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陶瓷增强Fe20Cr5Al基复合材料的激光粉末床熔融工艺及性能

Laser powder bed fusion process and properties of ceramic-reinforced Fe20Cr5Al composites

  • 摘要: 当前关于陶瓷增强金属复合材料在激光粉末床熔融(laser powder bed fusion, LPBF)增材制造领域的研究报道较为有限,在材料成分设计、加工参数优化、显微组织及力学性能的全面表征等方面需要进行系统研究。选取Fe20Cr5Al作为基体材料,以WC和球形铸造WC(cast tungsten carbide, CC)作为增强相,对陶瓷增强FeCrAl基复合材料的LPBF工艺及其性能进行了研究。通过响应曲面法开发了Fe20Cr5Al-20vol.%WC复合材料最优打印参数为:激光功率231 W,扫描速度1 259 mm/s,扫描间距0.068 mm;而Fe20Cr5Al-20vol.%CC复合材料相应的最优参数为:236 W-1 280 mm/s-0.06 mm。两种材料打印件的相对密度均在96%以上;研究发现在加工过程中,WC颗粒与基体之间发生反应,形成了Fe3W3C,同时伴随着W和C元素向基体扩散的现象;同纯Fe20Cr5Al合金相比,添加体积分数20%WC和CC后,复合材料的硬度显著提升了超110%,抗压强度也提升了超80%。

     

    Abstract: 【Objective】 This study aimed to address the scarcity of research on laser powder bed fusion(LPBF) of ceramic-reinforced metal composites, as systematic studies are lacking in material design, processing parameter optimization, and microstructure-mechanical property characterization. Given the demand for high-performance FeCrAl-based composites in high-temperature/corrosion-resistant fields, the work focused on developing LPBF strategies for WC/spherical cast tungsten carbide(CC)-reinforced Fe20 Cr5 Al composites, optimizing printing parameters, clarifying interfacial reaction mechanisms, and evaluating density/mechanical property improvements, thereby supporting practical applications and enriching additive manufacturing theory for metal matrix composites.【Method】 Fe20 Cr5 Al powder was used as the matrix, with WC and CC as reinforcements to prepare Fe20 Cr5 Al-20 vol.% WC/CC composite powders via mechanical mixing. The response surface method(RSM) was adopted to optimize LPBF parameters(laser power, scanning speed, hatch spacing). LPBF experiments were conducted, and the relative density was measured using the Archimedes method. Their microstructures, interfacial reactions, and element distributions were analyzed. Additionally, the hardness and compressive strength were evaluated with pure Fe20 Cr5 Al as the reference.【Result】 The results show that RSM effectively optimizes the LPBF parameters: Fe20 Cr5 Al-20 vol.% WC(231 W, 1 259 mm/s, 0.068 mm) and Fe20 Cr5 Al-20 vol.% CC(236 W, 1 280 mm/s, 0.06 mm). Both composites exhibit relative density above 96%. During LPBF, WC/CC reacts with the matrix to form Fe3W3C, accompanied by W/C diffusion into the matrix. Compared with pure Fe20 Cr5 Al, the composites show over 110% higher hardness and 80% higher compressive strength, confirming the significant strengthening effect of ceramic particles.【Conclusion】 LPBF is feasible for preparing high-performance WC/CC-reinforced Fe20 Cr5 Al composites. The optimal parameters ensure >96% relative density, and interfacial reactions(Fe3W3C formation + element diffusion) enhance interfacial bonding, which is key to improved mechanical properties. The remarkable performance enhancements provide a new approach for high-strength FeCrAl-based materials, filling the research gap in LPBF of ceramic-reinforced FeCrAl composites and offering theoretical/technical support for similar composites.

     

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