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| 镍基单晶高温合金的增材制造修复研究进展 |
| Research Progress on Additive Manufacturing and Repair of Nickel-based Single Crystal Superalloys |
| Received:September 01, 2024 |
| DOI：10.3969/j.issn.1674-6457.2024.10.002 |
| 中文关键词: 镍基单晶高温合金 增材制造 损伤修复 工艺调控 数值模拟 |
| 英文关键词: nickel-based single crystal superalloys additive manufacturing damage repair process control numerical simulation |
| 基金项目:国家自然科学基金(52074182，52304406，U23A20612);上海市自然科学基金(22ZR1430700，23TS1401900);上海交通大学新进教师启动计划 |
| Author Name | Affiliation | | ZHOU Zhixiang | School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China | | REN Neng | School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China | | WANG Yida | School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China | | ZENG Long | School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China | | XIA Mingxu | School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China | | LI Jun | School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China | | LI Jianguo | School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China |
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| 中文摘要: |
| 镍基单晶高温合金因其优异的高温强度、抗氧化性和抗蠕变性能被广泛应用于航空航天领域。单晶涡轮叶片在服役过程中极易受到损伤，损伤的修复再制造技术具有显著的经济价值，增材制造则为高温合金零件的修复提供了新途径。增材制造在CMSX-4、DD6等合金单晶叶片的修复中已得到初步实现，为确保修复后的叶片能够满足服役要求并投入生产实践，仍需解决修复层存在的裂纹、杂晶和气孔等问题。通过改善工艺参数、改变基材晶体取向、优化沉积或扫描策略等方法可实现单晶组织无缺陷和连续的外延生长，但其工艺窗口的确定和性能控制仍面临挑战。此外，针对增材制造修复单晶叶片的研究目前主要集中于定向能量沉积技术，对于激光粉末床熔融技术和电子束熔融技术，目前的研究尚处于起步阶段，仍需建立相关理论和探索工艺窗口。数值模拟在增材制造工艺参数研究中具有预测性、可视化和高效性等优势，通过建立熔池的热力学模型和动力学模型，可以有效预测增材制造过程中的热量传递、熔池形貌、金属液流动以及修复区应力分布等多物理场，并深入理解工艺参数与材料微观结构以及性能之间的关系，进而为优化工艺参数、避免孔隙和缺陷的形成、改善修复区微观组织、提高修复精度提供相应的参考。 |
| 英文摘要: |
| Nickel-based single crystal superalloys are widely used in the aerospace field due to their excellent high temperature strength, oxidation resistance and creep resistance. Single crystal turbine blades are extremely vulnerable to damage during service. The repair and remanufacturing technology of damage has significant economic value. Additive manufacturing provides a new way for the repair of superalloy parts, which has been preliminarily realized in the repair of single crystal blades of CMSX-4, DD6 and other alloys. In order to ensure that the repaired blades can meet the service requirements and can be put into production practice, additive manufacturing still needs to overcome the problems of cracks, stray grains and pores in the repair layer. Defect-free and continuous epitaxial growth of single crystal structure can be achieved by improving process parameters, changing substrate crystal orientation, optimizing deposition or scanning strategies, but the determination of process window and performance control still face challenges. Now the research on repairing single crystal blades by additive manufacturing mainly focuses on directional energy deposition technology. The research on laser powder bed melting technology and electron beam melting technology is still in its infancy, and relevant theories and exploration process windows still need to be established. Numerical simulation has the advantages of predictability, visualization and high efficiency in the study of additive manufacturing process parameters. By establishing the thermodynamic model and kinetic model of the molten pool, the multi-physical fields such as heat transfer, molten pool morphology, metal flow and stress distribution in the repair zone during the additive manufacturing process can be effectively predicted, and the relationship between the process parameters and the microstructure and properties of the material can be deeply understood, which provides corresponding reference for optimizing the process parameters, avoiding the formation of pores and defects, improving the microstructure of the repair zone and enhancing the repair accuracy. |
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