光粉交互对同轴送粉增材制造能量传输的影响

激光同轴送粉增材制造涉及复杂的光粉交互作用，也是决定粉末物化状态和激光能量有效利用的关键. 因此，借助背影增效瞬态影像捕捉技术和图像处理技术，以时间序列上粉末粒子亮区面积的实时值与平均值变化规律为依据，分析光粉交互作用过程及其对用于熔化基体剩余激光能量的影响. 结果表明，送粉速率和光粉作用距离是影响有效熔化基体能量的关键因素；送粉速率不变时，载气流量增加提高了粉末颗粒的飞行速度，但是对有效熔化基体的能量影响很小；粉末粒径较小时，光粉交互作用过程越激烈，有效熔化基体的能量随之下降. 总体而言，粉末颗粒飞行速度不变时，光粉作用过程中亮区面积的大小和有效熔化基体能量呈正相关.     

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.     

气体流量对射频等离子体球化GH4169合金粉末的影响

采用射频等离子体球化技术对多次激光3D打印废弃的不规则GH4169合金粉末进行二次改造，研究载气、氢气流量对球化粉末效果的影响机理.利用扫描电镜、霍尔流动仪、振实密度测试仪及激光粒度分析仪对球化前后粉末的形貌、流动性、松装比及粒度分布进行分析.结果表明，载气流量越大，粉末在等离子体火焰中停留时间越短、运动絮乱，球化率越低；氢气流量越大，单位时间内等离子体与粉末热交换越大，球化生产效率越高.经球化处理的GH4169合金粉末的流动性、松装比得到了显著的改善，粉末颗粒平均粒径增加，粒径分布变窄.     

Sintering of a nano-crystalline tungsten heavy alloy powder

A nano-crystalline Tungsten heavy alloy powder was obtained by mechanical alloying of elemental powders in a jar mill with a high ball to powder ratio. The chemical composition of the primary powder was 93 W-4.9Ni-2.1Fe (wt%). The mechanically alloyed powder had 22 nm sized tungsten crystallites distributed in an amorphous nickel base phase. Mechanical alloying reduced particle size of powders and also yielded to more uniform particles size distribution. Sintering behavior and microstructural development of that powder were studied and compared with a conventionally mixed powder. Mechanically stored energy and better distribution of primary elements in Nano-crystalline powder had decreased motivation energy of sintering and that powders showed more densification at relatively lower sintering temperatures. Sintering at low temperatures can depress grain growth during sintering and provide desirable properties. A transient intermetallic phase was formed in the nano-crystalline powder during sintering that has not been seen in conventionally mixed powders.     

机械研磨诱导316L不锈钢表层组织的演变

选取具有中等层错能的316L不锈钢进行表面机械研磨处理(SMAT)，制备出纳米结构表层，用X射线衍射(XRD)和透射电镜(TEM)研究横截面组织的演变过程．晶粒细化机理如下：奥氏体粗晶内部通过位错湮灭和重组形成位错胞；应变量和应变速率的增加诱发了机械孪生，形成了片层状孪晶；孪晶内部通过位错的运动使显微组织逐渐由片层状向等轴状转变，且晶粒尺寸逐渐减小、取向差逐渐增大；最终形成等轴状、取向呈随机分布的纳米晶组织．同时，对层错能对微观变形方式和纳米化行为的影响进行了讨论。     

Dynamical solidification behaviors and microstructural evolution during vibrating wavelike sloping plate process

A vibrating wavelike sloping plate process (VWSP) was proposed. Heat and solute transformations, nucleation mechanism and grain growth as well as microstructure evolution were investigated. It is shown that the sloping plate can provide strong undercooling, and a large quantity of heterogonous nuclei appear on the sloping plate surface, wavelike flow and vibration can enable heterogonous nucleus to escape off the plate, which lead to nucleus multiplication. Moreover, wavelike flow and vibration improve solute diffusion coefficient and cause uniform solute and temperature field, which lead to eruptive nucleation. Grain growth has two typical ways, direct globular growth and dendritic growth. Under relative uniform temperature and solute fields, some grains can keep stable growth surface, go on growing with the round surface and finally maintain their globular structure. However, there are always some grains that grow along a certain preferred direction, but under wavelike flow and vibration their dendritic arms break and transform into near spherical structure. During the casting process, microstructural evolution from globular/dendritic structure to globular/equiaxed structure and to globular structure was observed.     

Microstructure and mechanical properties of Mg-Al-Mn-Ca alloy sheet produced by twin roll casting and sequential warm rolling

Microstructural evolution and mechanical properties of twin roll cast (TRC) Mg-3.3 wt.%Al-0.8 wt.%Mn-0.2 wt.%Ca (AM31 + 0.2Ca) alloy strip during warm rolling and subsequent annealing were investigated in this paper. The as-TRC alloy strip shows columnar dendrites in surface and equiaxed dendrites in center regions, as well as finely dispersed primary Al₈Mn₅ particles on interdendritic boundaries which result in the beneficial effect on microstructural refinement of strip casting. The warm rolled sheets show intensively deformed band or shear band structures, as well as finely and homogeneously dispersed Al-Mn particles. No evident dynamic recrystallization (DRX) takes place during warm rolling process, which is more likely attributed to the finely dispersed particle and high solid solution of Al and Mn atoms in α-Mg matrix. After annealing at 350 °C for 1 h, the warm rolled TRC sheets show fine equiaxed grains around 7.8 μm in average size. It has been shown that the present TRC alloy sheet has superior tensile strength and comparative elongation compared to commercial ingot cast (IC) one, suggesting the possibility of the development of wrought magnesium alloy sheets by twin roll strip casting processing. The microstructural evolution during warm rolling and subsequent annealing as well as the resulting tensile properties were analyzed and discussed.     

Plasma spraying of Wc-Co part I: Theoretical investigation of particle heating and acceleration during spraying

Plasma-sprayed WC-Co coatings are used extensively in a variety of wear-resistant applications. The quality of these sprayed coatings depends greatly on the temperature and velocity of the powder particles impacting the substrate. Because it is both expensive and difficult to experimentally determine these particle parameters, the present study deals with a theoretical investigation of particle heatup and acceleration during plasma spraying of WC-Co based on a recently developed model. The effect of WC-Co particle size on the evolution of particle temperature and velocity is examined through calculations performed under typical spraying conditions. The implications of the powder particles, assuming an off-axis trajectory during their traverse through the plasma flame, are also discussed.     

Densification mechanism and microstructural evolution in selective laser sintering of Al-12Si powders

The role of processing parameters on the densification mechanism and microstructural evolution in laser sintered Al-12Si powder has been explored. It was established that both the densification mechanism and microstructural evolution in laser sintered Al-12Si powder were controlled by the specific laser energy input. Analysis of the cross-section of laser sintered microstructures of Al-12Si powders indicated that the tops of the grains in the previous layer are partially re-melted and then undergo epitaxial growth in the next layer where the heat affected zones (HAZ) grain boundaries and solidification grain boundaries (SGBs) are continuous along the fusion boundary.     

Effect of CuO Particle Size on the Microstructure Evolution of Al_2O_(3P)/Al Composites Prepared Via Displacement Reactions in the Al/CuO System

An Al2O3P/Al composite was successfully synthesized using a displacement reaction between 80 wt% Al and20 wt% Cu O powders at a heating rate of 5 °C/min. Two different sizes Cu O particles were used, and all the experiments were conducted under an argon atmosphere. To analyze the microstructural evolution during synthesis, the Al–20 wt%Cu O samples were heated to the temperatures selected according to the differential scanning calorimetry curve and then immediately quenched with water. The phase composites and microstructure of the water-quenching samples were investigated using X-ray diffraction, optical microscopy, scanning electron microscopy and energy-dispersive spectrometry.The results indicate that the Cu O particle size has a significant effect on the microstructural evolution of the samples during the heating stage and on the microstructure of synthesized composites. Smaller Cu O particles can decrease the reaction temperature, narrow the reaction temperature range at the different reaction stages during the heating stage and make the size and distribution of in situ Al2O3 particles more uniform. The reaction between Al and Cu O can be complete as the temperature rises to 900 °C. The size of the in situ Al2O3 particles is approximately 5 lm when the size of the Cu O particles is less than 6 lm. This sample has a relatively high Rockwell hardness of 60 HRB.     

高Mg含量Al-Mg-Sc-Zr合金选区激光熔化成形性及力学性能

基于宽粒径分布粉末(2~46μm),应用选区激光熔化(SLM)技术制备了高Mg含量Al-14.4Mg-0.33Sc-0.19Zr铝合金。系统研究了不同工艺参数和时效处理条件对合金SLM成形性、组织和力学性能的影响。结果表明,高激光功率可有效降低细粉飞溅对样品成形性的干扰,SLM成形样品的最大相对密度为98.6%。样品显微组织由熔池边界细小等轴晶和熔池内部粗大晶粒构成,Mg含量的增加降低了样品织构和柱状晶的含量。经不同温度时效处理后,SLM成形样品的硬度先增加后降低,在350℃时具有最大值。SLM成形样品在350℃时效处理时,硬度和压缩屈服强度均随时效时间的增加出现双峰值现象,时效1 h后样品的硬度(HV)和屈服强度均达到最大值,分别为(1670±30)MPa和(457±10)MPa,延伸率为(27±3)%。样品经350℃长时间时效处理后,由于第二相粒子的粗化,导致样品的硬度和强度有所降低。本研究通过保留铝合金粉末的细粉区,有效提升了粉末的利用率,降低了原料成本,获得了成形性和力学性能较优的高Mg含量SLM成形Al-Mg-Sc-Zr铝合金。     

GH864合金热加工过程中组织特征研究

为了观察分析烟气轮机动叶片GH864合金在热加工过程中组织演化规律,并进一步进行组织的优化控制,对取自棒材和成品叶片的热加工态及随后经热处理的样品进行系统的显微组织对比分析.结果表明:原始棒料晶粒度较均匀,叶片局部位置存在项链状组织;叶片晶粒度的不均匀性主要是由于锻造的过程中各部位的应变量不同,因而产生不同的动态再结晶行为;经过标准热处理后叶片发生了静态再结晶和晶粒长大现象,晶粒度较为均匀.在叶片的锻造过程中,M23C6和部分次生MC发生了回溶,在合金中仅有一些少量的TiC存在,它们主要分布于基体的晶界处;热处理之后大量的M23C6碳化物非连续地沿晶界呈块状析出.     

Effect of ball milling time on microstructures and mechanical properties of mechanically-alloyed iron-based materials

The microstructures and mechanical properties of an iron-based alloy (Fe-13Cr-3W-0.4Ti-0.25Y-0.30O) prepared by mechanical alloying were investigated with scanning electron microscope, optical microscope, X-ray diffractometer and hardness tester. The results show that the particle size does not decrease with milling time because serious welding occurs at 144 h. The density of the alloy sintered at 1 523 K is affected by the particle size of the powder. Finer particles lead to a high sintered density, while the bulk density by using particles milled for 144 h is as low as 70%. In the microstructures of the annealed alloy, large elongated particles and fine equiaxed grains can be detected. The elongated particle zone has a higher microhardness than the equiaxed grain area in the annealed alloys due to the larger residual strain and higher density of the precipitated phase.     

化学共沉淀法制备NiCuZn铁氧体及其性能研究

利用化学共沉淀法制备了NiCuZn铁氧体微粉,研究了反应温度、搅拌速率和盐溶液流速对前驱体粒径的影响。通过XRD、TEM、激光粒度仪（LPS）、精密阻抗分析仪、振动样品磁强计(VSM)等手段对最优条件下得到的样品进行表征。结果表明：当反应温度为70 ℃,盐溶液的流速为0.5 mL/min,搅拌速率为300 r/min时得到尖晶石相的粉体,粒度约为30 nm。将微粉体在500 ℃预烧,在900 ℃烧结后得到样品的相对密度为98%,起始磁导率μi约为200,品质因数Q约为150。截止频率约为70 MHZ     

电磁搅拌对激光熔凝TA15钛合金熔池凝固研究

为了研究电磁搅拌作用对激光熔凝熔池凝固过程的影响,采用有限体积法对施加磁场前后激光单道动态熔凝TA15钛合金过程进行三维磁-热耦合数值模拟。研究了磁场对激光熔池流场、熔凝单道及其周边基材温度分布、固液界面处温度梯度和凝固速度的影响,并采用试验手段对模拟结果进行了验证。模拟结果表明:电磁搅拌作用使激光熔池最大流速增加了约20%,对流加剧促进了熔池热交换作用,使其最高温度下降,固液分界面处温度梯度大幅降低,凝固速度小幅增大,从而有利于熔池顶部组织发生柱状晶-等轴晶转变(CET)。试验结果显示施加磁场后熔凝层顶部有等轴晶组织生成,且随着远离磁场中心,电磁力增大,等轴晶区有扩大趋势。试验结果和模拟结果一致性较好。     

Densification,microstructural evolutions of 90W-7Ni-3Fe tungsten heavy alloys during laser melting deposition process

Thin walled 90W-7Ni-3Fe tungsten heavy alloys (WHAs) have been prepared by a laser melting deposition (LMD) additive manufacturing technique using different input laser volume energy densities. Detailed investigations on densification and microstructural evolutions of the LMD process have been carried out. The result shows that the sample density increases with increasing input energy density by elimination of “lack of fusion” defects. However, some gas delivered with powders gets trapped in the molten pool due to the fast cooling rate and complex shapes of W particles, resulting in a prevalence of small round pore defects even under high input energy densities. Near full density can be obtained when the energy density reaches 74 J/mm³. The LMD WHAs have two phase microstructures consisting of polygonal or dendritic W particles embedded in a nickel‑iron matrix, which has large sized columnar grains due to epitaxial growth. The polygonal particles are partially dissolved/melted W powder particles. The dendritic particles are newly formed grains due to the reprecipitation of supersaturated W in the nickel‑iron matrix during solidification. The proportion of dendritic particles increases with the increasing input energy density. A microstructure evolution process adapted from traditional liquid phase sintering process containing three stages of rearrangement, solution-reprecipitation, and solid state is proposed for the LMD process.     

多管炉工作状况下的温度分布

本文以钨、钼粉末制备常用十五管还原炉为对象,采用特制的加长型热电偶,分别对每根炉管和各炉管的10个截面在通氢状况下的温度进行测定,比较两种炉子的截面温差和沿炉管方向温度分布。结果表明:天然气炉的截面温差最大达到134℃,而电炉最大为65℃;沿炉管方向的温度分布曲线电炉也更加平滑,即电炉的温度分布更均匀一致。从炉子传热过程和结构方式入手初步探讨了影响炉子温度分布和均匀性的原因,天然气炉因对流传热受到气体流速、压力和操作等多因素的影响而难以控制炉子的温度分布,电炉则相对简单和稳定。比较了两种设备生产细颗粒钨粉的粒度分布,结果表明天然气炉的钨粉粗颗粒含量高,粉末不均匀,在细颗粒生产上电炉质量更优。     

Optical Diagnostics Study of Gas Particle Transport Phenomena in Cold Gas Dynamic Spraying and Comparison with Model Predictions

Cold gas dynamic spraying (CGDS), a relatively new thermal spraying technique has drawn a lot of attention due to its inherent capability to deposit a wide range of materials at relatively low-operating temperatures. A De Laval nozzle, used to accelerate the powder particles, is the key component of the coating equipment. Knowledge concerning the nozzle design and effect of process parameters is essential to understand the coating process and to enable selection of appropriate parameters for enhanced coating properties. The present work employs a one-dimensional isentropic gas flow model in conjunction with a particle acceleration model to calculate particle velocities. A laser illumination-based optical diagnostic system is used for validation studies to determine the particle velocity at the nozzle exit for a wide range of process and feedstock parameters such as stagnation temperature, stagnation pressure, powder feed rate, particle size and density. The relative influence of process and feedstock parameters on particle velocity is presented in this work.     

Numerical model and experimental observation for distribution of SiCp in electromagnetic-centrifugally cast composites

A two-phase numerical model coupled with heat transfer was presented to describe the radial distribution of SiC particles on centrifugally-cast metal matrix composite,and a transverse static magnetic field was concurrently imposed to induce electromagnetic stirring of the melt as it revolved with the mold.Meanwhile,experimental observations were also carried out to examine the radial distribution of SiC particles in pure aluminum.The effects of the imposed magnetic field,particle size and the matrix metals were discussed.The computational results show that the particles tend to be congregated by the centrifugal force,and both increasing the imposed magnetic field and decreasing the particle size tend to result in even distribution of the particles.With the magnetic field varying from 0 to 1 T and the particle size from 550 to 180 μm,a uniform distribution of the particles in the aluminum matrix can be obtained among the computational results.The matrix metal can also influence the particle distributions due to the difference in physical properties of metals.Experimental observation shows similar tendency of particle distributions in aluminum matrix influenced by magnetic field and particle size.However,the chilling effect from the mold wall results in an outer particle-free zone,which is not involved in the numerical model.     

高温气相反应合成金红石型纳米TiO2颗粒的研究

在高温气相反应器中,利用掺 ＡｌＣｌ３的 ＴｉＣｌ４氧化反应制备金红石型纳米 ＴｉＯ２颗粒研究了氧气预热温度、反应器尾部氮气流量、反应温度、停留时间等对 ＴｉＯ２颗粒大小的影响结果表明：提高氧气预热温度和加大反应器尾部氮气流量对控制产物粒径有利, ＴｉＯ２粒径随反应温度升高和停留时间延长而增大当反应温度为１３７３Ｋ, ＡＩＣｌ３与ＴｉＣｌ４摩尔比为 ０．２５、停留时间为１．７３ｓ时,纯金红石相纳米ＴｉＯ２颗粒的粒径分布为 ３０－５０ｎｍ．