超高温氧化物陶瓷激光增材制造及组织性能调控研究进展

doi:10.15541/jim20230560

无机材料学报 ›› 2024, Vol. 39 ›› Issue (7): 741-753.DOI: 10.15541/jim20230560

• 综述 • 下一篇

超高温氧化物陶瓷激光增材制造及组织性能调控研究进展

陈乾¹(), 苏海军¹^,²(), 姜浩¹, 申仲琳¹, 余明辉¹, 张卓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:2023-12-05 修回日期:2024-01-04 出版日期:2024-07-20 网络出版日期:2024-01-31
通讯作者: 苏海军, 教授. E-mail: shjnpu@nwpu.edu.cn;
张卓, 副教授. E-mail: zhangzhuo@nwpu.edu.cn
作者简介:陈乾(2000-), 男, 硕士研究生. E-mail: cq12138@mail.nwpu.edu.cn
基金资助:
国家自然科学基金(52130204);国家自然科学基金(52174376);国家自然科学基金(51822405);陕西省科技创新团队计划(2021TD-17);中央高校基本科研业务费(D5000210902);航空科学基金(20220042053001);广东省基础与应用基础研究基金(2021B1515120028);创新特区项目(23-TQ09-02-ZT-01-005)

Progress of Ultra-high Temperature Oxide Ceramics: Laser Additive Manufacturing and Microstructure Evolution

CHEN Qian¹(), SU Haijun¹^,²(), JIANG Hao¹, SHEN Zhonglin¹, YU Minghui¹, ZHANG Zhuo¹()

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:2023-12-05 Revised:2024-01-04 Published:2024-07-20 Online:2024-01-31
Contact: SU Haijun, professor. E-mail: shjnpu@nwpu.edu.cn;
ZHANG Zhuo, associate professor. E-mail: zhangzhuo@nwpu.edu.cn
About author:CHEN Qian (2000-), male, Master candidate. E-mail: cq12138@mail.nwpu.edu.cn
Supported by:
National Natural Science Foundation of China(52130204);National Natural Science Foundation of China(52174376);National Natural Science Foundation of China(51822405);Science and Technology Innovation Team Plan of Shaanxi Province(2021TD-17);Fundamental Research Funds of the Central Universities(D5000210902);Aeronautical Science Foundation of China(20220042053001);Guangdong Basic and Applied Basic Research Foundation(2021B1515120028);TQ Innovation Foundation(23-TQ09-02-ZT-01-005)

摘要/Abstract

摘要：

氧化物陶瓷具有高硬度、高强度以及优异的抗氧化和抗腐蚀性能, 是高性能发动机极端高温、燃气腐蚀、氧化服役环境用重要的候选高温结构材料, 在航空航天用高端装备领域具有广阔的应用前景。与传统陶瓷制备技术相比, 激光增材制造技术能够一步实现从原材料粉末到高性能结构件的一体化高致密成型, 具有柔性度好、成型效率高的特点, 可以快速制备高性能、高精度、大尺寸复杂结构部件。近年来, 基于液固相变发展的熔体生长氧化物陶瓷激光增材制造技术已成为高温结构材料制备技术领域的前沿研究热点之一。本文首先概述了激光增材制造技术的基本原理, 着重介绍了选区激光熔化与激光定向能量沉积两种典型激光增材制造技术的工艺特点。在此基础上, 重点阐述了利用激光增材制造技术制备不同氧化物陶瓷的组织特征及工艺参数对微观组织的影响规律, 并总结比较了不同体系氧化物陶瓷力学性能的差异。最后, 对该领域存在的问题进行了梳理和分析, 并对未来的发展趋势进行了展望。

关键词: 超高温氧化物陶瓷, 激光增材制造, 选区激光熔化, 激光定向能量沉积, 组织调控, 综述

Abstract:

Oxide ceramics, known for their outstanding strength and excellent oxidation and corrosion resistance, are prime candidates for high-temperature structural materials of aero-engines. These materials hold vast potential for application in high-end equipment fields of the aerospace industry. Compared with traditional ceramic preparation methods, laser additive manufacturing (LAM) can directly realize the integrated forming from raw powders to high-performance components in one step. LAM stands out for its high forming efficiency and good flexibility, enabling rapid production of large complex structural components with high performance and high precision. Recently, research on LAM for melt-grown oxide ceramics, which involves liquid-solid phase transition, has surged as a hot topic. This paper begins by outlining the basic principles of LAM technology, with an emphasis on the process characteristics of two typical LAM technologies: selective laser melting and laser directed energy deposition. On this basis, the paper summarizes the microstructure characteristics of several different oxide ceramics prepared by LAM and examines how process parameters influence these microstructures. The differences in mechanical properties of laser additive manufactured oxide ceramics with different systems are also summarized. Finally, the existing problems in this field are sorted out and analyzed, and the future development trend is prospected.

Key words: ultra-high temperature oxide ceramic, laser additive manufacturing, selective laser melting, laser directed energy deposition, microstructure evolution, review

中图分类号:

TQ174

陈乾, 苏海军, 姜浩, 申仲琳, 余明辉, 张卓. 超高温氧化物陶瓷激光增材制造及组织性能调控研究进展[J]. 无机材料学报, 2024, 39(7): 741-753.

CHEN Qian, SU Haijun, JIANG Hao, SHEN Zhonglin, YU Minghui, ZHANG Zhuo. Progress of Ultra-high Temperature Oxide Ceramics: Laser Additive Manufacturing and Microstructure Evolution[J]. Journal of Inorganic Materials, 2024, 39(7): 741-753.

图/表 14

表1 LAM常用激光器及其特点[19]

Table 1 Lasers for LAM and their characteristics[19]

Laser type	CO₂ laser	Nd: YAG laser	Yb-fiber laser
Wavelength/μm	10.6	1.06	1.07
Efficiency/%	5-20	1-3	10-30
Output power/kW	~20	~16	~10
Beam quality factor	3-5	0.4-20	0.3-4
Preferred material	Ceramic/polymer	Metal	Metal

图1 选区激光熔化(SLM)技术原理及其制备的氧化物陶瓷样件

Fig. 1 Principle of selective laser melting (SLM) and as-prepared oxide ceramic samples (a) Schematic diagram[22]; (b) ZrO2 ceramic[23]; (c) Al2O3/GAP eutectic ceramic[24]; (d) Al2O3/GAP/ZrO2 eutectic ceramic[25]

图2 激光定向能量沉积(LDED)技术原理及其制备的氧化物陶瓷样件

Fig. 2 Principle of laser directed energy deposition (LDED) and as-prepared oxide ceramic samples (a) Schematic diagram[26]; (b) Al2O3/ GdAlO3/ZrO2 eutectic ceramic with complex structure[29]; (c) Graded Al2O3/ZrO2 eutectic ceramic[31]; (d) Rod-like Al2O3/GdAlO3/ZrO2 eutectic ceramic[30]

表2 SLM与LDED的工艺特点对比[32]

Table 2 Comparison of process characteristics of SLM and LDED[32]

Process	Preferred laser	Power/W	Building rate / (cm³·min^-1)	Dimensional accuracy/mm	Surface roughness/μm	Application
SLM	Nd: YAG laser/fiber laser	50-1000	1.3	0.04-0.2	7-20	High precision and small scale component
LDED	CO₂ laser	100-3000	11.5	0.5-1.0	4-10	Large scale component

图3 LDED制备的单相氧化物陶瓷微观组织

Fig. 3 Microstructures of single-phase oxide ceramics prepared by LDED (a, b) Cross section (a) and longitudinal section (b) of Al2O3 ceramic[33]; (c, d) Longitudinal section of ZrO2 ceramic (c) and its magnified image (d)[34]

表3 共晶生长中各相熔化熵及对应生长方式[35-36]

Table 3 Entropy of different phases in eutectic and corresponding growth manner[35-36]

Phase	Entropy/ (J·mol^-1·K^-1)	Jackson factor	Growth manner
Al₂O₃	48	5.74	Faceted
GAP	16.5	1.9	Non-faceted
YAG	122	14.72	Faceted
ZrO₂	30	3.55	Weak faceted

图4 LAM制备的氧化物共晶陶瓷的横、纵截面典型微观组织形貌

Fig. 4 Typical microstructure morphologies of cross/longitudinal sections of LAM fabricated oxide eutectic ceramics (a) Periodic banded structure and (b) magnified image[42]; (c) Three ways of intersectional dispersion microstructure[36]; (d) Colony structure and (d1, d2) magnified images[36]

图5 Al2O3/ZrO2共晶陶瓷的微观组织及其晶体取向[43]

Fig. 5 Microstructure of Al2O3/ZrO2 eutectic ceramic and corresponding crystallographic orientation[43] (a) Transversal section; (b) Corresponding EBSD pole figures of Al2O3 and ZrO2 with (b1) EBSD phases and (b2) IPF (inverse pole figure); (c) Transverse sectional TEM (transmission electron microscope) image with (c1) SAED (selected area electron diffraction) and (c2) HRTEM (high-resolution TEM) at Al2O3/ZrO2 interface

图6 Al2O3/YAG共晶陶瓷沿沉积方向的微观组织及晶体取向演变[37]

Fig. 6 Microstructure and orientation evolution of Al2O3/YAG eutectic ceramic along deposition direction[37] (a) Longitudinal section; (b) Orientation variations of Al2O3 and YAG along the height; (c1, c2) TEM images and SAED patterns of (c1) irregular and (c2) regular eutectic inverse pole figures

表4 不同制备工艺下氧化物共晶陶瓷的晶体取向关系

Table 4 Crystal orientation relationship of the oxide eutectic ceramics by different preparation methods

Eutectic system	Preparation method	Crystal orientation relationship
Al₂O₃/YAG/ZrO₂	Laser directed energy deposition^[43] Optical floating zone method^[44]	[0001]Al₂O₃∥[001]YAG∥[001]ZrO₂ <11¯00>Al₂O₃∥<001>YAG∥<001>ZrO₂
Al₂O₃/ZrO₂	Laser directed energy deposition^[35] Laser floating zone method^[45]	[112¯0]Al₂O₃∥[001]ZrO₂ [022¯1]Al₂O₃∥[111]ZrO₂
Al₂O₃/YAG	Bridgman^[46] Laser directed energy deposition^[37]	[101¯0]Al₂O₃∥[101]YAG [101¯0]Al₂O₃∥[111]YAG

图7 不同ZrO2含量下Al2O3/ZrO2复合材料的微观组织[49-50]

Fig. 7 Microstructures of Al2O3/ZrO2 parts with different ZrO2 contents[49-50]

图8 不同扫描速率下Al2O3/GAP共晶陶瓷的顶部微观组织[36]

Fig. 8 Microstructures at top region of the Al2O3/GAP eutectic ceramics under different scanning rates[36] (a) 4 mm/min; (b) 8 mm/min; (c) 16 mm/min; (d) 30 mm/min

图9 不同超声功率下Al2O3/ZrO2共晶陶瓷的微观组织形貌[57]

Fig. 9 Micro-morphologies of the Al2O3/ZrO2 eutectic ceramics with different ultrasonic powers[57] (a) 20-50 W; (b) 110 W; (c) 120-150 W; (d) 160 W

表5 不同LAM技术制备的氧化物陶瓷材料的力学性能对比

Table 5 Comparison of mechanical properties among different oxide ceramics prepared by different LAM technologies

Material	Hardness/GPa	Fracture toughness/(MPa·m^1/2)	Flexural strength/MPa	Preparation method
Al₂O₃	16 18.91	/ 3.55	/ 350	Sintering^[64] LDED^[65]
ZrO₂(Y₂O₃)	19.80	/	/	LDED^[34]
Al₂O₃/ZrO₂	/ 15.3 / 18.59 /	6.03 7.8 / 6.52 7.67/8.70	525 / 538 / /	Sintering^[66] DS^[67] SLM^[68] LDED^[63] LDED (ultrasonic assisted/C fiber)^[57,61]
Al₂O₃/GAP	23.36 17.1 15.16	3.12 4.5 4.3	/ / /	DS^[69] SLM^[36] LDED^[70]
Al₂O₃/TiO₂	16.38	3.75	212	LDED^[47]
Al₂O₃/SiO₂	11.10 18.39 18.64	2.54 3.07 3.54	350 310 504	Sintering^[71] LDED^[52]LDED (heat treatment)^[48]
Al₂O₃/YAG	17.50 17.35 21.50	3.60 3.14 5.86	/ / /	DS^[72] LDED^[73] LDED (water cooling)^[60]
Al₂O₃/GAP/ZrO₂	17.50 17.90 15.30	6.50 8.50 7.80	485 / /	Sintering^[74] DS^[75] SLM^[25]
Al₂O₃/YAG/ZrO₂	15.80 18.90	3.90 3.84	/ /	DS^[76] LDED^[35]

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超高温氧化物陶瓷激光增材制造及组织性能调控研究进展

Progress of Ultra-high Temperature Oxide Ceramics: Laser Additive Manufacturing and Microstructure Evolution

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