利用激光粉末床熔融技术快速成型 7xxx 铝合金

K Zhang, S Wenner, C D Marioara, E W Hovig, Q Du, M Onsøien, K Marthinsen
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摘要

高强度锻造级铝合金的增材制造在工业界和学术界引起了极大的兴趣,但由于其微观结构容易形成裂纹,因此在实践中仍然存在困难。本研究旨在利用激光粉末床熔融(LPBF)技术制备致密无裂纹的 AA7075 型铝合金样品,并对其微观结构进行研究。研究发现,纯 AA7075 粉末的 LPBF 在所有测试的 25 个加工参数下都会产生微裂纹,这些参数涵盖了很宽的激光功率和速度范围。为了避免出现裂纹,尝试了不同的方法,包括高预热温度、引入纳米颗粒和在合金中添加硅。通过机械混合的方法在 AA7075 中引入 ZrH2 纳米粒子,可以成功地利用 LPBF 制作出无裂纹的样品。通过机械混合在 AA7075 粉末中添加 5%的 Si 也能获得无裂纹且相对密度高的样品。研究还发现,在 250°C 下预热的成品样品硬度低至 70HV。对于含有 ZrH2 的 AA7075 变体和添加了硅的 AA7075 变体,在 480°C 下进行水淬固溶,然后在 120°C 下进行人工老化,可使硬度分别达到 140HV 和 120HV。详细的特性分析表明,预热温度和合金化对微观结构都有明显的影响。因此,在对高强度沉淀硬化铝合金进行 AM 时,应谨慎选择预热温度。
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Additive Manufacturing of 7xxx Aluminium Alloys by Laser Powder Bed Fusion
Additive manufacturing of high strength wrought grade aluminium alloys is of great industrial and academic interests, but still difficult in practice due to the tendency of crack formations in the microstructure. This work aimed at producing dense crack-free samples of AA7075-type aluminium alloys by the laser powder bed fusion (LPBF) technology, and to investigate the microstructure. It was found that LPBF of pure AA7075 powder gave micro-cracks for all tested 25 processing parameters which covered a wide range of laser power and speed. In order to avoid the cracks, different methods were tried including high preheating temperature, introducing nano-particles, and adding Si into the alloys. Introducing ZrH2 nano-particles into AA7075 by mechanical blending could successfully produce crack-free samples using LPBF. Adding 5% Si into the AA7075 powder by mechanical blending could also give crack-free samples with high relative density. It was also found that the as-built samples with preheating at 250°C had hardness as-low-as 70HV. Solutionizing at 480°C with water quenching followed by artificial aging at 120°C can bring the hardness to 140HV and 120HV, for the AA7075 variants with ZrH2 and with addition of Si, respectively. Detailed characterizations revealed clear influences of both preheating temperature and alloying on the microstructure. It is concluded that preheating temperature should be carefully selected for AM of high strength precipitation hardening Al alloys.
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