Laser metal deposition of refractory high-entropy alloys for high-throughput synthesis and structure-property characterization

Progress in materials development is often paced by the time required to produce and evaluate a large number of alloys with different chemical compositions.This applies especially to refractory high-entropy alloys(RHEAs),which are difficult to synthesize and process by conventional methods.To evaluate a possible way to accelerate the process,high-throughput laser metal deposition was used in this work to prepare a quinary RHEA,TiZrNbHfTa,as well as its quaternary and ternary subsystems by in-situ alloying of elemental powders.Compositionally graded variants of the quinary RHEA were also analyzed.Our results show that the influence of various parameters such as powder shape and purity,alloy composition,and especially the solidification range,on the processability,microstructure,porosity,and mechanical properties can be investigated rapidly.The strength of these alloys was mainly affected by the oxygen and nitrogen contents of the starting powders,while substitutional solid solution strengthening played a minor role.

Numerical simulation of thermal behavior during laser metal deposition shaping

Abstract: Based on the element life and death theory of finite element analysis(FEA), a three-dimensional multi-track and multi-layer model for laser metal deposition shaping(LMDS) was developed with ANSYS parametric design language(APDL), and detailed numerical simulations of temperature and thermal stress were conducted. Among those simulations, long-edge parallel reciprocating scanning method was introduced. The distribution regularities of temperature, temperature gradient, Von Mise’s effective stress, X-directional, Y-directional and Z-directional thermal stresses were studied. LMDS experiments were carried out with nickel-based superalloy using the same process parameters as those in simulation. The measured temperatures of molten pool are in accordance with the simulated results. The crack engendering and developing regularities of samples show good agreement with the simulation results.

Underwater Laser Welding/Cladding for High-performance Repair of Marine Metal Materials:A Review

With the rapid developments of marine resource exploitation,mounts of marine engineering equipment are settled on the ocean.When it is not possible to move the damaged equipment into a dry dock,welding operations must be performed in underwater environments.The underwater laser welding/cladding technique is a promising and advanced technique which could be widely applied to the maintenance of the damaged equipment.The present review paper aims to present a critical analysis and engineering overview of the underwater laser welding/cladding technique.First,we elaborated recent advances and key issues of drainage nozzles all over the world.Next,we presented the underwater laser processing and microstructural-mechanical behavior of repaired marine materials.Then,the newly developed powder-feeding based and wire-feeding based underwater laser direct metal deposition techniques were reviewed.The differences between the convection,conduction,and the metallurgical kinetics in the melt pools during underwater laser direct metal deposition and in-air laser direct metal deposition were illustrated.After that,several challenges that need to be overcame to achieve the full potential of the underwater laser welding/cladding technique are proposed.Finally,suggestions for future directions to aid the development of underwater laser welding/cladding technology and underwater metallurgical theory are provided.The present review will not only enrich the knowledge in the underwater repair technology,but also provide important guidance for the potential applications of the technology on the marine engineering.

An overview of laser-based multiple metallic material additive manufacturing: from macro- to micro-scales

Additive manufacturing(AM)is an emerging customized three-dimensional(3D)functional product fabrication technology.It provides a higher degree of design freedom,reduces manufacturing steps,cost and production cycles.However,existing metallic component 3D printing techniques are mainly for the manufacture of single material components.With the increasing commercial applications of AM technologies,the need for 3D printing of more than one type of dissimilar materials in a single component increases.Therefore,investigations on multi-material AM(MMAM)emerge over the past decade.Lasers are currently widely used for the AM of metallic components where high temperatures are involved.Here we report the progress and trend in laser-based macro-and micro-scale AM of multiple metallic components.The methods covered in this paper include laser powder bed fusion,laser powder directed energy deposition,and laser-induced forward transfer for MMAM applications.The principles and process/material characteristics are described.Potential applications and challenges are discussed.Finally,future research directions and prospects are proposed.

Simulation and Analysis of Electromagnetic Force in Laser Melting Deposition by Electromagnetic Impact

Magnetic field was introduced in laser melting deposition to reduce the pores in workpieces.Finite 3-D model of the coil-deposition layer-substrate was established.Simulation results show that the electromagnetic force in deposition layer mainly concentrates in the projection area of the coil.Axial electromagnetic force shows repulsion in one cycle.The experimental results indicate that the magnetic field is beneficial for grain refinement,microhardness increasement and decline of quantities and average sizes of pores.

Photoluminescence and lasing properties of InAs/GaAs quantum dots grown by metal-organic chemical vapour deposition

Photoluminescence （PL） and lasing properties of InAs/GaAs quantum dots （QDs） with different growth procedures prepared by metalorganic chemical vapour deposition are studied. PL measurements show that the low growth rate QD sample has a larger PL intensity and a narrower PL line width than the high growth rate sample. During rapid thermal annealing, however, the low growth rate sample shows a greater blueshift of PL peak wavelength. This is caused by the larger InAs layer thickness which results from the larger 2-3 dimensional transition critical layer thickness for the QDs in the low-growth-rate sample. A growth technique including growth interruption and in-situ annealing, named indium flush method, is used during the growth of GaAs cap layer, which can flatten the GaAs surface effectively. Though the method results in a blueshift of PL peak wavelength and a broadening of PL line width, it is essential for the fabrication of room temperature working QD lasers.

Quantum cascade lasers grown by MOCVD

Sharing the advantages of high optical power,high efficiency and design flexibility in a compact size,quantum cascade lasers(QCLs)are excellent mid-to-far infrared laser sources for gas sensing,infrared spectroscopic,medical diagnosis,and defense applications.Metalorganic chemical vapor deposition(MOCVD)is an important technology for growing high quality semiconductor materials,and has achieved great success in the semiconductor industry due to its advantages of high efficiency,short maintenance cycles,and high stability and repeatability.The utilization of MOCVD for the growth of QCL materials holds a significant meaning for promoting the large batch production and industrial application of QCL devices.This review summarizes the recent progress of QCLs grown by MOCVD.Material quality and the structure design together determine the device performance.Research progress on the performance improvement of MOCVD-grown QCLs based on the optimization of material quality and active region structure are mainly reviewed.

超高速激光金属沉积增材制造K648高温合金的显微组织与性能

采用一种新型的超高速激光金属沉积工艺以提高高铬高温合金的制造效率。分别使用透射电子显微镜、拉伸试验机、磨损试验机和电化学工作站对超高速激光金属沉积高铬K648高温合金的析出相生长行为、高温力学性能、耐磨性和耐腐蚀性进行研究,并与传统激光金属沉积工艺进行比较。结果表明,超高速激光金属沉积K648合金的析出相尺寸明显小于传统激光金属沉积工艺制备的K648合金,700℃下的高温强度更高,且具有良好的耐磨性和耐腐蚀性。总之,超高速激光金属沉积制造的K648高铬高温合金具有良好的综合性能。

MOCVD生长的中红外高功率量子级联激光器

量子级联激光器(QCL)是中远红外波段的优质光源,具有体积小、重量轻、电光转化效率高等诸多优势,在传感、通信和国防等领域有重要的应用前景。金属有机物化学气相沉积(MOCVD)技术作为更高效的外延方式,应发展适用于QCL的MOCVD外延生长技术以满足快速增长的市场需求。本文报道了全结构由MOCVD技术外延的QCL,通过将传统的“双声子共振”有源区结构修订为“单声子共振结合连续态抽取”结构,减少了电子的热逃逸,改善了器件的温度特性。针对该结构,进一步改变了有源区的掺杂浓度,并对比了不同掺杂浓度对器件性能的影响。腔长8 mm、平均脊宽约6.7μm的较高掺杂有源区器件在20℃下连续输出功率达3.43 W,中心波长约4.6μm,电光转化效率达13.1%;8 mm腔长的较低掺杂有源区器件在20℃下连续输出功率达2.73 W,中心波长约4.5μm,阈值电流仅0.56 A,峰值电光转化效率达15.6%。器件的输出功率和电光转化效率较之前文献报道的MOCVD制备的QCL有明显提高。该结果表明,MOCVD完全具备生长高功率QCL的能力,这对推动QCL的技术进步具有重要意义。

基于电沉积富集-LIBS的水中Cd元素高灵敏稳定测量研究

针对水体痕量Cd元素的高灵敏稳定检测,基于Al片电沉积富集(ED)结合激光诱导击穿光谱(LIBS)检测的ED-LIBS水中Cd分析方法,实验研究了富集时间、富集电压、导电溶质KCl浓度以及电极表面砂纸打磨对Cd元素富集结果的影响。结果表明,经砂纸打磨Al片电沉积富集后,Cd元素富集稳定性得到提升,同时优化确定的富集电压、富集时间和KCl浓度分别为−2.4 V、1200 s和2 g/L。利用该方法,Cd元素检测限和相对标准偏差分别为0.0021 mg/L和3.30%,满足《生活饮用水卫生标准》指标检测需求,为水体中痕量Cd元素的高灵敏稳定分析提供了有力的检测手段。

采用增减材复合制造技术的模具修复工艺研究

激光金属沉积增减材复合制造技术是实现模具等高附加值部件修复与再制造的理想候选工艺之一。为了提高模具修复的效率和精度,本文将增减材复合制造技术应用于模具修复领域,并且对修复工艺进行研究。首先根据具体使用工况和材料性能要求,确定了最佳模具修复参数,随后讨论了该模具修复工艺的应用条件和应用范围。实验结果表明:利用本文提出工艺方案进行模具修复时可以实现修复区域无拼接痕迹,并且修复区域硬度提升7.4 HRC,能够有效提升模具的使用性能。

激光熔化沉积Al-12Si合金成形工艺研究

为了满足结构件的一体式、轻量级以及专属定制的要求,笔者对激光熔化沉积(laser metal deposition,LMD)成形Al-12Si合金激光工艺参数进行了摸索,优化激光成形参数;在此基础之上,开展激光熔化沉积成形实验,通过金相分析、扫描电子显微镜(scanning electron microscope,SEM)等表征手段对激光熔化沉积制备Al-12Si合金显微组织进行表征。结果表明:在激光功率700~800 W、激光扫描速度为300~360 mm/min的工艺参数下能够获得高度致密的Al-12Si合金。激光熔化沉积Al-12Si合金成形工艺的研究旨在克服传统制造方式的局限性,通过科学的方法优化工艺参数并改善成形质量,最终获得高质量且性能优异的Al-12Si合金部件。

Influence of Electroshocking Treatment on Microstructure and Mechanical Properties of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si Thin-Wall Specimen Manufactured by Laser Melting Deposition

In order to improve the properties of titanium alloys manufactured by laser melting deposition(LMD),the electroshocking treatment(EST)was proposed in this work.The effects of EST on microstructure and mechanical properties of LMD Ti-6.5Al-3.5Mo-1.5Zr-0.3Si were investigated.The results showed that the width of the heat affected band decreased and disappeared under the thermal and athermal effects of EST,resulting in the uniform microstructure.In the microstructure,theαlaths became coarser gradually,and the quantity ofα/βinterface was reduced.The reduction of the quantity ofα/βinterface leads to make less resistant to dislocation,resulting in the reduction in hardness and strength.The discontinuous grain boundaryαphase and nucleationαcolony near grain boundary inhibited the crack propagation and improved the ductility.Summary,EST can manipulate the microstructure and improve the mechanical properties of LMD titanium alloys.

A novel method of utilizing static mixer to obtain mixing homogeneity of multi-species powders in laser metal deposition

Real-time mixing of multi-species powder challenges Laser Metal Deposition(LMD)of Functionally Graded Materials(FGMs).The current work proposes a novel method of using a static mixer to realize rapid,uniform multi-species powder mixing.Firstly,copper powder and 316L stainless steel powder are selected to complete the powder mixing observation experiment with Scanning Electron Microscope(SEM)and Energy Dispersive Spectrometer(EDS).Secondly,computational fluid dynamics and particle mixing simulation models are used to analyze the flow field and particle motion characteristics in the static mixer.Finally,LMD experiment and metallo-graphic observation are carried out with 316L stainless steel powder and WC powder to verify the feasibility of the static mixer.This study provides a theoretical and practical basis for powder mixing in laser processing with a static mixer.The conclusions can also be applied to other processing fields requiring real-time and uniform mixing of multi-species powders.

超声振动对激光熔化沉积GH3536高温合金摩擦磨损性能的影响

采用超声振动辅助激光熔化沉积GH3536高温合金,并对增材制造样品的微观组织和摩擦磨损性能进行了分析。结果表明:激光熔化沉积GH3536高温合金组织为粗大的柱状晶,平均晶粒宽度约180μm,施加超声振动后,柱状晶转变为等轴晶,平均晶粒尺寸下降到78μm。施加超声振动后,试样的平均摩擦系数由8.41降至8.17,磨损率由6.37×10^(-7)cm^(3)/(N∙m)降至4.25×10^(-7)cm^(3)/(N∙m),磨痕宽度由1122.81μm降至1003.21μm,磨痕深度由21.81μm降至19.71μm。。

单晶合金激光增材修复接头组织和性能研究

采用激光熔化沉积技术对DD6单晶高温合金进行修复,利用光学显微镜、扫描电镜和显微硬度仪对单晶母材和增材修复接头的组织特征和力学性能进行对比研究。结果表明:激光熔化沉积修复组织为外延生长的定向凝固柱状晶组织,由γ相基体和少量晶间MC型碳化物组成;DD6单晶合金基体热影响区微观形貌和物相组成与母材相似,但其γ′相的尺寸(≤0.2μm)更小,且γ′/γ的比例明显降低。经激光熔化沉积修复后,增材修复区的显微硬度可达450~470 HV,显著高于DD6单晶基体,具有更优异的耐磨损性能。

激光金属沉积成形304奥氏体不锈钢的缺陷和硬化现象

【目的】为了掌握激光金属沉积成形304奥氏体不锈钢的材料缺陷和硬化情况,为后续该技术成形金属材料的工程应用提供参考。【方法】该文对激光金属沉积成形304奥氏体不锈钢的材料缺陷和单调/循环交变载荷作用下的硬化现象进行了研究。【结果】研究结果表明,激光金属沉积成形材料的表面十分粗糙并具有明显的堆叠痕迹,成形材料中存在孔洞、氧化物夹杂和未熔颗粒等缺陷;在单调载荷作用下,成形材料表现出应变硬化,应变硬化指数为0.4,低于传统锻造工艺成形材料;在应变控制的循环交变载荷作用下,成形材料在试验起始阶段产生循环硬化,而在较低应力控制的循环交变载荷作用下,成形材料在试验起始阶段产生循环软化,随着循环加载次数的增加,成形材料产生循环硬化。【结论】由于独特的成形工艺,激光金属沉积成形304奥氏体不锈钢不可避免存在材料缺陷,在单调载荷、应变控制的循环交变载荷及较低应力控制的循环交变载荷作用下均会出现硬化现象。

窄孔内壁激光金属沉积Stellite6合金耐磨层组织及性能研究

为解决窄孔内壁堆焊的可达性差和提高304L不锈钢的耐磨性能,采用激光金属沉积的方式在深30 mm、直径14 mm的304L窄孔内壁制备了一层约2.5 mm厚、致密度为99.9981%、无裂纹、未熔合等缺陷的stellite6耐磨层。通过微纳CT、XRD、金相、硬度测试和摩擦磨损试验等方法,系统研究了耐磨层的组织、相组成、硬度分布和耐磨性能。结果表明,Stellite6耐磨层致密无缺陷,其显微组织从底部到顶部依次为平面晶、胞状晶、树枝晶和等轴晶。相组成主要为γ-Co、M_(23)C_(6)、CoCx及(Cr,Fe)_(7)C_(3)等。熔合线附近各种元素均匀分布,未出现明显聚集。耐磨层的显微硬度平均值是基体304L的2.38倍,且窄孔不同高度位置的显微硬度值相对稳定。耐磨层的磨损率较304L基体降低了29.3%,显示出优异的耐磨性能。该研究为大深宽比内孔壁激光金属沉积耐磨层在核电、能源动力等行业的应用提供了依据。