Laser sintering of Fe-Ni nanocomposites

The laser sintering of powders is one of new technologies of producing surface coatings from nanostructural materials. In this work, we used methods of transmission and scanning electron microscopy, X-ray diffraction analysis, and X-ray photoelectron spectroscopy to study the structure of layers synthesized using laser sintering of an ultradispersed powder consisting of Fe-Ni nanocomposites. For explaining the specific characteristics of the structure that was formed as a result of high-energy laser action, we carried out a mathematical simulation of the processes of heat transfer with the application of the model of a two-phase (mushy) zone. The coatings synthesized possess a multilevel system of connected pores and can be used in catalytic reactions and hydrogen power engineering.     

Research on Process and Microstructure Formation of W-Ni-Fe Alloy Fabricated by Selective Laser Melting

W-Ni-Fe alloys are important materials for many practical applications; however, at present, they are usually fabricated by conventional powder metallurgy techniques, which is difficult in fabrication with complex shapes. In this work, a selective laser melting (SLM) processing method was developed for fabricating W-Ni-Fe alloys parts. A process map was obtained for selection of proper laser parameters by optimizing processing conditions. Microstructures of laser fabricated samples in different laser energy inputs were investigated. There are two coexisting forming mechanisms in the SLM process: (i) liquid phase sintering (LPS) with full melting of Ni and Fe powders but non-melting of W powders and (ii) melting/solidification with full melting of W powders. Moreover, with increasing laser energy, a transition trend of forming mechanism from LPS to full melting/solidification can be observed.     

Processing of WC/W composites for extreme environments by colloidal dispersion of powders and SPS sintering

Tungsten and tungsten carbide are materials with high thermomechanical response that are used or have been proposed for extreme environment applications such as first plasma face, or cutting tools. The high melting temperature and strong bonding energy of both materials force the use of powder metallurgical processes and non-conventional sintering routes to achieve dense parts. Consequently, a high dispersion and close contacts of the starting powders are required. In this paper tungsten and tungsten carbide powders are colloidally processed and mixed to achieve composite powders that are sintered later by Spark Plasma Sintering. Starting micrometric tungsten carbide and nanosized tungsten powders are dispersed in water at pH 3. By using a cationic dispersant, the surface charge of the nanosized W suspended in water reverses to positive, ensuring its attachment to the carbide surfaces and the good dispersion of the two phases when both slurries are mixed.Composite powders with volumetric rations of 50WC/50W, 80WC/20W and 90WC/10W as well as pure WC and W are sintered by SPS following the dimensional change of the specimens during the process. It has been proved that complete coverage of the micronic WC by the nanosized W powders, achieved with this colloidal approach, makes the tungsten govern the initial sintering stages. The derivative of the sintering curves is used to detect the solid state reactive sintering temperature of W₂C. After sintering, XRD and SEM observations indicate that all the mixture compositions yield to ceramic materials with different W₂C/WC ratios, depending on the initial compositions. Dispersion of the two phases is high and no remaining W is detected. Flexure tests at room temperature show that composite materials present a slightly lower fracture strength than pure WC.     

Finite element analysis of melting and solidifying processes in laser rapid prototyping of metallic powders

To clarify the forming mechanism in laser rapid prototyping, the melting and solidifying processes of metallic powders are simulated by the finite element method, and the calculated amount of the solidified mass is compared with the experimental one. In the simulation, the melted part of the powders is assumed to change into a sphere due to the surface tension and a new finite element mesh is generated in the subsequent analysis. Latent heat and shrinkage due to solidification are taken into account. The thermal conductivity of the powder is measured for various densities and used in the calculation. Temperature distribution within the powders during heating and cooling is calculated to obtain the amount of the melted and solidified part of the powders. Experiments are made with Cu powders using a pulsed Nd:YAG laser. It is found that the amount of the solidified part after a pulse of laser irradiation is affected by the peak power of the laser rather than the duration of irradiation. There is an appropriate peak power of the laser in rapid prototyping of metallic powders. The calculated weights of the solidified powders by several pulses of the laser beam agree well with the experimental ones.     

Separation in liquid and the formation of supersaturated solid solutions in Fe–Cu alloys upon rapid laser melting

The structure of compacted specimens produced using the rapid laser melting of ultradispersed Fe–50 wt % Cu powders has been studied. The original powder was produced via the mechanical milling of iron and copper powders in a planetary-type ball mill. It has been found that the structure of the compacted specimens produced using rapid laser melting exhibits signs of the initial stages of separation in supercooled liquid. It has been shown using X-ray diffraction analysis as well as scanning and transmission electron microscopy that the final structure contains a supersaturated (Fe; Cu) solid solution formed from the high-speed movement of the solidification front and the nonequilibrium capture of copper by the moving front.     

Fe-Si-B-Cu体系中原位析出非晶/晶体复合粉末的制备与性能研究

本研究基于相图计算的CALPHAD方法和超音雾化技术,设计并制备了具有典型核/壳结构的(Fe0.75Si0.1B0.15)100-xCux(x=0,30,45,55,65,at%)非晶/晶体复合粉末。实验研究了该系列晶体/非晶复合粉体的显微组织,热稳定性,形成机理和磁性能。结果表明:本研究制备的复合粉体均由分布在核层的富FeSiB非晶相和壳层的富Cu相组成。磁滞回线结果表明,随着Cu含量的增加,饱和磁化强度呈线性关系逐渐降低,但对矫顽力的影响并不明显。该类非晶/晶体复合粉体的形成过程为:(1)高温下富Cu相和富FeSiB相的液相分离现象诱发形成核/壳组织;(2)由于富Cu相的玻璃形成能力远低于富FeSiB相,在超音雾化过程中,富FeSiB相从液态被冻结为非晶态,最终形成具有核/壳结构的非晶/晶体复合粉体。     

Modeling of the beam transportation behavior in selective laser transmission sintering the translucent core–shell composite powder

In the paper, selective laser transmission sintering the 2%PF/silica sand core–shell composite powders was studied based on a developed optical model by using a Zemax optical design program. The construction of the powder bed was made by the particle stacking model with the composite particle assumed as a three-component optical system. It showed that simulation results agreed well with the experimental data. A focus point after the first layer particle was produced by the translucent spherical lens of particles and then laser beam was quickly diverged by subsequent particles along the beam transportation path. The occurrence of the vaporization at the focus point had little effect on the whole properties of the sintered sample because of its relatively small size. Since no melting pool was produced in the sintering process owing to the thin polymer binder, the rearrangement of the powder bed was not remarkable which led to a constant porosity of the powder bed before and after laser sintering. Laser transmission sintering of core–shell composite powders was basically “contaction” sintering, where particles near to each other as well as within the beam transportation path had an opportunity to sinter together.     

Corrosion-electrochemical behavior of iron-based composite layers obtained by laser sintering

The corrosion-electrochemical behavior of composite layers obtained by high-speed laser sintering of Fe-C ultrafine powders (C in the amount of 0.5 ± 0.1 wt %) is studied using a recording of anodic poteniodynamic curves in borate buffer solutions in neutral and weak alkaline mediums. It is demonstrated that these layers formed on the surface of the steel substrate show the capacity for passivation. Variations in the surface composition and properties of the materials that occur in the course of laser sintering are confirmed using X-ray structural and X-ray electron analyses.     

TC4钛合金表面激光熔覆法制备Y_2O_3颗粒增强Ni/TiC复合涂层

采用激光熔覆法在TC4钛合金表面原位制备Y2O3颗粒增强Ni/TiC复合涂层,研究涂层的相组成、微结构、成分分布及性能。结果表明,复合涂层内的微结构和成分在深度方向具有分层现象,这主要是由激光熔覆过程的快速熔凝和冷却过程所致。在激光熔覆过程中,TiC粉末完全熔化并在凝固过程中析出为细小枝晶,这些TiC枝晶的尺寸随着深度的增加而减小,而Y2O3颗粒则分布在整个重熔层中。Y2O3颗粒增强Ni/TiC复合涂层具有较均匀的硬度,其最高值约为HV1380,比基体高4倍以上。由于复合涂层具有高的硬度,钛合金经过激光熔覆后其耐磨性得到大幅度提高。     

反应火焰喷涂TiC/Fe复合涂层组织及形成机理

以TiFe粉和碳的前驱体（石油沥青）为原料通过前驱体碳化复合技术制备了Ti-Fe-C系反应喷涂复合粉末,并用普通火焰喷涂技术制备了TiC/Fe陶瓷金属复合涂层.观测了喷涂粉末、淬熄实验获取的飞行粒子以及涂层的形态、相和组织结构.结果表明：前驱体碳化复合Ti-Fe-C系喷涂粉末有非常紧密的结构;可有效的解决反应喷涂过程中原料粉末分离的问题.在反应火焰喷涂过程中,每一个喷涂粉末颗粒构成独立的微小反应单元,原料之间反应充分.在整个喷涂过程中喷涂粉末经历了熔化扩散、物相形成、碰撞后快速凝固三个阶段.所得涂层由TiC和Ti2O3共生聚集片层和细小TiC颗粒弥散分布于金属基体所形成的内晶型复合强化片层交替叠加而成.     

激光烧结用复合蜡粉的筛选及成型工艺研究

研制开发了几种复合蜡粉,经过烧结测试,筛选出了一种适合激光选区烧结用精铸蜡粉。研究了激光烧结性能和烧结成型工艺,得到了激光烧结成型最佳工艺参数。结果表明,筛选出的精铸蜡粉最佳烧结为激光功率10 W、预热温度60℃、激光扫描速度2 000 mm/s、铺粉厚度0.15 mm。     

Microstructure and property of sub-micro WC- 10 %Co particulate reinforced Cu matrix composites prepared by selective laser sintering

1 Introduction Selective laser sintering(SLS) is one of a few rapid prototyping(RP) techniques, which enables fabrication of three-dimensional(3D) parts with arbitrary shapes directly from metal powder with no or minimal post-processing[1?3]. In this meth…     

3D激光熔覆陶瓷-金属复合涂层温度场的有限元仿真与计算

通过建立移动激光高斯热源作用下三维熔覆温度场的计算机数值分析模型，在分析过程中引入了复合材料热物性参数的计算方法，考虑了相变潜热和辐射对流散热等因素，用ANSYS中的ADPL语言编制了相应的计算机程序，具有较高的计算精度。在不同的工艺参数条件下，用该模型对激光熔覆陶瓷一金属复合涂层温度场进行了分析计算，得出了熔覆过程中试样表面、端面的温度等值线分布和温度梯度分布，预测了熔池的轮廓、热影响区的形状、交界面的结合情况等，为研究激光熔覆陶瓷．金属复合材料涂层的覆层成型和凝固机制、根据熔覆层的材料设计要求选择激光熔覆工艺参数等提供了依据。     

纯相低氧纳米WC-Co复合粉的制备

以紫钨、四氧化三钴、炭黑为原料,在高真空度条件下利用原位反应合成技术制备出物相纯净、平均粒径约为80 nm的WC-Co复合粉。研究了制备工艺参数对纳米复合粉相组成、粒径、氧含量及最终烧结硬质合金块体材料组织性能的影响。结果表明,纳米复合粉中氧含量较高时,会导致后续烧结过程中发生脱碳反应,使烧结制备的块体材料致密度和力学性能明显下降。将纳米复合粉在800℃下真空热处理2.5 h可有效降低粉末中的氧含量,同时热处理后的粉末颗粒无明显长大,平均粒径为85 nm。向复合粉中加入1.1%TiC与0.9%VC进行SPS烧结,烧结块体平均晶粒尺寸为105 nm,且尺寸分布均匀,致密度达99%以上,硬度(HV30)为21 450 MPa,断裂韧性达到9.81 MPa·m~(1/2)。     

The influence of powder characteristics on the sintering behaviour and impurity content of spark-plasma-sintered zirconium

At present, most zirconium products as well as its alloys are obtained by foundry methods. New technologies used to manufacture high-quality components, such as direct laser sintering or microwave sintering, require spherical powders of a narrow particle size distribution, as this affects the packing density and sintering mechanism. The powders also have to be chemically pure, as impurities such as H, O, C, N and S cause brittleness and problems with corrosion. Commercially procured, high purity zirconium powders from three different sources were characterised for their particle size and phase composition. Dilatometer studies have shown the effect of powder contamination at the beginning and at end of the sintering process. For powders of 99.9% purity, the start of sintering takes place at a temperature of about 700 °C. For powders of 98.8% purity, the sintering starts at 500 °C. In the studies presented in this paper, the SPS/FAST (Spark Plasma Sintering/Field Assisted Sintering Technique) method was chosen for densification processes. Sintered materials were characterised for their density using the Archimedes principle, relative density and Vickers hardness. A determination of the oxygen, nitrogen and hydrogen content in zirconium powders and sintered samples was carried out. The studies confirmed that SPS of zirconium powders in an argon atmosphere slightly decreases the content of oxygen and nitrogen. At 1000 °C, at pressure of 35 MPa, in argon, there is no decomposition of zirconium hydrides in sintered materials.     

单一立方相致密ReO3块材的烧结制备

采用直接烧结的方式将ReO3粉末压片制备成块材,并结合X射线衍射(XRD)、电输运、扫描电子显微镜(SEM)等表征手段优化了最佳烧结条件,获得了纯立方相、结晶均匀、致密的ReO3片状材料。初步的生长实验表明,该方法制备的材料可以用作脉冲激光沉积的靶材,为生长高质量ReO3薄膜的工作打下了基础。     

Manufacturing a TiAl alloy by high-energy ball milling and subsequent reactive sintering

A TiAl alloy was fabricated by high-energy ball milling and subsequent reactive sintering from the mixed powders of Ti and Al. High-energy ball milling produced a kind of particular composite powders with an extremely fine altemative Ti and Al lamella structure. The composite powders not only possessed good consolidation and densification characteristics, but also resulted in the augment of nucleation rate of α and γ titanium aluminides during solid-phase reactive sintering After a series of processing, pressing, degassing, extrusion, and sintering, the resultant TiAl alloy presented high relative density and refined grain sizes of （α2 ＋ γ） lamella and γ phases. The compressive yield strength of the sintered TiAl reached 600 MPa at 800℃.     

激光熔覆铁基合金涂层的研究进展

激光熔覆技术作为一种先进的材料表面改性技术,具有加工效率高、涂层稀释率低且与基体结合强度高、自动化程度高、环境友好等优点。在各类熔覆材料中,铁基合金在成分上与钢铁材料最为接近,且其成本相对较低,近年来在设备零部件表面强化和再制造领域得到广泛应用。结合国内外最新相关研究成果,从材料体系、工艺参数、外场辅助技术等方面对激光熔覆铁基合金涂层的研究进展进行了综述。总结了熔覆材料的选材依据以及铁基自熔性合金粉末、不锈钢粉末、铁基非晶合金粉末、铁基复合粉末等各类材料的特点和应用。系统讨论了激光功率、扫描速度、光斑直径、送粉速率等工艺参数对铁基涂层成形质量和微观组织及性能的影响机制,并介绍了工艺参数优化在高质量熔覆层制备中的应用。同时,论述了超声振动、电磁场、温度场等外场辅助技术在激光熔覆铁基合金涂层中的应用,阐明了外加能场对激光熔覆过程中熔池及凝固组织的作用机理。最后对激光熔覆铁基合金涂层未来的发展方向进行了展望。     

Ice-templated porous alumina structures

The formation of regular patterns is a common feature of many solidification processes involving cast materials. We describe here how regular patterns can be obtained in porous alumina by controlling the freezing of ceramic slurries followed by subsequent ice sublimation and sintering, leading to multilayered porous alumina structures with homogeneous and well-defined architecture. We discuss the relationships between the experimental results, the physics of ice, and the interaction between inert particles and the solidification front during directional freezing. The anisotropic interface kinetics of ice leads to numerous specific morphological features in the structure. The structures obtained here could have numerous applications, including ceramic filters and biomaterials, and could be the basis for dense multilayered composites after infiltration with a selected second phase.