激光增材制造超高温氧化物共晶陶瓷研究进展

doi:10.15541/jim20210608

无机材料学报 ›› 2022, Vol. 37 ›› Issue (3): 255-266.DOI: 10.15541/jim20210608 CSTR: 32189.14.10.15541/jim20210608

所属专题：【制备方法】3D打印(202409)；【结构材料】超高温结构陶瓷(202409)

激光增材制造超高温氧化物共晶陶瓷研究进展

刘海方¹^,²(), 苏海军¹^,²(), 申仲琳¹, 姜浩¹, 赵迪¹, 刘园¹, 张军¹, 刘林¹, 傅恒志¹

1.西北工业大学凝固技术国家重点实验室, 西安 710072
2.西北工业大学深圳研究院, 深圳 518057

收稿日期:2021-10-02 修回日期:2021-11-05 出版日期:2022-03-20 网络出版日期:2021-12-24
通讯作者: 苏海军, 教授. E-mail: shjnpu@nwpu.edu.cn
作者简介:刘海方(1987-), 男, 博士研究生. E-mail: liuhaifang@mail.nwpu.edu.cn
基金资助:
国家自然科学基金(51822405);国家自然科学基金(51472200);国家自然科学基金(52130204);国家自然科学基金(52174376);深圳市科技创新委员会(JCYJ20180306171121424);陕西省科技创新团队计划(2021TD-17);陕西省科技厅与西北工业大学联合研究基金(2020GXLH-Z-024);中央高校基础研究基金(D5000210902);凝固技术国家重点实验室研究基金(2019-QZ-02)(NPU 2019-QZ-02);西北工业大学博士论文创新基金(CX2021056);西北工业大学博士论文创新基金(CX2021066)

Research Progress on Ultrahigh Temperature Oxide Eutectic Ceramics by Laser Additive Manufacturing

LIU Haifang¹^,²(), SU Haijun¹^,²(), SHEN Zhonglin¹, JIANG Hao¹, ZHAO Di¹, LIU Yuan¹, ZHANG Jun¹, LIU Lin¹, FU Hengzhi¹

1. State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an 710072, China
2. Research & Development Institute of Northwestern Polytechnical University in Shenzhen, Shenzhen 518057, China

Received:2021-10-02 Revised:2021-11-05 Published:2022-03-20 Online:2021-12-24
Contact: SU Haijun, professor. E-mail: shjnpu@nwpu.edu.cn
About author:LIU Haifang (1987-), male, PhD candidate. E-mail: liuhaifang@mail.nwpu.edu.cn
Supported by:
National Natural Science Foundation of China(51822405);National Natural Science Foundation of China(51472200);National Natural Science Foundation of China(52130204);National Natural Science Foundation of China(52174376);Science, Technology and Innovation Commission of Shenzhen Municipality(JCYJ20180306171121424);Science and Technology Innovation Team Plan of Shaanxi Province(2021TD-17);Joint Research Funds of the Department of Science & Technology of Shaanxi Province and NPU(2020GXLH-Z-024);Fundamental Research Funds for the Central Universities(D5000210902);Research Fund of the State Key Laboratory of Solidification Processing(NPU 2019-QZ-02);Innovation Foundation for Doctor Dissertation of Northwestern Polytechnical University(CX2021056);Innovation Foundation for Doctor Dissertation of Northwestern Polytechnical University(CX2021066)

摘要/Abstract

摘要：

超高温氧化物共晶陶瓷具有优异的高温强度、高温蠕变性能、高温结构稳定性以及良好的高温抗氧化和抗腐蚀性能, 成为1400 ℃以上高温氧化环境下长期服役的新型候选超高温结构材料之一, 在新一代航空航天高端装备热结构部件中具有重要的应用前景。基于熔体生长技术, 以选择性激光熔化和激光定性能量沉积为代表的激光增材制造技术具有一步快速近净成形大尺寸、复杂形状构件的独特优势, 近年来已发展成为制备高性能氧化物共晶陶瓷最具潜力的前沿技术。本文从工作原理、成形特点、技术分类等方面概述了基于熔体生长的两种典型激光增材制造技术, 综述了激光增材制造技术在超高温氧化物共晶陶瓷制备领域的研究现状和特点优势, 重点介绍了选择性激光熔化和激光定向能量沉积超高温氧化物共晶陶瓷在激光成形工艺、凝固缺陷控制、凝固组织演化、力学性能等方面的研究进展。最后, 指出了实现氧化物共晶陶瓷激光增材制造工程化应用亟需突破的关键瓶颈, 并对该领域未来的重点发展方向进行了展望。

关键词: 氧化物共晶陶瓷, 激光增材制造, 选择性激光熔化, 激光定向能量沉积, 综述

Abstract:

Melt-grown oxide eutectic ceramics possess a large area of clean and firmly bonded phase interfaces through liquid-solid phase transformation, which makes them present excellent high-temperature properties such as strength retention, creep resistance, thermal stability, oxidation and corrosion resistance. As a result, directionally solidified oxide eutectic composite ceramics have been regarded as one of candidates for new generation of high temperature structural materials which can service above 1400 ℃ in oxidation environment for a long period. In recent years, laser additive manufacturing based on melt growth has developed into the most promising technique for preparing ultrahigh-temperature oxide eutectic ceramics due to its unique advantage in one-step fabricating highly dense parts with large sample size and complex shape. In this paper, laser additive manufacturing technology was summarized in terms of forming principle, technical features and classification. The research status and the encountered technical problems in additively manufacturing melt-grown oxide eutectic ceramics were reviewed. Moreover, the research progress on laser additive manufacturing oxide eutectic ceramics was introduced from the aspects of laser forming process, solidification defect control, solidification microstructure evolution, and mechanical properties. Finally, the key bottlenecks of realizing engineering applications of the laser 3D-printed oxide eutectic ceramics were pointed out, and the future development directions of this field were prospected. The focus of the future work can be summarized into four points: developing high-quality spherical eutectic ceramic powders, preparing large-scale eutectic parts with complex shapes, accurate controlling solidification defects, as well as strengthening and toughening eutectic composites.

Key words: oxide eutectic ceramic, laser additive manufacturing, selective laser melting, laser directed energy deposition, review

中图分类号:

TQ174

刘海方, 苏海军, 申仲琳, 姜浩, 赵迪, 刘园, 张军, 刘林, 傅恒志. 激光增材制造超高温氧化物共晶陶瓷研究进展[J]. 无机材料学报, 2022, 37(3): 255-266.

LIU Haifang, SU Haijun, SHEN Zhonglin, JIANG Hao, ZHAO Di, LIU Yuan, ZHANG Jun, LIU Lin, FU Hengzhi. Research Progress on Ultrahigh Temperature Oxide Eutectic Ceramics by Laser Additive Manufacturing[J]. Journal of Inorganic Materials, 2022, 37(3): 255-266.

图/表 13

图1 激光增材制造原理图[28]

Fig. 1 Schematic diagram of laser additive manufacturing[28] (a) Selective laser melting; (b) Laser directed energy deposition

表1 SLM与LDED技术特点对比[28]

Table 1 Comparison of the SLM and LDED technologies[28]

Technology	Scanning control	Molten pool size/mm	Energy density /(W·cm^-2)	Building rate /(cm³·min^-1)	Manufacturing precision	Preferred applications
SLM	Scanner	<0.2	10⁶-10⁷	~1.3	High	Net-shaping small- and medium-sized components
LDED	Laser nozzle	>3	~10⁵	11.5	Low	Preparing large-scale components

图2 独立控制各陶瓷组元输送的LDED成形工艺[39]

Fig. 2 LDED-processed oxide eutectic ceramic through independent controlling the delivery of ceramic powders[39]

图3 球形陶瓷粉末制备工艺及其特性[68]

Fig. 3 Preparation technology and characteristics of spherical ceramic powders[68] (a) Schematic diagram of centrifugal spray drying method; (b) Morphology of the initial ceramic powders; (c) Morphology of the modified ceramic powders; (d) Particle size distribution of the modified ceramic powders; (e) Powder feeding test

图4 扫描长度对裂纹形成的影响[68]

Fig. 4 Effect of scanning length on the formation of crack[68] (a, b) 15 mm; (c) 10 mm; (d) 4 mm

图5 超声振动对气孔的影响[43]

Fig. 5 Effect of assisted ultrasonic on porosity[43] (a) Sample sections before ultrasonic addition; (b) Sample sections after ultrasonic addition

图6 不同成形环境下制备的Al2O3/GAP/ZrO2共晶陶瓷试样

Fig. 6 Al2O3/GAP/ZrO2 eutectic ceramics prepared at different environments (a) Atmospheric atmosphere; (b) Ar atmosphere with oxygen content >200 μg/L; (c) Ar atmosphere with oxygen content <50 μg/L

图7 采用激光增材制造技术制备的氧化物共晶陶瓷试样

Fig. 7 Oxide eutectic ceramics prepared by laser additive manufacturing (a) SLM-processed Al2O3/ZrO2 eutectic ceramic with shape of framework for a dental restoration[30]; (b) LDED-processed Al2O3/ZrO2 eutectic ceramics with various shapes[43]; (c) LDED-processed Al2O3/GAP/ZrO2 eutectic ceramic rod[70]

图8 激光增材制造氧化物共晶陶瓷沿堆积方向的微观组织特征[68]

Fig. 8 Microstructure characteristics of the LAM-processed oxide eutectic ceramic along the building direction[68] (a) Periodic banded structure; (b) Magnified image of the banded structure

图9 LDED制备的Al2O3/GAP/ZrO2共晶陶瓷带状区附近的凝固组织特征[68]

Fig. 9 Microstructure characteristics in vicinity of the banded structure of the LDED-processed Al2O3/GAP/ZrO2 eutectic ceramic[68] (a) Banded structure; (b) Microstructure characteristic of the banded structure; (c) Microstructure at the lower boundary of the banded structure; (d) Microstructure at the upper boundary of the banded structure

图10 LDED制备的Al2O3/YAG/ZrO2共晶陶瓷沉积层内的凝固组织特征[47]

Fig. 10 Microstructure characteristics of the LDED-processed Al2O3/YAG/ZrO2 eutectic ceramic in a deposited layer[47] (a) Eutectic colony structure; (b) Microstructure inside the colony; (c-e) TKD (Transmission kikuchi diffraction) orientation maps of the phases of Al2O3, YAG and ZrO2, respectively; (f) Pole figures of Al2O3, YAG and ZrO2, corresponding to (c-e), respectively

图11 LDED制备的Al2O3/YAG共晶陶瓷各相在熔池凝固过程中的生长方向演变[46]

Fig. 11 Orientation variations of eutectic phases of the LDED-processed Al2O3/YAG eutectic ceramic during solidification process[46] (a) EBSD orientation maps of Al2O3 and YAG in bottom zone of the molten pool; (b) Orientation variations of Al2O3 and YAG along the height direction of the molten pool

表2 激光增材制造与定向凝固共晶陶瓷性能对比

Table 2 Mechanical property comparison of the oxide eutectic ceramics prepared by laser additive manufacturing and directional solidification (DS)

Eutectic system	Hardness /GPa	Fracture toughness /(MPa·m^1/2)	Preparation method
Al₂O₃/YAG	21.50	5.86	LDED^[41]
Al₂O₃/ZrO₂	16.22	7.67	LDED^[35]
Al₂O₃/YAG/ZrO₂	18.90	3.84	LDED^[47]
Al₂O₃/GAP/ZrO₂	15.30	7.80	SLM^[69]
Al₂O₃/YAG	17.50	3.60	DS^[77]
Al₂O₃/ZrO₂	16.53	6.50	DS^[78]
Al₂O₃/YAG/ZrO₂	16.70	8.00	DS^[79]
Al₂O₃/GAP/ZrO₂	17.90	8.50	DS^[80]

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激光增材制造超高温氧化物共晶陶瓷研究进展

Research Progress on Ultrahigh Temperature Oxide Eutectic Ceramics by Laser Additive Manufacturing

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