Ti-V-Cr系阻燃钛合金的激光原位合金化3D打印及Ti原料粉材的影响研究

钛合金作为先进金属材料的代表，具有比强度高、耐腐蚀性好等优越的性能特点，已在航空工业领域获得了广泛的应用。然而，钛合金的化学性质较为活泼，同时其表面氧化膜在高温下会自发溶解破裂，因此航空发动机等位置的钛合金部件易被摩擦点燃并引发“钛火”事故，限制了钛合金在航空领域的进一步应用。针对“钛火”问题，世界各国研发了多种具有阻燃效果的钛合金，并以Ti-V-Cr系阻燃钛合金为阻燃性能最好、应用最为成熟的代表。然而，当前Ti-V-Cr系阻燃钛合金依然面临冷、热加工难度大，加工过程中V等昂贵合金元素损耗量高等困扰其应用的严峻问题。
针对上述材料成型方面的挑战，本文提出以Ti、V、Cr单质元素粉为原材料，通过粉床铺粉式激光3D打印（Laser Powder Bed Fusion，LPBF）原位合金化技术，在热力学与动力学分析的基础上，灵活调整合金成分与打印、热处理工艺，实现了Ti-V-Cr系阻燃钛合金的高质量近净成型。同时，本文以降低原料成本为目的开发了改性Ti原料粉材，探究了低成本改性Ti粉的多方面特性，以及其对3D打印Ti-V-Cr系阻燃钛合金的组织、力学性能的影响与机理。
本文系统地对比分析了Ti-35V-15Cr、Ti-25V-15Cr两种主流阻燃钛合金的LPBF原位合金化3D打印成型质量、室温力学性能和微观组织，证实Ti-25V-15Cr为适用于打印的较优成分，并在此基础上开展了深入的组织与性能优化研究。运用透射电子显微、电子能量损失谱、背散射电子衍射等先进材料表征技术，深入研究了不同打印和热处理工艺所制备的Ti-25V-15Cr合金的工艺-组织-力学性能关联规律，并最终打印成型了近全致密、晶粒细小、化学成分分布均匀的Ti-25V-15Cr阻燃钛合金力学试样与典型航发部件等比例缩小模型。激光原位合金化3D打印的Ti-25V-15Cr试样最佳室温屈服/抗拉强度达1126/1149 MPa，断裂延伸率为5.51%；540 °C屈服/抗拉强度达833/890 MPa，断后延伸率为17.00%；其室/高温强度均显著高于传统锻件（参考室温、540 °C屈服/抗拉强度分别为980/1025 MPa、710/810 MPa）。
同时，本文针对自主开发的低成本改性Ti原料粉材，系统研究了粉体改性对于Ti粉的形貌、组织及成分的影响及机理，证实以该改性Ti粉作为3D打印原料将影响Ti-25V-15Cr阻燃钛合金的成型质量。该原料粉材可将自身成分与组织特性部分地“遗传”至打印后的试样中，降低β-Ti晶粒长大与再结晶所需的激活能阈值从而降低再结晶温度，并造成材料强度、塑性与高温持久性能等力学性能的波动。
本文验证了以LPBF原位合金化3D打印成型高质量Ti-25V-15Cr阻燃钛合金产品的可行性，奠定了相应的3D打印与热处理工艺基础，提出了材料组织与性能的调控方法，拓展了LPBF原位合金化技术制备超高合金比与硬脆金属材料的能力。同时，本文从原子尺度揭示了Ti-25V-15Cr阻燃钛合金在受热后的析出相类型与相变模式，为研究该合金在服役过程中的组织与力学性能变化提供了新的科学依据。此外，本文初步探索了低成本改性Ti原料粉材用于LPBF打印钛合金的可行性，并创造性地提出了基于原料粉材“遗传性”调控打印后材料组织与性能的新思路。

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