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2222材料工程  2022, Vol. 50 Issue (7): 1-17    DOI: 10.11868/j.issn.1001-4381.2021.000838
  陶瓷增材制造专栏 本期目录 | 过刊浏览 | 高级检索 |
熔体自生陶瓷激光直接能量沉积增材制造研究进展
牛方勇, 于学鑫, 赵紫渊, 赵大可, 黄云飞, 马广义, 吴东江()
大连理工大学 机械工程学院, 辽宁 大连 116024
Research progress in additive manufacturing of melt growth ceramics by laser directed energy deposition
Fangyong NIU, Xuexin YU, Ziyuan ZHAO, Dake ZHAO, Yunfei HUANG, Guangyi MA, Dongjiang WU()
School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, Liaoning, China
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摘要 

熔体自生陶瓷是一种原料经熔化凝固获得组织组成的新型陶瓷材料，原子共用的洁净高强度结合界面使其具有接近熔点的优异高温力学性能及组织稳定性，在未来高推重比航空发动机及重型燃气轮机热端部件领域展现了巨大的应用潜力。激光直接能量沉积技术能够有效克服熔体自生陶瓷传统制备方法在周期、能耗及结构复杂度等方面的局限，为直接增材制造熔体自生陶瓷构件提供了新的解决方案，成为国内外研究热点。本文在介绍激光直接能量沉积技术工艺原理的基础上，总结了国内外利用该技术制备的不同熔体自生陶瓷的微观组织特征及其主要力学性能，并综合论述了目前针对微观组织及开裂行为调控所开展的主要研究。基于现有研究进展，对该领域的发展趋势和需要进一步解决的关键科学问题进行了探讨，指出抑制开裂与改善组织性能是目前面临的首要问题，材料和新工艺的发展是突破现有瓶颈、推动熔体自生陶瓷激光直接能量沉积技术发展和应用的关键。
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牛方勇
于学鑫
赵紫渊
赵大可
黄云飞
马广义
吴东江
关键词 ： 陶瓷,  增材制造,  激光,  直接能量沉积,  熔体自生    
Abstract：

Melt growth ceramics (MGC) is a new type of ceramic material with microstructure obtained by melting and solidification of raw materials. The clean and high-strength bonding interface shared by atoms makes it have excellent high-temperature mechanical properties and microstructure stability close to the melting point. It shows great application potential in the field of high thrust weight ratio aero-engine and heavy gas turbine hot end components in the future. Laser directed energy deposition (LDED) technology can effectively overcome the limitations of traditional preparation methods of MGC in terms of cycle, energy consumption and structural complexity. It provides a new solution for direct additive manufacturing of MGC components, and has become a research hotspot at home and abroad. Based on the introduction of the process principle of LDED technology, the microstructure characteristics and properties of different MGCs prepared by this technology at home and abroad were summarized in this paper, and the main research on the control of microstructure and cracking behaviour was comprehensively discussed. Based on the existing research progress, the development trend and key scientific problems to be further solved in this field were discussed. It was pointed out that inhibiting cracking and improving microstructure and properties are the primary problems faced at present. The development of materials and new processes is the key to breaking through the existing bottleneck and promote the development and application of MGC-LDED.
Key words： ceramics    additive manufacturing    laser    directed energy deposition    melt growth
收稿日期: 2021-08-31      出版日期: 2022-07-18
中图分类号:  TH145.1  
基金资助:国家自然科学基金项目(51805070);国家自然科学基金项目(51790172);中央高校基本科研业务项目(DUT19RC(3)060);辽宁省自然科学基金(2019-ZD-0010);辽宁省自然科学基金(2020-BS-057);深圳市技术攻关重点项目(JSGG20210420091802007)
通讯作者: 吴东江     E-mail: djwudut@dlut.edu.cn
作者简介: 吴东江(1964—), 男, 教授, 博士, 主要从事陶瓷/金属激光增材制造、激光精密加工方面的研究, 联系地址: 辽宁省大连市甘井子区凌工路2号大连理工大学机械工程学院(116024), E-mail: djwudut@dlut.edu.cn
引用本文:   
牛方勇, 于学鑫, 赵紫渊, 赵大可, 黄云飞, 马广义, 吴东江. 熔体自生陶瓷激光直接能量沉积增材制造研究进展[J]. 材料工程, 2022, 50(7): 1-17.
Fangyong NIU, Xuexin YU, Ziyuan ZHAO, Dake ZHAO, Yunfei HUANG, Guangyi MA, Dongjiang WU. Research progress in additive manufacturing of melt growth ceramics by laser directed energy deposition. Journal of Materials Engineering, 2022, 50(7): 1-17.
链接本文:  
http://jme.biam.ac.cn/CN/10.11868/j.issn.1001-4381.2021.000838      或      http://jme.biam.ac.cn/CN/Y2022/V50/I7/1
Fig.1  LDED工艺原理
Material Microstructure characteristics Microhardness Fracture toughness/(MPa·m1/2) Flexural strength/MPa Relative density/%
Al2O3 [35] Directionally grown α-Al2O3 coarse 15.5-17 GPa 2.1 94
Al2O3 [36] columnar grains and intergranular 85
Al2O3 [37] two-dimensional structure 1700-2300HV0.2 2.7
Al2O3[34] 18.91 GPa 3.55 210 99.5
ZrO2[29] t-ZrO2 interlayer banded structure and t-ZrO2 embedded in c-ZrO2 matrix in convex mirror shape 19.8 GPa 98.7
Al2O3-ZrO2[38] Primary phase Al2O3 or ZrO2 and 19 GPa 3.7
Al2O3-ZrO2 [32] intergranular eutectic matrix 21.4 GPa 4.61
Al2O3-ZrO2 [39] 1680-1880HV 3.8 208
Al2O3-ZrO2 [40] 1972HV 5.91 237 98
Al2O3-TiO2 [41] Primary α-Al2O3 phase and continuously distributed Al6Ti2O13 matrix 1670HV 3.97 200
Al2O3-ZrO2 eutectics [42] Banded structure and eutectic colony 16.7 GPa 4.5
Al2O3-YAG eutectics [30] composed of fine eutectic structure 100
Al2O3-YAG eutectics [43] 17.35 GPa 3.14
Al2O3/ZrO2/YAG eutectics[44] (18.9±0.95) GPa 3.84±0.44 98
Al2O3/GdAlO3/ZrO2 eutectics[45]
Spinel[46] MgAl2O4 phase and intergranular Ca and Si rich phase 1400HV 2.5
Piezoelectric ceramics[47] Fine and uniform structure composed of perovskite phase and pyrochlore phase (358±28)HV 90
Calcium phosphate bioceramics[28] α-tricalcium phosphate (α-TCP) matrix and nucleated tetracalcium phosphate (TTCP) grains
Table 1  LDED制备的不同MGC材料的组织及性能
Fig.2  Al2O3陶瓷样件及典型组织特征
(a)成形样件[34-37]；(b)柱状晶组织[35]；(c)柱状晶表面二维组织[34]
Fig.3  Al2O3-ZrO2复合陶瓷
(a)典型样件[38-39]；(b)亚共晶组织[48]；(c)共晶组织[42]
Fig.4  Al2O3/GdAlO3/ZrO2三元共晶陶瓷[45]
(a)典型样件；(b)带状组织宏观形貌；(c)带状组织微观特征；(d)共晶团组织特征；(e)晶团内不规则共晶组织
Fig.5  铝镁尖晶石陶瓷
(a)典型样件[27]；(b)微观组织[27]；(c)透光特性[55]
Fig.6  磷酸钙陶瓷[28]
(a)典型样件；(b)微观组织；(c)生物特性
Method Material Effect
Increase heat input [32] Al2O3-ZrO2 Columnar dendrites become shorter, banded structure thickness increased
Increase scanning speed[31, 45] Al2O3/GdAlO3/ZrO2 eutectics Banded structure thickness decreased, eutectic spacing decreased
Increase laser power[27] Spinel Porosity decreased enhanced, grain coarsened, light transmittance enhanced
Substrate water cooling[43] Al2O3-YAG Eutectic spacing decreased, hardness increased, fracture toughness increased
Ultrasound assisted [26] Al2O3-ZrO2 Grain refinement, hardness improved, wear resistance improved
Ultrasound assisted [60] Al2O3-ZrO2 eutectics Eutectic spacing decreased, fracture toughness increased
Ultrasound assisted [61] Al2O3-YAG Grain refinement, hardness improved, wear resistance improved
C fiber doping[62] Al2O3-ZrO2 eutectics Eutectic spacing decreased, fracture toughness increased
SiCp doping[63] Al2O3-ZrO2 Porosity decreased, eutectic size decreased
Heat treatment[35] Al2O3 Density increased, microhardness increased, fracture toughness increased
Heat treatment[29] YSZ From dark brown to dark yellow
Heat treatment[31] Al2O3/GdAlO3/ZrO2 eutectics Eutectic structure coarsened, banded structure disappeared, microstructure uniformity improved
Table 2  MGC-LDED组织及性能调控方法
Fig.7  外场辅助LDED
(a)超声辅助成形Al2O3-ZrO2共晶陶瓷[60]；(b)水冷辅助成形Al2O3-YAG共晶陶瓷[43]
Control method Material Control effect
Increase laser power [26] Al2O3-ZrO2 The crack length and opening width are reduced
Change scanning direction [64] Al2O3 When the scanning angle is 45° and 67°, the sample has no obvious cracks
Increase laser power[29] YSZ The number of cracks decreased first and then increased
Increase scanning speed and Z-increment[67] Al2O3 Higher scanning speed and larger interlayer lift are easier to obtain crack free samples
Substrate heating[42] Al2O3-ZrO2 20 mm×8 mm×8 mm crack free samples
Substrate heating[30-31] Al2O3-YAG Al2O3-YAG samples without cracks were prepared
Substrate heating[49] Al2O3-ZrO2 The grain is refined and the cracks are obviously reduced
ZrO2doping[68] Al2O3-ZrO2 The eutectic ratio has the best crack suppression effect
SiCP doping[63] Al2O3-ZrO2 Cracks decreased significantly
ZrO2doping [39] Al2O3-ZrO2 When the ZrO2 content is 10%, the crack is suppressed
Ultrasound assisted [26] Al2O3-ZrO2 Conducive to crack suppression, crack-free 7 mm×7 mm×10 layers sample was fabricated
Table 3  MGC开裂抑制方法
Fig.8  材料复合化裂纹抑制效果[63, 67, 69]
(a)SiCP掺杂；(b)ZrO2掺杂；(c)TiO2掺杂
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