材料特性和工艺参数对粘结剂喷射制造93W-4.9Ni-2.1Fe合金坯体质量的影响

Influence of Material Characteristics and Process Parameters on the Quality of 93W-4.9Ni-2.1Fe Alloy Billet Produced by Binder Jetting

摘要:

粘结剂喷射是实现钨镍铁合金中大尺寸复杂异形部件低成本整体近净成形的可行方法,但面临坯体固化和脱脂易开裂的问题,需发展高强度坯体的粘结剂喷射制造工艺。本文分别设计以粉末粒径、粘结剂种类、粘结剂饱和度及单层打印层厚为变量,基于粘结剂喷射工艺制造了系列钨镍铁合金坯体并测试了其压缩强度,分析了材料特性和工艺参数对坯体质量的影响行为。结果表明,在本文所选数值范围内,粘结剂喷射制造钨镍铁合金坯体的压缩强度与粉末粒径及单层打印层厚呈现负相关关系,随粘结剂饱和度的提高持续增大。选用水性醇基粘结剂、D50粒径为7.65μm的粉末,粘结剂饱和度为70%、单层打印层厚为60μm,粘结剂喷射制造钨镍铁合金坯体兼顾较高强度和尺寸精度。

Abstract:

Binder jetting is a potential low-cost method to near-net-shape fabricate large-scale complex-shaped W-Ni-Fe alloy components. Nonetheless, it faces challenges such as billets cracking during curing and debinding. Developing the manufacturing process for high-strength W-Ni-Fe alloy billets is an inevitable requirement for ensuring the large-scale application of binder jetting. In this study, a series of W-Ni-Fe alloy billets were fabricated with variables including powder particle size, binder material, binder saturation, and single-layer printing thickness. The compressive strength of the billets was tested, as well as the influence of material characteristics and process parameters on the quality of W-Ni-Fe billets was analyzed. The results indicate that the compressive strength of binder-jetted W-Ni-Fe alloy billets exhibits a negative correlation with powder particle size and single-layer printing thickness, while increasing continuously with higher binder saturation. By employing a water-based alcohol binder, the W-Ni-Fe powders with a D50 particle size of 7.62 μm, a binder saturation of 70%, and a single-layer printing thickness of 60 μm, the binder-jetted W-Ni-Fe alloy billets achieve a balance between good strength and dimensional accuracy.