多脉冲飞秒激光精修面齿轮的烧蚀形貌研究

针对材质为18Cr2Ni4WA的面齿轮,采用飞秒脉冲激光烧蚀来提高其表面质量。建立电子-自旋-晶格三温复耦合模型,预测分析面齿轮材料电子、自旋和晶格单脉冲能量效应下的温度变化过程;结合多脉冲能量累积效应,进行面齿轮材料在激光能量密度为1.035~5.252 J/cm2下烧蚀凹坑直径和深度演变规律的预测与实验分析。研究结果表明：脉冲数的增加并不会持续增大面齿轮表面的平衡温度,基本在30个脉冲时就保持不变;能量密度的增加会使烧蚀凹坑直径和深度持续变大,但变大的速率会持续降低;烧蚀凹坑形貌在能量密度为2.467 J/cm2时最好;过大的扫描道间距会使被加工表面粗糙度值增加,扫描道间距为25 μm时粗糙度值最低为0.185 μm。     

纳秒脉冲激光对316L不锈钢微抛光效果的影响

激光微抛光过程中,激光的能量密度对微抛光效果的影响很大.采用纳秒紫外脉冲激光(波长为355 nm,脉冲宽度为35 ns)对316L不锈钢材料进行微抛光实验研究,分析了工件表面的形貌、扫描速度和离焦距离等因素对激光微抛光效果的影响.通过对4种不同表面形貌的抛光效果比较,发现不仅表面粗糙度会影响抛光质量,而且表面的形貌也对激光微抛光的效果有很大影响;激光微抛光时对确定的激光能量密度存在最佳微抛光效果的扫描速度和离焦距离.提出了355 nm紫外纳秒脉冲激光器对316L不锈钢微抛光效果的最佳工艺参数:激光能量密度为0.14 J/cm2,激光脉冲重复频率为20 Hz,扫描速度为18.6 mm/min,离焦距离为81.2μm.在此工艺参数下,316L不锈钢经过微抛光之后,表面粗糙度由123.23 nm降低至80.96 nm.     

脉冲激光沉积ZrW2O8薄膜的制备和性能

采用脉冲激光沉积法在石英基片上沉积制备了ZrW2O8薄膜.用X射线衍射仪(XRD)、原子力显微镜(AFM)研究了不同衬底温度对薄膜结构组分、表面粗糙度和形貌的影响,用台阶仪和分光光度计测量薄膜的厚度和不同衬底温度下制备薄膜的透射曲线,用变温XRD分析了ZrW2O8薄膜的负热膨胀特性.实验结果表明:在衬底温度为室温、550℃和650℃下脉冲激光沉积的ZrW2O8薄膜均为非晶态,非晶膜在1200℃保温3min后淬火得到立方相ZrW2O8薄膜;随着衬底温度的升高,ZrW2O8薄膜的表面粗糙度明显降低;透光率均约为80%,在20～600℃温度区间内,脉冲激光沉积制备的ZrW2O8薄膜的负热膨胀系数为-11.378×10-6 K-1.     

连续/脉冲激光再制造FeCrNiCu合金成形层温度场研究

采用非接触式红外高温测试仪对连续/脉冲激光成形两种模式下激光再制造FeCrNiCu合金成形层温度场进行分析,获取了熔池及热影响区温度场分布的一般规律,验证了脉冲激光工艺在控制热输入和成形形变以及降低熔池及热影响区温度方面的工艺优越性。结果表明:脉冲激光成形热影响区峰值温度为730.4~810.5℃,熔池峰值温度为998.7~1383.4℃,明显低于相同工艺下连续输出模式;脉冲激光成形层具有更快的升温及降温速率,利于形成细晶组织和获得良好的力学性能;实际成形实验也进一步验证脉冲激光工艺具有更小的热影响区范围。     

飞秒激光烧蚀MgAl2O4透明陶瓷的实验研究

实验研究了800nm飞秒激光与MgAl2O4透明陶瓷的相互作用，得到其在单脉冲、多脉冲情况下的损伤阈值和损伤面积，用CCD成像技术和扫描电镜观察了烧蚀点的形貌特征，用显微红外光谱仪测试了烧蚀区域的透过光谱．结果表明；单脉冲烧蚀条件下，烧蚀面积与脉冲能量近似为线性关系，而在多脉冲烧蚀条件下，烧蚀面积随着脉冲数量的增加呈近似波尔兹曼（Boltzmann）增大；当激光功率接近损伤阈值时，烧蚀后的区域在波数为2500-7000cm^-1范围内的红外透过率由82％提高到86％，当激光功率超过损伤阈值后，透过率降低20％左右．     

薄壁金属包装材料激光焊接工艺研究

本文探讨了激光焊接技术在金属包装制罐领域中的应用前景,通过对0.5mm镀铬马口铁包装金属薄板进行激光对焊试验,分析了主要工艺参数（包括激光功率、脉冲宽度、单脉冲能量）对薄壁金属包装材料焊接性能的影响;通过对焊缝表面形貌质量分析以及焊接强度的检测得到激光焊接0.5mm镀铬马口铁包装金属薄板的最佳工艺参数组合。     

双相Ti-48Al-2Cr-2Nb合金电解加工表面 微观形貌演变研究

针对各向异性合金材料电解加工过程中,加工表面形貌难以控制的问题,利用位置函数建立双相Ti-48Al-2Cr-2Nb合金微观材料模型,进而建立电解加工仿真微观物理模型,分析加工表面微观形貌随宏观工艺参数演变的规律。研究结果表明：电解液流速在14.7~23.4 m/s、进给速度在1.7~2.3 mm/min范围内,随着电解液流速和进给速度的增加,加工表面粗糙度Ry越低;当加工电压为21 V、进给速度为2.3 mm/min、电解液流速为23.4 m/s时,加工表面最光洁,Ry值达最小,为0.677 μm。从微观形貌演变仿真可以看出,获得最光洁加工表面经历了先粗化后抛光的过程。     

BP神经网络在电火花成形加工中的应用

针对电火花成形加工工艺特点,以峰值电流、脉冲间隔、脉冲宽度、峰值电压为输入参数,加工速度、电极损耗和表面粗糙度为输出参数,提出了用BP神经网络对电火花成形加工过程建立加工效果预测模型,通过计算机仿真的结果与实验数据对比,认为该模型能够比较精确地预测出一定条件下的加工速度、电极损耗和表面粗糙度,并能真实反映出机床的加工工艺规律。     

掺B金刚石膜的电火花抛光实验研究

通过化学气沉积过程中掺B,制备的金刚石膜电阻率下降10-19,导致金刚石膜整体导电,可采用电火花抛光。用扫描电镜和Raman分析了金刚石膜电加工表面的形貌和成分。金刚石膜的电火花抛光是多种效应综合作用的结果,即金刚石膜熔化、汽化、碳的氧化和蒸发、爆炸抛出、界面的化学反应以及金刚石的石墨化。通过实验研究了电加工参数对表面粗糙度和加工速度的影响,通过回归分析得到电火花抛光表面粗糙度和加工速度的经验公式,其相关系数的平方分别为0.91和0.99,表明拟合精度高。试验结果表明,放电电流和脉冲宽度对加工面的表面粗糙度和加工速度影响很大。放电电流为5 A、脉冲宽度为380μs时,抛光后表面粗糙度Ra<1μm。     

喷丸强度对不同粗糙度表面超高强度钢疲劳性能的影响

不同方式加工的高强度钢零件具有不同的表面状态,对其采用相同的喷丸工艺是否合理尚不明确。对不同表面粗糙度23Co14Ni12Cr3Mo E超高强度钢作不同强度的喷丸强化。采用扫描电镜及白光干涉仪观察了喷丸试样的表面形貌,采用金相显微镜观察喷丸试样的表面组织,采用旋弯疲劳试验机测试了喷丸试样的疲劳性能,采用X射线衍射残余应力测试仪测试喷丸试样的残余应力。研究了喷丸强度对不同表面粗糙度超高强度钢的表面组织、形貌、残余应力场及疲劳性能的影响。结果表明:喷丸过程可以细化表面组织,引入残余压应力场,改变表面形貌特征,从而引起表面应力集中状况的改变,其改善效果与原始表面状态有关;对于初始表面粗糙度Ra≤0.4μm的表面,喷丸强化过程能有效提高材料的疲劳寿命,促使疲劳裂纹源内移;随表面粗糙度的提高,当应力集中状况过于严重时,表面组织细化和残余压应力对疲劳性能的提升作用会被抑制,喷丸工艺对疲劳寿命的提升效果大幅下降,疲劳裂纹源均位于表面。     

ZrO2陶瓷颗粒在激光作用下组织形貌演变规律

采用激光表面处理技术制备ZrO_2复合热障涂层可使陶瓷颗粒与金属之间实现冶金结合,增加结合强度,但由于陶瓷颗粒和金属热膨胀系数之间的差异,制备大面积复合热障涂层仍存在比较严重的开裂问题.为降低复合材料层的开裂倾向,更好地控制ZrO_2陶瓷颗粒的离散规律,本文针对激光熔注过程中陶瓷颗粒的熔化问题,采用高速摄像、扫描电子显微镜研究了氧化锆陶瓷颗粒进入熔池前后激光对其形貌与离散规律的影响规律.结果表明,在激光能量密度较低的情况下,激光直接作用于氧化锆陶瓷颗粒会导致单个ZrO_2陶瓷颗粒发生裂解现象;当激光能量密度高于2.5 J/mm~2时,ZrO_2陶瓷颗粒熔化严重并发生球化现象.在激光熔注过程中,由于受到激光和高温熔池的双重作用,氧化锆陶瓷颗粒内部晶粒长大,高能量大尺寸晶界促进了Ti熔体向ZrO_2陶瓷颗粒内部扩散.     

Laser-induced surface oxidation of (Ni/Ti)/Si system with picosecond laser pulses

The surface oxidation of Ni/Ti bilayer, deposited on silicon substrate, affected by picosecond Nd: YAG laser radiation has been investigated. Fluence close to the target ablation threshold and multi-pulse laser irradiation regime were applied. Changes in the chemical composition of the formed surface oxide layer were studied by Elastic Recoil Detection Analysis (ERDA) and X-ray photoelectron spectroscopy (XPS). Morphological features analysis, at the oxide surface layer, was monitored, too. Laser modification as-deposited (Ni/Ti)/Si sample with 10 pulses induces a progressed interaction between Ni and Ti layers with the initial surface oxidation and formation of NiTi alloy phase. Progressed intermixing of components was achieved for the irradiation with 50 and more pulses, when all components were quite uniformly distributed to a depth of about 80 nm. An oxide layer was formed at the surface, with the specific combination of the oxide phases depending on the number of accumulated pulses. Changes in the morphological characteristics are reflected in the increase of the mean surface roughness and the generation of a certain number of cavities. These features are decreased with increasing number of pulses, caused by the surface melting and a pronounced mobility of the materials.     

Excimer laser-induced microstructural changes of alumina and silicon carbide

Surface treatments with a KrF excimer laser were applied on alumina and silicon carbide ceramic materials. Results on the surface modifications induced by laser were related to the processing parameters: laser fluence (1.8 and 7.5 J/cm²), number of laser pulses (1 to 500), frequency (1 to 120 Hz), pulse duration (25 ns), sample speed under the laser beam and working atmosphere. It was ascertained that alumina can be laser treated under air, while silicon carbide needs an inert atmosphere to avoid surface oxidation. Microstructural analyses of surface and cross section of the laser processed samples evidenced that at low fluence (1.8 J/cm²) the surface of both ceramics is covered by a scale due to melting/resolidification. At high fluence (7.5 J/cm²) there are no continuous scales on the surfaces; material is removed by decomposition/vaporisation and the depth of material removal is linearly dependent on the number of pulses. On alumina surface, a network of microcracks formed, while on silicon carbide different morphologies (flat and rugged areas, deposits of debris and discontinuous thin remelted scales) were detected. The evolution of surface morphology and roughness is discussed with reference to composition, microstructure and physical and optical properties of the two tested ceramics and to laser processing parameters.     

Parametric study of surface morphology for selective laser melting on Ti6Al4V powder bed with numerical and experimental methods

A three-dimensional (3D) selective laser melting (SLM) model comprising coupled heat transfer and flow behavior is proposed. The free surface of the melt pool is calculated by the volume-of-fluid (VOF) method, which is a means of acquiring the surface morphology. In this research, laser powers and laser scanning speeds were normalized to characterize the influence on the surface morphology. Results showed that when the scanning speed was increased, the surface morphology initially became flatter, but then roughness developed again at high speed case. Further, as the laser power was increased, the surface morphology gradually roughened. To better describe the surface-morphology phenomenon according to different laser parameters, the melt pool volume and melt pool lifetime were also investigated. With these two factors constrained, a fine surface could be obtained with a low melt pool volume and proper lifetime (approximately 100 to 130 μs). The surface morphology and the width of the melt track were experimentally acquired, and are in a good agreement with the results predicted by simulation.     

The effects of laser-induced modification of surface roughness of Al2O3-based ceramics on fluid contact angle

Laser surface treatment of Al₂O₃-based refractory ceramics, by melting and re-solidification, can be successfully applied to producing surfaces that are pore-free, homogeneous and crack-free. Such treated surfaces can lead to an increase in the corrosion and erosion resistances of the materials, due to lower permeability to corrosive species and higher surface hardness, respectively. Furthermore, the corrosion resistance can be influenced by the wetting characteristics of the treated surfaces in service environment. Therefore, it is important to investigate the effect of laser treatment of ceramic materials on the interaction of the surface with the various environmental elements. This work is concerned with an experimental investigation of the effects of laser surface treatment, by melting and re-solidification, on the fluid contact angles of Al₂O₃-based refractory ceramics. These effects are examined by the modification of the surface roughness characteristics induced by laser treatment. Laser-treated surfaces, both containing cracks and crack-free, are compared with untreated surfaces and the results are reported. The untreated surfaces demonstrated considerable non-uniformity in wetting, in contrast to the treated surfaces. The extent of wetting of the laser-treated surfaces containing cracks was proportional to laser power density. This is due to wetting being enhanced, among other factors, by surface roughness, which increased with power density. The crack-free surfaces were the most smooth and, thereby, exhibited the smallest extent of wettability variations. The reduction in wettability after the laser treatment (crack-free) may have an advantage for corrosion resistance.     

激光双面区熔Al2O3/Y3Al5O12共晶自生复合陶瓷的制备与表征

采用激光区熔凝固技术制备大尺寸Al2O3/Y3Al5O12(YAG)共晶自生复合陶瓷,考察双面区熔条件下大尺寸氧化物共晶陶瓷的熔化及凝固成形规律,采用扫描电镜、能谱和X射线衍射对其凝固组织特征进行了表征和分析.研究结果表明:在优化的凝固工艺下,激光双面区熔增加了熔凝层的厚度,获得了熔凝层厚度8.2 mm,长度65.0 mm,致密度达98.5%±1%的Al2O3/YAG共晶陶瓷;共晶熔凝层厚度随激光扫描速率的减小而增加,随激光功率的增大而增大,并且致密度随着激光功率的增大呈现先增大后减小的趋势;双面区熔后的Al2O3/YAG共晶陶瓷微观组织由均一分布、相互交织的Al2O3和YAG共晶相组成,共晶层片间距较小(1.0~3.5μm),且与凝固速度满足Jackson-Hunt公式;共晶间距随扫描速率的增大逐渐减小;双面区熔界面处共晶组织生长具有连续性,界面结合良好;共晶陶瓷的Vickers硬度为(18.6±1.0)GPa.     

Effects of Laser Repetition Rate and Fluence on Micromachining of TiC Ceramic

Micromachining of titanium carbide (TiC) ceramic is very difficult because of its high hardness and brittleness. Femtosecond pulsed laser was employed to process circular rings on the surface of TiC ceramic. The interaction area between femtosecond laser pulses and TiC at different laser repetition rates and fluences was studied. Morphology and composition of irradiated area were analyzed by scanning electron microscope, energy dispersive spectroscopy, and Raman spectrum. The results indicated that the radius of outer circle was close to the intended radius. Laser fluence had obvious effects on the radius and width of circular rings, compared to laser repetition rate. The width of circular rings increased rapidly with increasing laser fluence from 2.55 × 10^?2 to 1.27 × 10^?1 J/mm², and then stabilized at around 40 µm when laser fluence was above 7.64 × 10^?1 J/mm². The surface of circular rings was characterized by ripples at the lower laser fluence. With increasing laser fluence, four kinds of typical morphology were observed, including ripples, cauliflower-like particles, ball-like particles, and deposited oxide layer. Ball-like particles contained high concentration of titanium, which came from melt ball splashing from ablation area. The others came from the different oxidation stages occurred on the surface of TiC sample.     

激光增材制造超高温氧化物共晶陶瓷研究进展

超高温氧化物共晶陶瓷具有优异的高温强度、高温蠕变性能、高温结构稳定性以及良好的高温抗氧化和抗腐蚀性能, 成为1400 ℃以上高温氧化环境下长期服役的新型候选超高温结构材料之一, 在新一代航空航天高端装备热结构部件中具有重要的应用前景。基于熔体生长技术, 以选择性激光熔化和激光定性能量沉积为代表的激光增材制造技术具有一步快速近净成形大尺寸、复杂形状构件的独特优势, 近年来已发展成为制备高性能氧化物共晶陶瓷最具潜力的前沿技术。本文从工作原理、成形特点、技术分类等方面概述了基于熔体生长的两种典型激光增材制造技术, 综述了激光增材制造技术在超高温氧化物共晶陶瓷制备领域的研究现状和特点优势, 重点介绍了选择性激光熔化和激光定向能量沉积超高温氧化物共晶陶瓷在激光成形工艺、凝固缺陷控制、凝固组织演化、力学性能等方面的研究进展。最后, 指出了实现氧化物共晶陶瓷激光增材制造工程化应用亟需突破的关键瓶颈, 并对该领域未来的重点发展方向进行了展望。     

不同烧结工艺对K0.5Na0.5NbO3陶瓷微结构的影响

采用普通烧结方法和热压烧结方法制备了K0.5Na0.5NbO3(KNN)无铅压电陶瓷.着重研究了两种烧结工艺对陶瓷的微观结构、晶粒形貌及致密度的影响.研究结果表明,两种烧结方法制备的陶瓷样品都具有单一的正交钙钛矿结构,与普通烧结工艺相比,利用热压烧结工艺制备的样品呈现较高的相对密度(大于98%)、较小的晶粒尺寸(0.6μm左右)及较低的介电损耗(1 kHz,tanδ≤2.8%).实验中发现对于热压烧结的样品,通过改变后期退火温度,样品的晶粒尺寸,致密度可以有规律地变化.     

旋转超声磨削Si3 N4陶瓷用金刚石磨具磨损行为研究

热压烧结Si₃N₄陶瓷材料常应用于航天飞行器中关键耐高温零部件,但由于高硬度和低断裂韧性,其加工效率和加工表面质量难以满足制造需求。为了提高热压烧结Si₃N₄陶瓷旋转超声磨削加工质量,减小由于金刚石磨具磨损带来的加工误差,开展了磨具磨损行为研究。基于热压烧结Si₃N₄陶瓷旋转超声磨削加工实验,分析了金刚石磨具磨损形式;基于回归分析建立了金刚石磨具磨损量数学模型,揭示了加工参数及磨具参数与金刚石磨具磨损量间映射关系;并研究了磨损形式与磨具磨损量及加工表面粗糙度影响规律。结果表明：磨粒磨耗是旋转超声磨削Si₃N₄陶瓷用金刚石磨具最主要磨损形式,比例超过50%;主轴转速和磨粒粒度对磨具磨损量影响最为显著;且磨损量较小时,加工表面粗糙度值反而增加。以上研究可为提高旋转超声磨削Si₃N₄陶瓷加工精度和加工质量提供指导。