放电等离子烧结（SPS）制备细晶93W-5.6Ni-1.4Fe高比重合金
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摘要
W-Ni-Fe高比重合金是典型的双相复合材料，主要应用于需求高密度领域，如配重块、穿甲弹弹芯和屏蔽材料等。传统液相烧结W-Ni-Fe合金由于钨晶粒粗大（约30~60μm）而不利于其综合性能的进一步提高。后续形变强化虽然可以在一定程度上提高合金的力学性能，但是考虑到材料的利用率、加工成本及变形量等，限制了其在民用和国防工业中的扩大应用。细化钨晶粒被证明是提高合金力学性能的最有效途径，随着钨晶粒尺寸的降低，合金的强度、硬度、韧性等都将有所改善。因此，研究制备高性能细晶W-Ni-Fe合金，具有重要的学术价值和实际意义。
本文以93W-5.6Ni-1.4Fe元素混合粉末为原始材料，采用放电等离子烧结技术将其致密化，系统地研究了其烧结过程中的致密化与晶粒长大机制。以此为依据，开发了放电等离子循环烧结和瞬时液相烧结两种新的烧结工艺，最终获得了高性能细晶93W-5.6Ni-1.4Fe高比重合金。
根据经典的烧结动力学、微观组织演变规律以及脉冲电场下粉末孔隙处的局部温度梯度，93W-5.6Ni-1.4Fe粉末的SPS过程可以划为三个阶段：SPS初期，主要为颗粒重排与烧结颈形成和长大，镍铁通过扩散形成γ-(Ni, Fe)固溶体，外加压应力和特有的“SPS效应”促进烧结颈形成和长大；SPS中期，粘性流动（W晶粒转动与滑移）辅助下的W在粘结相中的溶解－再沉析和W晶界扩散共同主导致密化与晶粒长大；SPS后期，致密化停滞而W晶粒迅速长大，其机制为气相扩散与溶解－再沉析。加热速率对93W-5.6Ni-1.4Fe粉末的SPS致密化和晶粒长大行为影响很大。提高加热速率可以增强粘性流动作用，增加粉末的致密化速率，促进粉末SPS后期的致密化并最小化表面扩散进而抑制钨晶粒长大。
建立了两个不同加热速率阶段93W-5.6Ni-1.4Fe合金的放电等离子烧结MSC曲线。低加热速率阶段的MSC曲线可以准确预测93W-5.6Ni-1.4Fe粉末放电等离子烧结全过程的致密化行为，以及粉末压坯的收缩量和合金最终烧结密度。当加热速率过高时，由于宏观温差增大，其MSC曲线在预测合金的烧结密度上存在困难，但是仍能有效预测粉末的致密化趋势。
采用放电等离子循环烧结制备了细晶93W-5.6Ni-1.4Fe高比重合金（钨晶粒尺寸小于9μm）。1400oC循环烧结有效改善了合金的钨晶粒形态、粘结相分布以及钨－粘结相界面的内聚力，降低了W-W连接度，合金的力学性能显著提高，具体表现为合金弯曲断裂后，钨晶粒解理断裂与粘结相撕裂增多，且在W-W分离界面上存在许多微区粘结相延性撕裂与钨－粘结相界面分离，有效阻止了裂纹的扩展。合金准静态室温压缩屈服强度与其微观组织，如钨晶粒大小、粘结相体积分数以及W-W连接度有关；其动态力学行为有明显改善，沿最大剪切应力平面存在约30μm的剪切变形区，但是循环烧结对钨晶粒形状的改善有限，削弱了其高应变速率下剪切变形区内钨晶粒的变形协调性，因此其绝热剪切带深度有限。
通过有效控制SPS工艺（放电等离子瞬时液相烧结），制备了钨晶粒细小（钨晶粒尺寸约6μm）且呈球状的93W-5.6Ni-1.4Fe合金，其相对密度约为0.95，W-W连接度为0.53。与传统的液相烧结钨基高比重合金相比，放电等离子瞬时液相烧结合金的力学性能有明显提高，具体表现为准静态加载条件下具有高弯曲强度（约1580MPa）和高屈服强度（室温下约1050MPa和800oC高温下约640MPa），SPS改善了合金的界面性能，对屈服强度提供了一个额外的强化作用；动态加载条件下随着钨晶粒尺寸的减小，局部绝热剪切带变窄且扩展深度增加。细化球状钨晶粒有利于局部绝热剪切带的形成与扩展，提高穿甲侵彻过程的自锐化效应。
W-Ni-Fe heavy alloys are typical two phases composites used in the applicationsrequiring high density, such as counter weights, kinetic energy penetrators and radiationshields. Conventional liquid-phase sintered W-Ni-Fe alloys manifest a typical microstructurewhere coarsened spherical bcc tungsten grains are dispersed in a fcc Ni-Fe-W solid solutionmatrix. Further improvement of the mechanical properties is restricted. The performance isimproved to some extent after deformation. However，taken the material utilization, cost anddeformation degree, etc, into account, their expanded application in civilian and military fieldare confined. Tungsten grain refinment is proved to be the most effective approach to improvethe mechanical properties. The strength, hardness, toughness and other performances of thealloy will be improved with the decrease of tungsten grain size. For industrial applicationsand academic research, thus, it is of great interest to develop fine-grained W-Ni-Fe alloyswith high performance to meet the advanced requirements.
The aims of this study are, first, to use the spark plasma sintering (SPS) method toprepare bulk93W-5.6Ni-1.4Fe heavy alloys from blended elemental powders and study theinfluence of various SPS parameters (sintering temperature, dwell duration and heating rate)on the densification and grain growth of the powders, and secondly to perform a formalsintering analysis, in order to help formulate a hypothesis concerning the mechanism(s) whichcontrols densification and grain growth. Regard the above as the basis, cyclic SPS andtransient liquid-phase SPS are developed and fine-grained93W-5.6Ni-1.4Fe heavy alloyswith enhanced performance are prepared successfully.
Based on a detailed report on microstructure development and the local temperaturegradient in the vicinity of the pores, and by means of classical kinetics laws, the densificationand grain growth behavior are analyzed. The whole densification process can be roughlydivided into three stages. Particle rearrangement and neck formation and growth aredominating in the initial stage. The γ-(Ni, Fe) matrix phase has formed in this stage. Appliedpressure and particular “SPS effect” enhance the neck formation and growth. In theintermediate stage, dissolution-precipitation of W grains in the viscous matrix phase and Nienhanced grain boundary diffusion with viscous process (grain rotating and sliding) dominate the simultaneous densification and grain growth. During the final stage, grain growthpredominates and densification stagnates. The grain growth is controlled through both the gasphase diffusion and dissolution-precipitation mechanisms. Heating rate strongly influencedthe SPS densification and grain growth of93W-5.6Ni-1.4Fe heavy alloys. Higher heating rateincreases the viscous flow contribution to the densification, as well as the densification rate,resulting in an enhanced densification behavior at the SPS final stage. At the same time,coarsening induced by surface diffusion is minimized, and then grain growth is suppressed.
Two master sintering curves (MSC) in different heating rate stage of93W-5.6Ni-1.4Feheavy alloys during SPS process are developed. The master sintering curve in low heating ratestage can accurately predict the densification behavior of93W-5.6Ni-1.4Fe heavy alloysduring SPS process, as well as the shrinkage and final density. In the high heating rate stage,the developed MSC is difficult in prediction of the final density of93W-5.6Ni-1.4Fe heavyalloys, resulting from the increase of macroscopic temperature difference. However, it can beused to predict the densification behavior of93W-5.6Ni-1.4Fe heavy alloys.
Fine-grained93W-5.6Ni-1.4Fe heavy alloys are prepared by cyclic spark plasmasintering. Cyclic SPS at1400oC improves the tungsten grain morphology and the matrixdistribution, as well as the cohesion of tungsten-matrix interface, resulting in reduced W-Wcontiguities and enhanced performance of the alloys. The bending fracture is mainlycharacterized as tungsten-tungsten intergranular rupture, increased tungsten cleavage andmatrix rupture. Moreover, micro matrix ductile tearing and W-matrix separation at the W-Wseparated interfaces prevent the crack extension. Quasi-static compression yield strength atroom temperature of the93W-5.6Ni-1.4Fe heavy alloys is dependent on the microstructuralparameters such as tungsten grain size, matrix volume fraction and tungsten-tungstencontiguity. Dynamic mechanical behavior of the alloys is improved. Shear deformation zonealong the maximum shear stress plane is about30μm. However, the limited improvement ofthe tungsten grain morphology by Cyclic SPS weakens the deformation compatibility oftungsten grains within the shear deformation zone, and then the depth of the adiabatic shearband under high strain rate.
Finer spherical tungsten grains (about6μm in diameter) were obtained by control of theSPS process (transient liquid-phase SPS). After SPS, the alloy shows a relative density of0.95 and tungsten-tungsten contiguity of0.53. Compared with conventional liquid-phase sinteredtungsten heavy alloys, transient liquid-phase SP-sintered93W-5.6Ni-1.4Fe heavy alloysexhibit high bending strength (about1580MPa), and high yield strength (about1050MPa atroom temperature and about640MPa at800oC), due to the fine-grained structure. SPS offersan additional strengthening effect on the yield strength of the93W-5.6Ni-1.4Fe heavy alloys.The dynamic performance of transient liquid-phase SP-sintered93W-5.6Ni-1.4Fe heavyalloys is improved. The width of local adiabatic shear band decreases with the tungsten grainsize, whereas the depth of local adiabatic shear band increases with the decrease of tungstengrain size. Therefore, spherical tungsten grain refinement is beneficial for the formation andextension of local adiabatic shear band, as well as the self sharpening behavior duringpenetration.
本文以93W-5.6Ni-1.4Fe元素混合粉末为原始材料，采用放电等离子烧结技术将其致密化，系统地研究了其烧结过程中的致密化与晶粒长大机制。以此为依据，开发了放电等离子循环烧结和瞬时液相烧结两种新的烧结工艺，最终获得了高性能细晶93W-5.6Ni-1.4Fe高比重合金。
根据经典的烧结动力学、微观组织演变规律以及脉冲电场下粉末孔隙处的局部温度梯度，93W-5.6Ni-1.4Fe粉末的SPS过程可以划为三个阶段：SPS初期，主要为颗粒重排与烧结颈形成和长大，镍铁通过扩散形成γ-(Ni, Fe)固溶体，外加压应力和特有的“SPS效应”促进烧结颈形成和长大；SPS中期，粘性流动（W晶粒转动与滑移）辅助下的W在粘结相中的溶解－再沉析和W晶界扩散共同主导致密化与晶粒长大；SPS后期，致密化停滞而W晶粒迅速长大，其机制为气相扩散与溶解－再沉析。加热速率对93W-5.6Ni-1.4Fe粉末的SPS致密化和晶粒长大行为影响很大。提高加热速率可以增强粘性流动作用，增加粉末的致密化速率，促进粉末SPS后期的致密化并最小化表面扩散进而抑制钨晶粒长大。
建立了两个不同加热速率阶段93W-5.6Ni-1.4Fe合金的放电等离子烧结MSC曲线。低加热速率阶段的MSC曲线可以准确预测93W-5.6Ni-1.4Fe粉末放电等离子烧结全过程的致密化行为，以及粉末压坯的收缩量和合金最终烧结密度。当加热速率过高时，由于宏观温差增大，其MSC曲线在预测合金的烧结密度上存在困难，但是仍能有效预测粉末的致密化趋势。
采用放电等离子循环烧结制备了细晶93W-5.6Ni-1.4Fe高比重合金（钨晶粒尺寸小于9μm）。1400oC循环烧结有效改善了合金的钨晶粒形态、粘结相分布以及钨－粘结相界面的内聚力，降低了W-W连接度，合金的力学性能显著提高，具体表现为合金弯曲断裂后，钨晶粒解理断裂与粘结相撕裂增多，且在W-W分离界面上存在许多微区粘结相延性撕裂与钨－粘结相界面分离，有效阻止了裂纹的扩展。合金准静态室温压缩屈服强度与其微观组织，如钨晶粒大小、粘结相体积分数以及W-W连接度有关；其动态力学行为有明显改善，沿最大剪切应力平面存在约30μm的剪切变形区，但是循环烧结对钨晶粒形状的改善有限，削弱了其高应变速率下剪切变形区内钨晶粒的变形协调性，因此其绝热剪切带深度有限。
通过有效控制SPS工艺（放电等离子瞬时液相烧结），制备了钨晶粒细小（钨晶粒尺寸约6μm）且呈球状的93W-5.6Ni-1.4Fe合金，其相对密度约为0.95，W-W连接度为0.53。与传统的液相烧结钨基高比重合金相比，放电等离子瞬时液相烧结合金的力学性能有明显提高，具体表现为准静态加载条件下具有高弯曲强度（约1580MPa）和高屈服强度（室温下约1050MPa和800oC高温下约640MPa），SPS改善了合金的界面性能，对屈服强度提供了一个额外的强化作用；动态加载条件下随着钨晶粒尺寸的减小，局部绝热剪切带变窄且扩展深度增加。细化球状钨晶粒有利于局部绝热剪切带的形成与扩展，提高穿甲侵彻过程的自锐化效应。
W-Ni-Fe heavy alloys are typical two phases composites used in the applicationsrequiring high density, such as counter weights, kinetic energy penetrators and radiationshields. Conventional liquid-phase sintered W-Ni-Fe alloys manifest a typical microstructurewhere coarsened spherical bcc tungsten grains are dispersed in a fcc Ni-Fe-W solid solutionmatrix. Further improvement of the mechanical properties is restricted. The performance isimproved to some extent after deformation. However，taken the material utilization, cost anddeformation degree, etc, into account, their expanded application in civilian and military fieldare confined. Tungsten grain refinment is proved to be the most effective approach to improvethe mechanical properties. The strength, hardness, toughness and other performances of thealloy will be improved with the decrease of tungsten grain size. For industrial applicationsand academic research, thus, it is of great interest to develop fine-grained W-Ni-Fe alloyswith high performance to meet the advanced requirements.
The aims of this study are, first, to use the spark plasma sintering (SPS) method toprepare bulk93W-5.6Ni-1.4Fe heavy alloys from blended elemental powders and study theinfluence of various SPS parameters (sintering temperature, dwell duration and heating rate)on the densification and grain growth of the powders, and secondly to perform a formalsintering analysis, in order to help formulate a hypothesis concerning the mechanism(s) whichcontrols densification and grain growth. Regard the above as the basis, cyclic SPS andtransient liquid-phase SPS are developed and fine-grained93W-5.6Ni-1.4Fe heavy alloyswith enhanced performance are prepared successfully.
Based on a detailed report on microstructure development and the local temperaturegradient in the vicinity of the pores, and by means of classical kinetics laws, the densificationand grain growth behavior are analyzed. The whole densification process can be roughlydivided into three stages. Particle rearrangement and neck formation and growth aredominating in the initial stage. The γ-(Ni, Fe) matrix phase has formed in this stage. Appliedpressure and particular “SPS effect” enhance the neck formation and growth. In theintermediate stage, dissolution-precipitation of W grains in the viscous matrix phase and Nienhanced grain boundary diffusion with viscous process (grain rotating and sliding) dominate the simultaneous densification and grain growth. During the final stage, grain growthpredominates and densification stagnates. The grain growth is controlled through both the gasphase diffusion and dissolution-precipitation mechanisms. Heating rate strongly influencedthe SPS densification and grain growth of93W-5.6Ni-1.4Fe heavy alloys. Higher heating rateincreases the viscous flow contribution to the densification, as well as the densification rate,resulting in an enhanced densification behavior at the SPS final stage. At the same time,coarsening induced by surface diffusion is minimized, and then grain growth is suppressed.
Two master sintering curves (MSC) in different heating rate stage of93W-5.6Ni-1.4Feheavy alloys during SPS process are developed. The master sintering curve in low heating ratestage can accurately predict the densification behavior of93W-5.6Ni-1.4Fe heavy alloysduring SPS process, as well as the shrinkage and final density. In the high heating rate stage,the developed MSC is difficult in prediction of the final density of93W-5.6Ni-1.4Fe heavyalloys, resulting from the increase of macroscopic temperature difference. However, it can beused to predict the densification behavior of93W-5.6Ni-1.4Fe heavy alloys.
Fine-grained93W-5.6Ni-1.4Fe heavy alloys are prepared by cyclic spark plasmasintering. Cyclic SPS at1400oC improves the tungsten grain morphology and the matrixdistribution, as well as the cohesion of tungsten-matrix interface, resulting in reduced W-Wcontiguities and enhanced performance of the alloys. The bending fracture is mainlycharacterized as tungsten-tungsten intergranular rupture, increased tungsten cleavage andmatrix rupture. Moreover, micro matrix ductile tearing and W-matrix separation at the W-Wseparated interfaces prevent the crack extension. Quasi-static compression yield strength atroom temperature of the93W-5.6Ni-1.4Fe heavy alloys is dependent on the microstructuralparameters such as tungsten grain size, matrix volume fraction and tungsten-tungstencontiguity. Dynamic mechanical behavior of the alloys is improved. Shear deformation zonealong the maximum shear stress plane is about30μm. However, the limited improvement ofthe tungsten grain morphology by Cyclic SPS weakens the deformation compatibility oftungsten grains within the shear deformation zone, and then the depth of the adiabatic shearband under high strain rate.
Finer spherical tungsten grains (about6μm in diameter) were obtained by control of theSPS process (transient liquid-phase SPS). After SPS, the alloy shows a relative density of0.95 and tungsten-tungsten contiguity of0.53. Compared with conventional liquid-phase sinteredtungsten heavy alloys, transient liquid-phase SP-sintered93W-5.6Ni-1.4Fe heavy alloysexhibit high bending strength (about1580MPa), and high yield strength (about1050MPa atroom temperature and about640MPa at800oC), due to the fine-grained structure. SPS offersan additional strengthening effect on the yield strength of the93W-5.6Ni-1.4Fe heavy alloys.The dynamic performance of transient liquid-phase SP-sintered93W-5.6Ni-1.4Fe heavyalloys is improved. The width of local adiabatic shear band decreases with the tungsten grainsize, whereas the depth of local adiabatic shear band increases with the decrease of tungstengrain size. Therefore, spherical tungsten grain refinement is beneficial for the formation andextension of local adiabatic shear band, as well as the self sharpening behavior duringpenetration.
引文
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