DEFECTS, MICROSTRUCTURES AND MECHANICAL PROPERTIES OF MATERIALS FABRICATED BY METAL ADDITIVE MANUFACTURING
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摘要: 金属增材制造是近30年发展起来的一种新型制造技术, 不同于传统的减材制造过程, 它是基于离散-堆积原理, 根据设计的三维数据模型, 逐层加工获得立体实物的制造技术, 具有近净成形、快速制造、设计自由度高等优点, 特别适用于具有复杂几何结构的高熔点金属构件的直接成形, 在航天航空、核能工业、交通运输、生物医疗等领域具有巨大的技术优势和广阔的应用前景. 本文首先介绍了3种典型的金属增材制造技术原理, 包括选区激光熔化技术、激光金属沉积技术和选区电子束熔化技术. 随后对金属增材制造中的熔合不良、气孔、裂纹等缺陷的形成机理及其控制方法进行了综述, 以激光功率、扫描速度和扫描策略等工艺参数为例阐述了工艺参数对成形构件组织形貌的影响, 同时介绍了金属增材制造技术在传统合金、高熵合金以及非晶合金等材料中的应用及其力学性能. 最后对金属增材制造在扩充可打印的合金体系、量化缺陷与残余应力对材料性能的影响、发展可预测组织形貌的模拟方法、建立金属增材制造数据库和相关标准等方向进行了展望.Abstract: Metal additive manufacturing is an emerging manufacturing technique over the past 30 years. Different from the traditional subtractive manufacturing technology, metal additive manufacturing is based on the principle of discrete-stacking and is in fact a layer-by-layer processing to obtain three-dimensional structures, according to three-dimensional model generated by the computer-aided design. Metal additive manufacturing has the advantages of near net-shaping, rapid manufacturing, and high design freedom. Therefore, it is very suitable for the direct forming of high melting point metal materials and structures with complex structures. Metal additive manufacturing has huge technical advantages and broad application prospects in aerospace, nuclear industry, automotive industry, and biomedical engineering. We first briefly introduce the principles of three typical metal additive manufacturing technologies, including selective laser melting, laser metal deposition and selective electron beam melting. We also summarize their research advances and their differences. Then, we review the recent advances in the formation mechanisms and control methods of defects (such as lack of fusion, pores, and cracks) in metal additive manufacturing. We also emphasize the influences of process parameters (such as laser power, scanning speed, and scanning strategy) on the microstructures of metallic materials fabricated by metal additive manufacturing. We further summarize the printable materials (including traditional alloys, high-entropy alloys, and metallic glasses) and their mechanical properties and performances. Finally, we point out some open issues and challenges for future research, including the expansion of the printable alloy systems, the quantification of the influences of defects and residual stress on mechanical properties, the development of simulation methods to predict the microstructures of metallic materials produced by metal additive manufacturing, and the establishment of relevant databases and standards.
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Key words:
- metal additive manufacturing /
- defects /
- microstructure /
- printable material /
- mechanical properties
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图 2 金属增材制造技术原理示意图
Figure 2. Schematic illustrations of three typical metal additive manufacturing technologies
图 4 金属增材制造中的缺陷
Figure 4. Three typical defects in components fabricated by metal additive manufacturing
图 6 金属增材制造合金的极限拉伸强度与延展性的Ashby图
Figure 6. Ultimate tensile stress vs. elongation of various alloys produced by metal additive manufacturing
SLM LMD SEBM heating source laser laser electron beam powder feed powder bed blown powder powder bed environment argon argon vacuum preheating 80 °C ~ 300 °C 100 °C ~ 250 °C 200 °C ~ 1250 °C beam spot 30 ~ 250 μm 660 ~ 900 μm 200 ~ 1000 μm scan speed 10 ~ 2000 mm/s 1 ~ 20 mm/s 200 ~ 3500 mm/s layer thickness 20 ~ 100 μm 200 ~ 1000 μm 50 ~ 200 μm advantages high-quality surface
finish high strengthhigh building rate
gradient materialslow residual stress
malleabilitydisadvantages high residual stress
low building rateweak strength
poor surface finishpoor surface finish
high cost
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