尼龙12/铜复合粉末材料及其选择性激光烧结成形

通过溶剂沉淀法制备了尼龙12覆膜铜复合粉末材料，并制备了机械混合尼龙12／铜复合粉末材料。通过扫描电子显微镜（SEM）对两种粉末材料的微观形貌进行了观察，对两种粉末的选择性激光烧结（SLS）成形件的强度及翘曲变形行为进行了对比研究。结果表明：尼龙12覆膜铜复合粉末材料中尼龙12包覆均匀，无裸露Cu粉存在，而机械混合尼龙12／铜复合粉末材料中尼龙12颗粒是零散地非均匀性分散在Cu粉颗粒中。在尼龙12含量及烧结工艺参数相同的条件下，尼龙12覆膜铜复合粉末SLS成形件的拉伸强度及弯曲强度是机械混合尼龙12／铜复合粉末SLS成形件的两倍以上，翘曲变形也明显小于机械混合尼龙12／铜复合粉的SLS成形件。     

Study on the reinforcement of nanosilica on the selective laser sintered nylon–12 parts

使用纳米二氧化硅增强尼龙12选择性激光烧结(SLS)成形件, 通过溶剂沉淀法制备SLS用纳米二氧化硅/尼龙12复合粉末材料, 研究了纳米二氧化硅对SLS成形件力学性能的影响. 结果表明: 纳米二氧化硅以纳米尺寸均匀分散在尼龙12基体中: 复合粉末的粒径比纯尼龙12的粉末小, 因而有利于提高烧结速率及成形件精度; 复合粉末比尼龙12的粉末具有更高的热稳定性; 复合粉末烧结件的拉伸强度、拉伸模量以及冲击强度比纯尼龙12烧结件分别提高了约20.9%、39.4%和9.5%, 说明纳米二氧化硅对尼龙12 SLS成形件的增强效果显著.     

纳米二氧化硅增强尼龙12选择性激光烧结成形件

使用纳米二氧化硅增强尼龙12选择性激光烧结(SLS)成形件,通过溶剂沉淀法制备SLS用纳米二氧化硅/尼龙12复合粉末材料,研究了纳米二氧化硅对SLS成形件力学性能的影响,结果表明:纳米二氧化硅以纳米尺寸均匀分散在尼龙12基体中:复合粉末的粒径比纯尼龙12的粉末小,因而有利于提高烧结速率及成形件精度;复合粉末比尼龙12的粉末具有更高的热稳定性;复合粉末烧结件的拉伸强度、拉伸模量以及冲击强度比纯尼龙12烧结件分别提高了约20.9%、39.4%和9.5%,说明纳米二氧化硅对尼龙12 SLS成形件的增强效果显著.     

选择性激光烧结铝/尼龙复合粉末材料

制备了不同铝粉含量的尼龙12覆膜复合粉末,利用扫描电镜(SEM),能谱分析(EDX),差示扫描量热分析(DSC),热失重分析(TG)对粉末材料的形貌以及热性能进行了表征。对复合粉末进行激光烧结成形,并研究了不同铝粉含量对烧结件尺寸精度以及力学性能的影响。结果表明:尼龙与铝粉表面粘结良好,烧结过程中尼龙熔融,铝粉均匀分布在尼龙基体中;随着铝粉含量的增多,烧结件的弯曲强度和模量显著提高,冲击强度逐渐降低;铝粉质量分数为50 wt%时,烧结试样的弯曲强度和模量与纯尼龙烧结试样相比分别提高了62. 1%和122.3%;铝粉含量的增多能够有效抑制尼龙基体的收缩,提高烧结件的精度。      

选择性激光烧结用尼龙12覆膜Cu粉的制备

提出了溶剂沉淀法制备选择性激光烧结(SLS)用尼龙12覆膜Cu粉复合粉末材料,利用扫描电镜(SEM)观察了复合粉末材料的微观形貌,通过差示扫描量热分析(DSC)、热重分析(TGA)对复合粉末材料的熔融、结晶行为,烧结温度窗口及热稳定性进行了研究,并测试了其烧结件的力学性能。结果表明,复合粉末材料的熔点、结晶速度及热稳定性较纯尼龙粉末有所提高,烧结温度窗口变宽,因而烧结性能优于纯尼龙粉。复合粉末材料烧结件的弯曲强度、弯曲模量、硬度均高于纯尼龙粉的烧结件。     

高分子材料在选择性激光烧结中的应用——(Ⅱ)材料特性对成形的影响

结合高分子材料的选择性激光烧结(SLS)机理,研究了材料特性对SLS成形的影响,结果表明,表面张力是决定高分子材料烧结速率的重要因素,但不是造成高分子材料之间烧结速率存在差别的主要因素;粉末粒径越小,烧结速率越大,SLS成形件的表面光洁度、精度越高;粉末粒径分布会影响粉床密度;球形粉末成形件的形状精度、铺粉效果好于不规则粉末;材料黏度越小,烧结速率越大;材料本体强度越大,成形件强度越高;非晶态聚合物成形件的致密度低于晶态聚合物,而尺寸精度高于晶态聚合物。为SLS用高分子材料的选择与制备提供理论依据。     

选择性激光烧结尼龙-12/聚苯乙烯复合材料

采用机械共混法制备不同成分的尼龙12(PA12)与聚苯乙烯(PS)复合粉末,对其进行选择性激光烧结制备成形制件,研究了PA12/PS复合粉末的成分对成形件的力学性能、尺寸精度及断口形貌的影响。结果表明:当PS的质量分数超过40%时PA12/PS成形件的力学性能明显降低,而当PS质量分数为20%时复合粉末烧结成形件的拉伸强度、断裂延伸率、弯曲强度以及弯曲模量比PA12烧结的成形件分别提高了7.08%、10.19%、6.51%和8.89%,且各方向尺寸精度同比PA12也均有提高。     

聚苯乙烯/聚酰胺-12合金的选择性激光烧结成形

在选择性激光烧结(SLS)成形中,聚苯乙烯(PS)成形件精度高但其力学性能差,而聚酰胺-12(PA12)成形件力学性能高但其尺寸精度较差。为此,通过添加增容剂合成了PS/PA12合金粉末并用于SLS成形,研究了PS/PA12合金、PS及PA12成形件的力学性能、精度及断口微观形貌。结果表明,PS/PA12合金成形件的拉伸强度、断裂伸长率、冲击强度、弯曲强度及弯曲模量分别是PS成形件的4.72倍、1.94倍、4.92倍、4.57倍及1.37倍;PS/PA12合金粉末成形件在x、y及z方向的尺寸误差比PA12分别降低了46.9%,47.3%及20.3%。说明PS/PA12合金粉末成形件兼顾了PS成形件精度高及PA12成形件力学性能好的优点,具有较高的推广使用价值。     

高分子材料选择性激光烧结中的Z轴“盈余”

Z轴"盈余"是选择性激光烧结(SLS)成形中广泛存在并影响成形件精度的问题。文中分析了Z轴"盈余"的形成原因,并通过尼龙12对SLS成形过程中影响Z轴"盈余"的因素进行了实验研究。结果表明,Z轴"盈余"是由于烧结第一层粉末材料时,激光烧结深度大于切片厚度而产生的,表现在烧结件在Z方向上尺寸变大;提高预热温度和激光能量密度及降低切片厚度都会增大Z轴"盈余"。研究结果对控制高分子SLS成形过程中的Z轴"盈余",提高SLS成形件精度具有重要的参考价值。     

铝粉改性共聚尼龙6/66的性能研究

以共聚尼龙6/66(COPA6/66)为基材,金属铝粉为填料,采用熔融共混法制备铝粉改性COPA6/66复合材料。测定了复合材料的力学性能、维卡软化点和熔体流动速率(MFR),并观察了复合材料冲击断面扫描电子显微镜(SEM)图。结果表明,随着铝粉含量的增大,复合材料的拉伸强度先增大后减小,弯曲模量逐渐增大,冲击强度逐渐减小;维卡软化点逐渐增大;熔体体积流动速率(MVR)先增大后减小;其SEM图中的微观形貌说明了铝粉分散良好。     

Preparation, characterisation and processing of carbon fibre/polyamide-12 composites for selective laser sintering

Aiming at developing carbon fibre/polyamide-12 (CF/PA) composite powders for manufacturing high-performance components by selective laser sintering (SLS), the preparation, characteristics and sintering process of the composite powders and mechanical properties of sintered components were studied. Surfaces of the carbon fibres were treated by the oxidation modification and coated with polyamide-12 through the dissolution-precipitation process to provide good interfacial adhesion and homogenous dispersion within the polyamide-12 matrix. The particle size and micro-morphology analyses show that the CF/PA composite powders with 30 wt%, 40 wt% and 50 wt% carbon fibres present the suitable powder sizes and format for SLS. The incorporation of carbon fibres into the polyamide-12 matrix decreases the initial melting temperature and consequently lowers the SLS part bed temperatures, implying lower energy requirement and less thermal degradation in the sintering process. The CF/PA composites also represent higher thermal stability than the pure polyamide-12. The CF/PA sintered components with 30 wt%, 40 wt% and 50 wt% carbon fibres exhibit the greatly enhanced flexural strengths by 44.5%, 83.3%, 114%, and the flexural modulus by 93.4%, 129.4%, 243.4%, respectively, as compared with the pure polyamide-12 sintered parts. Fractured surface analysis shows that the carbon fibres are encapsulated and bonded well with the polyamide matrix. The complex SLS parts with the thinnest wall of 0.6 mm, the density of 1.09 ± 0.02 g/cm³ and the relatively density of 94.13 ± 1.72% were manufactured using the CF/PA composite powder with 30 wt% carbon fibres. This study demonstrates that the CF/PA composite powders prepared by the surface treatment and dissolution-precipitation method represent suitable interfacial adhesion, filler dispersion, particle sizes and sintering behaviours for SLS and enable the manufacture of complex components with high performance.     

固相剪切碾磨制备尼龙12/多壁碳纳米管复合粉体及选择性激光烧结3D打印

采用固相剪切碾磨(S~3M)技术并结合冷冻粉碎制备了适于选择性激光烧结(SLS)的尼龙12(PA12)/多壁碳纳米管(CNTs)复合粉体及相应的烧结制品。采用激光粒度分析仪、扫描电镜、透射电镜、动态力学分析、傅里叶变换红外光谱分析、差示扫描量热仪等对所得PA12/CNTs复合粉体和相应SLS制品的结构与性能进行了表征。结果表明,固相剪切碾磨-冷冻粉碎制备的复合粉体颗粒以椭球形为主,平均粒径75μm,SLS加工窗口为10℃左右,满足SLS对被烧结材料的性能要求,通过加入质量分数为0.1%的流动助剂纳米SiO_2能进一步改善复合粉体的SLS加工性能。磨盘碾磨通过其强大的三维剪切力场实现了CNTs的切割及在PA12基体中的良好分散以及CNTs与PA12大分子链的接枝,显著改善了二者之间的界面相容性。此外,通过优化SLS加工参数,成功制备了表面平整、结构复杂、性能良好的PA12/CNTs烧结制品。所得PA12/CNTs烧结样品具有优良的力学性能,拉伸强度达到44.2 MPa,缺口冲击强度达到8.12 k J/m~2。     

Enhancement of mechanical properties of aluminium/epoxy composites with silane functionalization of aluminium powder

In this study, the effect of surface modification of aluminum powders on the tensile, fracture, and tribological behaviors of aluminum/epoxy composites was investigated. Aluminum powders were surface-modified with 3-aminopropyltriethoxysilane. Aluminium/epoxy composites were fabricated by cast molding method using 10 wt.% untreated and silane-treated aluminium powders. Tensile, mode I fracture, and tribological tests were performed on both composites. The results showed that the tensile modulus and strength of silane-treated aluminum/epoxy composites were ～9% and ～12% greater, respectively than those of untreated aluminum/epoxy composites. The results also showed that the fracture toughness and wear resistance of silane-treated aluminum/epoxy composites were ～32% and ～56% greater than that of untreated aluminum/epoxy composites. Scanning electron microscope (SEM) examination showed the improvement of tensile and fracture properties of silane-treated aluminum/epoxy composites was attributed to the improved dispersion and bonding of aluminum particles in the epoxy, due to the silanization of aluminium powders.     

正交试验法优选正硅酸乙酯包覆铝粉的条件

为提高铝粉的耐腐蚀性,研究了片状铝粉原料的表面预处理方法,以达到有效除去表面脂肪酸的目的,以正硅酸乙酯为原料,利用溶胶-凝胶法(Sol-Gel)在表面预处理后的铝粉表面包覆一层SiO2薄膜,以达到增加铝粉耐腐蚀性的目的。将包覆完的铝粉置于一定浓度的盐酸溶液中,以相同时间内的析氢量作为评价标准,通过正交试验的极差分析与方差分析优选出最佳的包覆条件。结果显示:铝粉耐腐蚀性的因素影响大小为正硅酸乙酯添加量>温度>时间>H2O添加量>催化剂添加量;包覆15 g铝粉的最佳工艺条件为温度55℃,反应时间6 h,TEOS添加量12 g,H2O添加量16 g,NH3·H2O添加量1 g;采用最佳方案制备的包覆型铝粉具有较好的耐腐蚀性能。     

A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing,microstructure, and properties

Manufacturing businesses aiming to deliver their new customised products more quickly and gain more consumer markets for their products will increasingly employ selective laser sintering/melting (SLS/SLM) for fabricating high quality, low cost, repeatable, and reliable aluminium alloy powdered parts for automotive, aerospace, and aircraft applications. However, aluminium powder is known to be uniquely bedevilled with the tenacious surface oxide film which is difficult to avoid during SLS/SLM processing. The tenacity of the surface oxide film inhibits metallurgical bonding across the layers during SLS/SLM processing and this consequently leads to initiation of spheroidisation by Marangoni convection. Due to the paucity of publications on SLS/SLM processing of aluminium alloy powders, we review the current state of research and progress from different perspectives of the SLS/SLM, powder metallurgy (P/M) sintering, and pulsed electric current sintering (PECS) of ferrous, non-ferrous alloys, and composite powders as well as laser welding of aluminium alloys in order to provide a basis for follow-on-research that leads to the development of high productivity, SLS/SLM processing of aluminium alloy powders. Moreover, both P/M sintering and PECS of aluminium alloys are evaluated and related to the SLS process with a view to gaining useful insights especially in the aspects of liquid phase sintering (LPS) of aluminium alloys; application of LPS to SLS process; alloying effect in disrupting the surface oxide film of aluminium alloys; and designing of aluminium alloy suitable for the SLS/SLM process. Thereafter, SLS/SLM parameters, powder properties, and different types of lasers with their effects on the processing and densification of aluminium alloys are considered. The microstructure and metallurgical defects associated with SLS/SLM processed parts are also elucidated by highlighting the mechanism of their formation, the main influencing factors, and the remedial measures. Mechanical properties such as hardness, tensile, and fatigue strength of SLS/SLM processed parts are reported. The final part of this paper summarises findings from this review and outlines the trend for future research in the SLS/SLM processing of aluminium alloy powders.     

Surface modification of organic powders for enhanced rheology via atomic layer deposition

Some organic additive manufacturing feedstocks can be cohesive and tend to agglomerate in suspensions, which can lead to significant challenges in formulating solids-loaded fluids, like those used in many additive manufacturing processes. By depositing an ultra-thin, layer of a second material conformally with the surface of the feedstock powder, Atomic Layer Deposition (ALD) can be used to uniquely modify the surface and, thereby, cohesion of the powder material without changing the properties of the bulk material. This paper demonstrates low temperature (<115 °C), ALD of aluminum oxide on temperature-sensitive materials: first, on polyimide thin film flats, then, on melamine and nylon organic powder feedstocks with the goal of improving their powder rheology. The process produced amorphous aluminum oxide-hydroxide coatings that are both uniform and conformal to the powder’s surface. Aluminum oxide coatings on the nylon powders did not show a significant change in the flow properties of the powder, given the already low cohesivity of nylon. In contrast, the highly cohesive melamine powders exhibited significant improvements in flowability after being coated with a layer as thin as 20 nm, due to a reduction in inter-particle cohesivity. The basic flowability decreased from 199 to 185 mJ and the specific energy increased from 4.95 to 6.39 mJ/g.