面向金属增材制造的气体雾化与离心雾化粉末性能比较研究

    金属增材制造技术因其成形优势明显，制件性能好，在各行各业中有广阔的 应用前景。然而，因其制件成本高、工艺稳定性以及构件可重复性低，使其产品应 用研究仍然停留在实验室阶段。粉末作为金属增材制造工艺的主要原材料是解决 上述问题的关键之一。然而粉末原料特性—粉末可打印性能—3D 打印成形件性能 之间的关系尚不明确，没有形成完善的行业标准，使得粉末的开发、生产以及选择 缺乏有效的指导。因此，加强对现有工艺制备的粉末原料特性以及可打印性能的 研究对推动行业发展尤其重要。本文对主流的气体雾化以及离心雾化（包括等离 子旋转电极雾化和旋转盘雾化）两类工艺制备的粉末的性能及其可打印性能进行 比较研究，有助于推动低成本高质量金属粉末制备技术的发展，推动金属增材制 造产业化的进程。本文完成的主要工作如下：

（1）分别利用气体雾化法和等离子旋转电极雾化法制备了两种 IN718 粉末， 利用气体雾化法和旋转盘雾化法制备了两种 AlSi10Mg 粉末。分别利用图像分析 法、激光衍射法、CT 扫描、标准漏斗法、XRD 等方法对四种粉末的形貌、赘生物 指数、钝度、粒径分布、空心粉含量、粉末流动性、松装密度、粉末中物相等性能 进行定量表征。结果显示，与其对应的离心雾化粉末相比，两种材料的气体雾化 粉末整体球形度低，小颗粒的细粉体积分数高，粉末孔隙率高、流动性差、松装密 度低。

（2）在激光粉床熔融工艺中，研究激光功率以及扫描速度对试样的致密度、 表面粗糙度以及硬度的影响，确定了两种 IN718 粉末的打印工艺窗口，确定了最 佳的打印工艺参数。在最佳的打印工艺参数下，成功制备出两种性能优良的 IN718 激光粉床熔融成形试样。研究发现，虽然球形度高、粒度均匀的等离子旋转电极 雾化粉末具有更大的工艺窗口以及更稳定的成形质量，但是粉末原料特性差异对 成形件的最佳机械性能无明显影响。气体雾化试样硬度为 328 ± 16 HV，等离子旋 转电极雾化试样硬度为 335 ± 7 HV。常温下，气体雾化试样抗拉强度为 1105 ± 20 MPa，等离子旋转电极雾化试样抗拉强度为 1130 ± 9 MPa。高温（650 ℃ ）下，气 体雾化试样抗拉强度为 962 ± 3 MPa，等离子旋转电极雾化试样抗拉强度为 947 ± 4 MPa。

（3）在激光熔融沉积工艺中，研究激光功率以及扫描速度（送粉速度与扫描 速度同步改变）对试样的致密度、硬度的影响，确定了两种 AlSi10Mg 粉末的打印 I 摘 要 工艺窗口，并在最佳打印工艺参数下成功制备出性能优良的块状试样。研究发现， 旋转盘雾化粉末在打印过程中送粉效率高，烟尘少，成形质量稳定，沉积态试样 的表面光滑；气体雾化粉末在打印过程中烟尘多，成形精度差，沉积态试样边缘 存在局部坍塌。两种铝合金沉积态试样的力学性能相近。经过 T6 热处理后，两种 铝合金试样的力学性能提升显著，但是旋转盘雾化试样的微观组织更加细小均匀， 强度提升更大。

    本文通过对不同雾化工艺制备的粉末原料的性能进行定量表征，并研究粉末 原料特性在特定工艺中对打印工艺窗口以及成形质量的影响，将粉末的制备工艺 —粉末原料性能—3D 打印成形件质量相关联。本研究有助于为 3D 打印用金属粉 末的开发、生产以及选择提供指导，从而实现对金属增材制造成形件成本以及质 量的控制与优化，进一步推动金属增材制造技术的应用与发展。

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