Optimization of process parameters for TC11 alloy via tailoring scanning strategy in laser powder bed fusion

IF 2.5 4区材料科学 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY Frontiers of Materials Science Pub Date : 2024-12-10 DOI:10.1007/s11706-024-0710-z

Chang Shu, Zhiyu Zheng, Peiran Lei, Haijie Xu, Xuedao Shu, Khamis Essa

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Abstract

TC11, with a nominal composition of Ti–6.5Al–3.5Mo–1.5Zr–0.3Si, is the preferred material for engine blisk due to its high-performance dual-phase titanium alloy, effectively enhancing engine aerodynamic efficiency and service reliability. However, in laser powder bed fusion (L-PBF) of TC11, challenges such as inadequate defect control, inconsistent part quality, and limited optimization of key processing parameters hinder the process reliability and scalability. In this study, computational fluid dynamics (CFD) was used to simulate the L-PBF process, while design of experiments (DoE) was applied to analyze the effect of process parameters and determine the optimal process settings. Laser power was found to have the greatest impact on porosity. The optimal process parameters are 170 W laser power, 1100 mm·s⁻¹ scanning speed, and 0.1 mm hatch spacing. Stripe, line, and chessboard scanning strategies were implemented using the optimal process parameters. The stripe scanning strategy has ∼33% (∼400 MPa) greater tensile strength over the line scanning strategy and ∼12% (∼170 MPa) over the chessboard scanning strategy. This research provides technical support for obtaining high-performance TC11 blisks.

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基于定制扫描策略的TC11合金激光粉末床熔合工艺参数优化

TC11的标称成分为Ti-6.5Al-3.5Mo-1.5Zr-0.3Si，采用高性能双相钛合金，可有效提高发动机气动效率和使用可靠性，是发动机叶片的首选材料。然而，在TC11的激光粉末床熔融（L-PBF）中，缺陷控制不足、零件质量不一致、关键工艺参数优化有限等挑战阻碍了工艺的可靠性和可扩展性。本研究采用计算流体力学（CFD）方法对L-PBF过程进行模拟，并采用实验设计（DoE）方法分析工艺参数的影响，确定最佳工艺设置。激光功率对孔隙率的影响最大。最佳工艺参数为：激光功率170 W，扫描速度1100 mm·s−1，舱口间距0.1 mm。采用最优工艺参数实现了条纹、直线和棋盘扫描策略。条纹扫描策略的抗拉强度比线扫描策略高约33%（约400 MPa），比棋盘扫描策略高约12%（约170 MPa）。本研究为获得高性能TC11磁盘提供技术支持。

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来源期刊

Frontiers of Materials Science MATERIALS SCIENCE, MULTIDISCIPLINARY-

CiteScore

4.20

自引率

3.70%

发文量

515

期刊介绍： Frontiers of Materials Science is a peer-reviewed international journal that publishes high quality reviews/mini-reviews, full-length research papers, and short Communications recording the latest pioneering studies on all aspects of materials science. It aims at providing a forum to promote communication and exchange between scientists in the worldwide materials science community. The subjects are seen from international and interdisciplinary perspectives covering areas including (but not limited to): Biomaterials including biomimetics and biomineralization; Nano materials; Polymers and composites; New metallic materials; Advanced ceramics; Materials modeling and computation; Frontier materials synthesis and characterization; Novel methods for materials manufacturing; Materials performance; Materials applications in energy, information and biotechnology.