喷射成形多孔材料的致密化工艺综述

介绍了6种常用的喷射成形多孔材料致密化工艺,即热挤压、轧制、锻造、热等静压、楔形压制和陶粒压制工艺,重点介绍了各种工艺的原理、特点、优缺点以及针对某些缺点而采取的一些改进措施.发现热挤压、轧制、锻造、热等静压和陶粒压制工艺能单次使喷射成形多孔材料整体成形致密化,而楔形压制是一种通过局部小变形累积以实现整体成形致密化的工艺;楔形压制在致密化喷射成形大尺寸材料方面具有独到的优势.最后,探讨和展望了今后的发展方向.     

喷射沉积SiC_P/Al复合材料的塑性变形致密化与冶金缺陷消除研究进展

喷射沉积SiC_P/Al基复合材料具有优异的力学性能,但因孔隙、沉积颗粒边界、沉积颗粒表面的氧化皮等冶金缺陷无法完全消除而使其应用受限,消除冶金缺陷和改进致密化技术对于提高喷射沉积铝基复合材料的性能和扩大其应用尤为重要。本文论述了喷射沉积颗粒增强铝基复合材料的致密化技术,着重介绍了楔形压制工艺、陶粒轧制、旋球同步致密化等新型致密化技术;展望了喷射沉积铝基复合材料的发展趋势,认为热等静压、陶粒轧制的剪切作用小,不能完全消除孔洞和沉积颗粒边界等缺陷;提出颗粒增强铝基复合材料的喷射沉积制备与致密化同步进行有利于减少晶粒与弥散粒子的粗化,提高复合材料的力学性能和成形性能。采用旋球同步致密减少坯料孔隙,降低坯料沉积坯中的氧含量,再通过楔形压制实现沉积颗粒间的完全冶金结合。     

多层喷射沉积颗粒增强铝基复合材料的研究现状与发展趋势

通过多层喷射沉积技术制备颗粒增强铝基复合材料,强化了冷却效果,能获得细小均匀的显微组织,优化复合材料中增强相的分布及其与基体的结合状态。本文综述了喷射沉积颗粒增强铝基复合材料的发展现状;介绍了多层喷射沉积技术的原理与工艺参数;概述了喷射沉积颗粒增强Al-Zn—Mg系、Al—Fe系与Al-Si系复合材料;并介绍喷射沉积颗粒增强铝基复合材料的致密化技术,着重介绍在小吨位设备上致密大块多孔材料的楔形压制工艺、外框限制轧制、陶粒包覆轧制工艺和热压后轧制工艺;展望了喷射沉积铝基复合材料的的发展趋势,认为增强颗粒与基体界面的结合强度有待进一步提高,提出了多层喷射沉积技术将朝在可编程控制下制备组织均匀、细小且致密度高的大尺寸坯料方向发展,而致密化技术也将朝小吨位设备制备大尺寸致密材料的方向发展,认为热压和楔形压制作为预致密方式能有效提高大尺寸喷射沉积坯料的成形能力,有利于进一步成形。     

喷射沉积多孔材料的轧制变形理论

根据"表观总应变能达到一个临界值时材料开始屈服"这一概念,研究和建立了多孔材料轧制塑性变形屈服准则,根据"多孔材料变形时质量不变"原理建立了轧制变形过程中高向变形与相对密度、高向变形与纵向变形、泊松比与相对密度的关系.理论预测与用喷射沉积制备的FVS0812耐热铝合金多孔材料的轧制结果符合得较好;建立了多孔材料轧制变形相对密度与高向应力的关系,提高多孔材料所处的压应力状态可以加速材料的致密化速度,改善多孔材料的轧制成形性能.     

耐热铝合金的致密化工艺与材料性能

本文对多层喷射沉积耐热铝合金管坯经过挤压、旋压、轧制后的密度、显微结构及力学性能进行了检测和分析。在致密化加工过程中 ,材料的密度和力学性能明显提高 ,沉积坯中的界面和孔洞明显愈合 ,材料的显微组织趋于均匀。采用挤压 +旋压或挤压 +轧制致密化成型工艺可以获得高性能多层喷射沉积耐热铝合金材料。     

耐热粉末铝合金筒体热旋成形试验

介绍了喷射沉积耐热铝合金管坯经挤压变形,变薄旋压筒体的研制过程;重点论述了热旋成形筒体的工艺路线.试验探讨了耐热铝合金的旋压温度为350～450℃,道次变薄率约为20%,累计变薄率约50%,需中间退火,退火温度宜取350℃.热旋结果认为,喷射沉积耐热粉末铝合金铸坯直接热旋成形困难,需经挤压比大于4的变形致密,有助于热旋成形.耐热粉末铝合金挤压坯加热变薄旋压,应采用小压下量多道次的变形过程,逐渐细化晶粒组织,才能旋出综合性能良好的筒形件.     

喷射轧制技术的研究进展

喷射轧制加工技术是一种金属半固态近净成形新技术。与铸轧、喷射沉积、铸锭冶金制备的材料相比,喷射轧制材料具有均匀细晶组织和优异综合性能。综述了近年来喷射轧制技术的理论研究,以及数值模拟等方面的研究进展。针对喷射轧制理论研究方面存在不够深入的问题,提出了借鉴喷射成形和双辊铸轧较为成熟的理论。采用实验研究和数值模拟相结合的方法,研究工艺参数对喷射轧制过程中液滴的动力学行为和热力学行为的影响,以及对材料的显微组织和力学性能的影响,探索喷射轧制的基本规律。最终预测了该技术能为金属加工业提供一种节能节材、短流程的板带材生产新途径的发展前景,对该技术及其过程原理的深入研究将形成金属半固态近终形加工的新理论。     

喷射成形颗粒增强金属基复合材料研究进展

喷射成形是将熔融金属雾化和沉积过程相结合,直接由熔融金属制备具有快速凝固组织特征坯体的新型金属材料成形工艺。被引入到非连续增强体金属基复合材料制备领域后,先后发展出了预混喷射成形、反应喷射成形和喷射沉积等工艺方法。介绍了上述颗粒增强金属基复合材料喷射成形工艺方法的基本原理、特点及研究现状。通过对比分析发现喷射沉积技术由于其成形条件限制较少,适用范围广等特点得到了更为广泛的发展,最后结合自身研究对传统喷射沉积技术进行了一定的改进,采用气体-增强颗粒两相流作为雾化介质以期获得提高雾化效率和改善增强颗粒分布均匀性的双重效果。     

结构材料喷射成形技术与雾化沉积高温合金

喷射成形是利用快速凝固方法直接制备金属材料坯料或半成品的先进材料制造技术 ,喷射沉积高温结构材料的冶金性能好、生产效率高、成本低 ,因而在近几年得到了迅速发展 .本项研究的主要目的是要通过喷射成形工艺参数的调整、最大限度地直接减少喷射成形坯中的孔隙度 ,进而得到优质坯料 .利用优化的雾化喷射沉积技术制备了多种高温合金沉积坯 ,沉积坯整体致密、晶粒细小、组织均匀、无宏观偏析、含气量低、力学性能提高 .还简要地比较了喷射成形高温合金与用常规铸锭冶金工艺和粉末冶金工艺制备高温合金的异同 ;总结了航空材料研究院喷射成形高温材料近年来的研究状况 ,包括专用高温材料喷射成形装置和技术及其应用 .     

喷射成形工艺过程数值计算的研究进展

主要介绍了国内外目前对喷射成形过程中3个重要工艺环节(即雾化过程、金属熔滴沉积坯凝固时的热传输以及沉积坯形状控制)数值计算的研究进展,同时简介了喷射成形工艺流程,并对喷射成形数值计算以后的发展提出了一些观点.     

大尺寸重力铸造A356铝硅合金管坯楔压致密化

为了消除铸造铝硅合金中的孔洞、疏松等缺陷,提高合金性能,采用基于多道次局部小变形累积整体成型的楔压成型工艺,压制出力学性能良好,整体致密化,外形圆整的A356管坯。通过金相组织、室温拉伸、布氏硬度和SEM等手段,对楔形压制致密化的规律及其合金的微观组织和力学性能进行研究。试验结果表明:楔形压制工艺能显著压合甚至消除重力铸造产生的孔洞,力学性能得到显著提高,抗拉强度和延伸率分别从楔压前的148MPa,2.5%提高到224MPa,7.3%。     

Microstructural Features and Mechanical Properties Induced by the Spray Forming and Cold Rolling of the Cu-13.5 wt pct Sn Alloy

Copper alloys with high strength and high conductivity are an important functional material with full of potential applications. In the present investigation, a bronze with higher tin content （Cu-13.5 wt pct Sn） was prepared successfully by spray forming, the feasibility of cold roiling this alloy was investigated, and the cold roiling characteristics of this alloy have also been discussed. The results indicate that the spray-formed Cu-13.5 wt pct Sn alloy, compared with the as-cast ingot, shows a quite fine and homogeneous single-phase structure, and, therefore shows an excellent workability. It can be cold-roiled with nearly 15% reduction in the thickness per pass and the total reduction can reach 80%. The classical border between the wrought and cast alloys is shifted to considerably higher tin contents by spray forming. After proper thermo-mechanical treatment, spray-formed Cu-13.5 wt pct Sn alloy exhibits excellent comprehensive mechanical properties. Particularly, it shows a low elastic modulus （-88 GPa） and a high flow stress （over 800 MPa） after cold forming. This combination of properties is unique in the domain of metallic materials and could open new possibilities in spring technology field.     

Structure, mechanical and tribological properties of diamond-like carbon films on aluminum alloy by arc ion plating

The low hardness and poor tribological performance of aluminum alloys restrict their engineering applications. However, protective hard films deposited on aluminum alloys are believed to be effective for overcoming their poor wear properties. In this paper, diamond-like carbon (DLC) films as hard protective film were deposited on 2024 aluminum alloy by arc ion plating. The dependence of the chemical state and microstructure of the films on substrate bias voltage was analyzed by X-ray photoelectron spectroscopy and Raman spectroscopy. The mechanical and tribological properties of the DLC films deposited on aluminum alloy were investigated by nanoindentation and ball-on-disk tribotester, respectively. The results show that the deposited DLC films were very well-adhered to the aluminum alloy substrate, with no cracks or delamination being observed. A maximum sp³ content of about 37% was obtained at −100 V substrate bias, resulting in a hardness of 30 GPa and elastic modulus of 280 GPa. Thus, the surface hardness and wear resistance of 2024 aluminum alloy can be significantly improved by applying a protective DLC film coating. The DLC-coated aluminum alloy showed a stable and relatively low friction coefficient, as well as narrower and shallower wear tracks in comparison with the uncoated aluminum alloy.     

Ultralow-temperature superplasticity in nanoceramic composites

We report the successful demonstration for low-temperature and high-strain-rate superplastic forming of nanoceramic composites for the first time. Porous preforms of nanoceramic composites that were partially densified at low temperatures were superplastically deformed by SPS at the record low temperatures of approximately 1000 to 1050 degrees C, which are comparable to those of Ni-based superalloys. The maximum strain rate achieved is over 10(-2) s(-1), and a compressive strain over 200% can be obtained without cracking. The final products have nanosized grains with excellent optical properties. The present findings present a new strategy for nanoceramic superplasticity, demonstrating that a more practical application of nanoceramic superplasticity is not in the shaping of already-dense materials but in the near-net-shape forming of partially dense parts.     

原位自生TiC颗粒对Al8.5Fe1.4V1.7Si耐热铝合金的组织及性能的影响

利用原位自生技术向Al8.5Fe1.4V1.7Si耐热铝合金中添加一定数量的TiC颗粒,利用金相、X-射线以及透射电镜等手段,分析了材料的组织结构特点,研究了原位TiC粒子对材料的组织结构的影响规律,并测试了材料的力学性能.研究结果表明:原位TiC粒子可以有效地抑制合金中粗大相的产生,促进球状Al12(Fe,V)3Si相的形成;通过添加原位TiC粒子,可以将材料的力学性能提高10%左右,而材料塑性变化不大.     

Enhanced sandwich structure of powder-based composites

The enhanced sandwich structure of powder-based composite with relatively high volume fraction of powders composed of fine densified skins and periodically localized densified core-material for improving their mechanical properties and formability is presented. The structurized composites are fabricated by rolling process with the aid of a novel dynamic three-dimensional rolling technique. This methodology with various actuating phases exhibits different characteristics of forming schemes to fabricate desired structure of composites and provides assorted effects on the forming properties. Consequently, the enhanced sandwich structures of the composite sheet enable the tensile strength and the failure strain to be controllable and improved significantly. In addition, the bendability and the flowability of the composite sheets meaningfully related to their formability are greatly enhanced.     

Recrystallization and fatigue failure of DS alloy blades

This paper analyzed cracks and fractures of DS alloy blades. The failure modes and causes were studied on the basis of fracture surfaces and metallographical examination, and prevention measures were given. The results showed that the cracks and fractures failed in the same mode—fatigue failure caused by surface recrystallization of the blades. The surface recrystallization formed during the solution heat treatment because the blades deformed plastically.