选区激光熔化制备多孔316L不锈钢和多孔钛的研究
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摘要
选区激光熔化是一种典型的快速原型制造技术,可以在没有工装夹具或模具的条件下,利用激光束将粉体材料熔融堆积而快速成形出任意复杂形状的三维零件。本文将选区激光熔化技术引入多孔金属制备领域,选用316L不锈钢、钛为基体,以NH_4HCO_3、TiH_2粉末为造孔剂,成功制备出了多孔316L不锈钢和多孔Ti。利用XRD、SEM、EDX等分析和检测手段,研究了获得的多孔结构的物相、显微组织和成分,分析了造孔剂种类、含量及激光功率与扫描速率等激光工艺参数对成形的多孔试样显微组织特征和性能的影响规律;并阐述了不同造孔剂组分和激光工艺条件下多孔结构的成形机制。
使用NH_4HCO_3粉末作为造孔剂成形多孔316L不锈钢时,在优化的工艺条件(NH_4HCO_3造孔剂含量为4.0 wt.%、激光功率800 W、扫描速率0.01 m/s)下,获得了新颖的蜂窝状微孔结构。该多孔结构中孔隙分布均匀,孔径在2～5μm之间,开孔孔隙率达到45%,多孔结构中不存在造孔剂残余物,具有较高的化学纯度。
使用TiH_2粉末作为造孔剂成形多孔316L不锈钢时,在激光功率650 W、扫描速率0.03 m/s工艺条件下,制备出平均孔径在亚毫米量级(约250～300μm)的多孔不锈钢,当TiH_2造孔剂含量由2 wt.%增至10 wt.%时,多孔试样的孔隙率由28.7%增加到38.7%;此外,还研究了SiC陶瓷颗粒的加入对316L不锈钢/TiH_2混合粉体SLM成形多孔结构的影响,研究表明SiC陶瓷的加入有利于获得较高的孔隙率,但同时也恶化了粉体成形性能。
对TiH_2/Ti粉末体系进行了SLM实验研究,在TiH_2组分含量60 wt.%及激光功率1000 W、扫描速率0.02 m/s工艺条件下,成形出孔隙率为42.8%、平均孔径约350μm的多孔Ti试样,且大部分孔隙为近圆形,孔径分布较为均匀,分布范围为~200– ~600μm。研究发现,在激光工艺过程中TiH_2粉末除了充当造孔剂外,还可提供保护气氛,粉体成形时未发生显著氧化,保证了获得的多孔Ti结构具有较高的化学纯度。
研究还发现,所用扫描速率对成形的多孔Ti试样的孔隙率及孔壁显微硬度有重要影响。在TiH_2含量60 wt.%、激光功率固定为1000 W的实验条件下,当扫描速率由0.01 m/s增加到0.03 m/s时,多孔试样的孔隙率由32.4%增大到47.2%,而扫描速率进一步增至0.05 m/s时,多孔试样的孔隙率下降至18.4%;而多孔试样孔壁显微硬度随扫描速率的变化趋势与上述孔隙率的变化趋势相反,当扫描速率从0.01 m/s增加至0.03 m/s时,孔壁显微硬度从442.3 HV_(0.025)降至403.6 HV_(0.025);扫描速率进一步增加至0.05 m/s时,孔壁显微硬度增加至430.9 HV_(0.025)。
Selective Laser Melting (SLM), as a typical Rapid Manufacturing (RM) technique, enables the quick production of complex shaped three-dimensional (3D) components by layerwise fusing powder materials with a scanning laser beam, without the use of fixture or tooling. In the present paper, SLM method is introduced into the field of porous metals fabrication. 316L stainless steel base and titanium base porous metals were successfully prepared using NH_4HCO_3 and TiH_2 powders as the pore-forming agents. Phases, microstructures and compositions of the processed porous structures were investigated using XRD, SEM and EDX. The effects of componential (the types and contents of pore-forming agents) and processing conditions (laser powder and scanning speed) on microstructural features of the obtained porous structures and their properties were analyzed. The formation mechanisms of porous structures under various ingredients of pore-forming agents and laser processing conditions were also elucidated.
The selective laser melting of a blended powder system consisting of 316L stainless steel powder and gas-generating powder NH_4HCO_3 was performed. A novel honeycomb-like microcellular structure possessing unusually micrometer scaled pores was prepared, with the addition of 4.0 wt.% NH_4HCO_3 powder and using optimized processing conditions (laser power of 800 W and scanning speed of 0.01 m/s). The obtained porous structure presented a uniform pore distribution in the range of ~2 to ~5μm and had an open porosity of 45%. A high chemical purity was also yielded for this porous structure without the detection of residual gas-generating agent.
Porous 316L stainless steel with sub-millimeter scaled pores (~250 to ~300μm) was prepared with the addition of TiH_2 pore-forming agent, using a laser power of 650 W and a scanning speed of 0.03 m/s. As the content of TiH_2 powder rose from 2 wt.% to 10 wt.%, the porosity of the porous samples increased accordingly from 28.7% to 38.7%. The role of SiC ceramic particles addition on the SLM-processed porous structures from 316L stainless steel and TiH_2 blended powder was also investigated. The results showed that the SiC addition was favorable to achieve a high porosity, but was infaust for degrading the forming property.
The selective laser melting of the TiH_2-Ti blended powder was carried out. Porous titanium samples characterized by a porosity of 42.8% and an averaged pore size of 350μm were obtained with 60 wt.% TiH_2 addition, at a laser power of 1000 W and a scanning speed of 0.03 m/s. The majority of the pores in the porous structures exhibited a near-round shape, and the pore sizes distributed uniformly in the range of ~200 to ~600μm.
The experimental results also revealed that the applied scanning speed exerted a significant effect on the porosity of porous Ti samples and the microhardness of Ti walls. With 60 wt.% TiH_2 powder addition and the laser power fixed at 1000 W, the porosity of porous samples increased from 32.4% to 47.2% when the applied scanning speed rose from 0.01 m/s to 0.03 m/s. As the scanning speed further increased to 0.05 m/s, the porosity decreased to 18.4%. In contrast, the changes of the microhardness of Ti walls with the scanning speed showed a reverse tendency. When the scanning speed rose from 0.01 m/s to 0.03 m/s, the microhardness of Ti walls declined from 442.3 HV_(0.025) to 403.6 HV_(0.025). While as the scanning speed further increased to 0.05 m/s, the microhardness value of Ti walls increased slightly to 430.9 HV_(0.025).
使用NH_4HCO_3粉末作为造孔剂成形多孔316L不锈钢时,在优化的工艺条件(NH_4HCO_3造孔剂含量为4.0 wt.%、激光功率800 W、扫描速率0.01 m/s)下,获得了新颖的蜂窝状微孔结构。该多孔结构中孔隙分布均匀,孔径在2～5μm之间,开孔孔隙率达到45%,多孔结构中不存在造孔剂残余物,具有较高的化学纯度。
使用TiH_2粉末作为造孔剂成形多孔316L不锈钢时,在激光功率650 W、扫描速率0.03 m/s工艺条件下,制备出平均孔径在亚毫米量级(约250～300μm)的多孔不锈钢,当TiH_2造孔剂含量由2 wt.%增至10 wt.%时,多孔试样的孔隙率由28.7%增加到38.7%;此外,还研究了SiC陶瓷颗粒的加入对316L不锈钢/TiH_2混合粉体SLM成形多孔结构的影响,研究表明SiC陶瓷的加入有利于获得较高的孔隙率,但同时也恶化了粉体成形性能。
对TiH_2/Ti粉末体系进行了SLM实验研究,在TiH_2组分含量60 wt.%及激光功率1000 W、扫描速率0.02 m/s工艺条件下,成形出孔隙率为42.8%、平均孔径约350μm的多孔Ti试样,且大部分孔隙为近圆形,孔径分布较为均匀,分布范围为~200– ~600μm。研究发现,在激光工艺过程中TiH_2粉末除了充当造孔剂外,还可提供保护气氛,粉体成形时未发生显著氧化,保证了获得的多孔Ti结构具有较高的化学纯度。
研究还发现,所用扫描速率对成形的多孔Ti试样的孔隙率及孔壁显微硬度有重要影响。在TiH_2含量60 wt.%、激光功率固定为1000 W的实验条件下,当扫描速率由0.01 m/s增加到0.03 m/s时,多孔试样的孔隙率由32.4%增大到47.2%,而扫描速率进一步增至0.05 m/s时,多孔试样的孔隙率下降至18.4%;而多孔试样孔壁显微硬度随扫描速率的变化趋势与上述孔隙率的变化趋势相反,当扫描速率从0.01 m/s增加至0.03 m/s时,孔壁显微硬度从442.3 HV_(0.025)降至403.6 HV_(0.025);扫描速率进一步增加至0.05 m/s时,孔壁显微硬度增加至430.9 HV_(0.025)。
Selective Laser Melting (SLM), as a typical Rapid Manufacturing (RM) technique, enables the quick production of complex shaped three-dimensional (3D) components by layerwise fusing powder materials with a scanning laser beam, without the use of fixture or tooling. In the present paper, SLM method is introduced into the field of porous metals fabrication. 316L stainless steel base and titanium base porous metals were successfully prepared using NH_4HCO_3 and TiH_2 powders as the pore-forming agents. Phases, microstructures and compositions of the processed porous structures were investigated using XRD, SEM and EDX. The effects of componential (the types and contents of pore-forming agents) and processing conditions (laser powder and scanning speed) on microstructural features of the obtained porous structures and their properties were analyzed. The formation mechanisms of porous structures under various ingredients of pore-forming agents and laser processing conditions were also elucidated.
The selective laser melting of a blended powder system consisting of 316L stainless steel powder and gas-generating powder NH_4HCO_3 was performed. A novel honeycomb-like microcellular structure possessing unusually micrometer scaled pores was prepared, with the addition of 4.0 wt.% NH_4HCO_3 powder and using optimized processing conditions (laser power of 800 W and scanning speed of 0.01 m/s). The obtained porous structure presented a uniform pore distribution in the range of ~2 to ~5μm and had an open porosity of 45%. A high chemical purity was also yielded for this porous structure without the detection of residual gas-generating agent.
Porous 316L stainless steel with sub-millimeter scaled pores (~250 to ~300μm) was prepared with the addition of TiH_2 pore-forming agent, using a laser power of 650 W and a scanning speed of 0.03 m/s. As the content of TiH_2 powder rose from 2 wt.% to 10 wt.%, the porosity of the porous samples increased accordingly from 28.7% to 38.7%. The role of SiC ceramic particles addition on the SLM-processed porous structures from 316L stainless steel and TiH_2 blended powder was also investigated. The results showed that the SiC addition was favorable to achieve a high porosity, but was infaust for degrading the forming property.
The selective laser melting of the TiH_2-Ti blended powder was carried out. Porous titanium samples characterized by a porosity of 42.8% and an averaged pore size of 350μm were obtained with 60 wt.% TiH_2 addition, at a laser power of 1000 W and a scanning speed of 0.03 m/s. The majority of the pores in the porous structures exhibited a near-round shape, and the pore sizes distributed uniformly in the range of ~200 to ~600μm.
The experimental results also revealed that the applied scanning speed exerted a significant effect on the porosity of porous Ti samples and the microhardness of Ti walls. With 60 wt.% TiH_2 powder addition and the laser power fixed at 1000 W, the porosity of porous samples increased from 32.4% to 47.2% when the applied scanning speed rose from 0.01 m/s to 0.03 m/s. As the scanning speed further increased to 0.05 m/s, the porosity decreased to 18.4%. In contrast, the changes of the microhardness of Ti walls with the scanning speed showed a reverse tendency. When the scanning speed rose from 0.01 m/s to 0.03 m/s, the microhardness of Ti walls declined from 442.3 HV_(0.025) to 403.6 HV_(0.025). While as the scanning speed further increased to 0.05 m/s, the microhardness value of Ti walls increased slightly to 430.9 HV_(0.025).
引文
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