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 baUing 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.     

MICROSTRUCTURES OF LASER SINTERED MICRON/ NANO-SIZED Cu-W POWDER

研究了激光烧结工艺条件下微/纳米Cu-W粉体致密化的过程及对显微组织的影响. 结果表明,合理增加激光功率或降低扫描速率, 可提高烧结致密度及组织均匀性; 降低扫描间距至0.15 mm, 可改善烧结表面光洁度; 铺粉厚度降至0.15 mm, 可提高烧结层间结合性. 经工艺优化, 最高成形致密度达到95.2%, 且在烧结组织中形成一系列规则的W环/Cu芯结构; 并探讨了该结构的成形机制.     

磷元素对铜基金属粉末选区激光烧结作用机理

对不同CuP含量的多组分铜基金属粉末(Cu-CuSn-CuP)进行了选区激光烧结实验。利用X射线衍射和扫描电镜研究了添加元素P对烧结致密度及显微组织的影响。研究表明:P元素能在烧结过程中充当脱氧剂而与Cu反应生成CuPO3;但当P过量时,则会因熔体过热倾向明显而加剧氧化;适量增加P元素能改善烧结件层间结合性;而P元素过量则会因生成过多磷渣而降低润湿性及致密度;P元素亦能充当稀释剂而降低熔体粘度及表面张力,从而改善烧结致密度及组织均匀性;但若P元素过量时,则会因熔体粘度过低而导致球化现象。实验结果证实,该组铜基金属粉末体系中CuP的最佳含量为15%。     

Titanium sintering science: A review of atomic events during densification

The sintering densification trajectory for titanium powder is identified in terms of the interaction between mass transport processes and microstructure evolution. During initial heating, as surface oxides dissolve, surface diffusion forms bonds between contacting particles without densification. Grain boundaries form in the bonds due to random crystal orientations at the contacts. Except for mixed powder Kirkendall swelling, subsequent diffusion in these interparticle grain boundaries leads to densification. Most importantly, the alpha-beta transformation provides strain, defects, and interfaces that accelerate densification in the 800–1100 °C temperature range. This is below a typical peak sintering temperature. Final densification involves beta phase volume diffusion and grain boundary diffusion. Densification slows due to grain growth and the loss of grain boundary area. Pores close near 92% density to trap impurities and reaction products inside the closed pores, often limiting sintered density to about 95% of theoretical. High final density requires slow heating or long holds at intermediate temperatures to evaporate impurities prior to pore closure. The master sintering curve is a means to link densification to process parameters without concern over detailing this cascade of transport mechanisms and microstructure changes.     

Microstructural Evolution and Grain Refining Efficiency of Al-10Ti Master Alloy Improved by Copper Mold Die Casting

The microstructural evolution and grain refining efficiency of sub-rapidly solidified (SRS) Al-10Ti master alloy has been studied. The results show that the mean size of Al₃Ti particles in the SRS Al-10Ti master alloy decreased significantly and the morphology changed from strip-like to blocky and short rod-like compared with the conventional Al-10Ti master alloy. Grain refining experiments show that the SRS Al-10Ti master alloy is more effective than the conventional master alloy for refining Al-7Si alloy. The conversion rate of columnar to fine equiaxed grain structure in the Al-7Si alloy was promoted by the addition of SRS master alloy, and the microhardness of Al-7Si alloy increased. The mechanisms of grain refinement of aluminum by inoculation with improved Al-10Ti master alloy are discussed based on the solute theory. The decrease in size, increase in quantity, and change in morphology of Al₃Ti particles are considered as the reasons for the improvement of microstructure and microhardness.     

Sintering of a quasi-crystalline powder using spark plasma sintering and hot-pressing

Sintering experiments on a granulated AlCuFeB quasi-crystalline powder were performed using hot-pressing (HP) and spark plasma sintering (SPS). By coupling the analysis of a sintering law (derived from creep rate equations) and comparative observations of almost fully dense sintered samples using mainly microprobe analysis and transmission electron microscopy, hypotheses about the densification mechanism(s) involved were expressed. Whatever sintering is performed by SPS or HP, it is proposed that two regimes exist, the difference between them lying in the fact that grain boundaries are/are not perfect sources/sinks of vacancies.     

Effects of isothermal heat treatment on microstructural evolution of semisolid Al-4Cu-Mg alloy

The authors investigated the effects of the isothermal heat-treatment conditions on the microstructural evolution and composition distribution of semisolid Al-4Cu-Mg alloy during isothermal heat treatment. The experimental results show that the microstructural evolution and composition distribution of semisolid Al-4Cu-Mg alloy are controlled by atom diffusion during the isothermal heat treatment process. Grain growth and spheroidization were promoted with the increase of the isothermal temperature and/or the holding time. Moreover, the higher the isothermal temperature, or the longer the holding time, the more segregation constituent elements occurred to the grain boundaries. The low melting structure at grain boundary is greatly affected by Cu. The microstructural evolution in the isothermal heat-treatment process is as follows: recovery, recrystallization, fragmentation, spheroidization, and coarsening. Such fragmentation, spheroidization, and grain growth of coalescence and Ostwald ripening are involved as main mechanisms in the isothermal heat-treatment process.     

Enhanced sintering, microstructure evolution and mechanical properties of 316L stainless steel with MoSi2 addition

Sintering 316L stainless steel to near full density with an appropriate sintering additive can ensure high mechanical properties and corrosion resistance. We present here a sintering approach which exploits the dissociation of ceramics in steels at high temperatures to activate sintering densification to achieve near full dense 316L stainless steel materials. MoSi₂ ceramic powder was used as a sintering additive for pre-alloyed 316L stainless steel powder. Sintering behavior and microstructure evolution were investigated at various sintering temperatures and content of MoSi₂ as sintering additive. The results showed that the sintering densification was enhanced with temperature and MoSi₂ content. The distribution of MoSi₂ was characterized by XMAPs. It was found that MoSi₂ dissociated during sintering and Mo and Si segregated at the grain boundaries. Excess Mo and Si were appeared as separate phases in the microstructure. Above 98% of theoretical density was achieved when the specimens were sintered at 1300 °C for 60 min with 5 wt.% MoSi₂ content. The stainless steel sintered with 5 wt.% MoSi₂ exhibited very attractive mechanical properties.     

Nanostrucmred A1-Zn-Mg-Cu alloy synthesized by cryomilling and spark plasma sintering

Nanocrystallized Al-10.0%Zn-3.0%Mg-1.8%Cu (mass fraction) alloy powder was prepared by cryomilling, and then the nanostructured powder was consolidated into bulk material by spark plasma sintering (SPS). The microstructural evolution and phase transformation were studied. A supersaturated face-centered cubic solid solution is formed after cryomilling for 10 h, and the average grain size is 28 nm. Two typical nanostructures of the bulk nanostructured alloy are observed: primarily equiaxed grains with size of 150 nm, and occasionally occurring sub-micron grains up to 500 nm. Two types of MgZn₂ particles precipitate during consolidation. One is the sub-micron particles distributed along the boundaries of the powders, and the other is fine particles with size of several nanometers in the matrix, especially at the boundaries of sub-micron grains. These second phase particles can be completely dissolved into matrix by proper solid solution treatment.     

Microstructure Evolution of Hot-Dip Al-10% Si Coating During the Austenitization of 22MnB5 Hot Stamping SteelEI北大核心CSCD

Hot stamping is an alternative technology to produce ultra-high strength steel (UHSS) with a tensile strength above 1 GPa for automotive bodies. At present, the hot-dip Al-10% Si (mass fraction) coating is used as a shield coating for the hot stamping steels, which protects the steels from surface oxidation and decarburization, and enhances their corrosion resistance. However, the microstructure evolution and compounds of hot-dip Al-10% Si coating during austenitization of 22MnB5 hot stamping steel are not clear yet. In this work, the thermo-mechanically induced microstructure evolution of hot-dip Al-10% Si coating is observed using SEM after austenitization of 22MnB5 hot stamping steel at 900 degrees C for different times, and the elemental depth profiles are analyzed in hot-dip Al-10% Si coating by EDS and GD-OES. The results show that before austenitization, the hot-dip Al-10% Si coating consisted of an aluminum matrix, pure silicon, and the intermetallic compound Fe2SiAl7, which was formed by eutectic reaction, there was a thin layer, which was composed of Fe2Al5 and FeAl3 between the intermetallic compound Fe2SiAl7 and the steel substrate. When 22MnB5 hot stamping steel was austenitized at 900 degrees C, the ternary eutectic phase Al+ Si+ tau(6) was transformed into an Al-Fe-Si ternary intermetallic compound or Fe-Al binary intermetallic compound gradually in the hot-dip Al-10% Si coating. When the austenitizing time was 2 min, the Al-10% Si coating was composed of the intermetallic compound Fe2SiAl7, Fe2Al5 and FeAl2 phases; when the austenitizing time was 5 min, the Al-10% Si coating was composed of FeAl2, Fe2SiAl2 and Fe5SiAl4 phases; when the austenitizing time was 8 min, the Al-10% Si coating was composed of FeAl2 and Fe5SiAl4 phases. Because the diffusion rate of Al atoms was much larger than that of Fe atoms in the diffusion layer of intermetallic compound Fe2SiAl2 and coating/steel substrate, the amount of Al atoms which diffused and reacted from the coating to the grain boundaries or grain of steel substrate was much larger than that of the Fe atoms which diffused from the steel substrate to the Al10% Si coating, also the number of vacancies which diffused from the steel substrate to the Al-10% Si coating was much larger than the other way round. Due to this imbalance, the Kirkendall void was formed in the interface between the diffusion reaction layer and the Al-10% Si the coating. The hot-dip Al-10% Si coating can be used as the protective layer, since it has a stable Al2O3 film formed on its surface, and its thermal oxidation was very limited, during the 22MnB5 hot stamping steel austenitizing. But the protective performances of Al-10% Si coating could be poor, because the high temperature ductility of brittle intermetallic compound was low, which induced a lot of micro cracks that were perpendicular to the interface of coating/steel substrate, and penetrated the whole coating during the diffusion process of hot-dip Al-10% Si coating.     

Ni-CuSn混合粉末选区激光烧结试验

通过对双组分Ni-CuSn混合粉末进行激光烧结试验,表明此组粉末体系成形机制是粉末半熔化状态下的液相烧结机制。详细讨论了激光工艺参数对成形机制及烧结质量的影响,结果表明,将激光功率和扫描速率控制在适宜的范围内,才可实现预期的成形机制,并获得较好的烧结质量。对烧结件显微组织分析表明,组分M和CuSn间存在较为明显的熔点差、及两者之间较高的固溶度,是保证液相烧结机制、获得较高烧结致密度的前提。     

An Al-12Si/ZnS powder inoculant for eutectic silicon in Al-12Si alloy

To obtain high-performance Al-Si-based cast alloys,refinement and modification of Si phases are required.An Al-12Si/ZnS powder inoculant was designed and fabricated using a chemical bath deposition method.The efficiency of the inoculant for modifying the eutectic Si phase in as-cast Al-12Si alloy was studied.Results show that Al-12Si/ZnS powder can significantly refine the eutectic Si in Al-Si cast alloys.The best refinement effect for eutectic Si is achieved with 17.5wt.%Al-12Si/ZnS powder.Coarse long needle-shaped eutectic Si with a length of 18μm was modified into approximately spherical shape with a diameter of 6.53μm,which is evenly distributed throughout the alloy.The E2EM model calculation indicates that the inter-plane misfit(F_p)and inter-atomic spacing misfit(F_r)between ZnS and Si are all less than 0.5%,which confirms that ZnS is a potential nucleation site for Si phase.The hardness,tensile strength,and elongation of Al-12Si alloys modified with 17.5%Al-12Si/ZnS powder increase 6.30%,16.18%and 55.45%,respectively,compared to the unmodified Al-12Si alloy.The fracture behavior of the alloy with 17.5wt.%Al-12Si/ZnS powder is dominated by transgranular fracture supplemented by intergranular fracture.     

非磁性合金激光焊旋转磁场搅拌机理

详细地研究了激光焊非磁性材料时,熔池液态金属的电磁搅拌机理;探讨了旋转磁场对激光焊接Al-12Si合金显微组织的影响.结果表明,尽管激光束既无磁性又非导体,Al-12Si合金为非磁性材料,但旋转磁场能改变液态Al-12Si合金的运动状态,产生磁搅拌作用,细化晶粒、消除焊接缺陷.对于激光焊,旋转磁场切割焊接熔池中的液态金属,液态金属中产生感生电流,带电的液态金属受到电磁力的作用使熔池中液态金属产生旋转运动.磁场的旋转速率越高,液态金属受到的电磁搅拌作用力越强.     

低C高Si高Mn合金高温氧化动力学及形貌特征分析

研究低C高Si高Mn钢氧化皮随温度的变化,对Fe2SiO4和基体外侧氧化物的分布、形貌进行观察。结果表明,850～960℃时Fe2SiO4在Fe1-xO层中呈颗粒状均匀分布,随着温度升高致密化,呈层状分布,1140℃时首次观察到Fe2SiO4呈岛状分布,1200℃时变成网状分布。基体中Si、Mn元素在850～960℃时先在晶界处氧化,形成网状氧化物,随着温度升高,氧化物在三角晶界处发生球化。     

Al-12.7Si合金表面强烈塑性变形诱发的纳米化

对Al-12.7Si合金进行表面机械研磨处理,在表层制备纳米-微米梯度结构,利用XRD和TEM研究结构演变过程.Al-12.7Si合金形变诱发的纳米化机理归纳如下：在外加载荷的反复作用下,Al基体高密度位错通过滑移,湮灭和重组形成位错胞/亚微晶;通过不断吸收位错,位错胞/亚微晶之间的取向差逐渐增大;亚微晶内高密度位错重...     

Grain growth inhibition by connected porosity in sintered niobium

Pore–boundary interaction plays an important role in densification during solid-state sintering. This paper reports the evolution of porosity and grain size in niobium sintered at 2073 and 2273 K for different sintering times. The densification curves show a decrease in porosity up to 8 and 4 vol.% after 10,800 s for the samples sintered at 2073 and 2273 K, respectively. Grain growth is observed to take place together with this decrease in porosity. A new model for grain growth inhibition during sintering is proposed for connected porosity. This model considers that the moving grain boundaries and the outer surface of cylindrical pores remain in contact during grain growth and that energy dissipation takes place owing to the fact that the grain boundary is moving relative to the porosity. Our mechanism is akin to a friction between the grain boundary and the connected porosity at their contact region. In contrast to the traditional particle–grain boundary bypassing mechanisms, the present model is not a purely geometrical relationship but is material dependent. The model gives agrees well with experimental results obtained in this paper for sintered niobium as well as for other sintered materials reported in the literature. Our model is a novel approach to treating grain growth inhibition by pores during the sintering stage in which the porosity becomes interconnected.     

材料特性和工艺参数对DMLS制件质量的影响

分析了金属粉末直接激光烧结(DMLS)中三类粉末材料的粘结机制,讨论了材料特性和工艺参数对成型件质量的影响。建立了液相体积分数和颗粒尺寸与烧结件致密度之间的关系式,提出从材料特性和工艺参数方面改善烧结件质量的途径。最后讨论了金属粉末激光直接烧结成行进一步研究的三个主要方向。     

热轧工艺对高铝铁素体耐热不锈钢组织性能的影响

电站锅炉的连接件需具有优良的抗高温氧化性、冲击韧性和塑性，主要采用铁素体耐热不锈钢0.1C-18Cr-1Al-1Si制造，热轧工艺对其塑韧性能有至关重要的影响。采用热轧试验，研究了不同热轧工艺对铁素体耐热不锈钢0.1C-18Cr-1Al-1Si组织性能的影响规律。结果表明，热轧温度为700 ℃时，0.1C-18Cr-1Al-1Si热轧板的再结晶最充分；横纵轧和纵轧不同轧制方式下0.1C-18Cr-1Al-1Si板材小角度晶界比例均较高，边部小角度晶界出现频率更高；采用横纵轧工艺可以明显减轻0.1C-18Cr-1Al-1Si板材力学性能的各向异性。     

添加Si粉对AZ91D镁合金激光表面改性

为提高镁合金的表面硬度,对预置Si粉的AZ91D进行高能CO2激光表面改性处理.采用光学显微镜、扫描电镜、电子探针微区分析和X射线衍射仪等方法研究了激光改性层的组织结构.结果表明:AZ91D表面改性层主要由α-Mg,Al12Mg17和Mg2Si组成.Si粉与镁合金完全发生反应形成金属间化合物Mg2Si,Mg2Si以树枝状分布.Al-Mn相由AZ91D基体中的团聚棒状变为激光改性层中的分散球状.激光表面改性后.由于Mg2Si相产生的强化和Mg17Al12产生的细晶强化,显微硬度从80 HV提高到324 HV.     

热轧工艺对高铝铁素体耐热不锈钢组织性能的影响

电站锅炉的连接件需具有优良的抗高温氧化性、冲击韧性和塑性,主要采用铁素体耐热不锈钢0.1C-18Cr-1Al-1Si制造,热轧工艺对其塑韧性能有至关重要的影响。采用热轧试验,研究了不同热轧工艺对铁素体耐热不锈钢0.1C-18Cr-1Al-1Si组织性能的影响规律。结果表明,热轧温度为700 ℃时,0.1C-18Cr-1Al-1Si热轧板的再结晶最充分;横纵轧和纵轧不同轧制方式下0.1C-18Cr-1Al-1Si板材小角度晶界比例均较高,边部小角度晶界出现频率更高;采用横纵轧工艺可以明显减轻0.1C-18Cr-1Al-1Si板材力学性能的各向异性。