection.
  • step (3) Build a three-dimensional CAD model on the computer according to the shape of the part; use the software to slice and layer the model and import it into the additive manufacturing system; through the numerical control system, use the focused high-energy laser beam to press the uniformly mixed powder in step (2).
  • the determined scanning route is scanned back and forth, layer-by-layer powder is applied, fused, and stacked layer by layer until a three-dimensional part is formed.
  • the present invention is a method for preparing nano-phase reinforced nickel-based superalloy by using micron ceramic particles.
  • the micron ceramic particle raw material A and part of the nickel-based superalloy powder B are first mixed, and the mass ratio is 1:1 ⁇ 1:5.
  • the present invention is a method for preparing nano-phase reinforced nickel-based superalloy by using micron ceramic particles.
  • the ball milling parameters are: the ball-to-material ratio is 10:1-5:1, the ball-milling speed is 150-300rpm, and the ball-milling time is 5-20h; the dry grinding process is carried out in an inert gas, and the ball-milling parameters are: the ball-to-material ratio is 5:1 ⁇ 1:1, the ball milling speed is 100 ⁇ 200rpm, and the ball milling time is 4 ⁇ 10h.
  • the present invention is a method for preparing nano-phase reinforced nickel-based superalloy by using micro-ceramic particles.
  • the mixed powder obtained in the step (2) needs to be dried in an inert gas at 60-150 ° C for 2- 12h.
  • the present invention is a method for preparing a nano-phase reinforced nickel-based superalloy by using micron ceramic particles.
  • the substrate used for 3D printing in the step (3) is a stainless steel substrate or a similar nickel-based superalloy substrate.
  • the present invention is a method for preparing nano-phase reinforced nickel-based superalloy by using micron ceramic particles.
  • the laser process parameters of the step (3) are as follows: the diameter of the laser spot is 70-110 ⁇ m, the laser power is 150-300W, and the laser scanning rate is 500-1100mm /s, the laser scanning spacing is 60-120 ⁇ m, and the thickness of the powder layer is 30-50 ⁇ m.
  • the present invention is a method for preparing nano-phase reinforced nickel-based superalloy by using micro-ceramic particles, the inert gas should be helium, argon, or a mixture of argon and helium, the purity is 99.99wt%, and the oxygen content is less than 0.0001 wt%.
  • the present invention provides a method for preparing nano-phase reinforced nickel-based superalloy by using micron ceramic particles to solve the problems of easy agglomeration of nano-ceramic particles, uneven distribution in the matrix and poor interface with the matrix.
  • Ceramic particles are used as raw materials, and a specific ball milling process is used to prepare composite powder with uniform distribution of nano-ceramic particles; 3D printing technology is used to prepare nano-ceramic phase reinforced nickel-based superalloy, which realizes the uniform distribution of nano-ceramic phase in the alloy matrix; solves the problem of nano-ceramic
  • the agglomeration, segregation and distribution of the phases are not uniform, and the interface defect between the metal matrix and the metal matrix is caused by the poor wettability; the second phase distribution of the prepared parts is uniform, the matrix grains are fine, and the mechanical properties are excellent.
  • micro-ceramic particles are used as raw materials, mixed with the matrix alloy powder and ball-milled by a specific ball milling process, so that the micro-ceramic particles are broken, nanosized, and evenly coated by the matrix alloy powder, which effectively solves the problem of nano-ceramic particles.
  • the micro-ceramic particles A and part of the nickel-based superalloy powder B are first wet-milled and then dry-milled to obtain a composite powder with uniform distribution of nano-ceramic particles; through wet-grinding, the micro-ceramic particles are fast and uniform. Crush and realize nanometerization; through dry grinding, the powder is further crushed and uniformly dispersed; ceramic particles A are mixed with some metal powder B and ball-milled, which reduces the amount of ball-milled powder and improves the efficiency.
  • a certain proportion of micron ceramic particle raw material A and nickel-based superalloy powder B are treated by wet grinding and dry grinding with specific parameters, so that micron ceramic particles A are broken and nanosized, and they are nested with metal matrix powder B to obtain
  • the nickel-based superalloy composite powder with the uniform distribution of the nano-ceramic phase provides conditions for the uniform distribution of the nano-ceramic phase in the melt; then the composite powder is uniformly mixed with the remaining nickel-based superalloy powder B to obtain the nano-ceramic for 3D printing.
  • the uniformly distributed nickel-based superalloy mixed powder ensures the maximum fluidity of the mixed powder and ensures the smooth progress of 3D printing.
  • the powder Before 3D printing, the powder is wet-milled and dry-milled to obtain a metal matrix composite powder with a uniform distribution of nano-ceramic phases; during the 3D printing process, Marangoni convection is used to stir the melt to promote the ceramic particles in the process. Rearrangement in the melt, inhibiting particle agglomeration, and uniform distribution of nano-ceramic particles in the melt; rapid solidification prevents nano-ceramics from agglomerating during the solidification process, obtaining a solidified structure with uniform distribution of nano-ceramic phases, and improving the uniformity of the structure.
  • the present invention solves the problem of interface defects caused by poor wettability between the reinforcing phase and the metal matrix through high-temperature melting and rapid solidification of laser or electron beam, so that the reinforcing phase of the prepared composite material maintains nano-characteristics, and finally a composite material is produced. Parts with no defects, high density, fine and dense microstructure and excellent mechanical properties.
  • the nano-ceramic phase acts as nucleation particles, refines the grains, obtains an equiaxed grain structure, effectively inhibits the cracking phenomenon of the 3D printed nickel-based superalloy, and obtains high-performance 3D printed parts.
  • the present invention proposes a method for preparing nano-phase reinforced nickel-based superalloy by using micron ceramic particles.
  • the use of 3D printing technology can effectively solve the problem of preparing difficult-to-machine materials and integrally forming complex parts, without forming molds and shortening the manufacturing cycle. and cost.
  • the present invention proposes a method for preparing nano-phase reinforced nickel-based superalloy by using micro-ceramic particles.
  • the micro-ceramic particles are used as raw materials, and the size of the prepared composite reinforcing phase is nano-scale, uniformly distributed, well combined with the matrix, and synchronized.
  • the strength and plasticity of the formed parts are improved; the micro-ceramic particles adopted in the present invention have low cost, simple method and can be applied on a large scale.
  • Figure 1 is a scanning electron microscope (SEM) photograph of the surface morphology of the nanocomposite powder prepared by wet grinding and dry grinding of micron-scale ceramic particles and nickel-based superalloy powder in Example 1.
  • FIG. 2 is an SEM photo of the microstructure of the XY plane of the bulk René 104 nickel-based superalloy composite material prepared by laser 3D printing with nano-TiC ceramic particles in Example 1.
  • FIG. 2 is an SEM photo of the microstructure of the XY plane of the bulk René 104 nickel-based superalloy composite material prepared by laser 3D printing with nano-TiC ceramic particles in Example 1.
  • FIG. 3 is a SEM photograph of the XZ surface microstructure of the nano-TiC ceramic particle reinforced René 104 nickel-based superalloy composite block prepared by laser 3D printing technology in Example 1.
  • FIG. 3 is a SEM photograph of the XZ surface microstructure of the nano-TiC ceramic particle reinforced René 104 nickel-based superalloy composite block prepared by laser 3D printing technology in Example 1.
  • FIG. 4 is a SEM photograph of the powder morphology of one of the comparative examples subjected to wet grinding treatment.
  • Figure 5 is a SEM photograph of the powder morphology of Comparative Example 2 which was subjected to dry grinding treatment.
  • a method for preparing a nano-phase reinforced nickel-based superalloy by using micron ceramic particles The René104 nickel-based superalloy is used as a matrix, and TiC ceramic particles with an average particle size of 1.5 ⁇ m are used as a reinforcing phase, and the added mass percentage is 2.0%.
  • the matrix material is René104 nickel-based superalloy spherical powder with a particle size of 15-53 ⁇ m.
  • the composition of René104 nickel-based superalloy is: 20.6Co ⁇ 13Cr ⁇ 3.4Al ⁇ 3.9Ti ⁇ 3.8Mo ⁇ 2.1W ⁇ 2.4Ta ⁇ 0.9Nb ⁇ 0.05Zr ⁇ 0.03B ⁇ 0.04C ⁇
  • the balance is Ni.
  • the preparation steps of the nano-ceramic particle reinforced nickel-based superalloy composite material are as follows.
  • step (2) Load the composite powder and nickel-based superalloy powder prepared in step (1) into a V-type mixer, and mix uniformly to obtain a mixed powder; when mixing, use an inert atmosphere for protection.
  • step (3) Establish a three-dimensional CAD model on the computer according to the shape of the part; use the software to slice and layer the model and import it into the additive manufacturing system; through the numerical control system, use the focused high-energy laser beam to uniformly mix the powder prepared in step (2). Scan back and forth according to the determined scanning route, lay powder layer by layer, fuse, and superimpose layer by layer until a three-dimensional part is formed.
  • anhydrous ethanol is used as the ball milling medium, and the ball milling parameters are: the ball-to-material ratio is 7.5:1, the ball milling speed is 250 rpm, and the ball milling time is 20 h; the dry milling process is carried out in an inert gas, and the ball milling The parameters are: the ball-to-material ratio is 3:1, the ball milling speed is 150rpm, and the ball milling time is 8h.
  • the laser process parameters of the step (3) are as follows: the laser spot diameter is 70 ⁇ m, the laser power is 250 W, the laser scanning rate is 900 mm/s, the laser scanning spacing is 90 ⁇ m, the thickness of the powder layer is 40 ⁇ m, and the substrate heating temperature is 200 ° C.
  • the inert gas is argon, the purity is 99.99wt%, and the oxygen content is less than 0.0001wt%.
  • Figure 1 is an SEM photograph of the surface morphology of the nanocomposite powder prepared by wet grinding and dry grinding of micron-scale ceramic particles and nickel-based superalloy powder in Example 1. It can be observed that the micron TiC ceramic particles are broken into nanometer sizes, and together with the matrix René 104 alloy powder, a composite powder with uniform distribution of nano-ceramic particles is formed.
  • Example 2 is a SEM photo of the microstructure of the XY plane of the nano-TiC ceramic particle reinforced nickel-based superalloy composite block prepared by using the laser 3D printing technology in Example 1.
  • Example 3 is a SEM photo of the microstructure of the XZ surface of the nano-TiC ceramic particle reinforced nickel-based superalloy composite block prepared by using the laser 3D printing technology in Example 1.
  • nano-TiC ceramic particles prepared by 3D printing are uniformly distributed in the matrix, and the prepared composite bulk has fine and uniform grains and a dense structure.
  • the room temperature tensile strength of the prepared material sample is 1801MPa; the microhardness test points are 20, of which the maximum hardness is 613HV 0.2 , the minimum hardness is 569HV 0.2 , and the average value is 585HV 0.2 .
  • the superalloy matrix is increased by 62.3%; the friction and wear performance test shows that the friction coefficient is 0.41, which is very stable, and the wear amount in 30min is 6.2 ⁇ 10 -4 (mm 3 /Nm).
  • a method for preparing nano-phase reinforced nickel-based superalloy by using micron ceramic particles taking René 104 nickel-based superalloy as the matrix, using A1 2 O 3 ceramic particles with an average particle size of 2.0 ⁇ m as the reinforcing phase, and adding a mass percentage of 3.0 %.
  • the matrix material is René104 nickel-based superalloy spherical powder with a particle size of 15-53 ⁇ m.
  • the composition of René104 nickel-based superalloy is: 20.6Co ⁇ 13Cr ⁇ 3.4Al ⁇ 3.9Ti ⁇ 3.8Mo ⁇ 2.1W ⁇ 2.4Ta ⁇ 0.9Nb ⁇ 0.05Zr ⁇ 0.03B ⁇ 0.04C ⁇
  • the balance is Ni.
  • the preparation steps of the nano-ceramic particle reinforced nickel-based superalloy composite material are as follows.
  • step (2) Load the composite powder prepared in step (1) and the remaining nickel-based superalloy powder into a V-type mixer, and mix evenly to obtain a mixed powder; when mixing, use an inert atmosphere for protection.
  • step (3) Establish a three-dimensional CAD model on the computer according to the shape of the part; use the software to slice and layer the model and import it into the additive manufacturing system; through the numerical control system, use the focused high-energy laser beam to uniformly mix the powder prepared in step (2). Scan back and forth according to the determined scanning route, lay powder layer by layer, fuse, and superimpose layer by layer until a three-dimensional part is formed.
  • anhydrous ethanol is used as the ball milling medium, and the ball milling parameters are as follows: the ball-to-material ratio is 10:1, the ball milling speed is 200 rpm, and the ball milling time is 20 hours; the dry milling process is carried out in an inert gas, and the ball milling The parameters are: the ball-to-material ratio is 5:1, the ball milling speed is 100rpm, and the ball milling time is 10h.
  • the laser process parameters of the step (3) are as follows: the laser spot diameter is 70 ⁇ m, the laser power is 225 W, the laser scanning rate is 900 mm/s, the laser scanning spacing is 90 ⁇ m, the thickness of the powder layer is 30 ⁇ m, and the substrate heating temperature is 170 ° C.
  • the inert gas is argon, the purity is 99.99wt%, and the oxygen content is less than 0.0001wt%.
  • the room temperature tensile strength of the prepared material sample is 1785MPa; there are 20 microhardness test points, of which the maximum hardness is 621HV 0.2 , the minimum hardness is 577HV 0.2 , and the average value is 603HV 0.2 .
  • the superalloy matrix is increased by 68.9%; the friction and wear performance test shows that the friction coefficient is 0.45, which is very stable, and the wear amount in 30min is 6.9 ⁇ 10 -4 (mm 3 /Nm).
  • the matrix material is René104 nickel-based superalloy spherical powder with a particle size of 15-53 ⁇ m.
  • the composition of René104 nickel-based superalloy is: 20.6Co ⁇ 13Cr ⁇ 3.4Al ⁇ 3.9Ti ⁇ 3.8Mo ⁇ 2.1W ⁇ 2.4Ta ⁇ 0.9Nb ⁇ 0.05Zr ⁇ 0.03B ⁇ 0.04C ⁇
  • the balance is Ni.
  • the preparation steps of the nano-ceramic particle reinforced nickel-based superalloy composite material are as follows.
  • step (2) Load the composite powder prepared in step (1) and the remaining nickel-based superalloy powder into a V-type mixer, and mix evenly to obtain a mixed powder; when mixing, use an inert atmosphere for protection.
  • step (3) Establish a three-dimensional CAD model on the computer according to the shape of the part; use the software to slice and layer the model and import it into the additive manufacturing system; through the numerical control system, use the focused high-energy laser beam to uniformly mix the powder prepared in step (2). Scan back and forth according to the determined scanning route, lay powder layer by layer, fuse, and superimpose layer by layer until a three-dimensional part is formed.
  • anhydrous ethanol is used as the ball milling medium, and the ball milling parameters are as follows: the ball-to-material ratio is 10:1, the ball milling speed is 225 rpm, and the ball milling time is 20 h; the dry milling process is carried out in an inert gas, and the ball milling The parameters are: the ball-to-material ratio is 3:1, the ball milling speed is 150rpm, and the ball milling time is 8h.
  • the laser process parameters of the step (3) are as follows: the laser spot diameter is 70 ⁇ m, the laser power is 250 W, the laser scanning rate is 900 mm/s, the laser scanning distance is 90 ⁇ m, the thickness of the powder layer is 45 ⁇ m, and the substrate heating temperature is 200 ° C.
  • the inert gas is argon, the purity is 99.99wt%, and the oxygen content is less than 0.0001wt%.
  • the room temperature tensile strength of the prepared material sample is 1782MPa; the microhardness test points are 20, of which the maximum hardness is 627HV 0.2 , the minimum hardness is 588HV 0.2 , and the average value is 611HV 0.2 .
  • the superalloy matrix is increased by 71.1%; the friction and wear performance test shows that the friction coefficient is 0.55, which is very stable, and the wear amount in 30min is 7.4 ⁇ 10 -4 (mm 3 /Nm).
  • Example 1 The difference from Example 1 is that the step (1) only performs wet grinding treatment, and the others remain unchanged.
  • Figure 4 shows the morphology of the composite powder after only wet milling.
  • the composite powder formed by only wet grinding is easy to agglomerate, which is not conducive to the subsequent powder mixing with nickel-based superalloys, resulting in uneven distribution of ceramic particles.
  • the room temperature tensile strength of the prepared material sample is 1631MPa; the microhardness of the prepared composite material varies greatly in different positions, and there are 20 microhardness test points, of which the maximum hardness is 615HV 0.2 , and the lowest point is 363HV 0.2 , the average value is 554HV 0.2 , indicating that the ceramic phase distribution is uneven; the friction and wear performance test shows that the friction coefficient is 0.61, and the wear amount in 30min is 9.5 ⁇ 10 -4 (mm 3 /Nm).
  • Example 1 The difference from Example 1 is that the step (1) only performs dry grinding, and the others remain unchanged.
  • Figure 5 shows the morphology of the composite powder after only dry grinding. Only dry grinding treatment can not break the ceramic particles well, and no nano-composite powder particles are formed.
  • the room temperature tensile strength of the prepared material sample is 1609MPa ; the microhardness of the prepared composite material varies greatly in different positions. 374HV 0.2 , the average value is 514HV 0.2 , indicating that the ceramic phase distribution is uneven; the friction and wear performance test shows that the friction coefficient is 0.63, and the 30min wear amount is 9.2 ⁇ 10 -4 (mm 3 /Nm).
  • Example 1 The difference from Example 1 is that the step (1) is dry-grinding and then wet-grinding, and the rest remain unchanged.
  • the room temperature tensile strength of the prepared material sample is 1702MPa; the microhardness test points are 20, of which the maximum hardness is 589HV 0.2 , the minimum hardness is 445HV 0.2 , and the average value is 562HV 0.2 ; friction and wear performance tests show that , the friction coefficient is 0.53, and it is very stable, and the wear amount in 30min is 7.6 ⁇ 10 -4 (mm 3 /Nm).
  • Example 1 The difference from Example 1 is that the step (1) is first wet-milled and then dry-milled.
  • anhydrous ethanol is used as the ball-milling medium.
  • the wet-milling parameters are: the ball-to-material ratio is 4:1, and the ball-milling speed is 200rpm.
  • the ball milling time is 10h; the dry milling process is carried out in an inert gas, and the ball milling parameters are: the ball-to-material ratio is 10:1, the ball-milling speed is 200rpm, and the ball-milling time is 5h. Others remain unchanged.
  • the room temperature tensile strength of the prepared material sample is 1654MPa; the microhardness test points are 20, of which the maximum hardness is 620HV 0.2 , the minimum hardness is 447HV 0.2 , and the average value is 536HV 0.2 ; friction and wear performance test shows that , the friction coefficient is 0.58, and it is very stable, and the wear amount in 30min is 8.3 ⁇ 10 -4 (mm 3 /Nm).
  • the René104 nickel-based superalloy was used as the matrix, and the TiC ceramic particles with an average particle size of 5 ⁇ m were used as the reinforcing phase, and the added mass percentage was 2.5%.
  • the matrix material is René104 nickel-based superalloy spherical powder with a particle size of 15-53 ⁇ m.
  • the composition of René104 nickel-based superalloy is: 20.6Co ⁇ 13Cr ⁇ 3.4Al ⁇ 3.9Ti ⁇ 3.8Mo ⁇ 2.1W ⁇ 2.4Ta ⁇ 0.9Nb ⁇ 0.05Zr ⁇ 0.03B ⁇ 0.04C ⁇
  • the balance is Ni.
  • Example 1 of the Chinese patent (CN107116217A) a TiC ceramic phase-reinforced René104 nickel-based superalloy was prepared.
  • the ball milling parameters of the method are: the ball milling speed is 200r/s, and the ball milling time is 8h.
  • the SLM process parameters are: laser power 200W, scanning speed 1000mm/s, processing layer thickness 0.03, and scanning spacing 0.04mm.
  • the room temperature tensile strength of the prepared material sample is 1591MPa; there are 20 microhardness test points, of which the maximum hardness is 617HV 0.2 , the minimum hardness is 383HV 0.2 , and the average value is 475HV 0.2 ; friction and wear performance tests show that , the friction coefficient is 0.68, and the wear amount in 30min is 10.2 ⁇ 10 -4 (mm 3 /Nm).

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Abstract

一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，以镍基高温合金为基体，以TiC、TiB 2、WC和Al 2O 3中的一种或多种作为增强相。作为增强相的陶瓷颗粒原料粒径为1～5μm，添加量为1～5wt.％，通过特定的球磨工艺制备纳米陶瓷均匀分布的镍基高温合金复合粉末，通过3D打印技术制备纳米陶瓷相增强镍基高温合金，所制备的材料纳米陶瓷相分布均匀，具有优异的力学性能。采用微米级陶瓷颗粒，成本低；可以一体成形制备任意复杂形状的零件，提高材料利用率。

Description

采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法 技术领域
本发明提供一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，属于镍基合金制备领域。
 背景技术
镍基高温合金具有较高的高温强度、高温蠕变强度、良好的疲劳性能、断裂韧性、良好的抗氧化和抗腐蚀性等，在高温下具有良好的组织稳定性和使用可靠性，被广泛地用来制造航空喷气发动机、各种工业燃气轮机的热端部件。高推重比航空发动机的发展，对镍基高温合金的综合性能（强度、服役温度、持久性能等）提出了更高的要求。
陶瓷颗粒增强金属基复合材料具有高比强、比模量、耐高温、热膨胀系数小、抗磨损、抗腐蚀、尺寸稳定性好等性能优点。其中，纳米颗粒增强的镍基高温合金复合材料，能在提高强度和硬度等力学性能的同时，保持良好的韧性、高温蠕变强度和疲劳强度。但是，纳米陶瓷颗粒增强镍基高温合金制备的主要难点在于：①纳米陶瓷颗粒巨大的比表面能使其极易发生团聚，而且陶瓷颗粒与基体金属密度差异大，很难均匀分散，从而降低了增强相对基体金属的强化效应；②陶瓷材料的高熔点，与基体材料的润湿性差、膨胀系数差异较大，导致陶瓷相与基体界面结合差；③直接使用纳米陶瓷颗粒会显著提高原材料的成本。
针对上述问题，国内外进行了探索性的研究。中国专利（CN101649398B）公开了原位反应合成TiCx颗粒增强镍基复合材料的方法, 制备工艺包括（1）混合粉末的制备：粉末材料由Ti、C、Al、Fe、 Mo组成，其中Al粉8-12wt.％，Fe粉12-15wt.％，Mo粉3-5wt.％，石墨C粉8-12wt.％，余量为Ti粉，粉末中Ti粉重量与C粉重量的比值需满足(5-6.7)∶1的关系；（2）粉芯片的制备：将Ni箔卷成直径16-25mm的圆筒，在圆筒内灌入球磨混料后的混合粉末；（3）熔炼及浇铸工艺：利用真空中频感应熔炼炉制备TiCx/Ni复合材料。制备出TiCx体积分数为20-40%的TiCx/Ni复合材料，致密度接近100%，高温强度、硬度显著高于常规镍基高温合金。中国专利（CN107116217A）公开了选择性激光熔化成形法制备TiC增强镍基复合材料的方法，将镍基合金与增强基合金按照配比分别称重，加入的TiC增强相颗粒直径为5-8微米，将称重的粉末放置在低温行星球磨机制备镍基混合粉末，将所制备的镍基混合粉末在选择性激光熔化成形机器上制备镍基复合材料，所制备的合金材料的屈服强度、抗拉强度分别为599.6~649.6MPa和998.5~1079.5MPa。中国专利（CN104745887A）公开了一种纳米陶瓷颗粒增强镍基高温合金复合材料及其激光3D打印成形方法，以粒径为15~45μm的镍基高温合金为基体，以粒径为40~100nm的CrC为增强相，CrC添加的重量百分比为复合材料基体的2.0~8.0%，制备出纳米CrC颗粒混杂增强镍基高温合金复合材料零件。
本发明首次提出采用微米陶瓷颗粒作为原料，通过特定的球磨工艺制备纳米陶瓷颗粒均匀分布的镍基高温合金复合粉末，通过3D打印技术制备纳米陶瓷相增强镍基高温合金的方法，实现了纳米陶瓷相在基体中的均匀分布，解决了纳米陶瓷相团聚问题，以及陶瓷增强相与金属基体之间因润湿性差导致的界面缺陷问题；采用微米级陶瓷颗粒，成本低；本发明可以一体成形任意复杂形状的零件，提高材料利用率。
 技术问题
本发明针对纳米陶瓷颗粒易团聚、与基体界面结合差等问题，提供了一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，首次提出采用微米陶瓷颗粒作为原料，采用特定的球磨工艺制备纳米陶瓷颗粒均匀分布的复合粉末；采用3D打印技术制备纳米陶瓷相增强镍基高温合金，实现了纳米陶瓷相在合金基体中均匀分布。在3D打印过程中，利用Marangoni对流对熔体产生搅拌作用，促进陶瓷颗粒在熔体中重排，解决了纳米陶瓷相团聚问题，实现纳米陶瓷相在熔体中均匀分布；通过激光或电子束的高温熔化和快速凝固，解决纳米陶瓷相的偏聚、陶瓷增强相与金属基体之间因润湿性差导致的界面缺陷问题；采用微米级陶瓷颗粒，成本低；本发明可以一体成形任意复杂形状的零件，提高材料利用率。
 技术解决方案
本发明一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，以微米级陶瓷颗粒为原料A，以镍基高温合金粉末为原料B；先将原料A和部分原料B通过先湿磨后干磨处理，得到纳米陶瓷颗粒均匀分布的复合粉末；然后再将复合粉末和剩余的原料B混合均匀得到混合粉末；混合粉末经3D打印，得到成品；所述原料A与原料B的质量比为(1-5)：(99-95)。
本发明一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，所述镍基高温合金的粒径为15～53μm或53～106μm；所述微米级陶瓷颗粒选自TiC、TiB 2、WC、A1 2O 3中的至少一种；所述微米级陶瓷颗粒的粒径为1～5μm。
所述3D打印选自选区激光熔融（SLM）技术、电子束熔化（EBM）技术、同轴送粉激光成形（LENS）技术中的一种。
本发明一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，包括以下步骤。
（1）以微米级陶瓷颗粒为原料A，以镍基高温合金粉末为原料B；按质量比，原料A：原料B=(1-5)：(99-95)；配取原料；然后将原料A与部分原料B通过先湿磨后干磨处理，得到纳米陶瓷颗粒均匀分布的复合粉末。
（2）将步骤（1）制备的复合粉末、配取的剩余原料B装入V型混料机中，混合均匀，得到混合粉末；混料时，采用惰性气氛进行保护。
（3）根据零件形状在计算机上建立三维CAD模型；利用软件将模型切片分层，并导入增材制造系统；通过数控系统，利用聚焦的高能激光束对步骤（2）中的均匀混合粉末按确定的扫描路线往复扫描，逐层铺粉、熔凝，层层叠加，直至形成三维零件。
本发明一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，所述步骤（1）中先将微米陶瓷颗粒原料A与部分镍基高温合金粉末B混合，质量比为1：1～1：5。
本发明一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，所述步骤（1）中湿磨过程以无水乙醇作为球磨介质（加入的无水乙醇需没过粉末，防止原料粉末氧化），球磨参数为：球料比为10：1～5：1，球磨转速为150～300rpm，球磨时间为5～20h；干磨过程在惰性气体中进行，球磨参数为：球料比为5：1～1：1，球磨转速为100～200rpm，球磨时间为4～10h。
本发明一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，所述步骤（3）3D打印前需对步骤（2）中得到的混合粉末在惰性气体中60-150℃干燥2-12h。
本发明一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，所述步骤（3）中3D打印所用的基板为不锈钢基板或同类镍基高温合金基板。
本发明一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，所述步骤（3）的激光工艺参数如下：激光光斑直径70～110μm，激光功率150～300W，激光扫描速率500～1100mm/s，激光扫描间距60～120μm，铺粉层厚为30～50μm。
本发明一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，所述的惰性气体应为氦气、氩气，或氩、氦混合气体，纯度为99.99wt%，其中氧含量小于0.0001wt%。
 有益效果
（1）本发明针对纳米陶瓷颗粒易团聚、在基体中分布不均匀且与基体界面结合差等问题，提供了一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，首次提出采用微米陶瓷颗粒作为原料，采用特定的球磨工艺制备纳米陶瓷颗粒均匀分布的复合粉末；采用3D打印技术制备纳米陶瓷相增强镍基高温合金，实现了纳米陶瓷相在合金基体中均匀分布；解决了纳米陶瓷相的团聚、偏聚和分布不均匀，与金属基体之间因润湿性差导致的界面缺陷问题；所制备的制件第二相分布均匀、基体晶粒细小，力学性能优异。
（2）采用微米陶瓷颗粒作为原料，与基体合金粉末混合球磨、并采用特定的球磨工艺球磨，使得微米陶瓷颗粒破碎、纳米化，并被基体合金粉末均匀包覆，有效解决了纳米陶瓷颗粒的团聚问题；微米陶瓷颗粒破碎、纳米化过程中，实现在基体合金粉末中均匀分布，制备得到纳米陶瓷颗粒均匀分布的复合粉末；为纳米陶瓷颗粒在熔体中均匀分布提供了条件。
（3）本发明先将微米陶瓷颗粒A与部分镍基高温合金粉末B通过先湿磨后干磨处理，得到纳米陶瓷颗粒均匀分布的复合粉末；通过湿磨处理，使微米陶瓷颗粒快速、均匀破碎并实现纳米化；通过干磨处理，使粉末进一步破碎、均匀分散；采用陶瓷颗粒A与部分金属粉末B混合、球磨，减少了球磨粉末量，提高效率。
（4）对一定比例的微米陶瓷颗粒原料A与镍基高温合金粉末B采用特定参数的湿磨加干磨处理，使得微米陶瓷颗粒A破碎、纳米化，与金属基体粉末B相互嵌套，得到纳米陶瓷相均匀分布的镍基高温合金复合粉末，为纳米陶瓷相在熔体中均匀分布提供了条件；再将复合粉末与剩余镍基高温合金粉末B均匀混合，得到用于3D打印的纳米陶瓷相均匀分布的镍基高温合金混合粉末，最大限度的保证了混合粉末的流动性，保证3D打印的顺利进行。
（5）3D打印成形前，对粉末进行湿磨加干磨处理，得到纳米陶瓷相均匀分布的金属基复合粉末；3D打印成形过程中，利用Marangoni对流对熔体产生搅拌作用，促进陶瓷颗粒在熔体中重排，抑制颗粒团聚，使纳米陶瓷颗粒在熔体中均匀分布；快速凝固防止纳米陶瓷在凝固过程中聚集，得到纳米陶瓷相均匀分布的凝固组织，改善了组织均匀性。
（6）本发明通过激光或电子束的高温熔化和快速凝固，解决增强相与金属基体之间因润湿性差导致的界面缺陷问题，使制备的复合材料的增强相保持纳米特性，最终制造出无缺陷，致密度高，显微组织细小致密，力学性能优异的零件。
（7）本发明3D打印成形过程中，纳米陶瓷相作为形核质点，细化晶粒，获得等轴晶组织，有效抑制3D打印镍基高温合金开裂现象，获得高性能3D打印制件。
（8）本发明提出一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，使用3D打印技术可有效解决难加工材料的制备和复杂零件一体成形难题，无需成形模具，缩短了制造周期和成本。
（9）本发明提出一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，采用微米陶瓷颗粒作为原料，制备的复合材料增强相尺寸为纳米级别，分布均匀，与基体结合良好，同步提高成形件的强度和塑性；本发明采用的微米陶瓷颗粒成本低，方法简单，可以大规模应用。
 附图说明
图1为实施例一，微米级陶瓷颗粒和镍基高温合金粉末进行湿磨加干磨处理，制备的纳米复合粉末表面形貌扫描电镜（SEM）照片。
图2为实施例一采用激光3D打印制备的纳米TiC陶瓷颗粒增强René104镍基高温合金复合材料块体XY面显微组织SEM照片。
图3为实施例一采用激光3D打印技术制备的纳米TiC陶瓷颗粒增强René104镍基高温合金复合材料块体XZ面显微组织SEM照片。
图4为对比例一只进行湿磨处理的粉末形貌SEM照片。
图5为对比例二只进行干磨处理的粉末形貌SEM照片。
 本发明的实施方式
下面结合附图和具体实施例，对本发明做进一步的阐述。
实施例一。
一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，以René104镍基高温合金为基体，以平均粒径为1.5μm的TiC陶瓷颗粒为增强相，添加的质量百分比为2.0%。
基体材料是粒径为15～53μm的René104镍基高温合金球形粉末，René104镍基高温合金的组分为：20.6Co～13Cr～3.4Al～3.9Ti～3.8Mo～2.1W～2.4Ta～0.9Nb～0.05Zr～0.03B～0.04C～余量为Ni。
所述一种纳米陶瓷颗粒增强镍基高温合金复合材料的制备步骤如下。
（1）先将所述比例平均粒径为1.5μm的TiC陶瓷颗粒与部分René104镍基高温合金粉末混合（比例为2:3），然后使用高能球磨机对混合粉末进行湿磨加干磨处理，得到纳米陶瓷颗粒均匀分布的复合粉末。
（2）将步骤（1）制备的复合粉末、镍基高温合金粉末装入V型混料机中，混合均匀，得到混合粉末；混料时，采用惰性气氛进行保护。
（3）根据零件形状在计算机上建立三维CAD模型；利用软件将模型切片分层，并导入增材制造系统；通过数控系统，利用聚焦的高能激光束对步骤（2）制备的均匀混合粉末，按确定的扫描路线往复扫描，逐层铺粉、熔凝，层层叠加，直至形成三维零件。
所述步骤（1）的湿磨过程以无水乙醇作为球磨介质，球磨参数为：球料比为7.5：1，球磨转速为250rpm，球磨时间为20h；干磨过程在惰性气体中进行，球磨参数为：球料比为3：1，球磨转速为150rpm，球磨时间为8h。
所述步骤（3）的激光工艺参数如下：激光光斑直径70μm，激光功率250W，激光扫描速率900mm/s，激光扫描间距90μm，铺粉层厚为40μm，基板加热温度200℃。
所述的惰性气体为氩气，纯度为99.99wt%，氧含量小于0.0001wt%。
图1为实施例一通过微米级的陶瓷颗粒和镍基高温合金粉末进行湿磨加干磨处理，制备的纳米复合粉末表面形貌的SEM照片。可以观察到微米TiC陶瓷颗粒破碎为纳米尺寸，与基体René104合金粉末共同形成了纳米陶瓷颗粒均匀分布的复合粉末。
图2为实施例一中采用激光3D打印技术，制备的纳米TiC陶瓷颗粒增强镍基高温合金复合材料块体XY面的显微组织SEM照片。
图3为实施例一中采用激光3D打印技术，制备的纳米TiC陶瓷颗粒增强镍基高温合金复合材料块体XZ面的显微组织SEM照片。
从图2和图3可以观察到，3D打印制备的纳米TiC陶瓷颗粒在基体中分布均匀，制备的复合材料块体晶粒细小、均匀，结构致密。
经测试，所制备材料样品的室温抗拉强度为1801MPa；显微硬度测试点为20个，其中硬度最大值为613HV 0.2、硬度最小值为569HV 0.2、平均值为585HV 0.2，相较René104镍基高温合金基体提高了62.3%；摩擦磨损性能测试表明，摩擦系数为0.41，且很稳定，30min磨损量为6.2×10 -4（mm 3/Nm）。
实施例二。
一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，以René104镍基高温合金为基体，以平均粒径为2.0μm的A1 2O 3陶瓷颗粒为增强相，添加的质量百分比为3.0%。
基体材料是粒径为15～53μm的René104镍基高温合金球形粉末，René104镍基高温合金的组分为：20.6Co～13Cr～3.4Al～3.9Ti～3.8Mo～2.1W～2.4Ta～0.9Nb～0.05Zr～0.03B～0.04C～余量为Ni。
所述一种纳米陶瓷颗粒增强镍基高温合金复合材料的制备步骤如下。
（1）先将所述比例平均粒径为1.5μm的TiC陶瓷颗粒与部分René104镍基高温合金粉末混合（比例为1:2），然后使用高能球磨机对混合粉末进行湿磨加干磨处理，得到纳米陶瓷颗粒均匀分布的复合粉末。
（2）将步骤（1）制备的复合粉末和剩余的镍基高温合金粉末装入V型混料机中，混合均匀，得到混合粉末；混料时，采用惰性气氛进行保护。
（3）根据零件形状在计算机上建立三维CAD模型；利用软件将模型切片分层，并导入增材制造系统；通过数控系统，利用聚焦的高能激光束对步骤（2）制备的均匀混合粉末，按确定的扫描路线往复扫描，逐层铺粉、熔凝，层层叠加，直至形成三维零件。
所述步骤（1）中湿磨过程以无水乙醇作为球磨介质，球磨参数为：球料比为10：1，球磨转速为200rpm，球磨时间为20h；干磨过程在惰性气体中进行，球磨参数为：球料比为5：1，球磨转速为100rpm，球磨时间为10h。
所述步骤（3）的激光工艺参数如下：激光光斑直径70μm，激光功率225W，激光扫描速率900mm/s，激光扫描间距90μm，铺粉层厚为30μm，基板加热温度170℃。
所述的惰性气体为氩气，纯度为99.99wt%，氧含量小于0.0001wt%。
经测试，所制备材料样品的室温抗拉强度为1785MPa；显微硬度测试点为20个，其中硬度最大值为621HV 0.2、硬度最小值为577HV 0.2、平均值为603HV 0.2，相较René104镍基高温合金基体提高了68.9%；摩擦磨损性能测试表明，摩擦系数为0.45，且很稳定，30min磨损量为6.9×10 -4（mm 3/Nm）。
实施例三。
一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，以René104镍基高温合金为基体，以平均粒径为1.5μm的TiC陶瓷颗粒和平均粒径为2.5μm的WC陶瓷颗粒为增强相，添加的质量分数均为1.5%。
基体材料是粒径为15～53μm的René104镍基高温合金球形粉末，René104镍基高温合金的组分为：20.6Co～13Cr～3.4Al～3.9Ti～3.8Mo～2.1W～2.4Ta～0.9Nb～0.05Zr～0.03B～0.04C～余量为Ni。
所述一种纳米陶瓷颗粒增强镍基高温合金复合材料的制备步骤如下。
（1）先将所述比例平均粒径为1.5μm的TiC陶瓷颗粒与部分René104镍基高温合金粉末混合（比例为1:2），然后使用高能球磨机对混合粉末进行湿磨加干磨处理，得到纳米陶瓷颗粒均匀分布的复合粉末。
（2）将步骤（1）制备的复合粉末和剩余的镍基高温合金粉末装入V型混料机中，混合均匀，得到混合粉末；混料时，采用惰性气氛进行保护。
（3）根据零件形状在计算机上建立三维CAD模型；利用软件将模型切片分层，并导入增材制造系统；通过数控系统，利用聚焦的高能激光束对步骤（2）制备的均匀混合粉末，按确定的扫描路线往复扫描，逐层铺粉、熔凝，层层叠加，直至形成三维零件。
所述步骤（1）中湿磨过程以无水乙醇作为球磨介质，球磨参数为：球料比为10：1，球磨转速为225rpm，球磨时间为20h；干磨过程在惰性气体中进行，球磨参数为：球料比为3：1，球磨转速为150rpm，球磨时间为8h。
所述步骤（3）的激光工艺参数如下：激光光斑直径70μm，激光功率250W，激光扫描速率900mm/s，激光扫描间距90μm，铺粉层厚为45μm，基板加热温度200℃。
所述的惰性气体为氩气，纯度为99.99wt%，氧含量小于0.0001wt%。
经测试，所制备材料样品的室温抗拉强度为1782MPa；显微硬度测试点为20个，其中硬度最大值为627HV 0.2、硬度最小值为588HV 0.2、平均值为611HV 0.2，相较René104镍基高温合金基体提高了71.1%；摩擦磨损性能测试表明，摩擦系数为0.55，且很稳定，30min磨损量为7.4×10 -4（mm 3/Nm）。
对比例一。
与实施例一不同的是所述步骤（1）只进行湿磨处理，其他不变。
图4为只进行湿磨处理后的复合粉末形貌。只进行湿磨处理形成的复合粉末容易团聚，不利于后续与镍基高温合金的混粉，导致陶瓷颗粒分布不均问题。
经测试，所制备材料样品的室温抗拉强度为1631MPa；制备的复合材料不同位置的显微硬度相差较大，显微硬度测试点为20个，其中硬度最大值为615HV 0.2，最低处363HV 0.2，平均值为554HV 0.2表明陶瓷相分布不均匀；摩擦磨损性能测试表明，摩擦系数为0.61，30min磨损量为9.5×10 -4（mm 3/Nm）。
对比例二。
与实施例一不同的是所述步骤（1）只进行干磨处理，其他不变。
图5为只进行干磨处理后的复合粉末形貌。只进行干磨处理，不能很好的破碎陶瓷颗粒，没有形成纳米复合粉末颗粒。
经测试，所制备材料样品的室温抗拉强度为1609MPa；制备的复合材料不同位置的显微硬度相差较大，显微硬度测试点为20个，其中硬度最大值为592HV 0.2，最低处仅为374HV 0.2，平均值为514HV 0.2，表明陶瓷相分布不均匀；摩擦磨损性能测试表明，摩擦系数为0.63，30min磨损量为9.2×10 -4（mm 3/Nm）。
对比例三。
与实施例一不同的是所述步骤（1）先干磨后湿磨处理，其他不变。
先干磨后湿磨处理，球形粉末被破坏，导致粉末流动性变差，不利于3D打印制备优质产品。
经测试，所制备材料样品的室温抗拉强度为1702MPa；显微硬度测试点为20个，其中硬度最大值为589HV 0.2、硬度最小值为445HV 0.2、平均值为562HV 0.2；摩擦磨损性能测试表明，摩擦系数为0.53，且很稳定，30min磨损量为7.6×10 -4（mm 3/Nm）。
对比例四。
与实施例一不同的是所述步骤（1）先湿磨后干磨处理，湿磨过程以无水乙醇作为球磨介质，湿磨参数为：球料比为4：1，球磨转速为200rpm，球磨时间为10h；干磨过程在惰性气体中进行，球磨参数为：球料比为10：1，球磨转速为200rpm，球磨时间为5h。其他不变。
经测试，所制备材料样品的室温抗拉强度为1654MPa；显微硬度测试点为20个，其中硬度最大值为620HV 0.2、硬度最小值为447HV 0.2、平均值为536HV 0.2；摩擦磨损性能测试表明，摩擦系数为0.58，且很稳定，30min磨损量为8.3×10 -4（mm 3/Nm）。
对比例五。
以René104镍基高温合金为基体，以平均粒径为5μm的TiC陶瓷颗粒为增强相，添加的质量百分比为2.5%。
基体材料是粒径为15～53μm的René104镍基高温合金球形粉末，René104镍基高温合金的组分为：20.6Co～13Cr～3.4Al～3.9Ti～3.8Mo～2.1W～2.4Ta～0.9Nb～0.05Zr～0.03B～0.04C～余量为Ni。
采用中国专利（CN107116217A）实施例一的方法，制备TiC陶瓷相增强的René104镍基高温合金。所述方法球磨参数为：球磨转速为200r/s，球磨时间为8h。
所述SLM工艺参数为：激光功率200W，扫描速度1000mm/s，加工层厚0 .03，扫描间距0.04mm。
采用中国专利（CN107116217A）的方法制备的复合粉末，微米TiC陶瓷颗粒没有形成纳米复合粉末，球磨处理导致球形粉末变为片状，显著降低粉末流动性，不利于3D打印制备优质产品。
经测试，所制备材料样品的室温抗拉强度为1591MPa；显微硬度测试点为20个，其中硬度最大值为617HV 0.2、硬度最小值为383HV 0.2、平均值为475HV 0.2；摩擦磨损性能测试表明，摩擦系数为0.68，30min磨损量为10.2×10 -4（mm 3/Nm）。

Claims (10)

  1. 一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，其特征在于：以微米级陶瓷颗粒为原料A，以镍基高温合金粉末为原料B；先将原料A和部分原料B通过先湿磨后干磨处理，得到纳米陶瓷颗粒均匀分布的复合粉末；然后再将复合粉末和剩余的原料B混合均匀得到混合粉末；混合粉末经3D打印，得到成品；所述原料A与原料B的质量比为：(1-5)：(99-95)。
  2. 根据权利要求1所述的一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，其特征在于：
    所述镍基高温合金的粒径为15～53μm或53～106μm；
    所述微米级陶瓷颗粒选自TiC、TiB 2、WC、A1 2O 3中的至少一种；所述微米级陶瓷颗粒的粒径为1～5μm；
    所述3D打印选自选区激光熔化熔融（SLM）技术、电子束熔化（EBM）技术、同轴送粉激光成形（LENS）技术中的一种。
  3. 根据权利要求1所述的一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，其特征在于：包括以下步骤：
    （1）以微米级陶瓷颗粒为原料A，以镍基高温合金粉末为原料B；按质量比，原料A：原料B=(1-5)：(99-95)；配取原料；然后将原料A与部分原料B通过先湿磨后干磨处理，得到纳米陶瓷颗粒均匀分布的复合粉末；
    （2）将步骤（1）制备的复合粉末、配取的剩余原料B装入V型混料机中，混合均匀，得到混合粉末；混料时，采用惰性气氛进行保护；
    （3）根据零件形状在计算机上建立三维CAD模型；利用软件将模型切片分层，并导入增材制造系统；通过数控系统，利用聚焦的高能激光束对步骤（2）制备的均匀混合粉末按确定的扫描路线往复扫描，逐层铺粉、熔凝，层层叠加，直至形成三维零件。
  4. 根据权利要求3所述的一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，其特征在于，步骤（1）中先将陶瓷颗粒与部分镍基高温合金粉末混合，所述质量比为1：1～1：5。
  5. 根据权利要求3所述的一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，其特征在于：步骤（1）中湿磨过程以无水乙醇作为球磨介质，球磨参数为：球料比为10：1～5：1，球磨转速为150～300rpm，球磨时间为5～20h；干磨过程在惰性气体中进行，球磨参数为：球料比为5：1～1：1，球磨转速为100～200rpm，球磨时间为4～10h。
  6. 根据权利要求3所述的一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，其特征在于：步骤（3）3D打印前需对步骤（2）中得到的混合粉末在惰性气体中60-150℃干燥2-12h。
  7. 根据权利要求3所述的一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，其特征在于：所述镍基高温合金为René104镍基高温合金。
  8. 根据权利要求3所述的一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，其特征在于：步骤（3）中3D打印所用的基板为不锈钢基板或同类镍基高温合金基板。
  9. 根据权利要求3所述的一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，其特征在于；步骤（3）的激光工艺参数如下：激光光斑直径70～110μm，激光功率150～300W，激光扫描速率500～1100mm/s，激光扫描间距60～120μm，铺粉层厚为30～50μm。
  10. 根据权利要求3所述的一种采用微米陶瓷颗粒制备纳米相增强镍基高温合金的方法，其特征在于：所述的惰性气体应为氦气、氩气，或氩、氦混合气体，纯度为99.99wt%，其中氧含量小于0.0001wt%。
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