CN106216703B - 一种3d打印用球形铝合金粉末的制备方法 - Google Patents
一种3d打印用球形铝合金粉末的制备方法 Download PDFInfo
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Abstract
一种3D打印用球形铝合金粉末的制备方法，属于3D打印技术领域。包括将铝合金加工成棒料，直径为35～70mm；将棒料安装在送料装置上，进行抽真空处理并充入氩气保护气体；加热棒料，尖端金属熔化温度超过铝合金熔点5～30℃后打开风机进行雾化；金属液流在高速气体的冲击作用下形成球形铝合金粉末。优点在于，制备出的铝合金粉末粒度细小、均匀，流动性好、氧含量低，有效节约制造成本。
Description
技术领域
本发明属于3D打印技术领域，特别涉及一种3D打印用球形铝合金粉末的制备方法。尤其涉及一种3D打印用高纯球形铝合金粉末的制备方法。
背景技术
3D打印，被称为引发第三次技术革命的智能制造技术，彻底改变了传统金属零件，特别是高性能、难加工、构型复杂等金属零件的加工模式，在航空航天、汽车制造领域有着广阔的应用。金属3D打印技术是整个3D打印体系中最前沿和最有潜力的技术，也是今后3D打印技术的主要发展方向。
球形金属粉末是金属3D打印的原材料和耗材，也是限制3D打印技术发展的巨大瓶颈。因此，3D打印专用材料的研发是3D打印技术发展的重中之重。高性能金属粉末的制备受到工业发达国家的高度重视。我国的金属粉体行业发展滞后，产品单一，粉末品质较差，高性能金属粉末尚需大量依赖进口，极大制约了我国航空航天产业的发展。
铝合金密度小，比强度高，生产制造成本低，是航空航天用关键承力零部件的原材料。航空航天用复杂形状零部件多采用粉末冶金及3D打印方法制备，组织和性能均匀，近净成形且加工余量小。伴随着我国航空航天技术的飞速发展，作为粉末冶金及3D打印技术的原材料，高性能球形铝合金粉末的研制迫在眉睫。
3D打印对球形粉末的粒度、流动性、纯度、氧含量要求较高，而目前我国与3D打印用粉体材料制备工艺有关的专利或文献较少。一种制备3D打印用超细球形金属粉末的方法及装置，申请号201510044848.9，公开了一种超细球形金属粉末的制备方法，但是金属熔体仍采用坩埚熔炼的方法制备。用于激光3D打印的球形TC4钛合金粉末及其制备方法，申请号201610025205.4，公开了一种真空感应气雾化法制备球形TC4钛合金粉末的方法，所采用的材料及工艺参数与本专利完全不同。文章《氮气雾化Al-20Si-7.5Ni-3Cu-1Mg-0.25Fe合金粉末形貌及组织》刊登于塑性工程学报，利用激光粒度分析仪等设备对合金粉末的粒度分布、组织、形貌、组成相和相演变规律进行了研究，并没有提及氮气雾化制备合金粉末的工艺方法。
发明内容
本发明的目的在于提供一种3D打印用球形铝合金粉末的制备方法，解决了目前金属粉体产品单一、品质差且制造成本偏高的问题。
一种3D打印用球形铝合金粉末的制备方法是一种由电极感应线圈加热、将熔化态铝合金直接雾化制成铝合金粉末的无坩埚熔炼法。包括加工棒料、送料、感应熔炼、雾化、筛分等制备过程。
一种3D打印用球形铝合金粉末的制备方法，其步骤及参数控制如下：
1、将铝合金加工成棒料。棒料的直径为35～70mm，在距离棒料顶端10mm处加工出3～10mm宽的凹槽，便于安装到送料装置上；棒料末端加工成圆锥状，锥度为60～120°。
2、将洁净的铝合金棒料安装在连续送料装置上，调节卡具上的螺钉，保证棒料具有良好的垂直度。依次打开机械泵和罗茨泵，对装料室、熔炼室、雾化室进行抽真空处理，极限真空度为1×10-4～1×10-2Pa，充入氩气保护气体，调节熔炼室压力为0～0.50MPa，装料室与熔炼室的压差为0.001～0.05MPa；
3、启动送料装置，将铝合金棒料送递至熔炼室，下降速度为1～5mm/s，自转速度为100～500r/s。电极感应线圈的锥度为40～60°，管径为10～15mm，管间距为20～30mm，线圈最大中心距为100～150mm，待棒料传送至线圈中部时，棒料停止下降。启动加热电源，调节功率至10～30KW；加热棒料，待尖端金属熔化，温度超过铝合金熔点5～30℃后打开风机，使熔化金属在风机吸力作用下形成连续、稳定的液流，并将送料装置的下降速度调节至0.005～0.08mm/s，自转速度调节至100～500r/s，加热功率调节至15～40kw。
4、采用拉瓦尔环缝式紧耦合喷嘴对合金液流进行雾化，中心距为10～40mm，出气口汇聚角度为10～40°，喷嘴喷出总压力为1～6MPa，气体流量为800～2000m3/h，金属液流在高速气体的冲击作用下形成球形铝合金粉末。
5、冷却后的铝合金粉末汇集至二级旋风分离收粉装置中，在高纯氩气气氛下筛分，不同粒径等级的粉末进行惰性气体保护封装。
采用本发明方法制备的3D打印用高纯铝合金粉末的粒度为0～53μm，氧含量为500～1300ppm，纯度高，流动性好，满足航空航天3D打印关键零部件的使用要求
本发明适用于铝合金牌号ISO 3522-2007、GB/T 1173-2013和GB/T 3190-2008全部产品牌号，主要材质为纯铝、Al-Si系、Al-Cu系、Al-Mg系或Al-Zn系铝合金。
本发明的优点在于：采用连续送料装置将铝合金棒料传递至熔炼室，通过高频感应线圈加热直接将棒料熔化，形成连续液流，进入雾化室。在整个过程中，避免了合金与坩埚接触，保证了粉末的纯净度，能够制备出纯度高、球形度好、氧含量低、粒度分布窄、流动性好的符合3D打印要求的高纯球形铝合金粉末。
本发明的制备方法主要工作在于：
1、送料进给及装卡结构优化。通过对传动装置螺距、转速及装卡部位螺钉尺寸的控制，调整棒料的对中度及进给速度，在熔炼过程中实现连续送料。
2、高频铜感应线圈的设计。通过对感应线圈管径、管层间距、中心距及冷却水流速等参数的控制，调整熔炼室内部的温度场分布，在铝合金棒料的熔化端形成连续、稳定的液流。
3、喷嘴结构优化。通过对喷嘴出气口汇聚角度、中心距、雾化压力、气体流量等参数的控制，调整气流与金属液流的动力交互作用，以便获得具有良好性能(球形度、均匀度等)的粉末。
本发明制备方法的原理基于高速气流击碎金属液流的二流雾化法，采用感应线圈将铝合金棒料熔炼成连续、稳定的液流，通过对喷嘴气体流量、出气口总压力等工艺的控制，提高气体动能与金属液滴表面能之间的转化效率，形成细小的粉末。
本发明的优点在于：
1、以铝合金棒料为原料，采用传动装置实现连续送料，高频铜感应线圈进行熔炼，避免了合金熔体与坩埚接触，减少了杂质元素的混入及坩埚中的熔体残留，提高了材料利用率及粉末纯净度。
2、采用的拉瓦尔环缝式紧耦合喷嘴为切向进气，气体流量为800～2000m3/h，喷嘴喷出总压力为1～6MPa，能够有效将铝合金液流破碎成细小颗粒，从而保证粉末粒度为0～53μm。
3、采用本发明制备的球形铝合金粉末粒度细小、均匀，流动性好、球形度高、氧含量低，细粉收得率高达25％。
附图说明
图1为本发明制备的微细球形Al-Si-10Mg铝合金粉末的粒度分布图。
具体实施方式
实施例1
高纯Al-Si-10Mg合金球形粉末制备
1、将高纯Al-Si-10Mg合金加工成直径为45mm的棒料，在距离棒料顶端10mm处加工5×5mm的凹槽，尾端加工成90°度的锥形；
2、将洁净的铝合金棒料安装在连续送料装置上，对装料室、熔炼室、雾化室进行抽真空处理，极限真空度为1×10-4Pa，充入氩气保护气体，熔炼室气压为0.11MPa；
3、启动送料装置，棒料的下降速度为1mm/s，自转速度为100r/s，待棒料运送至感应线圈中部时，棒料停止下降，启动加热电源，功率为10kw，电极感应线圈的锥度为60°，管径为15mm，管间距为20mm，线圈最大中心距为150m，熔炼室温度超过铝合金熔点5℃后，开启风机，将送料装置下降速度调节至0.02mm/s，加热功率调节至30kw，形成连续、稳定的液流；
4、采用拉瓦尔环缝式紧耦合喷嘴对合金液流进行雾化，中心距为40mm，出气口汇聚角度为40°，喷嘴喷出总压力为1～6MPa，气体流量为1500m3/h，将液流雾化为铝合金粉末；
5、将冷却后的铝合金粉末收集并在高纯氩气气氛下进行筛分处理。最终得到的Al-Si-10Mg合金球形粉末氧含量为600ppm，粉末粒径为0～53μm。从粉末的扫描照片可以看出，采用本方法制备的Al-Si-10Mg合金粉末球形度高、粒度分布均匀、卫星粉含量低、粉末无粘接团聚现象，符合3D打印用金属粉末的外观要求。
Claims (3)
1.一种3D打印用球形铝合金粉末的制备方法，其特征在于，具体步骤及参数如下：
1)将铝合金加工成棒料，棒料直径为35～70mm，在距离棒料顶端10mm处加工出3～10mm宽的凹槽，便于安装到送料装置上；棒料末端加工成圆锥状，锥度为60～120°；
2)将洁净的铝合金棒料安装在连续送料装置上，调节卡具上的螺钉，保证棒料具有良好的垂直度；依次打开机械泵和罗茨泵，对装料室、熔炼室、雾化室进行抽真空处理，充入氩气保护气体，调节熔炼室压力为0～0.50MPa，装料室与熔炼室的压差为0.001～0.05MPa；
3)启动送料装置，将铝合金棒料送递至熔炼室，下降速度为1～5mm/s，自转速度为100～500r/s；电极感应线圈的锥度为40～60°，管径为10～15mm，管间距为20～30mm，线圈最大中心距为100～150mm，待棒料传送至线圈中部时，棒料停止下降；启动加热电源，调节功率至10～30KW；加热棒料，待尖端金属熔化，温度超过铝合金熔点5～30℃后打开风机，使熔化金属在风机吸力作用下形成连续、稳定的液流，并将送料装置的下降速度调节至0.005～0.08mm/s，自转速度调节至100～500r/s，加热功率调节至15～40kw；
4)采用拉瓦尔环缝式紧耦合喷嘴对合金液流进行雾化，中心距为10～40mm，出气口汇聚角度为10～40°，喷嘴喷出总压力为1～6MPa，气体流量为800～2000m3/h，金属液流在高速气体的冲击作用下形成球形铝合金粉末；
5)冷却后的铝合金粉末汇集至二级旋风分离收粉装置中，在高纯氩气气氛下筛分，不同粒径等级的粉末进行惰性气体保护封装；
铝合金粉末的粒度为0～53μm，氧含量为500～1300ppm，细粉收得率最高达25％，满足航空航天3D打印关键零部件的使用要求。
2.根据权利要求1所述的3D打印用球形铝合金粉末的制备方法，其特征在于，步骤2)中所述的抽真空处理，真空度为1×10-4～1×10-2Pa。
3.根据权利要求1所述的3D打印用球形铝合金粉末的制备方法，其特征在于，本方法适用于铝合金牌号ISO 3522-2007、GB/T 1173-2013和GB/T 3190-2008全部产品牌号。
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