摘要
可控多孔结构因其具有质量轻、高耐蚀、高熔点、高疲劳和高塑性等优点被广泛用于航空航天领域和生物医学领域。针对常规方法难以制备的Ti6Al4V可控多孔结构，本文采用激光选区熔化技术制备该可控多孔结构并对其成型机理进行研究。机理分析中建立了激光选区熔化Ti6Al4V可控多孔结构温度场模型，系统研究了Ti6Al4V可控多孔结构成型参数优化，着重研究了Ti6Al4V可控多孔结构作为功能材料的表面粗糙度计算模型和作为结构材料的承载能力计算模型。
论文的主要内容及结果如下：
1.建立激光选区熔化Ti6Al4V可控多孔结构温度场模型，考虑了等离子体的逆轫致辐射效应对温度场的影响，得到了等离子体作用下熔池吸收激光能量的表达式；分析了激光加热作用下粉末不同物相对激光吸收率的影响，提出了粉末随时间变化的动态吸收率公式；研究了熔池流动对温度的影响，修正了流体方程中的冯卡门解，使得该解适合金属液体计算；阐述了粉末升华对气—液—固界面迁移的影响，得到了气—液—固界面迁移公式；揭示了温度对粉末热物性的影响，获得了热物性参数与温度之间的对应关系。结果表明，所建立的温度场模型与实际情况基本吻合，满足一定实际要求。
2.优化了激光选区熔化Ti6Al4V可控多孔结构的工艺参数。以田口实验为基础，建立成型参数与致密度之间的回归模型，通过Design-Expert软件得到最佳工艺参数。检测了采用最佳工艺参数成型零件的组织和性能。结果表明影响致密度的成型参数是线能量密度（激光功率/扫描速度），层厚，扫描策略和线间距，其中线间距、扫描策略与致密度呈反比，线能量与致密度呈正比；所有参数中层厚对致密度的影响最为显著。
3.研究了激光选区熔化Ti6Al4V可控多孔结构支杆的表面粗糙度的影响因素。以单熔道形貌为基础，建立了激光选区熔化Ti6Al4V可控多孔结构支杆表面粗糙度的计算公式。以实际成型零件表面粗糙度为基准，修正了激光选区熔化Ti6Al4V可控多孔结构支杆表面粗糙度计算公式，分析了影响表面粗糙度的主要因素。阐述了提高激光选区熔化成型零件表面粗糙度的方法。研究结果表明，激光选区熔化加工中单熔道形貌近似圆形曲线；采用轮廓最小二乘中线法计算与实际情况最为接近，单熔道宽度和搭接宽度与Ra、Rz和Rsm呈正比；电化学抛光等后续处理手段可大大提高激光选区熔化成型零件的表面粗糙度。
4.制备了正六面体和正八面体可控多孔结构。研究了正八面和正六面单元体及其组成的可控多孔结构的最大承载能力与形变位移的关系。建立了单元体及其组成的可控多孔结构承载能力和形变位移的计算简化模型，用该模型得到了单元体和由其组成的可控多孔结构断裂载荷和最大形变位移的解析公式并进行理论计算。通过压缩实验得到单元体及其组成的可控多孔结构的实际断裂载荷和实际形变位移。实验结果表明，Ti6Al4V单元体及其组成的可控多孔结构的实际断裂载荷和实际形变位移理论计算值与实验数值相吻合。本文所给出的断裂载荷和形变位移计算公式具有实际应用价值。
5.研究表明，优化后的成型参数是：激光功率：80W，扫描速度：200mm/s，层厚：0.02mm，扫描策略：正交层错，线间距：0.06mm；成型零件的组织主要由针状马氏体、α相和β相组成。其中初生α相晶粒细小，尺寸为0.5-1.5μm。晶粒的生长方向沿热流密度方向和最接近<100>方向择优生长，显微硬度平均值为492.56HV0.2，最大拉伸强度是987MP，试样的加工方向对试样的拉伸强度有较大影响。成型零件的表面粗糙度是：Ra=7.54μm，Rz=52.26μm，Rsm=187.39μm。正八面单元体最大承载力是218.10N，最大形变位移是0.1570mm，由正八面单元体组成的可控多孔结构最大承载力是21990.7N。正六面单元体最大承载力是612.6N，最大形变位移是0.6895mm，由正六面单元体组织的可控多孔结构最大承载力是1789.9N，最大形变位移是0.3917mm。
Controllable porous structure, possessing merits of light weight, high corrosion resistance, high melting point, high fatigue strength and plasticity, etc., has been widely applied in the fields of aerospace and biomedicine. This article uses Selective Laser Melting (SLM) technology to form the Ti6A14V controlled porous structure which is difficult to form with the conventional method, and then studies its forming mechanism. The mechanism analysis in this paper, which builds the temperature field model of Ti6A14V controlled porous structure processed by SLM, systematic studies the forming parameters optimization of Ti6A14V controlled porous structure, mainly focuses on the surface roughness calculation model of the Ti6A14V controllable porous structure as a functional material, and the bearing capability calculation model of it as a structural material.
The main content and the results of the paper are as follows:
1. The experiment in this paper establishes the temperature field model of Ti6A14V controlled porous structure processed by SLM; obtains the expression of laser energy absorption by molten pool with consideration of the influence of the plasma inverse bremsstrahlung on temperature field; analyzes the influence of different phases of powder on the laser absorption rate with laser heating, and so as to put forwards the dynamic absorption rate equation that the powder changes with the time; adjusts the Von Carmen solution of liquid equation to fit the metal liquid calculation by researching the influence of the flow of molten pool on temperature; obtains the formula of migration of gas liquid-solid interface while expounding the influence of powder sublimation on the migration of gas-liquid-solid interface; moreover, obtains the corresponding relationship between the parameters of thermal properties and the temperature through revealing the influence of temperature on the powder thermal properties. To conclude, the temperature field model, close to actual situation, meets actual requirements.
2. The technological parameters of SLM Ti6A14V controllable porous structure are optimized through Design-Expert software by building the regression model of forming parameters and density on the basis of Taguchi experiment. It proved, through tests of the microstructure and function of parts manufactured with the optimum technological parameters, that the forming parameters affecting the density are linear energy density ((laser power/scanning speed), thickness, scanning strategy and hatching space, in which the hatching space and scanning strategy are inversely proportional to the density; while the linear energy density is direct proportional to the density; moreover, the thickness has the most significant effect on the density among all these parameters.
3. This paper also studies the influencing factors of surface roughness of SLM Ti6A14V controllable porous structure strut; establishes the calculating formula of it on the basis of single track; then revises this formula with the surface roughness of actual forming parts as criterion so as to analyzes the main factors which affects the strut's roughness; expounds the methods to improve the strut's surface roughness. And the results show that the morphology of single track in SLM processing approximates circular curve; and the calculated results obtained through least square midline method is closest to the actual situation; the width and lap width of single track are direct proportional to Ra、Rz and Rsm; and the post-processing methods such as electrochemical polishing can greatly improve the surface roughness of the parts formed by SLM.
4. The controllable porous structures of hexahedron and octahedron are manufactured. The relationships between maximum bearing capacity and deformation displacement of hexahedral units, octahedral units and controllable porous structures are researched; the analytic formulas of bearing capacity and deformation displacement of these structures are acquired with the building of their simplified models, with which realizes theoretical calculation of Ti6A14V materials. The actual fracturing load and deformation displacement of units and controllable porous structures are obtained via compression test, which are proved that are close to theoretical ones. Therefore it is safe to draw the conclusion that the fracturing load and deformation displacement formula given in this paper has practical application value.
5. The studies show that the optimum parameters are:laser power-80W; scanning speed200mm/s; the thickness-0.02mm; scanning strategy-X-Y inter-layer stagger scanning; and hatching space-0.08mm. The microstructure of formed part is mainly composed of acicular martensite, a phase and β phase, in which the grains of primary a phase are fine with the size of0.5-1.5μm. The preferred orientation of primary phase a is along the maximum heat flux direction and the direction closest to<100>. The microhardness is492.56HV0.2; and maximum tensile strength, which is significantly affected by the processing direction, is987MP. The surface roughness of the formed parts are Ra=7.54μm;Rz=52.26μm;RSm=187.39μm. As for octahedral unit, its maximum bearing capacity is218.ION and maximum deformation displacement is0.1570mm; maximum bearing capacity of controllable porous structure composed by it is21990.7N. However, as for hexahedral unit, its maximum bearing capacity is612.6N and maximum of deformation displacement0.6895mm; and the maximum bearing capacity and maximum deformation displacement of controllable porous structure composed by it are1789.9N and0.3917mm respectively.
引文
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