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

Effect of Material Characteristics and Process Parameters on Quality of 93W-4.9Ni-2.1Fe Alloy Billet Manufactured 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。本工作分别以粉末粒径、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93W-4.9Ni-2.1Fe合金坯体并测试其压缩强度，分析材料特性和工艺参数对坯体质量的影响规律。结果表明，在所选数值范围内，粘结剂喷射制造93W-4.9Ni-2.1Fe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7.65 μm的粉末，粘结剂饱和度为70%、单层打印层厚为60 μm，粘结剂喷射制造93W-4.9Ni-2.1Fe合金坯体兼顾较高强度和尺寸精度。

Abstract:

Binder jetting is a potential low-cost near-net-shape forming method for 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. In this study, a series of 93W-4.9Ni-2.1Fe alloy billets were prepared by binder jetting with variables including powder particle size, binder material, binder saturation, and single-layer printing thickness. The compressive strength of the billets was tested, and the effects of material characteristics and process parameters on the quality of 93W-4.9Ni-2.1Fe billets was analyzed. The results show that the compressive strength of binder-jetted 93W-4.9Ni-2.1Fe alloy billets exhibits a negative correlation with powder particle size and single-layer printing thickness, which improves continuously with the increase in higher binder saturation. By employing a water-based alcohol binder, the 93W-4.9Ni-2.1Fe powders with a D₅₀ particle size of 7.65 μm, a binder saturation of 70%, and a single-layer printing thickness of 60 μm, the binder-jetted 93W-4.9Ni-2.1Fe alloy billets achieve a balance between good strength and dimensional accuracy.