CN116673472A - Composite aluminum alloy powder and large-scale preparation method and application thereof - Google Patents
Composite aluminum alloy powder and large-scale preparation method and application thereof Download PDFInfo
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- CN116673472A CN116673472A CN202310794813.1A CN202310794813A CN116673472A CN 116673472 A CN116673472 A CN 116673472A CN 202310794813 A CN202310794813 A CN 202310794813A CN 116673472 A CN116673472 A CN 116673472A
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- 239000000843 powder Substances 0.000 title claims abstract description 222
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 150
- 239000002131 composite material Substances 0.000 title claims abstract description 58
- 238000002360 preparation method Methods 0.000 title claims abstract description 12
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims abstract description 59
- 238000004519 manufacturing process Methods 0.000 claims abstract description 42
- 238000002156 mixing Methods 0.000 claims abstract description 40
- 239000000654 additive Substances 0.000 claims abstract description 36
- 230000000996 additive effect Effects 0.000 claims abstract description 36
- 239000002245 particle Substances 0.000 claims abstract description 27
- 238000000034 method Methods 0.000 claims abstract description 26
- 238000000151 deposition Methods 0.000 claims description 23
- 230000008021 deposition Effects 0.000 claims description 23
- 238000000465 moulding Methods 0.000 claims description 20
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 12
- 238000002844 melting Methods 0.000 claims description 11
- 230000008018 melting Effects 0.000 claims description 11
- 238000007711 solidification Methods 0.000 claims description 11
- 230000008023 solidification Effects 0.000 claims description 11
- 230000004927 fusion Effects 0.000 claims description 9
- 238000011031 large-scale manufacturing process Methods 0.000 claims description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 6
- 238000009826 distribution Methods 0.000 claims description 6
- 229910052757 nitrogen Inorganic materials 0.000 claims description 6
- 210000001787 dendrite Anatomy 0.000 claims description 5
- 239000012535 impurity Substances 0.000 claims description 5
- 230000001681 protective effect Effects 0.000 claims description 5
- 229910052786 argon Inorganic materials 0.000 claims description 3
- 229910001250 2024 aluminium alloy Inorganic materials 0.000 claims description 2
- 238000003860 storage Methods 0.000 abstract description 5
- 150000001875 compounds Chemical class 0.000 abstract 1
- 238000000280 densification Methods 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 19
- 239000000047 product Substances 0.000 description 19
- 229910045601 alloy Inorganic materials 0.000 description 15
- 239000000956 alloy Substances 0.000 description 15
- 229910052751 metal Inorganic materials 0.000 description 10
- 239000002184 metal Substances 0.000 description 10
- 230000000052 comparative effect Effects 0.000 description 9
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- 239000012467 final product Substances 0.000 description 4
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- 238000005516 engineering process Methods 0.000 description 3
- 238000009776 industrial production Methods 0.000 description 3
- 239000011229 interlayer Substances 0.000 description 3
- 238000007639 printing Methods 0.000 description 3
- 238000011160 research Methods 0.000 description 3
- 238000001878 scanning electron micrograph Methods 0.000 description 3
- 229910021364 Al-Si alloy Inorganic materials 0.000 description 2
- 229910000789 Aluminium-silicon alloy Inorganic materials 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 238000001465 metallisation Methods 0.000 description 2
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- 229910018520 Al—Si Inorganic materials 0.000 description 1
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- 239000011825 aerospace material Substances 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
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- 238000010923 batch production Methods 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
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- 239000007789 gas Substances 0.000 description 1
- 238000009689 gas atomisation Methods 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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Classifications
-
- 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
- B22F1/12—Metallic powder containing non-metallic particles
-
- 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
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- 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
-
- 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
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Powder Metallurgy (AREA)
Abstract
The invention provides composite aluminum alloy powder, a large-scale preparation method and application thereof, wherein the composite aluminum alloy powder comprises aluminum alloy powder and boron powder loaded on the surface of the aluminum alloy powder; the aluminum alloy powder is micron-sized powder; the mass ratio of the powder with the particle diameter smaller than 1 μm in the boron powder is more than or equal to 90 percent. The large-scale preparation method comprises the following steps: and mixing the aluminum alloy powder and the boron powder by a mixer to obtain the composite aluminum alloy powder. The composite aluminum alloy powder can be produced in a large scale, the boron powder and the aluminum alloy powder are not easy to separate in the storage and transportation process, an aluminum alloy powder source can be well provided for laser additive manufacturing, and the compound use of the aluminum alloy powder and the boron powder can effectively inhibit hot tearing in the laser additive manufacturing process, so that densification and excellent mechanical properties are finally realized.
Description
Technical Field
The invention relates to the technical field of aluminum alloy powder, in particular to composite aluminum alloy powder, and a large-scale preparation method and application thereof.
Background
The aluminum alloy has a series of excellent properties such as low density, high specific stiffness and specific strength, high plasticity, strong corrosion resistance, good electric conduction and heat conduction properties, no toxicity, environmental friendliness and recycling, and thus, the aluminum alloy has increasingly wide application in the fields of aerospace, transportation, ships or chemical industry and the like. For example, aluminum materials are used in aerospace vehicles in amounts of 70% of their own weight, and in high speed rail vehicles in amounts of more than 85% of their own weight.
However, for high-strength aluminum alloy parts with complex geometric shapes, the processing of the high-strength aluminum alloy parts by using the traditional material reduction manufacturing method faces the problems of long process flow, difficulty in processing and forming and the like. The complexity of the part geometry directly leads to the complexity of the process flow and the processing costs rise substantially accordingly.
Laser additive manufacturing is a near net shape production method in which a focused laser beam is scanned in a preprogrammed pattern to melt a metal or alloy feedstock and produce a desired geometry during laser additive manufacturing of a metallic material. Due to the characteristic of layer-by-layer printing of the laser additive manufacturing technology, three-dimensional parts with highly complex geometric characteristics can be produced at one time theoretically, and the process flow is greatly simplified. In addition, laser additive manufacturing can achieve part integration, namely, through designing and manufacturing parts with more complex topological structures, production cost and part fault risk can be reduced, and performance of the parts is also improved remarkably. Therefore, the integrated forming of the light and high-strength aluminum alloy complex structural member with excellent mechanical properties is realized by the laser additive manufacturing method, and the integrated forming has very broad market prospect in the key fields of aerospace, automobiles, ships and the like.
Laser additive manufacturing involves two broad categories of techniques, laser powder bed melting and laser directed energy deposition. The laser powder bed melting technology uses laser beams as energy sources, scans the metal or alloy powder bed layer by layer according to a planned path in the three-dimensional section model, and finally obtains the metal part designed by the model through melting and solidification of the scanned metal or alloy powder to reach a metallurgical bonding state. Laser directed energy deposition takes a laser beam as an energy source to melt synchronously supplied metal or alloy powder to achieve one-time molding of complex parts.
The laser additive manufacturing process has complex thermal cycle and serious thermal stress, and is easy to cause thermal cracking. There are only a few Al-Si based cast aluminum alloys (e.g. AlSi 10 Mg，AlSi 12 ) Compatible with laser additive manufacturing processes, the near eutectic composition of these cast aluminum alloys allows them to have a narrower solidification temperature range during solidification, which is beneficial for reducing crack sensitivity.
However, cast aluminum alloys such as al—si alloys cannot compete with wrought aluminum alloys having higher strength, and wrought aluminum alloys (e.g., 2xxx, 6xxx, 7xxx wrought aluminum alloys) precipitate a precipitation strengthening phase during aging, with yield strengths up to 400MPa and elongations up to 10% as compared to cast aluminum alloys such as al—si alloys, which are typical aerospace materials. However, these precipitation hardening wrought aluminum alloys are poorly compatible with laser additive manufacturing processes, exhibiting a severe tendency to thermally crack, the root cause of which is: the unstable supercooled state of the solidification interface and the larger solidification interval and temperature gradient induce columnar crystal formation, and shrinkage in the later stage of solidification causes holes and thermal cracks. In particular, when large-sized, complex-shaped aluminum alloy parts are printed using laser additive manufacturing methods, more complex thermal stress cycles and more severe cracking phenomena are encountered.
Therefore, it is necessary to develop high-performance aluminum alloy powder suitable for laser additive manufacturing, in particular for industrial laser additive manufacturing, and a large-scale preparation method thereof, which are important for accelerating the application of the laser additive manufacturing of high-performance and complex aluminum alloy parts in the key fields of aerospace and the like.
Disclosure of Invention
In view of the problems in the prior art, the invention provides composite aluminum alloy powder, a large-scale preparation method and application thereof, and solves the problem that hot tearing occurs in the final laser additive manufacturing process due to uneven powder mixing in the industrialized mixing process of boron powder and aluminum alloy powder.
To achieve the purpose, the invention adopts the following technical scheme:
in a first aspect, the present invention provides a composite aluminum alloy powder comprising an aluminum alloy powder and a boron powder supported on the surface of the aluminum alloy powder; the aluminum alloy powder is micron-sized powder; the mass ratio of the powder with the particle diameter smaller than 1 μm in the boron powder is more than or equal to 90 percent.
In order to avoid hot tearing of the high-strength aluminum alloy powder in the additive manufacturing process, boron powder and aluminum alloy powder are mixed, so that the printability of the aluminum alloy powder is improved. However, the aluminum alloy powder and the boron powder are difficult to mix uniformly in the industrial production process, simple mixing is difficult due to the density and chemical property difference of the aluminum alloy powder and the boron powder, and when the aluminum alloy powder and the boron powder are not uniformly mixed, the problem of local hot tearing still easily occurs in the subsequent additive manufacturing process. According to the invention, the uniform dispersion and storage of the aluminum alloy powder and the boron powder are difficult to realize by simply relying on simple mixing, and the unexpected finding that when the aluminum alloy powder is limited to be micron-sized powder and the mass ratio of the powder with the particle size smaller than 1 mu m in the boron powder is more than or equal to 90%, the boron powder is adsorbed on the surface of the aluminum alloy powder in the mixing process, so that a composite aluminum alloy powder structure with the boron powder adsorbed on the surface of the micron-sized aluminum alloy powder is formed, and the formation of the structure ensures that the boron powder and the aluminum alloy powder are difficult to be unevenly distributed due to the influence of gravity in the storage and transportation process, and the composition uniformity of the composite aluminum alloy powder is maintained.
The boron powder according to the invention is preferably of particle size less than 1 μm, but allows the presence of boron powder >1 μm. Thus, the mass ratio of the powder having a particle diameter of < 1 μm in the boron powder is defined to be 90% or more, and may be 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% or 100% or the like, for example.
Preferably, the particle size distribution of the aluminum alloy powder is not less than 90% in a ratio of 10 to 200. Mu.m, and may be 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% or 100% or the like.
The invention further preferably has the particle size distribution of the aluminum alloy powder with the ratio of more than or equal to 90 percent of 10-200 mu m, which is more beneficial to meeting the particle size demand in the subsequent additive manufacturing on one hand, and is more beneficial to compounding with the boron powder with the specific particle size defined by the invention on the other hand, thereby improving the printability of the final composite aluminum alloy powder.
Preferably, the maximum particle diameter of the boron powder is not more than 2. Mu.m, for example, 2. Mu.m, 1.8. Mu.m, 1.7. Mu.m, 1.5. Mu.m, 1.0. Mu.m, etc. The invention further prefers that the maximum grain diameter is less than or equal to 2 mu m, and the large-grain boron powder is more difficult to be adsorbed on the surface of the aluminum alloy powder stably for a long time due to the action of gravity, so that the maximum grain diameter is less than or equal to 2 mu m, the component distribution is more favorable to be uniform, and the industrialized powder mixing is more uniform.
Preferably, the mass ratio of the powder with the particle size smaller than 1 μm in the boron powder is 100%. This definition can further improve the uniformity of the composite aluminum alloy powder.
Preferably, the mass ratio of the boron powder in the composite aluminum alloy powder is 0.1-5 wt%, for example, 0.1wt%, 0.2wt%, 0.3wt%, 0.5wt%, 0.8wt%, 1wt%, 2wt%, 3wt%, 4wt%, 5wt%, or the like, and preferably 0.5-2 wt%.
The action mechanism of the boron powder in the invention is as follows: the introduction of boron promotes the formation of fine equiaxed crystals in the laser additive manufacturing process, is favorable for coordinating the grain boundary strain and inhibiting hot tearing; when the content of the boron powder is too low, the equiaxed crystal forming capability is insufficient, and the along-crystal hot cracking still exists; when the content of boron powder is too high, the material is obviously embrittled.
Preferably, the boron powder is adsorbed on the surface of the aluminum alloy powder.
Preferably, the aluminum alloy powder is 2024 aluminum alloy powder.
The aluminum alloy powder is preferably solid, hollow or coexistent. The aluminum alloy powder can be prepared by a powder method common in any additive manufacturing field such as rotary electrode atomization, gas atomization, water atomization and the like, and can also be prepared by a common secondary processing method such as ball milling and the like.
Preferably, the aluminum alloy powder comprises the following components in percentage by mass: cu:3.8 to 4.9 weight percent; mg:1.2 to 1.8 weight percent; mn:0.3 to 0.9 weight percent; si <0.5wt%; fe <0.5wt%; cr <0.1wt%; zn <0.25wt%; ti <0.15wt%, the balance Al and unavoidable impurities.
The aluminum alloy powder comprises the following components in percentage by mass: cu:3.8 to 4.9wt%, for example, 3.8wt%, 4wt%, 4.1wt%, 4.2wt%, 4.3wt%, 4.5wt%, 4.6wt%, 4.7wt%, 4.8wt% or 4.9wt% and the like may be used, but the present invention is not limited to the recited values, and other values not recited in the range are equally applicable.
Mg:1.2 to 1.8wt%, for example, 1.2wt%, 1.27wt%, 1.34wt%, 1.4wt%, 1.47wt%, 1.54wt%, 1.6wt%, 1.67wt%, 1.74wt% or 1.8wt% may be used, but not limited to the values recited, and other values not recited in the range are equally applicable.
Mn:0.3 to 0.9wt%, for example, 0.3wt%, 0.37wt%, 0.44wt%, 0.5wt%, 0.57wt%, 0.64wt%, 0.7wt%, 0.77wt%, 0.84wt% or 0.9wt% may be used, but the present invention is not limited to the values recited, and other values not recited in the range are equally applicable.
Si <0.5wt%, for example, 0wt%, 0.1wt%, 0.15wt%, 0.19wt%, 0.23wt%, 0.28wt%, 0.32wt%, 0.36wt%, 0.41wt%, 0.45wt%, or 0.49wt%, etc., but not limited to the recited values, other non-recited values within this range are equally applicable.
Fe <0.5wt%, for example, may be 0wt%, 0.1wt%, 0.15wt%, 0.19wt%, 0.23wt%, 0.28wt%, 0.32wt%, 0.36wt%, 0.41wt%, 0.45wt%, or 0.49wt%, etc., but is not limited to the recited values, and other non-recited values within this range are equally applicable.
Cr <0.1wt%, for example, 0wt%, 0.01wt%, 0.02wt%, 0.03wt%, 0.04wt%, 0.05wt%, 0.06wt%, 0.07wt%, 0.08wt% or 0.09wt%, etc., but not limited to the recited values, other non-recited values within this range are equally applicable.
Zn <0.25wt%, for example, 0wt%, 0.01wt%, 0.04wt%, 0.07wt%, 0.09wt%, 0.12wt%, 0.15wt%, 0.17wt%, 0.2wt%, 0.23wt% or 0.24wt% etc., but not limited to the recited values, other non-recited values within this range are equally applicable.
The Ti content is less than 0.15wt%, for example, 0wt%, 0.01wt%, 0.03wt%, 0.05wt%, 0.06wt%, 0.08wt%, 0.09wt%, 0.11wt%, 0.12wt%, or 0.14wt%, etc., but the present invention is not limited to the above-mentioned values, and other values not mentioned in the above range are equally applicable.
Preferably, the surface of the aluminum alloy powder has dendrite solidification morphology.
Preferably, the specific surface area of the aluminum alloy powder is 80-100 m 2 Kg may be 80m, for example 2 /kg、82m 2 /kg、85m 2 /kg、89m 2 /kg、90m 2 /kg、92m 2 /kg、95m 2 /kg or 100m 2 For example,/kg, etc., but are not limited to the recited values, other values not recited in this range are equally applicable.
As described above, the key point of the present invention is that the problem of mixing uniformity of aluminum alloy powder and boron powder is easy to occur in the process of industrial production, storage and transportation, or the problem of non-uniform mixing during the mixing process, and research shows that when the specific surface area of the aluminum alloy powder is controlled in the above range, the adsorption of the aluminum alloy powder to the boron powder is facilitated, and the aluminum alloy powder and the boron powder are not in a simple material stacking relationship, but form an adsorption force, thereby improving the performance of the industrial production product.
In a second aspect, the present invention provides a method for preparing the composite aluminum alloy powder according to the first aspect on a large scale, the method comprising: and mixing the aluminum alloy powder and the boron powder by a mixer to obtain the composite aluminum alloy powder.
At present, most of related researches are concentrated in laboratories, and laboratory-level powder mixing modes have larger differences from large-scale and batch powder mixing, so that the research and solving of how to overcome the powder mixing non-uniformity in the large-scale and batch powder mixing process and realize batch production so as to be suitable for industrial-level laser additive manufacturing requirements are needed.
Preferably, the mixer is a double cone mixer.
Preferably, the mixing is performed in a protective atmosphere. It is necessary to perform a purging operation with a protective gas such as nitrogen or argon, and to remove air from the apparatus to prevent oxidation of the composite aluminum alloy powder.
Preferably, the protective atmosphere comprises argon and/or nitrogen.
Preferably, the rotation speed of the mixture is 5-100 r/min, for example, 5r/min, 16r/min, 27r/min, 37r/min, 48r/min, 58r/min, 69r/min, 79r/min, 90r/min or 100r/min, etc., but the rotation speed is not limited to the recited values, and other non-recited values within the range are equally applicable, preferably 20-50 r/min.
Preferably, the mixing time is 0.5 to 10 hours, for example, 0.5 hours, 1.6 hours, 2.7 hours, 3.7 hours, 4.8 hours, 5.8 hours, 6.9 hours, 7.9 hours, 9 hours or 10 hours, etc., but not limited to the recited values, other non-recited values within the range are equally applicable, preferably 0.5 to 2 hours.
The invention has low mixing speed and short mixing time, and greatly reduces the energy consumption of mixing powder.
In a third aspect, the present invention provides a use of the composite aluminium alloy powder according to the first aspect in laser additive manufacturing.
The laser additive manufacturing method can comprise any process for manufacturing solid parts by using laser beams as heat sources and using metal or alloy powder as a carrier through layer-by-layer accumulation of materials, such as laser powder bed melting or laser directed energy deposition.
In the invention, in concept, a laser powder bed is melted (laser powder bed fusion) by taking a laser beam as an energy source, scanning is carried out on a metal or alloy powder bed layer by layer according to a planned path in a three-dimensional section model, and the scanned metal or alloy powder is melted and solidified to reach a metallurgical bonding state, so that a metal part designed by the model is finally obtained. Since the selective laser melting (selective laser melting) and the like all adopt similar principles, the method belongs to laser powder bed melting according to the invention.
In the present invention, laser directed energy deposition (laser directed energy deposition) conceptually refers to an additive manufacturing method of melting synchronously supplied metal or alloy powder with a laser beam as an energy source. Since laser engineering near net shape (laser engineered net shaping), laser metal deposition (laser metal deposition), laser rapid prototyping (laser rapid forming) and the like all use similar principles, they are directed laser energy deposition in accordance with the present invention.
Preferably, the use of the composite aluminium alloy powder in laser powder bed fusion forming.
The particle size of the composite aluminum alloy powder in the laser powder bed melt molding is preferably 15 to 53 μm, and may be, for example, 15 μm, 20 μm, 24 μm, 28 μm, 32 μm, 37 μm, 41 μm, 45 μm, 49 μm, 53 μm, or the like, but is not limited to the recited values, and other non-recited values within the range are equally applicable.
The laser power in the laser powder bed melt molding is preferably 100 to 500W, and may be, for example, 100W, 145W, 180W, 230W, 270W, 320W, 360W, 410W, 450W, 500W, or the like, but is not limited to the values recited, and other values not recited in the range are equally applicable.
Preferably, the laser scanning rate in the laser powder bed melt molding is 200-1600 mm/s, for example, 200mm/s, 350mm/s, 510mm/s, 660mm/s, 820mm/s, 970mm/s, 1130mm/s, 1280mm/s, 1445mm/s, 1600mm/s, etc., but not limited to the recited values, and other non-recited values within this range are equally applicable.
Preferably, the line spacing in the melt molding of the laser powder bed is 50 to 200. Mu.m, for example, 50 μm, 67 μm, 84 μm, 100 μm, 117 μm, 134 μm, 150 μm, 167 μm, 184 μm or 200 μm, etc., but not limited to the values recited, and other values not recited in the range are equally applicable.
The layer thickness in the laser powder bed melt molding is preferably 20 to 40. Mu.m, for example, 20 μm, 23 μm, 25 μm, 27 μm, 29 μm, 32 μm, 34 μm, 36 μm, 38 μm or 40 μm, etc., but not limited to the values recited, and other values not recited in the range are equally applicable.
Preferably, the laser powder bed is melt-molded with a rotation angle between layers of 0 to 90 °, for example, 0 °, 10 °, 20 °, 30 °, 40 °, 50 °, 60 °, 70 °, 80 °, or 90 °, etc., but the laser powder bed is not limited to the recited values, and other non-recited values within the range are equally applicable.
Preferably, the use of the composite aluminium alloy powder in laser directed energy deposition modeling.
The particle size of the composite aluminum alloy powder in the laser directional energy deposition modeling is preferably 50 to 150 μm, and may be, for example, 50 μm, 56 μm, 62 μm, 67 μm, 73 μm, 78 μm, 84 μm, 89 μm, 95 μm, 100 μm, 108 μm, 112 μm, 117 μm, 122 μm, 127 μm, 133 μm, 138 μm, 142 μm, 147 μm, 150 μm, or the like, but is not limited to the recited values, and other values not recited in the range are equally applicable.
Preferably, the laser power in the laser directional energy deposition modeling is 200 to 700W, for example, 200W, 230W, 260W, 300W, 330W, 360W, 400W, 430W, 460W, 500W, 530W, 560W, 600W, 630W, 660W, 700W, etc., but not limited to the recited values, and other non-recited values within the range are equally applicable.
Preferably, the laser scanning rate in the laser directional energy deposition modeling is 1 to 30mm/s, for example, 1mm/s, 5mm/s, 8mm/s, 11mm/s, 14mm/s, 18mm/s, 21mm/s, 24mm/s, 27mm/s, or 30mm/s, etc., but not limited to the recited values, and other non-recited values within this range are equally applicable.
Preferably, the line spacing in the laser directed energy deposition modeling is 200-600 μm, for example, 200 μm, 245 μm, 280 μm, 330 μm, 370 μm, 420 μm, 460 μm, 515 μm, 556 μm, 600 μm, etc., but not limited to the recited values, and other non-recited values within this range are equally applicable.
The layer thickness in the laser directional energy deposition modeling is preferably 100 to 600 μm, and may be, for example, 100 μm, 138 μm, 190 μm, 250 μm, 310 μm, 360 μm, 420 μm, 480 μm, 540 μm, 600 μm, or the like, but not limited to the values recited, and other values not recited in the range are equally applicable.
Preferably, the rotation angle between the layers in the laser directional energy deposition modeling is 0 to 90 °, for example, 0 °, 10 °, 20 °, 30 °, 40 °, 50 °, 60 °, 70 °, 80 °, or 90 °, etc., but not limited to the recited values, and other non-recited values within the range are equally applicable.
Compared with the prior art, the invention has at least the following beneficial effects:
(1) The composite aluminum alloy powder provided by the invention basically keeps the spherical shape and size, the boron powder is uniformly adhered to the surface of the aluminum alloy powder, the composite aluminum alloy powder has good fluidity, and the requirements of laser powder bed melting and laser directional energy deposition equipment on the fluidity of the powder can be met;
(2) The large-scale preparation method of the composite aluminum alloy powder provided by the invention is simple to operate, short in time, suitable for large-scale production and industrial-scale laser additive manufacturing, capable of realizing hundred kg-level production, overcoming the problem of non-uniform mixed powder in the prior art, and the printed product has excellent mechanical properties, and under the preferred condition, the yield strength is above 385MPa, the tensile strength is above 495MPa, and the elongation is more than or equal to 7.9%;
(3) The composite aluminum alloy powder provided by the invention has wide printable window in laser additive manufacturing, and the mechanical property is obviously improved; in addition, the invention proves that the composite aluminum alloy powder prepared by the industrial mixed powder can be used for printing industrial parts with large size and complex shape.
Drawings
FIG. 1 is an SEM image of an aluminum alloy powder used in example 1 of the present invention.
Fig. 2 is an SEM image of boron powder used in example 1 of the present invention.
FIG. 3 is an SEM image of the composite aluminum alloy powder obtained in example 1 of the present invention.
Fig. 4 is a partial enlarged view of fig. 3.
FIG. 5 is an optical microscopic image of the surface of a 3D-printed product at 250W and 600mm/s in application example 1 of the present invention.
FIG. 6 is an optical microscopic image of the surface of a 3D-printed product at 250W and 800mm/s in application example 1 of the present invention.
FIG. 7 is an optical microscopic image of the surface of a 3D-printed product at 250W and 1000mm/s in application example 1 of the present invention.
FIG. 8 is an optical microscopic image of the surface of a 3D-printed product at 250W and 1200mm/s in application example 1 of the present invention.
FIG. 9 is an optical microscopic image of the surface of a 3D-printed product at 350W and 600mm/s in application example 1 of the present invention.
FIG. 10 is an optical microscopic image of the surface of a 3D-printed product at 350W and 800mm/s in application example 1 of the present invention.
FIG. 11 is an optical microscopic image of the surface of a 3D-printed product at 350W and 1000mm/s in application example 1 of the present invention.
FIG. 12 is an optical microscopic image of the surface of a 3D-printed product at 350W and 1200mm/s in application example 1 of the present invention.
FIG. 13 is a graph showing stress strain of a sample obtained under the conditions of 250W and 800mm/s in application example 1 of the present invention.
Detailed Description
The technical scheme of the invention is further described below by the specific embodiments with reference to the accompanying drawings.
The present invention will be described in further detail below. The following examples are merely illustrative of the present invention and are not intended to represent or limit the scope of the invention as defined in the claims.
Examples 1 to 8 and comparative examples 1 to 2 provide a large-scale production method of aluminum alloy powder, the large-scale production method comprising: the double-cone mixer firstly discharges air in the equipment through nitrogen, and then the aluminum alloy powder (2024 alloy powder, the specific composition of which is Cu 4.85wt%, mg 1.56wt%, mn 0.47wt%, si 0.2wt%, fe 0.15wt%, cr 0.019wt%, zn 0.02wt%, ti 0.001wt% and the balance of Al and unavoidable impurities is mixed through the double-cone mixer, wherein the surface of the aluminum alloy powder has dendrite solidification morphology, the aluminum alloy powder in the embodiment 1 is shown in the figure 1) and the boron powder in the embodiment 1 is shown in the figure 2, and the mixing rotating speed is 10r/min and the time is 1h, so that the composite aluminum alloy powder is obtained.
The proportions and particle size selections of the aluminum alloy powder and the boron powder were adjusted within the above ranges, as shown in table 1.
TABLE 1
As shown in fig. 1, as can be seen from fig. 3 to 4, the composite aluminum alloy powder prepared in example 1 still maintains a spherical shape, the morphology and size are not destroyed, and boron powder is uniformly adhered to the surface of the aluminum alloy powder, which indicates the feasibility of batch-scale powder mixing by using a double cone powder mixer.
Example 9
The embodiment provides a large-scale preparation method of aluminum alloy powder, which comprises the following steps: the double-cone mixer firstly discharges air in the equipment through nitrogen, then the aluminum alloy powder (2024 alloy powder, the specific composition of the alloy powder is Cu 4.75wt%, mg 1.68wt%, mn 0.55wt%, si 0.15wt%, fe 0.18wt%, cr 0.02wt%, zn 0.018wt%, ti 0.007wt%, the rest is Al and unavoidable impurities, the proportion of grain size range is 15-62 mu m is 98%, the surface of the aluminum alloy powder has dendrite solidification morphology, the specific surface area is 92m 2 And (3) mixing the aluminum alloy powder with boron powder (the mass ratio of the powder with the particle size less than 1 mu m is 98 percent, the maximum particle size is 1.2 mu m) by a double-cone mixer, wherein the mixing speed is 50r/min, and the time is 0.5h, so as to obtain the composite aluminum alloy powder.
Example 10
The embodiment provides a large-scale preparation method of aluminum alloy powder, which comprises the following steps: the double cone mixer firstly discharges the air in the equipment through nitrogen, and then the aluminum alloy powder (2024 alloy powder is combined)The gold powder comprises the following specific components: cu:4.75wt%; mg:1.68wt%; mn:0.55wt%; si:0.15wt%; fe:0.18wt%; cr:0.02wt%; zn:0.018wt%; ti:0.007wt% of Al and unavoidable impurities in balance; the grain diameter is 53-160 mu m, the ratio is 97%, the surface of the aluminum alloy powder has dendrite solidification morphology, and the specific surface area is 85m 2 Mixing/kg) with boron powder (the mass ratio of the powder with the particle size less than 1 mu m is 99%, the maximum particle size is 1.15 mu m) by a double-cone mixer, and obtaining the composite aluminum alloy powder, wherein the mixing speed is 20r/min and the mixing time is 1.5 h.
Example 11
Based on the embodiment 1, the mixing powder of the double cone powder mixer is replaced by ball milling mixing powder, the ball-material ratio is 1:1, and the mixture is dispersed for 40 hours.
In this embodiment, the ball milling process has high energy, and the grinding body is easy to cause plastic deformation of the test powder, damage the sphericity of the powder, reduce the fluidity of the powder, and is extremely unfavorable for the laser additive manufacturing, especially the coaxial powder feeding laser directional energy deposition process, and the poor fluidity of the powder is easy to cause difficult powder supply, thereby affecting the formability. More seriously, the ball milling process may lead to breakage and refinement of the test powder, failing to meet the particle size requirements of the laser powder bed melting and laser directed energy deposition equipment for the powder.
Example 12
Based on example 11, the charge was modified to 1980g and 20g, the remainder being the same as in example 11.
As can be seen from comparative examples 11 to 12, the ball milling scheme is suitable for mixing about 1kg of powder to obtain a uniformly mixed product, and the effect of large-scale batch and large-scale powder mixing of the material is poor, i.e. the composite powder obtained in example 11 is not uniform.
Example 13
Based on the embodiment 1, the mixing of the double cone powder mixer is replaced by adopting an electrostatic assembly mode for mixing, the electrostatic assembly process in the comparative example generally has extremely high environmental requirements and is generally completed in a glove box with oxygen and water of less than 5ppm, and the problem that the electrostatic assembly technology is difficult to be used for mass and large-scale production of composite powder is also determined.
Application example 1
Exploration of the printing window of the composite aluminum alloy powder in the present invention provides a use of the composite aluminum alloy powder in laser additive manufacturing in example 1, the use comprising:
the composite aluminum alloy powder described in example 1 was used as a raw material, and laser powder bed fusion molding was performed on the surface of a substrate, wherein the laser power was 250W or 350W, the laser scanning speed was 600mm/s, 800mm/s, 1000mm/s or 1200mm/s, the layer thickness of each layer of powder molding was 30 μm, the line spacing was 125 μm, the interlayer rotation angle of each layer of powder molding was 67 °, the substrate was an aluminum alloy substrate, and the substrate was preheated to 150 ℃.
The alloy samples obtained in application example 1 were subjected to longitudinal section analysis, and optical micrographs thereof are shown in fig. 5 to 12, and it was found that all the samples were free from cracking, and that unfused and air hole defects occurred only when a few molding parameters were improper, indicating that the printability of the composite powder prepared from the industrial grade powder blend was excellent.
Application examples 2 to 8 and application comparative example 1 the same process parameters as application example 1 were used, wherein the laser power was 250W and the laser scanning speed was 800mm/s, and the rest was the same as application example 1 except that the composite aluminum alloy powders of examples 2 to 8 and comparative example 1 were used as the powder raw materials, respectively.
Application example 9
The present application example provides a use of the composite aluminum alloy powder in example 9 in laser additive manufacturing, the use comprising:
the composite aluminum alloy powder described in example 9 was used as a raw material, and laser powder bed fusion molding was performed on the surface of a substrate, wherein the laser power was 300W, the laser scanning speed was 900mm/s, the layer thickness of each layer of powder molding was 40 μm, the line spacing was 200 μm, the interlayer rotation angle of each layer of powder molding was 90 °, and the substrate was an aluminum alloy substrate and was preheated to 130 ℃.
Application example 10
The present application provides a use of the composite aluminum alloy powder of embodiment 10 in laser additive manufacturing, the use comprising:
the composite aluminum alloy powder described in example 10 was used as a raw material, and laser directional energy deposition molding was performed on the surface of a substrate, wherein the laser power was 400W, the laser scanning speed was 20mm/s, the layer thickness of each layer of powder molding was 200 μm, the line spacing was 460 μm, and the interlayer rotation angle of each layer of powder molding was 90 °.
The printed alloy samples were tested for yield strength, tensile strength and elongation according to GB/T228.1-2010 by tensile testing at room temperature, and the results are shown in Table 2.
The stress-strain curves of the samples obtained under the conditions of 250W and 800mm/s in application example 1 are shown in FIG. 13, and it can be seen that the yield strength of the alloy sample obtained by the composite powder prepared by batch powder mixing reaches 385MPa, the tensile strength reaches 504MPa, and the elongation reaches 8.2%.
TABLE 2
| Yield strength (MPa) | Tensile strength (MPa) | Elongation (%) | |
| Application example 2 | 375 | 490 | 7.8 |
| Application example 3 | 378 | 483 | 7.2 |
| Application example 4 | 370 | 480 | 7.6 |
| Application example 5 | 203 | 220 | 2.1 |
| Application example 6 | 85 | 106 | 0.6 |
| Application example 7 | 373 | 472 | 6.8 |
| Application example 8 | 365 | 476 | 7.0 |
| Application example 9 | 385 | 495 | 7.9 |
| Application example 10 | 390 | 502 | 8.1 |
| Comparative example 1 was used | 362 | 465 | 7.0 |
From table 1, the following points can be seen:
(1) The comprehensive application examples 1 and 9-10 show that the large-scale preparation method of the aluminum alloy powder provided by the invention not only can be suitable for large-scale production of hundred kilograms, but also can be used for laser additive manufacturing after uniform mixing of boron powder and aluminum alloy powder, and the printed product has excellent mechanical properties, the yield strength is above 385MPa, the tensile strength is above 495MPa, and the elongation is not less than 7.9%.
(2) It can be seen from comprehensive application example 1 and application comparative example 1 that under the condition of the same mass ratio, the particle size of the boron powder in the application comparative example 1 is too large to form stable adsorption force on the surface of the aluminum alloy powder, and the final printed product has poor performance, so that the particle size of the boron powder is critical to the performance of the final product, and the boron powder and the aluminum alloy powder are extremely easy to separate in the storage and transportation process even after being uniformly mixed to cause uneven distribution due to the difference of the densities of the boron powder and the aluminum alloy powder in the large-scale production process.
And further, as can be seen from the comprehensive application examples 1 and 2-3, in application example 1, the particle size of the boron powder is strictly controlled to be smaller than 1 μm, and compared with the particle size of the boron powder in application examples 2-3, the yield strength, the tensile strength and the elongation of the product printed in application example 1 are better than those of the product printed in application examples 2-3, so that the invention preferably controls the particle size of the boron powder to be smaller than 1 μm, and further improves the mechanical property of the product obtained after the laser additive manufacturing of the composite aluminum alloy powder. (3) As can be seen from the comprehensive application examples 1, 4 and 2, the grain size distribution of the aluminum alloy powder in application example 4 is not within the preferred range, the mechanical properties of the final product are obviously reduced compared with the application example 1, while in application comparative example 2, the grain size of the aluminum alloy powder is too small, so that on one hand, a good adsorption bonding state is difficult to form with the boron powder, and on the other hand, the grain size is too small to meet the requirement of laser additive manufacturing, so that the later 3D printing cannot be performed, therefore, the grain size of the aluminum alloy powder is controlled within a specific range, and the application of the aluminum alloy powder in laser additive manufacturing is facilitated;
(3) The comprehensive application examples 1 and 5-6 show that the mass ratio of the boron powder to the aluminum alloy powder has remarkable influence on the performance of the final product, and the performance of the product is improved by controlling the adding amount of the boron powder in a reasonable range.
(4) As can be seen from the combination of application example 1 and application examples 7 to 8, the specific surface area of application example 1 is 82m 2 As to the aluminum alloy powder of/kg, 73m of specific surface area was selected as compared with the aluminum alloy powder of application examples 7 to 8 2 Kg and 113m 2 The mechanical properties of the product prepared in application example 1 are better than those of the product prepared in application examples 7-8, so that the specific surface area of the aluminum alloy powder is controlled within a specific range, the aluminum alloy powder is more beneficial to large-scale mixing, and the mechanical properties of the final product are improved.
The applicant declares that the above is only a specific embodiment of the present invention, but the scope of the present invention is not limited thereto, and it should be apparent to those skilled in the art that any changes or substitutions that are easily conceivable within the technical scope of the present invention disclosed by the present invention fall within the scope of the present invention and the disclosure.
Claims (10)
1. The composite aluminum alloy powder is characterized by comprising aluminum alloy powder and boron powder loaded on the surface of the aluminum alloy powder;
the aluminum alloy powder is micron-sized powder;
the mass ratio of the powder with the particle diameter smaller than 1 μm in the boron powder is more than or equal to 90 percent.
2. The composite aluminum alloy powder according to claim 1, wherein the grain size distribution of the aluminum alloy powder is more than or equal to 90% in a ratio of 10-200 μm;
preferably, the maximum grain diameter of the boron powder is less than or equal to 2 mu m;
preferably, the mass ratio of the powder with the particle size smaller than 1 μm in the boron powder is 100%.
3. The composite aluminum alloy powder according to claim 1, wherein the mass ratio of the boron powder in the composite aluminum alloy powder is 0.1-5 wt%, preferably 0.5-2 wt%;
preferably, the boron powder is adsorbed on the surface of the aluminum alloy powder.
4. The composite aluminum alloy powder of claim 1, wherein the aluminum alloy powder is 2024 aluminum alloy powder;
preferably, the aluminum alloy powder comprises the following components in percentage by mass: cu:3.8 to 4.9 weight percent; mg:1.2 to 1.8 weight percent; mn:0.3 to 0.9 weight percent; si <0.5wt%; fe <0.5wt%; cr <0.1wt%; zn <0.25wt%; ti <0.15wt%, the balance Al and unavoidable impurities.
5. The composite aluminum alloy powder of claim 1, wherein the surface of the aluminum alloy powder has a dendrite solidification morphology;
preferably, the specific surface area of the aluminum alloy powder is 80-100 m 2 /kg。
6. A method for the large-scale production of the composite aluminum alloy powder of any one of claims 1 to 5, characterized in that the method comprises:
and mixing the aluminum alloy powder and the boron powder by a mixer to obtain the composite aluminum alloy powder.
7. The large-scale preparation method according to claim 6, wherein the mixer is a double-cone mixer;
preferably, the mixing is carried out in a protective atmosphere;
preferably, the protective atmosphere comprises argon and/or nitrogen;
preferably, the rotation speed of the mixing is 5-100 r/min;
preferably, the mixing time is 0.5 to 10 hours.
8. Use of the composite aluminum alloy powder of any of claims 1-5 in laser additive manufacturing.
9. Use according to claim 8, characterized in that the use of the composite aluminium alloy powder in laser powder bed melt forming;
preferably, the particle size of the composite aluminum alloy powder in the laser powder bed fusion forming is 15-53 mu m;
preferably, the laser power in the laser powder bed fusion forming is 100-500W;
preferably, the laser scanning speed in the laser powder bed fusion forming is 200-1600 mm/s;
preferably, the interval between the melting and forming center lines of the laser powder bed is 50-200 mu m;
preferably, the thickness of the layer in the laser powder bed fusion forming is 20-40 mu m;
preferably, the rotation angle between the middle layers in the laser powder bed fusion forming is 0-90 degrees.
10. Use according to claim 8, characterized in that the use of the composite aluminium alloy powder in laser directed energy deposition modeling;
preferably, the grain diameter of the composite aluminum alloy powder in the laser directional energy deposition molding is 50-150 mu m;
preferably, the laser power in the laser directional energy deposition molding is 200-700W;
preferably, the laser scanning speed in the laser directional energy deposition molding is 1-30 mm/s;
preferably, the line spacing of the laser directional energy deposition molding is 200-600 mu m;
preferably, the layer thickness in the laser directional energy deposition modeling is 100-600 μm; preferably, the laser directional energy deposition modeling is used for forming the angle of rotation between the middle layers to be 0-90 degrees.
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