WO2022041258A1 - 一种用于3d打印的纳米陶瓷金属复合粉末及应用 - Google Patents

一种用于3d打印的纳米陶瓷金属复合粉末及应用 Download PDF

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WO2022041258A1
WO2022041258A1 PCT/CN2020/112701 CN2020112701W WO2022041258A1 WO 2022041258 A1 WO2022041258 A1 WO 2022041258A1 CN 2020112701 W CN2020112701 W CN 2020112701W WO 2022041258 A1 WO2022041258 A1 WO 2022041258A1
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powder
nano
composite powder
printing
ceramic
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PCT/CN2020/112701
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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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    • B22F1/0003—
    • 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
    • B22F1/14—Treatment of metallic powder
    • 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
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention provides a nano-ceramic metal composite powder for 3D printing and application thereof, belonging to the technical field of metal matrix composite materials and additive manufacturing.
  • Ceramic-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. Nano-ceramic reinforced metal matrix composites can maintain good toughness while improving mechanical properties such as strength and hardness.
  • additive Manufacturing (AM) technology is a technology that accumulates and superimposes materials point by point and layer by layer to form a three-dimensional entity through the principle of discrete-accumulation.
  • SLM selective laser melting
  • EBM electron beam melting
  • LENS coaxial powder feeding laser forming
  • 3D printing technology to prepare nano-ceramic reinforced metal matrix composite materials can simplify and shorten the processing process, form three-dimensional complex structural parts at one time, and save raw material loss.
  • the 3D printing of nano-ceramic reinforced metal matrix composites has the following difficulties: (1) 3D printing technology has high requirements on the sphericity, fluidity and particle size distribution of raw material powders.
  • Chinese patent (CN111168057A) discloses a nano-ceramic reinforced high-entropy alloy composite powder for additive manufacturing and its preparation method and application.
  • the high-entropy alloy is used as the matrix powder, and the nano-ceramic particles are used as the reinforcing phase particles.
  • Ultrasonic dispersion + mechanical The high-entropy alloy powder with the nano-ceramic particles uniformly adhered on the surface is obtained by stirring, and then the spherical nano-ceramic particle-reinforced high-entropy alloy composite powder is prepared by the radio frequency plasma spheroidization technology.
  • Chinese patent (CN108480625A) discloses a silicon carbide particle reinforced aluminum matrix composite forming method based on selective laser melting technology. The method includes: (1) selecting spherical AlSi10Mg powder with a purity of more than 99.9% and an average particle size distribution of 30 ⁇ m; 99.9% or more SiC powder with an average particle size distribution of 10 ⁇ m; (2) the above two powders are uniformly mixed by a powder mixer without destroying the sphericity of the aluminum matrix powder, wherein the weight of the SiC powder accounts for the total weight of the mixed powder 8 ⁇ 12%.
  • the uniformly mixed powder is used for selective laser melting and forming, and a high-density silicon carbide particle reinforced aluminum matrix composite material is successfully prepared by controlling the thickness of the powder layer and process regulation.
  • the powder will not be deformed and broken during the powder mixing process in the mixer, so the silicon carbide particle reinforcing phase in the prepared composite material still maintains an average particle size of about 10 ⁇ m.
  • the invention proposes for the first time that nanometer ceramic metal spherical composite powder is prepared by using micron-scale ceramic particles as raw materials, and a nanometer ceramic reinforced metal composite material is prepared by 3D printing technology.
  • micron-sized ceramic particles as raw materials, through a specific ball milling process, plasma spheroidization, airflow classification and sieving, a metal composite powder with high sphericity, good fluidity and narrow particle size range is obtained. Higher requirements for powders; nano-ceramic reinforced metal composites are prepared by 3D printing technology.
  • the Marangoni convection is used to stir the melt, which promotes the rearrangement of ceramic particles in the melt, realizes the uniform distribution of nano-ceramic phases in the melt, solves the problem of nano-ceramic phase agglomeration, and rapidly solidifies to obtain nano-ceramics Solidification structure with uniform phase distribution; high temperature melting and rapid solidification by laser or electron beam to solve the problem of interface defects caused by poor wettability between the ceramic reinforcing phase and the metal matrix; using micron-sized ceramic particles to achieve uniform dispersion through nanometerization , low cost; can be integrally formed to prepare parts of any complex shape, and improve the utilization rate of materials.
  • the prepared metal composite material has uniform nano-ceramic phase distribution and excellent mechanical properties.
  • the present invention proposes a nano-ceramic metal composite powder for 3D printing and its application. Using micron-scale ceramic particles as raw materials, nano-ceramic metal spherical composite powder is prepared, and nano-ceramic reinforced composite powder is prepared by 3D printing technology. Metal composites.
  • micron-sized ceramic particles as raw materials, through a specific ball milling process, plasma spheroidization, airflow classification and sieving, a metal composite powder with high sphericity, good fluidity and narrow particle size range is obtained. Higher requirements for powders; nano-ceramic reinforced metal composites are prepared by 3D printing technology.
  • the Marangoni convection is used to stir the melt, which promotes the rearrangement of ceramic particles in the melt, realizes the uniform distribution of nano-ceramic phases in the melt, solves the problem of nano-ceramic phase agglomeration, and rapidly solidifies to obtain nano-ceramics Solidification structure with uniform phase distribution; high temperature melting and rapid solidification by laser or electron beam to solve the problem of interface defects caused by poor wettability between the ceramic reinforcing phase and the metal matrix; using micron-sized ceramic particles to achieve uniform dispersion through nanometerization , low cost; can be integrally formed to prepare parts of any complex shape, and improve the utilization rate of materials.
  • the prepared metal composite material has uniform nano-ceramic phase distribution and excellent mechanical properties.
  • a nano-ceramic metal composite powder for 3D printing of the present invention is prepared by the following scheme, and the scheme includes the following steps.
  • Preparation of composite powder take micron ceramic particles as raw material A and metal powder as raw material B; first wet and then dry-grind raw material A and part of raw material B to obtain composite powder C with uniform distribution of nano-ceramic particles .
  • the present invention is a preparation method of nano-ceramic metal composite powder for 3D printing.
  • the mass ratio of the raw material A and the raw material B is: (0.5-10): (100-90);
  • the metal powder B is selected from aluminum One of alloys, copper alloys, magnesium alloys, rare earth-containing nickel alloys, nickel-based superalloys, iron alloys, and high-entropy alloys;
  • the particle size of the metal material powder is 15-53 ⁇ m or 53-106 ⁇ m.
  • the micro-scale ceramic particles are selected from at least one of TiC, SiC, TiB 2 , WC, A1 2 O 3 , Y 2 O 3 , and TiO 2 ; the micro-scale ceramic particles have a particle size of 1-10 ⁇ m.
  • the present invention is a preparation method of nano-ceramic metal composite powder for 3D printing.
  • step (1) raw material A and part of raw material B are first wet-milled and then dry-milled.
  • raw material A and used The mass ratio of raw material B is 1:1 to 1:5.
  • the present invention provides a method for preparing nano-ceramic metal composite powder for 3D printing.
  • step (1) firstly, micron-scale ceramic particles are crushed by wet grinding to obtain composite powder with uniform distribution of nano-ceramic particles; Water ethanol is used as the ball milling medium.
  • the ball milling parameters are: the ratio of ball to material is 10:1 to 5:1, the ball milling speed is 150 to 300 rpm, and the ball milling time is 5 to 20 hours.
  • the dry grinding process is carried out in an inert gas, and the ball milling parameters are: the ratio of ball to material is 5:1 to 1:1, the ball milling speed is 100 ⁇ 200rpm, and the ball milling time is 2 ⁇ 10h.
  • the present invention provides a method for preparing nano-ceramic metal composite powder for 3D printing, wherein the plasma spheroidization parameters are: the flow rate of the carrier gas is 0.2-1.5 m 3 /h, the flow rate of the plasma argon gas is 0.5-3 m 3 /h, The cooling gas flow rate is 1-6 m 3 /h, and the powder feeding rate is 1-5 kg/h.
  • the present invention is a nano-ceramic metal composite powder for 3D printing and its application.
  • the mixed powder F is formed by 3D printing technology to prepare a nano-ceramic particle reinforced metal matrix composite material; the 3D printing is selective laser melting (SLM). , Electron beam melting (EBM), coaxial powder feeding laser forming (LENS) technology.
  • SLM selective laser melting
  • EBM Electron beam melting
  • LENS coaxial powder feeding laser forming
  • the invention relates to a nano-ceramic metal composite powder for 3D printing and its application.
  • the 3D printing process is as follows: establishing a three-dimensional CAD model on a computer according to the shape of the part; using software to slice and layer the model and import it into an additive manufacturing system; Through the numerical control system, the mixed powder F is scanned reciprocally by the focused high-energy laser or electron beam according to the determined scanning route, and the powder is spread layer by layer, fused, and superimposed layer by layer until a three-dimensional part is formed.
  • the invention relates to a nano-ceramic metal composite powder for 3D printing and its application.
  • the mixed powder F needs to be dried at 60-150° C. for 2-12 hours in a vacuum or an inert atmosphere.
  • the invention relates to a nano-ceramic metal composite powder for 3D printing and its application.
  • the substrate used in the 3D printing is a stainless steel substrate or a similar metal material substrate.
  • the present invention is a nano-ceramic metal composite powder for 3D printing and its application.
  • the 3D printing technology adopts SLM, and the process parameters are as follows: the diameter of the laser spot is 70-110 ⁇ m, the laser power is 150-400W, and the laser scanning rate is 500-1300mm/s , the laser scanning spacing is 60-120 ⁇ m, and the thickness of the powder layer is 30-50 ⁇ m.
  • the inert gas should be helium, argon, or a mixed gas of argon and helium, with a purity of 99.99 wt %, wherein the oxygen content is less than 0.0001 wt %.
  • the present invention proposes a nano-ceramic-metal composite powder for 3D printing and its application.
  • Micro-ceramic particles are used as raw materials, mixed with matrix alloy powder, and ball-milled by a specific ball milling process, so that the micro-ceramic particles are broken and nano-sized. , and is evenly coated by the base alloy powder, which effectively solves the problem of the agglomeration of nano-ceramic particles; in the process of crushing and nano-sized micro-ceramic particles, it is uniformly distributed in the base alloy powder, and a composite powder with uniform distribution of nano-ceramic particles is prepared; The conditions are provided for the uniform distribution of nano-ceramic particles in the melt.
  • the present invention proposes a nano-ceramic metal composite powder for 3D printing and its application.
  • the micro-ceramic particles A and part of the metal powder B are processed by wet grinding and then dry grinding to obtain a composite powder with uniform distribution of nano-ceramic particles. ;Through wet grinding, the micro-ceramic particles are quickly and uniformly broken and nano-sized; through dry grinding, the powder is further broken and uniformly dispersed; Ceramic particles A are mixed with some metal powders B and ball-milled to reduce the amount of ball-milled powder. ,Improve efficiency.
  • the present invention proposes a nano-ceramic metal composite powder for 3D printing and its application.
  • the metal composite powder with a uniform distribution of nano-ceramic phases is subjected to plasma spheroidization, airflow classification and screening to obtain high sphericity and good fluidity.
  • Metal composite powder with a narrow particle size range of nano-ceramic uniform distribution which meets the requirements of 3D printing technology for powder and ensures the smooth progress of 3D printing.
  • the present invention proposes a nano-ceramic metal composite powder for 3D printing and its application.
  • the powder is wet-milled and dry-milled to obtain a metal-based composite powder with a uniform distribution of nano-ceramic phases; 3D
  • the Marangoni convection is used to stir the melt, which promotes the rearrangement of ceramic particles in the melt, inhibits particle agglomeration, makes the nano-ceramic particles evenly distributed in the melt, and rapidly solidifies to obtain a solidified structure with uniform distribution of nano-ceramic phases. , improved tissue uniformity.
  • the present invention proposes a nano-ceramic metal composite powder for 3D printing and its application.
  • a metal matrix composite powder with uniform distribution of nano-ceramic phases is obtained.
  • powder which greatly improves the bonding force between the nano-ceramic phase and the metal matrix; through the high temperature melting and rapid solidification of laser or electron beam, the problem of interface defects caused by poor wettability between the reinforcing phase and the metal matrix is solved, and the prepared composite material is
  • the enhanced phase maintains nano-characteristics, and finally produces parts with no defects, high density, fine and dense microstructure, and excellent mechanical properties.
  • the present invention proposes a nano-ceramic metal composite powder for 3D printing and its application.
  • the nano-ceramic phase acts as a nucleation particle, refines the grains, obtains an equiaxed grain structure, and effectively inhibits the 3D printing process.
  • the present invention proposes a nano-ceramic-metal composite powder for 3D printing and its application.
  • the use of 3D printing technology can solve the problem of preparing difficult-to-process materials and integral forming of complex parts, without forming molds, and shortening the manufacturing cycle and cost. .
  • the present invention proposes a nano-ceramic-metal composite powder for 3D printing and its application.
  • the prepared composite material has a reinforcing phase size of nanometer level, uniform distribution, good combination with the matrix, and can improve the performance of the composite material at the same time.
  • the strength and plasticity of the formed part; 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) photo of the composite powder with uniform distribution of nano-ceramic particles obtained by wet grinding and dry grinding of micron-sized ceramic particles and René 104 nickel-based superalloy powder before forming in Example 1.
  • SEM scanning electron microscope
  • Figure 2 is an example of a pair of composite powders prepared in step (1) with uniformly distributed nano-ceramic particles subjected to plasma spheroidization, airflow classification and sieving to obtain SEM images of metal composite powders with uniformly distributed nano-ceramics.
  • Figure 3 is the particle size distribution curve of the TiC/René104 composite powder prepared in Example 1.
  • Example 4 is a SEM photograph of the microstructure of the XY and XZ surfaces of the nano-ceramic phase-reinforced René 104 nickel-based superalloy bulk prepared by using the SLM technology in Example 1.
  • Figure 5 is the particle size distribution curve of the TiB2/TC4 composite powder prepared in Example 3.
  • Figure 6 is a SEM photograph of the morphology of the composite powder prepared in Comparative Example 4 by wet grinding and dry grinding with the parameters of step (1).
  • a nano-ceramic-metal composite powder for 3D printing and its application using René104 nickel-based superalloy as a matrix, using TiC ceramic particles with an average particle size of 2.5 ⁇ m as a reinforcing phase, and adding a mass percentage of 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 nano-ceramic metal composite powder for 3D printing and its application, the steps are as follows.
  • step (1) In an inert gas atmosphere, the composite powder obtained in step (1) is placed in a plasma spheroidization device for spheroidization and cooling to obtain spherical composite powder with uniform distribution of nano-ceramic particles.
  • step (3) The spherical composite powder obtained in step (2) is classified by air flow and ultrasonic vibration sieving under the protection of inert gas to obtain spherical composite powder with a particle size of 15-53 ⁇ m.
  • 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 5:1, the ball milling speed is 150rpm, and the ball milling time is 8h.
  • the plasma spheroidization parameters in the step (2) are: the flow rate of the carrier gas is 0.8m 3 /h, the flow rate of the plasma argon gas is 2.0m 3 /h, the flow rate of the cooling gas is 3.5m 3 /h, and the powder feeding rate is 4.0 kg/h.
  • the SLM process parameters of the step (5) 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 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 a scanning electron microscope (SEM) photograph of the morphology of the composite powder with uniform distribution of nano-ceramic particles obtained by wet grinding and dry grinding of micron-scale ceramic particles and René 104 alloy powder before forming in Example 1. It can be observed that the micro-scale TiC ceramic particles are broken into nano-sized, and together with the matrix René 104 alloy powder, a composite powder with uniform distribution of nano-ceramic particles is formed.
  • SEM scanning electron microscope
  • Figure 2 is an example of a pair of composite powders prepared in step (1) with uniformly distributed nano-ceramic particles subjected to plasma spheroidization, airflow classification and sieving to obtain SEM images of metal composite powders with uniformly distributed nano-ceramics. It can be observed that after plasma spheroidization, airflow classification and sieving, the composite powder has high sphericity and uniform size.
  • Figure 3 is the particle size distribution curve of the TiC/René104 composite powder prepared in Example 1. It can be seen that the average particle size of the prepared TiC/René 104 composite powder is 30.3 ⁇ m, the Dv(10) is 21.8 ⁇ m, and the Dv(90) is 52.4 ⁇ m.
  • Example 4 is a SEM photograph of the microstructure of the XY and XZ surfaces of the nano-ceramic phase-reinforced René 104 nickel-based superalloy bulk prepared by using the laser 3D printing technology in Example 1. It can be observed from Figure 4 that the nano-TiC ceramic particles prepared by 3D printing are uniformly distributed in the René104 nickel-based superalloy matrix, and the prepared composite bulk has fine and uniform grains and a dense structure.
  • the fluidity of the prepared TiC/René104 composite powder 50g/2.5mm aperture is 24.8s; the particle size is in the range of 15-53 ⁇ m, which can meet the SLM forming requirements.
  • the yield strength of the SLM-prepared samples was 1513 MPa, the tensile strength was 1854 MPa, and the elongation was 8.6%.
  • a spherical composite material is prepared by using the raw materials in a silicon carbide particle reinforced aluminum matrix composite material forming method based on the selective laser melting technology described in the Chinese patent (CN108480625A). powder, and using the SLM process parameters of the Chinese patent (CN108480625A) example, the SiC/AlSi10Mg composite material was prepared. include.
  • the spherical AlSi10Mg powder with an average particle size of 30 ⁇ m is used as the matrix, and the SiC powder with an average particle size of 10 ⁇ m is used as the reinforcing particle, wherein the mass fraction of the SiC powder is 10%, and the purity of both is above 99.9%.
  • the specific preparation steps are as follows.
  • step (1) In an inert gas atmosphere, the composite powder obtained in step (1) is placed in a plasma spheroidization device for spheroidization and cooling to obtain spherical composite powder with uniform distribution of nano-ceramic particles.
  • step (3) The spherical composite powder obtained in step (2) is classified by air flow and ultrasonic vibration sieving under the protection of inert gas to obtain spherical composite powder with a particle size of 15-53 ⁇ m.
  • step (3) Mix the spherical composite powder screened in step (3) and the remaining AlSi10Mg powder under the protection of an inert gas using a V-type mixer to obtain a powder in which the spherical composite powder and the AlSi10Mg powder are uniformly mixed.
  • anhydrous ethanol is used as the ball milling medium, and the ball milling parameters are: the ball-to-material ratio is 10:1, the ball milling speed is 200 rpm, and the ball milling time is 15 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 3:1, the ball milling speed is 200rpm, and the ball milling time is 8h.
  • the plasma spheroidization parameters in the step (2) are: the flow rate of the carrier gas is 1.0m 3 /h, the flow rate of the plasma argon gas is 2.0m 3 /h, the flow rate of the cooling gas is 4.0m 3 /h, and the powder feeding rate is 3.5 kg/h.
  • the SLM process parameters of the step (5) are as follows: the laser spot diameter is 100 ⁇ m, the laser power is 290 W, the laser scanning rate is 1100 mm/s, the laser scanning distance is 0.12 mm, the thickness of the powder layer is 30 ⁇ 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 fluidity of the prepared SiC/AlSi10Mg composite powder 50g/2.5mm pore size is 30.4s; the median particle size is 29.6 ⁇ m, which can meet the SLM forming requirements in the range of 15-53 ⁇ m.
  • the density of the samples measured by Archimedes drainage method was 98.85%; the average microhardness of the prepared samples was 262 HV 0.1 , the yield strength was 354MPa, the tensile strength was 403MPa, and the elongation was 9.6%.
  • the density and mechanical properties are significantly improved.
  • a nano-ceramic-metal composite powder for 3D printing and its application using TC4 titanium alloy as a matrix, using TiB2 ceramic particles with an average particle size of 5 ⁇ m as a reinforcing phase, and adding a mass percentage of 2.0%.
  • the matrix material is a spherical powder of TC4 titanium alloy with a particle size of 53-106 ⁇ m.
  • the nano-ceramic metal composite powder for 3D printing and its application, the steps are as follows.
  • step (1) In an inert gas atmosphere, the composite powder obtained in step (1) is placed in a plasma spheroidization device for spheroidization and cooling to obtain spherical composite powder with uniform distribution of nano-ceramic particles.
  • step (3) The spherical composite powder obtained in step (2) is classified by air flow and ultrasonic vibration sieving under the protection of inert gas to obtain spherical composite powder with a particle size of 53-106 ⁇ m.
  • step (3) Mix the spherical composite powder screened in step (3) and the remaining TC4 alloy powder with a V-type mixer under the protection of inert gas to obtain a powder in which the spherical composite powder and the TC4 alloy powder are uniformly mixed.
  • anhydrous ethanol is used as the ball milling medium, and the ball milling parameters are: the ball-to-material ratio is 10:1, the ball milling speed is 200 rpm, and the ball milling time is 16 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 200rpm, and the ball milling time is 8h.
  • the plasma spheroidization parameters in the step (2) are: the flow rate of the carrier gas is 0.7m 3 /h, the flow rate of the plasma argon gas is 1.5m 3 /h, the flow rate of the cooling gas is 3.0m 3 /h, and the powder feeding rate is 3.0 kg/h.
  • the EBM process parameters of the step (5) are as follows: the accelerating voltage is 60 kV, the electron beam current is 13.5 mA, the scanning speed is 7.6 m/s, the thickness of the powder layer is 50 ⁇ m, and the substrate heating temperature is 780 °C.
  • the inert gas is argon, the purity is 99.99wt%, and the oxygen content is less than 0.0001wt%.
  • Figure 5 is the particle size distribution curve of the TiB 2 /TC4 composite powder prepared in Example 3. It can be seen that the average particle size of the prepared TiB 2 /TC4 composite powder is 75.3 ⁇ m, Dv(10) is 31.4 ⁇ m, and Dv(90) is 100.6 ⁇ m.
  • the fluidity of the prepared TiB 2 /TC4 composite powder 50g/2.5mm pore size is 13.5s; the median particle size is 75.3 ⁇ m, which can meet the EBM forming requirements in the range of 53-106 ⁇ m.
  • the yield strength of the EBM-prepared samples was 1032 MPa, the tensile strength was 1145 MPa, and the elongation was 10.6%.
  • the matrix material is a spherical powder of René104 nickel-based superalloy with a particle size of 15-53 ⁇ m and a trace amount of rare earth Sc added.
  • the balance of 2.4Ta ⁇ 0.9Nb ⁇ 0.05Zr ⁇ 0.03B ⁇ 0.04C ⁇ 0.08Sc is Ni.
  • the nano-ceramic metal composite powder for 3D printing and its application, the steps are as follows.
  • step (1) In an inert gas atmosphere, the composite powder obtained in step (1) is placed in a plasma spheroidization device for spheroidization and cooling to obtain spherical composite powder with uniform distribution of nano-ceramic particles.
  • step (3) The spherical composite powder obtained in step (2) is classified by air flow and ultrasonic vibration sieving under the protection of inert gas to obtain spherical composite powder with a particle size of 15-53 ⁇ m.
  • step (3) Mix the spherical composite powder screened in step (3) with the remaining René104-Sc alloy powder under the protection of an inert gas using a V-type mixer to obtain a powder in which the spherical composite powder and the René104 nickel-based superalloy powder are uniformly mixed .
  • 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 5:1, the ball milling speed is 150rpm, and the ball milling time is 8h.
  • the plasma spheroidization parameters in the step (2) are: the flow rate of the carrier gas is 0.8m 3 /h, the flow rate of the plasma argon gas is 2.0m 3 /h, the flow rate of the cooling gas is 3.5m 3 /h, and the powder feeding rate is 4.0 kg/h.
  • the SLM process parameters of the step (5) 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 40 ⁇ m, and the substrate heating temperature is 150 ° C.
  • the inert gas is argon, the purity is 99.99wt%, and the oxygen content is less than 0.0001wt%.
  • the prepared TiC/René104-Sc composite powder with 50g/2.5mm pore size has a fluidity of 14.5s and a median particle size of 30.6 ⁇ m, which can meet the SLM forming requirements within the range of 15-53 ⁇ m.
  • the yield strength of the SLM-prepared samples was 1521 MPa, the tensile strength was 1863 MPa, and the elongation was 11.4%.
  • Example 1 The difference from Example 1 is that the step (1) only performs wet grinding treatment, and the others remain unchanged.
  • the prepared TiC/René104 composite powder with 50g/2.5mm pore size has a fluidity of 38.4s and a median particle size of 36.5 ⁇ m, which can meet the SLM forming requirements within the range of 15-53 ⁇ m.
  • the yield strength of the SLM preparation was 1345 MPa, the tensile strength was 1654 MPa, and the elongation was 4.6%.
  • Example 1 The difference from Example 1 is that the step (1) only performs dry grinding, and the others remain unchanged.
  • the prepared TiC/René104 composite powder has no fluidity after 50g/2.5mm aperture test; it cannot meet the SLM forming requirements.
  • 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 prepared TiC/René104 composite powder with 50g/2.5mm pore size has a fluidity of 43.7s and a median particle size of 26.2 ⁇ m, which can meet the SLM forming requirements within the range of 15-53 ⁇ m.
  • the yield strength of the SLM-prepared samples was 1385 MPa, the tensile strength was 1516 MPa, and the elongation was 3.7%.
  • 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.
  • Figure 6 is a SEM photograph of the morphology of the composite powder prepared by wet grinding and dry grinding with the parameters of the above step (1).
  • Figure 4 The micron TiC ceramic particles did not form nano-composite powder, and the spherical powder was broken due to the ball milling treatment, which significantly reduced the fluidity of the powder, which was not conducive to the subsequent plasma spheroidization, airflow classification and screening, and could not meet the requirements of 3D printing technology. High requirements for powder sphericity, fluidity and particle size distribution; cannot be used for 3D printing technology.
  • step (2) does not carry out plasma spheroidization, airflow classification and screening treatment, and the others remain unchanged.
  • the fluidity of the prepared TiC/René104 composite powder 50g/2.5mm aperture is 41.2s; the median particle size is 27.5 ⁇ m, in the range of 15-53 ⁇ m.
  • the prepared composite powder has low sphericity, poor fluidity, and more fine powder, which is not conducive to 3D printing.
  • the yield strength of the SLM-prepared sample was 1422 MPa, the tensile strength was 1810 MPa, and the elongation was 6.3%.

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

一种用于3D打印的纳米陶瓷金属复合粉末及应用 技术领域
本发明提供一种用于3D打印的纳米陶瓷金属复合粉末及应用，属于金属基复合材料及增材制造技术领域。
 背景技术
陶瓷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。纳米陶瓷增强金属基复合材料能够在提高强度和硬度等力学性能的同时保持良好的韧性。
增材制造(Additive  Manufacturing，AM)技术是通过离散-堆积原理将材料逐点、逐层累积叠加形成三维实体的技术。目前，金属增材制造技术主要有3种：选区激光熔融（SLM）技术、电子束熔化（EBM）技术和同轴送粉激光成形（LENS）技术。将3D打印技术用于制备纳米陶瓷增强金属基复合材料，可以简化、缩短加工工序，一次成形三维复杂结构制件，节省原材料损耗等。但是，纳米陶瓷增强金属基复合材料的3D打印成形存在以下难点：①3D打印技术对原料粉末的球形度、流动性及粒度分布具有很高的要求，如何制备满足3D打印的球形复合粉末是制备纳米陶瓷增强金属基复合材料的关键；②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，解决纳米陶瓷颗粒的团聚和分散均匀性，获得纳米陶瓷颗粒分散均匀的球形复合粉末，是制备纳米陶瓷增强金属基复合材料的难点，目前未见相关报道；③陶瓷材料与金属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，降低强化效果；④直接使用纳米陶瓷颗粒，无法解决颗粒团聚、实现均匀分散问题，且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（CN111168057A）公开了一种增材制造用纳米陶瓷增强高熵合金复合粉末及其制备方法和应用，以高熵合金为基体粉末，以纳米陶瓷颗粒为增强相颗粒，采用超声分散+机械搅拌的方式获得表面均匀粘附有纳米陶瓷颗粒的高熵合金粉末，再通过射频等离子球化技术，制备得到球形的纳米陶瓷颗粒增强高熵合金复合粉末。中国专利（CN111118323A）公开一种用于激光3D打印金属陶瓷复合材料粉末的制备方法，(1)在Ti/B4C混合粉末中加入PVA黏结剂溶液，其中，PVA黏结剂溶液的质量分数为15％，Ti/B4C混合粉末的质量分数为85％，搅拌均匀、干燥、球磨后得到Ti颗粒与B4C颗粒充分接触的混合粉末，Ti/B4C复合粉体中m(Ti):m(B4C)＝2.6:1；(2)将Ti/B4C复合粉体材料与AlSi10Mg粉末加入球磨机中，进行球磨、混料最终制得激光3D打印金属陶瓷复合材料用粉末。该方法通过真空球磨制备的金属陶瓷复合材料粉末，很难保证激光3D打印用粉末对粉末球形度、流动性以及粒度分布的高要求。中国专利（CN108480625A）公开了一种基于选区激光熔化技术的碳化硅颗粒增强铝基复合材料成形方法，该方法包括：(1)选用纯度99.9％以上，平均粒度分布为30μm的球形AlSi10Mg粉末；纯度99.9％以上，平均粒度分布为10μm的SiC粉末；(2)将上述两种粉末通过混粉机在不破坏铝基体粉末球形度的情况下进行均匀混合，其中SiC粉末重量占混合后粉末总重量的8‑12％。(3)将均匀混合后的粉末用于选区激光熔化成形，通过铺粉层厚的控制和工艺调控成功制备出较高致密度的碳化硅颗粒增强铝基复合材料。为了确保不破坏铝基体粉末球形度，在混粉机中的混粉过程不会使粉末发生变形与破碎，因此所制备的复合材料中碳化硅颗粒增强相仍然保持平均粒径10μm左右。
本发明首次提出采用微米级陶瓷颗粒作为原料，制备得到纳米陶瓷金属球形复合粉末，通过3D打印技术制备纳米陶瓷增强的金属复合材料。
采用微米级陶瓷颗粒作为原料，通过特定的球磨工艺、等离子球化、气流分级以及筛分，得到球形度高、流动性好、粒度范围窄的纳米陶瓷均匀分布的金属复合粉末，满足3D打印技术对粉末较高的要求；通过3D打印技术制备纳米陶瓷增强的金属复合材料。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，实现纳米陶瓷相在熔体中均匀分布，解决了纳米陶瓷相团聚问题，快速凝固得到纳米陶瓷相均匀分布的凝固组织；通过激光或电子束的高温熔化和快速凝固，解决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，通过纳米化实现均匀分散，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。所制备的金属复合材料，纳米陶瓷相分布均匀，具有优异的力学性能。
 技术问题
针对目前制备的纳米陶瓷金属复合粉末难以满足3D打印技术对粉末的球形度、流动性及粒度分布的要求，以及纳米陶瓷相增强金属基复合材料制备过程中，纳米陶瓷颗粒易团聚、与基体界面结合差的问题，本发明提出了一种用于3D打印的纳米陶瓷金属复合粉末及应用，采用微米级陶瓷颗粒作为原料，制备得到纳米陶瓷金属球形复合粉末，通过3D打印技术制备纳米陶瓷增强的金属复合材料。
采用微米级陶瓷颗粒作为原料，通过特定的球磨工艺、等离子球化、气流分级以及筛分，得到球形度高、流动性好、粒度范围窄的纳米陶瓷均匀分布的金属复合粉末，满足3D打印技术对粉末较高的要求；通过3D打印技术制备纳米陶瓷增强的金属复合材料。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，实现纳米陶瓷相在熔体中均匀分布，解决了纳米陶瓷相团聚问题，快速凝固得到纳米陶瓷相均匀分布的凝固组织；通过激光或电子束的高温熔化和快速凝固，解决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，通过纳米化实现均匀分散，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。所制备的金属复合材料，纳米陶瓷相分布均匀，具有优异的力学性能。
 技术解决方案
为实现上述技术目的，本发明一种用于3D打印的纳米陶瓷金属复合粉末，通过下述方案制备，所述方案包括如下步骤。
(1)复合粉末制备：以微米级陶瓷颗粒为原料A，以金属粉末为原料B；先将原料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C。
(2)复合粉末等离子球化：在惰性气体氛围中，将步骤(1)得到的复合粉末C置于等离子球化装置中进行球化，冷却，得到纳米陶瓷颗粒均匀分布的球形复合粉末D。
(3)粉末筛分：将步骤(2)得到的球形复合粉末D，在惰性气体保护下使用气流分级和超声震动筛分，得到粒径为15～53μm和53～106μm的球形复合粉末E。
(4)粉末均匀混合：将步骤(3)筛选的球形复合粉末E与剩余的原料B，在惰性气体保护下使用V型混料机混合，得到球形复合粉末E与金属粉末B均匀混合的粉末F。
本发明一种用于3D打印的纳米陶瓷金属复合粉末的制备方法，所述原料A与原料B的质量比为：（0.5-10）:（100-90）；所述金属粉末B选自铝合金、铜合金、镁合金、含稀土镍合金、镍基高温合金、铁合金、高熵合金中的一种；所述金属材料粉末的粒径为15～53μm或53～106μm。
所述微米级陶瓷颗粒选自TiC、SiC、TiB 2、WC、A1 2O 3、Y 2O 3、TiO 2中的至少一种；所述微米级陶瓷颗粒的粒径为1～10μm。
本发明一种用于3D打印的纳米陶瓷金属复合粉末的制备方法，步骤（1）中先将原料A与部分原料B通过先湿磨后干磨处理，步骤（1）中，原料A与所用原料B的质量比为1：1～1：5。
本发明一种用于3D打印的纳米陶瓷金属复合粉末的制备方法，步骤（1）中先通过湿磨处理使微米级陶瓷颗粒破碎，得到纳米陶瓷颗粒均匀分布的复合粉末；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；通过干磨处理使前面湿磨团聚的复合粉末分散，干磨过程在惰性气体中进行，球磨参数为：球料比5：1～1：1，球磨转速为100～200rpm，球磨时间为2～10h。
本发明一种用于3D打印的纳米陶瓷金属复合粉末的制备方法，所述等离子球化参数为：运载气体流量为0.2～1.5m 3/h，等离子氩气流量为0.5～3m 3/h，冷却气体流量为1～6m 3/ h，粉末进料速率为1～5kg/h。
本发明一种用于3D打印的纳米陶瓷金属复合粉末及应用，采用3D打印技术对混合粉末F进行成形，制备得到纳米陶瓷颗粒增强金属基复合材料；所述3D打印为选区激光熔融（SLM）、电子束熔化（EBM）、同轴送粉激光成形（LENS）技术中的一种。
本发明一种用于3D打印的纳米陶瓷金属复合粉末及应用，所述3D打印过程为：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或电子束对混合粉末F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。
本发明一种用于3D打印的纳米陶瓷金属复合粉末及应用，3D打印前需对混合粉末F在真空或惰性气氛中60-150℃干燥2-12h。
本发明一种用于3D打印的纳米陶瓷金属复合粉末及应用，3D打印所用的基板为不锈钢基板或同类金属材料基板。
本发明一种用于3D打印的纳米陶瓷金属复合粉末及应用，所述3D打印技术采用SLM，工艺参数如下：激光光斑直径70～110μm，激光功率150～400W，激光扫描速率500～1300mm/s，激光扫描间距60～120μm，铺粉层厚为30～50μm。
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）本发明提出一种用于3D打印的纳米陶瓷金属复合粉末及应用，采用微米陶瓷颗粒作为原料，与基体合金粉末混合、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。
（2）本发明提出一种用于3D打印的纳米陶瓷金属复合粉末及应用，先将微米陶瓷颗粒A与部分金属粉末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。
（3）本发明提出一种用于3D打印的纳米陶瓷金属复合粉末及应用，将纳米陶瓷相均匀分布的金属复合粉末进行等离子球化、气流分级以及筛分，得到球形度高、流动性好、粒度范围窄的纳米陶瓷均匀分布的金属复合粉末，满足3D打印技术对粉末的要求，保证3D打印的顺利进行。
（4）本发明提出一种用于3D打印的纳米陶瓷金属复合粉末及应用，在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，快速凝固得到纳米陶瓷相均匀分布的凝固组织，改善了组织均匀性。
（5）本发明提出一种用于3D打印的纳米陶瓷金属复合粉末及应用，通过对微米陶瓷颗粒与金属的混合粉末，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，大幅提高纳米陶瓷相与金属基体的结合力；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。
（6）本发明提出一种用于3D打印的纳米陶瓷金属复合粉末及应用，在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。
（7）本发明提出一种用于3D打印的纳米陶瓷金属复合粉末及应用，使用3D打印技术可解决难加工材料的制备和复杂零件的一体成形难题，无需成形模具，缩短了制造周期和成本。
（8）本发明提出一种用于3D打印的纳米陶瓷金属复合粉末及应用，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，可以同时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。
【以微米级陶瓷颗粒A，与部分金属粉末B进行混合球磨的优点：这是本发明的核心优势】1、湿磨：快速、均匀破碎并纳米化；干磨：均匀化；2、部分混合、球磨：提高球磨效率。
 附图说明
图1为实施例一成形前通过微米级陶瓷颗粒和René104镍基高温合金粉末进行湿磨加干磨处理，得到的纳米陶瓷颗粒均匀分布的复合粉末形貌扫描电镜（SEM）照片。
图2为实施例一对步骤（1）制备的纳米陶瓷颗粒均匀分布的复合粉末进行等离子球化处理、气流分级以及筛分，得到纳米陶瓷均匀分布的金属复合粉末SEM照片。
图3为实施例一所制备的TiC/René104复合粉末的粒度分布曲线。
图4为实施例一采用SLM技术，制备的纳米陶瓷相增强René104镍基高温合金块体XY和XZ面的显微组织SEM照片。
图5为实施例三所制备的TiB2/TC4复合粉末的粒度分布曲线。
图6为对比例四采用步骤（1）的参数进行的湿磨加干磨处理，制备的复合粉末形貌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。
一种用于3D打印的纳米陶瓷金属复合粉末及应用，以René104镍基高温合金为基体，以平均粒径为2.5μm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。
所述一种用于3D打印的纳米陶瓷金属复合粉末及应用，步骤如下。
（1）先将所述比例平均粒径为2.5μm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）在惰性气体氛围中，将步骤(1)得到的复合粉末置于等离子球化装置中进行球化，冷却，得到纳米陶瓷颗粒均匀分布的球形复合粉末。
（3）将步骤(2)得到的球形复合粉末，在惰性气体保护下使用气流分级和超声震动筛分，得到粒径为15～53μm的球形复合粉末。
（4）将步骤(3)筛选的球形复合粉末与剩余的René104镍基高温合金粉末，在惰性气体保护下使用V型混料机混合，得到球形复合粉末与René104镍基高温合金粉末均匀混合的粉末。
（5）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SLM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（4）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5：1，球磨转速为150rpm，球磨时间为8h。
所述步骤（2）中等离子球化参数为：运载气体流量为0.8m 3/h，等离子氩气流量为2.0m 3/h，冷却气体流量为3.5m 3/ h，粉末进料速率为4.0kg/h。
所述步骤（5）的SLM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为实施例一成形前通过对微米级的陶瓷颗粒和René104合金粉末进行湿磨加干磨处理，得到的纳米陶瓷颗粒均匀分布的复合粉末形貌的扫描电镜（SEM）照片。可以观察到，微米级的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为实施例一对步骤（1）制备的纳米陶瓷颗粒均匀分布的复合粉末进行等离子球化处理、气流分级以及筛分，得到纳米陶瓷均匀分布的金属复合粉末SEM照片。可以观察到，经等离子球化处理、气流分级以及筛分后，复合粉末的球形度高、大小均匀。
图3为实施例一所制备的TiC/René104复合粉末的粒度分布曲线。由此可知，所制备的TiC/René104复合粉末的平均粒径为30.3μm，Dv(10)为21.8μm，Dv(90)为52.4μm。
图4为实施例一采用激光3D打印技术，制备的纳米陶瓷相增强René104镍基高温合金块体XY和XZ面的显微组织SEM照片。从图4可以观察到，3D打印制备的纳米TiC陶瓷颗粒在René104镍基高温合金基体中分布均匀，制备的复合材料块体晶粒细小、均匀，结构致密。
经测试，所制备的TiC/René104复合粉末50g/2.5mm孔径的流动性为24.8s；粒径在15-53μm范围内，能满足SLM成形要求。SLM制备样品的屈服强度为1513MPa，抗拉强度为1854MPa，伸长率为8.6%。
实施例二。
按照本发明一种用于3D打印的纳米陶瓷金属复合粉末，采用中国专利（CN108480625A）所述的一种基于选区激光熔化技术的碳化硅颗粒增强铝基复合材料成形方法中的原料，制备球形复合粉末，并采用中国专利（CN108480625A）实施例的SLM工艺参数，制备SiC/AlSi10Mg复合材料。包括。
选用平均粒度为30μm的球形AlSi10Mg粉末作为基体，平均粒度为10μm的SiC粉末为增强颗粒，其中SiC粉末质量分数为10％，两者纯度均在99.9％以上，具体制备步骤如下。
（1）先将所述比例平均粒径为10μm的SiC陶瓷颗粒与部分AlSi10Mg粉末混合（比例为1:2），然后使用高能球磨机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）在惰性气体氛围中，将步骤(1)得到的复合粉末置于等离子球化装置中进行球化，冷却，得到纳米陶瓷颗粒均匀分布的球形复合粉末。
（3）将步骤(2)得到的球形复合粉末，在惰性气体保护下使用气流分级和超声震动筛分，得到粒径为15～53μm的球形复合粉末。
（4）将步骤(3)筛选的球形复合粉末与剩余的AlSi10Mg粉末，在惰性气体保护下使用V型混料机混合，得到球形复合粉末与AlSi10Mg粉末均匀混合的粉末。
（5）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SLM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（4）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15h；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200rpm，球磨时间为8h。
所述步骤（2）中等离子球化参数为：运载气体流量为1.0m 3/h，等离子氩气流量为2.0m 3/h，冷却气体流量为4.0m 3/ h，粉末进料速率为3.5kg/h。
所述步骤（5）的SLM工艺参数如下：激光光斑直径100μm，激光功率290W，激光扫描速率1100mm/s，激光扫描间距0 .12mm，铺粉层厚为30μm，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，所制备的SiC/AlSi10Mg复合粉末50g/2.5mm孔径的流动性为30.4s；中位粒径为29.6μm，在15-53μm范围内，能满足SLM成形要求。利用阿基米德排水法测得试样致密度为98.85%；所制备样品的平均显微硬度为262 HV 0.1，屈服强度为354MPa，抗拉强度为403MPa，伸长率为9.6%。与中国专利（CN108480625A）实施例制备的样品的致密度97.76%和显微硬度216.2HV 0.1相比，致密度和力学性能显著提高。
实施例三。
一种用于3D打印的纳米陶瓷金属复合粉末及应用，以TC4钛合金为基体，以平均粒径为5μm的TiB 2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53～106μm的TC4钛合金球形粉末。
所述一种用于3D打印的纳米陶瓷金属复合粉末及应用，步骤如下。
（1）先将所述比例的TiB 2陶瓷颗粒与部分TC4合金粉末混合（比例为2:3），然后使用高能球磨机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）在惰性气体氛围中，将步骤(1)得到的复合粉末置于等离子球化装置中进行球化，冷却，得到纳米陶瓷颗粒均匀分布的球形复合粉末。
（3）将步骤(2)得到的球形复合粉末，在惰性气体保护下使用气流分级和超声震动筛分，得到粒径为53～106μm的球形复合粉末。
（4）将步骤(3)筛选的球形复合粉末与剩余的TC4合金粉末，在惰性气体保护下使用V型混料机混合，得到球形复合粉末与TC4合金粉末均匀混合的粉末。
（5）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EBM增材制造系统；通过数控系统，利用聚焦的高能电子束对步骤（4）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16h；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200rpm，球磨时间为8h。
所述步骤（2）中等离子球化参数为：运载气体流量为0.7m 3/h，等离子氩气流量为1.5m 3/h，冷却气体流量为3.0m 3/ h，粉末进料速率为3.0kg/h。
所述步骤（5）的EBM工艺参数如下：加速电压为60 kV，电子束电流为13.5mA，扫描速度为7.6 m/s，铺粉层厚为50μm，基板加热温度780℃。
所述的惰性气体为氩气，纯度为99.99wt%，氧含量小于0.0001wt%。
图5为实施例三所制备的TiB 2/TC4复合粉末的粒度分布曲线。由此可知，所制备的TiB 2/TC4复合粉末的平均粒径为75.3μm，Dv(10)为31.4μm，Dv(90)为100.6μm。
经测试，所制备的TiB 2/TC4复合粉末50g/2.5mm孔径的流动性为13.5s；中位粒径为75.3μm，在53-106μm范围内，能满足EBM成形要求。EBM制备样品的屈服强度为1032MPa，抗拉强度为1145MPa，伸长率为10.6%。
实施例四。
一种用于3D打印的纳米陶瓷金属复合粉末及应用，以René104镍基高温合金为基体，添加微量稀土Sc元素；以平均粒径为2.0μm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、添加微量稀土Sc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～0.08Sc余量为Ni。
所述一种用于3D打印的纳米陶瓷金属复合粉末及应用，步骤如下。
（1）先将所述比例平均粒径为2.0μm的TiC陶瓷颗粒与部分René104-Sc合金粉末混合（比例为2:3），然后使用高能球磨机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）在惰性气体氛围中，将步骤(1)得到的复合粉末置于等离子球化装置中进行球化，冷却，得到纳米陶瓷颗粒均匀分布的球形复合粉末。
（3）将步骤(2)得到的球形复合粉末，在惰性气体保护下使用气流分级和超声震动筛分，得到粒径为15～53μm的球形复合粉末。
（4）将步骤(3)筛选的球形复合粉末与剩余的René104-Sc合金粉末，在惰性气体保护下使用V型混料机混合，得到球形复合粉末与René104镍基高温合金粉末均匀混合的粉末。
（5）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SLM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（4）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5：1，球磨转速为150rpm，球磨时间为8h。
所述步骤（2）中等离子球化参数为：运载气体流量为0.8m 3/h，等离子氩气流量为2.0m 3/h，冷却气体流量为3.5m 3/ h，粉末进料速率为4.0kg/h。
所述步骤（5）的SLM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40μm，基板加热温度150℃。
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，所制备的TiC/René104-Sc复合粉末50g/2.5mm孔径的流动性为14.5s；中位粒径为30.6μm，在15-53μm范围内，能满足SLM成形要求。SLM制备样品的屈服强度为1521MPa，抗拉强度为1863MPa，伸长率为11.4%。
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。
经测试，所制备的TiC/René104复合粉末50g/2.5mm孔径的流动性为38.4s；中位粒径为36.5μm，在15-53μm范围内，能满足SLM成形要求。SLM制备品的屈服强度为1345MPa，抗拉强度为1654MPa，伸长率为4.6%。
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。
经测试，所制备的TiC/René104复合粉末经50g/2.5mm孔径测试，没有流动性；不能满足SLM成形要求。
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。
经测试，所制备的TiC/René104复合粉末50g/2.5mm孔径的流动性为43.7s；中位粒径为26.2μm，在15-53μm范围内，能满足SLM成形要求。SLM制备样品的屈服强度为1385MPa，抗拉强度为1516MPa，伸长率为3.7%。
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。
图6为采用上述步骤（1）的参数进行的湿磨加干磨处理，制备的复合粉末形貌SEM照片。如图4所示：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破碎，显著降低粉末流动性，不利于后续的等离子球化、气流分级以及筛分，不能满足满足3D打印技术对粉末的球形度、流动性及粒度分布的高要求；不能用于3D打印技术制备。
对比例五。
与实施例一不同的是所述步骤（2）不进行等离子球化、气流分级和筛分处理，其他不变。
经测试，所制备的TiC/René104复合粉末50g/2.5mm孔径的流动性为41.2s；中位粒径为27.5μm，在15-53μm范围内。不进行等离子球化、气流分级和筛分处理，制备得到的复合粉末球形度低、流动性较差、细粉较多，不利于3D打印成形。经测试，SLM制备样品的屈服强度为1422MPa，抗拉强度为1810MPa，伸长率为6.3%。

Claims (10)

  1. 一种用于3D打印的纳米陶瓷金属复合粉末的制备方法，其特征在于，包括如下步骤：
    (1)复合粉末制备：以微米级陶瓷颗粒为原料A，以金属粉末为原料B；先将原料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C；
    (2)复合粉末等离子球化：在惰性气体氛围中，将步骤(1)得到的复合粉末C置于等离子球化装置中进行球化，冷却，得到纳米陶瓷颗粒均匀分布的球形复合粉末D；
    (3)粉末筛分：将步骤(2)得到的球形复合粉末D，在惰性气体保护下使用气流分级和超声震动筛分，得到粒径为15～53μm和53～106μm的球形复合粉末E；
    (4)粉末均匀混合：将步骤(3)筛选的球形复合粉末E与剩余的原料B，在惰性气体保护下使用V型混料机混合，得到球形复合粉末E与金属粉末B均匀混合的粉末F。
  2. 根据权利要求1所述的一种用于3D打印的纳米陶瓷金属复合粉末的制备方法，其特征在于：所述原料A与原料B的质量比为：（0.5-10）:（100-90）；所述金属粉末B选自铝合金、铜合金、镁合金、含稀土镍合金、镍基高温合金、铁合金、高熵合金中的一种；所述金属材料粉末的粒径为15～53μm或53～106μm；
    所述微米级陶瓷颗粒选自TiC、SiC、TiB 2、WC、A1 2O 3、Y 2O 3、TiO 2中的至少一种；所述微米级陶瓷颗粒的粒径为1～10μm。
  3. 根据权利要求1所述的一种用于3D打印的纳米陶瓷金属复合粉末的制备方法，其特征在于：步骤（1）中先将原料A与部分原料B通过先湿磨后干磨处理，步骤（1）中，原料A与所用原料B的质量比为1：1～1：5。
  4. 根据权利要求1所述的一种用于3D打印的纳米陶瓷金属复合粉末的制备方法，其特征在于：步骤（1）中先通过湿磨处理使微米级陶瓷颗粒破碎，得到纳米陶瓷颗粒均匀分布的复合粉末；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；通过干磨处理使前面湿磨团聚的复合粉末分散，干磨过程在惰性气体中进行，球磨参数为：球料比5：1～1：1，球磨转速为100～200rpm，球磨时间为2～10h。
  5. 根据权利要求1所述的一种用于3D打印的纳米陶瓷金属复合粉末的制备方法，其特征在于，所述等离子球化参数为：运载气体流量为0.2～1.5m 3/h，等离子氩气流量为0.5～3m 3/h，冷却气体流量为1～6m 3/ h，粉末进料速率为1～5kg/h。
  6. 根据权利要求1-5任意一项所述的一种用于3D打印的纳米陶瓷金属复合粉末及应用，其特征在于：采用3D打印技术对混合粉末F进行成形，制备得到纳米陶瓷颗粒增强金属基复合材料；所述3D打印为选区激光熔融（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。
  7. 根据权利要求6所述的一种用于3D打印的纳米陶瓷金属复合粉末及应用，其特征在于，所述3D打印过程为：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或电子束对混合粉末F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。
  8. 根据权利要求6所述的一种用于3D打印的纳米陶瓷金属复合粉末及应用，其特征在于：3D打印前需对混合粉末F在真空或惰性气氛中60-150℃干燥2-12h。
  9. 根据权利要求6所述的一种用于3D打印的纳米陶瓷金属复合粉末及应用，其特征在于：3D打印所用的基板为不锈钢基板或同类金属材料基板。
  10. 根据权利要求6所述的一种用于3D打印的纳米陶瓷金属复合粉末及应用，其特征在于：所述3D打印技术采用SLM，工艺参数如下：激光光斑直径70～110μm，激光功率150～400W，激光扫描速率500～1300mm/s，激光扫描间距60～120μm，铺粉层厚为30～50μm。
    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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