Microstructural evolution during direct laser sintering of multi-component Cu-based metal powder

A multi-component Cu-based metal powder was chosen for direct laser sintering. The powder consists of a mixture of high-purity Cu powder, pre-alloyed CuSn and CuP powder. Liquid phase sintering with complete melting of the binder (CuSn) but non-melting of the cores of structural metal (Cu) proves to be a feasible mechanism for laser sintering of this powder system. The microstructural evolution of the sintered powder with variation of laser processing parameters was presented. High sintering activities and sound densification response were obtained by optimizing the laser powers and scan speeds. Using a high laser power accompanied by a high scan speed gives rise to balling effect. At a high laser power with a slow scan speed the sintering mechanism may change into complete melting/solidification, which decreases the obtainable sintered density. The role of additive phosphorus in the laser sintering process is addressed. Phosphorus can act as a fluxing agent and has a preferential reaction with oxygen to form phosphatic slag, protecting the Cu particles from oxidation. The phosphatic slag shows a concentration along grain boundaries due to its light mass as well as the short thermal cycle of SLS.

Fabrication and Analysis of Vanadium-Based Metal Powders for Selective Laser Melting

Vanadium Alloy is a type of advanced nuclear material with many ideal properties compared as traditional nuclear materials, which has very wide and important application in first-wall and blanket structural material for fusion power plant applications. So it has attracted increasing attentions, especially on new manufacturing methods, such as selective laser melting and so on. In this paper, the comparative study of the powders obtained by mechanical mixing method, dry grinding method and wet grinding method respectively was performed to evaluate the effect of ball milling process on the microstructure and degree of alloying of the vanadium-based powder mixtures with the nominal composition of V5Cr5Ti vanadium alloy. The powders prepared by dry grinding method exhibits better spherical-like morphology and degree of alloying than those prepared by mechanical mixing method and wet grinding method, which indicates that dry grinding method can be used to prepare the superfine vanadium alloy powders for selective laser melting. This work provides a new method as well as important insights into the preparation of superfine vanadium alloy powders for selective laser melting additive manufacturing technology.

Development of Cu-Exfoliated Graphite Nanoplatelets (xGnP) Metal Matrix Composite by Powder Metallurgy Route

In the present investigation the possibility of using exfoliated graphite nanoplatelets (xGnP) as reinforcement in order to enhance the mechanical properties of Cu-based metal matrix composites is explored. Cu-based metal matrix composites reinforced with different amounts of xGnP were fabricated by powder metallurgy route. The microstructure, sliding wear behaviour and mechanical properties of the Cu-xGnP composites were investigated. xGnP has been synthesized from the graphite intercalation compounds (GIC) through rapid evaporation of the intercalant at an elevated temperature. The thermally exfoliated graphite was later sonicated for a period of 5 h in acetone in order to achieve further exfoliation. The xGnP synthesized was characterized using SEM, HRTEM, X-ray diffraction, Raman spectroscopy and Fourier transform infrared spectroscopy. The Cu and xGnP powder mixtures were consolidated under a load of 565 MPa followed by sintering at 850°C for 2 h in inert atmosphere. Cu-1, 2, 3 and 5 wt% xGnP composites were developed. Results of the wear test show that there is a significant improvement in the wear resistance of the composites up to addition of 2 wt% of xGnP. Hardness, tensile strength and strain at failure of the various Cu-xGnP composites also show improvement upto the addition of 2 wt% xGnP beyond which there is a decrease in these properties. The density of the composites decreases with the addition of higher wt% of xGnP although addition of higher wt% of xGnP leads to higher sinterability and densification of the composites, resulting in higher relative density values. The nature of fracture in the pure Cu as well as the various Cu-xGnP composites was found to be ductile. Nanoplatelets of graphite were found firmly embedded in the Cu matrix in case of Cu-xGnP composites containing low wt% of xGnP.

混合钎料对镍基单晶高温合金大间隙钎焊接头组织和性能的影响

【目的】采用一种新型镍基钎料和母材成分一致的高熔点合金粉混合的方法制备出混合钎料,研究了添加的高熔点合金粉的粒径和配比对钎缝微观组织和力学性能的影响。【方法】采用扫描电子显微镜对钎焊接头的析出相、元素分布、微观组织进行了分析,并对钎焊接头的硬度及持久性能进行了测试。【结果】研究表明,接头主要由钎料合金区(FAZ)、界面连接区(IBZ)和扩散影响区(DAZ)三部分组成。钎料合金区主要由M3B2和M8B型硼化物及γ/γ′相组成。界面连接区由γ和γ′沉淀强化相组成。当合金粉粒径为44μm和75μm时,均可得到无缺陷的焊接接头;但当合金粉粒径尺寸达177μm时,钎缝内会形成孔洞缺陷。【结论】随着合金粉比例的提高,接头连接区的显微硬度有所上升。当合金配比由30%到50%,接头的持久寿命由15 h增加至34 h;但进一步提升比例至60%时,接头的持久寿命下降至0.6 h。该文的结果可为实现高温热端零部件的连接和修复工程应用提供理论依据和参考价值。

液态金属改性微米Al-氟聚物的3D打印及性能表征

为了研究镓基液体金属(GLM)-Al-氟聚物的能量释放性能,制备了GLM质量分数分别为1%、3%、5%、7%的GLM-Al,通过3D打印获得了GLM-Al-氟聚物复合反应性材料;采用SEM、EDS、XRD、XPS、DSC-TG、高速摄影仪和万能拉伸仪对GLM-Al及GLM-Al-氟聚物的微观结构、燃烧性能、力学性能等进行测试。结果表明,质量分数3%的GLM改性的GLM-Al放热量和氧化增重均最大,分别为6181 J/g和42.92%;改性前的Al-氟聚物不能被点燃,改性后GLM-Al-氟聚物可以点燃且可以持续稳定燃烧,在当量比为3.5时的燃速最大,为6.0 mm/s;此时GLM-Al-氟聚物的抗拉强度和断裂伸长率均最大,分别为1.73 MPa、11486%,是改性前Al-氟聚物的1.5倍和1.3倍。

Synthesis, Spectral Characterization and Thermal Behavior of Newly Derived La(III), Co(III) and Mn(II) Complexes with Schiff Base Derived from Methionine and Salicylaldehyde

Many metal complexes of Schiff base derived from different amino acids are widely employed as biologically active materials, especially as antibacterial agents. Three new metal [Co(III), Mn(II) and La(III)] complexes with the Schiff base (L) derived from salicylaldehyde and amino acid (methionine) were synthesized and investigated by using various physico-chemical techniques such as elemental analysis, FTIR, UV-visible spectroscopy, magnetic measurement, thermo gravimetric analysis (TGA) and X-ray powder diffraction (XRD) method. From spectral studies, it has been concluded that the synthesized ligand acts as a tetra-dentate molecule, coordinates metal through azomethine nitrogen, sulfur, phenolic oxygen and carboxylate oxygen. UV-visible spectrophotometry showed the characteristic absorption bands corresponding to a square planar geometry for La(III) and Mn(II) metal complexes and tetrahedral geometry for Co(III) complex. The XRD data demonstrated that the manganese and cobalt complexes were crystalline but the lanthanum complex was amorphous in nature. The empirical formula of the synthesized complexes based on analytical data were [Co(C12H13SNO3)]·(NO3), [La(C12H13SNO3)](Cl)(H2O) and [Mn (C12H13SNO3)].

Fe-Based Powders Prepared by Ball-Milling with Considerable Degradation Efficiency to Methyl Orange Compared with Fe-Based Metallic Glasses

In this study, the degradation efficiencies of zero-valent iron （ZVI） powders with different structures and components wereevaluated for methyl orange （MO）. The results show that the structure is an essential factor that affects degradation, andadded non-metallic elements help optimize the structure. The amorphous and balled-milled crystalline Fe7oSiloB2o hascomparative degradation efficiencies to MO with tl/2 values of 6.9 and 7.0 min, respectively. Increasing the boron contentcan create a favorable structure and promote degradation. The ball-milled crystalline Fe70B30 and Fe43.64B56.36 powdershave relatively short tl/2 values of 5.2 and 3.3 rain, respectively. The excellent properties are mainly attributed to theirheterogeneous structure with boron-doped active sites in ZVI. Composition segregation in the nanoscale range in anamorphous FeSiB alloy and small boron particles in the microscale range embedded in large iron particles prepared by ball-milling, both constitute effective galvanic cells that promote iron electron loss and therefore decompose organic chemicals.These findings may provide a new, highly efficient, low-cost commercial method for azo dye wastewater treatment usingZVI.

Study on the Formability of Iron-Based Powder Metal Materials in Plasma Arc Direct Metal Forming Process

The specific Fe-based alloy for direct metal forming was designed and prepared under multi-layer cladding condition.The powder was designed for getting the better formability,toughness and hardness.The experiment used KR6 robot and NW5000 digital power supply as the hardware environment.Microstructure and hardness of the layer formed by different powder were analyzed by using X-ray diffraction (XRD) and Transmission Electron Microscope (TEM).The result shows that thermal expansion coefficient correlated with processing formability is not linearity.Hardness of the layers is correlated to elements phase of the coatings was formed by γ(FeNi) and α(FeCrNi),and a little Cr23C6、Fe3Si and MoO2.

粉末冶金在CNTs增强金属基复合材料中的应用

碳纳米管(CNTs)具有优异的力学和物理化学性能,是理想的复合材料增强体之一。综述了近几年国内外通过粉末冶金方法进行CNTs增强金属基复合材料制备的应用,阐述了用粉末冶金法制备CNTs/金属基复合粉末和块体材料的进展,最后对其应用前景进行了展望。

多组分铜基金属粉末选区激光烧结致密化机理

研究了选区激光烧结专用多组分铜基金属粉末(组分包括纯Cu,预合金CuSn,CuP)的烧结性能。结果表明,通过合理控制激光工艺参数(特别是激光功率和扫描速率),能顺利实现粉末烧结成形,且无明显的“球化”效应和翘曲变形。扫描电镜和X射线衍射分析证实,此组粉末体系的激光烧结是基于液相烧结机制,其中熔点较低的CuSn充当粘结金属,熔点较高的Cu充当结构金属;而添加元素P则起稀释剂的作用,能避免Cu颗粒表面氧化。研究了粉末体系中粘结金属含量对粉末烧结致密化和烧结件微观组织的影响。结果表明,在一定范围内粘结金属含量的提高有利于改善烧结致密度;但若粘结金属过量,则会因“球化”效应而降低致密度。

保温时间对K452高温合金钎焊接头组织与性能的影响

采用钴基钎料及镍基合金粉料,分别在1170℃保温10min、60min和120min的钎焊工艺下,对K452镍基铸造高温合金进行真空钎焊实验,通过扫描电镜和能谱分析仪进行了接头显微组织观察与物相分析,并测试钎焊接头的高温力学性能。结果表明:在保温60min的工艺规范下,界面实现较好的结合,钎缝内部孔洞缺陷较少,钎缝组织均匀,有利于钎焊接头性能的提高;在更长的保温时间120min下,钎缝内部又有蚀孔缺陷形成,且较多的白色块状化合物在合金粉颗粒间聚集长大,但界面结合良好,钎焊接头性能较高,900℃抗拉强度达到400MPa,900℃/100MPa持久寿命为141h55min。

铜基金属粉末直接激光烧结工艺及成形件显微组织研究

对多组分铜基金属粉末(组分包括Cu、Cu-10Sn、Cu-8.4P)进行了直接激光烧结实验。优化激光功率和扫描速率,以实现粉末部分熔化状态下的液相烧结,其中Cu作为结构金属,Cu-10Sn作为粘结金属,而P元素则作为脱氧剂。激光烧结直接成形了尺寸为210mm×70mm×9mm的复杂形状铜基金属零件,在零件底部设置了预烧结层,以保证良好的激光烧结过程及成形精度。烧结致密度达理论密度的94.7%,而最大尺寸误差仅为0.78%。

CuSn预合金对金属粉末选区激光烧结过程及烧结体质量的影响

研究了CuSn预合金对Cu基金属粉末和Ni基金属粉末选区激光烧结的影响。结果表明,对于Cu-CuSn-CuP和Ni-CuSn-CuP两类合金粉末,通过合理控制激光工艺参数(特别是激光功率和扫描速率),能顺利实现粉末烧结成形,且无明显的“球化”效应和翘曲变形。对于Cu-CuSn-CuP合金,由于结构金属Cu的熔点相对较低,在一定的工艺条件下,可以通过调整CuSn的配比,得到致密的显微组织均匀的烧结件;而对于Ni-CuSn-CuP合金,结构金属Ni的熔点相对较高,虽然也可以得到较为致密的烧结件,但其微观组织存在明显的不均匀性。

粉体特性对铜基金属粉末选区激光烧结的影响

设计制备了多组分铜基金属粉末(组分包括Cu,Cu-10Sn,Cu-8.4P),并基于液相烧结机制实现了粉体激光烧结成形。研究了粉体特性(粉末粒度、颗粒形貌、化学成分、组分比例及混粉均匀性)对烧结致密度及显微组织的影响。结果表明:粗细粉末共混并使其具有较宽粒度分布,使用球形或近球形细粉,均能提高粉末松装密度及烧结致密度;元素P能充当脱氧剂而改善润湿性,但若CuP含量多于15%质量分数,会因生成过多磷渣而降低烧结性;提高粘结金属CuSn比例能使烧结致密度得以改善,但若其含量超过30%质量分数,则会导致“球化”效应;提高混粉均匀性,有利于改善烧结致密度和组织均匀性。

不同摩擦条件下铜-铁基粉末冶金材料的摩擦性能

采用粉末冶金技术制备铜-铁基复合材料,在制动压力0.5～1.2MPa范围内,通过定速摩擦试验机研究干、湿条件下,速度、压力与材料摩擦磨损性能的关系。结果表明,干摩擦系数随摩擦速度增加而降低,湿摩擦明显降低了低速摩擦系数而对高速摩擦系数影响不大。低速摩擦系数随摩擦压力增加而增加,摩擦压力对高速摩擦系数影响不明显。

多组分铜基合金粉末选区激光烧结的组织形成机制

对多组分铜基金属粉末(组分Cu、CuSn、CuP,质量比为55:35:10)进行了选区激光烧结试验,其中熔点较低的CuSn充当粘结金属,熔点较高的Cu充当结构金属,CuP则作为脱氧剂而改善润湿性。粉体激光烧结的主导成形机制为液相生成和颗粒重排。合理调控激光工艺参数(激光功率275～400 W,扫描速率0．03～0．06 m·s-1),以使粘结金属CuSn发生熔化,而结构金属Cu保持未熔状态。在保证粉末部分熔化的液相烧结机制的前提下,适当增加激光功率或减小扫描速率,有利于提高烧结致密度及组织均匀性。

机械合金化和放电等离子烧结技术制备Ti基大块非晶合金

将0.075mm的Ti,Cu,Ni,Sn4种金属粉按合金成分为Ti50Cu23Ni20Sn7进行配比,并在行星式球磨机中进行机械合金化(MA)球磨。试验中的球磨机转速为300r/m,球料比为10:1。XRD和DSC分析结果表明,经过30h球磨之后,金属粉末已经全部合金化,并且为非晶态结构。继续进行球磨只能减小粉末颗粒尺寸,却会引入更多的杂质,所以30h是制备Ti50Cu23Ni20Sn7非晶合金粉末最为合适的时间。SEM下观察发现,经机械合金化所获得的非晶粉为层状团聚结构。将所制备的非晶合金粉装入碳化钨模具中,并在放电等离子烧结(SPS)设备中进行快速烧结。其烧结的温度分别为480、490、500和510℃,烧结压力为500MPa,保温时间为1min。从XRD和DSC分析结果可以看出,烧结后的合金基体为非晶结构,并伴有少量晶化相。烧结件放在光学显微镜下观察可以看到少许缩孔和疏松等烧结缺陷。将温度为490℃下烧结的试件破碎,并将断口在SEM下观察可以发现,试件断裂方式为层状脆性断裂。试验结果表明采用机械合金化和放电等离子烧结技术可以成功制备出Ti基大块金属玻璃。

铜基金属粉末温压工艺致密化的研究

研究了铜基金属粉末的温压压制行为,并与冷压压制进行了比较。结果表明:相同压力下,温压压制的压坯密度明显高于冷压压制,在压制压力为500-600 MPa时,密度增加达0.24 g/cm3;温压温度有一个最佳值,必须高于润滑剂的玻璃化温度,低于润滑剂的熔点温度;石墨含量增加,压坯密度下降,当石墨含量小于1%时,温压压制的优势较为明显。

多组分铜基金属粉末选择性激光烧结成形的工艺研究

对多组分铜基金属粉末(组分包括纯Cu,预合金CuSn和CuP)进行了选择性激光烧结试验,其成形机制为粉末部分熔化状态下的液相烧结机制。研究了激光功率、光斑直径、扫描速率、扫描间距、铺粉厚度等工艺参数对粉末激光烧结致密化的影响。为便于整体调控激光烧结过程,本文将各工艺参数综合为“能量体密度”这一个参数,结果表明,增加激光功率或减小扫描速率能增加液相生成量,且利于液相的铺展和流动,进而提高润湿性和烧结性;扫描速率越高,则越易引起“球化”现象。减小铺粉厚度有利于获得较好的层间结合,并提高烧结致密度;若铺粉厚度过小,会降低铺粉均匀性,进而有损层间结合性。减小扫描间距使烧结线从断续分布转变为较为平整的结合状态,进而提高烧结致密度。当能量体密度增至一临界值(约0.15 kJ/mm3)时,烧结致密度有显著提高;但若增至过高(大于0.30 kJ/mm3),烧结致密度则呈下降趋势。

大间隙钎焊用混合粉状高温镍基钎料的润湿性和显微组织

用一种含Al,Ti元素的镍基钎料粉末与γ'相沉淀强化型镍基高温合金FGH95的粉末混合,制备了大间隙钎焊用混合粉状高温镍基钎料。实验表明,采用合适的混合比例,混合粉状钎料对1Cr18Ni9Ti不锈钢具有较好的润湿铺展性。该混合钎料所获得的钎缝金属的合金化效应显著,Al+Ti合金元素的最大含量达到了5.49%。焊态钎缝中,除Nb,W等个别元素外,其他主要强化元素无明显偏析,且经1180℃/4h扩散处理可消除合金元素的偏析。钎缝金属的组织状态较为均匀,基体为等轴γ固溶体枝晶,枝晶间分布有颗粒状、短条状的化合物相以及少量的γ+γ'共晶组织。另外,在γ固溶体中分布着大量弥散细小γ'沉淀强化相。