Article(id=1212410690581730161, tenantId=1146029695717560320, journalId=1146031591421210625, issueId=1212410683682099946, articleNumber=null, orderNo=20, doi=10.3981/j.issn.1000-7857.2025.06.00043, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1749484800000, receivedDateStr=2025-06-10, revisedDate=1754323200000, revisedDateStr=2025-08-05, acceptedDate=null, acceptedDateStr=null, onlineDate=1766990834135, onlineDateStr=2025-12-29, pubDate=1762963200000, pubDateStr=2025-11-13, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1766678400000, onlineIssueDateStr=2025-12-26, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1766990834135, creator=13701087609, updateTime=1774080295345, updator=sys-migrate, issue=Issue{id=1212410683682099946, tenantId=1146029695717560320, journalId=1146031591421210625, year='2025', volume='43', issue='21', pageStart='1', pageEnd='136', issueExtLink='null', onlineDate='null', pubDate='1762963200000', pubDateStr='2025-11-13', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1766990832490, creator='13701087609', updateTime=1774330578192, updator='13041195026', preIssue=null, nextIssue=null, articleTotal=null, ext={EN=IssueExt(id=1243195808502366441, tenantId=1146029695717560320, journalId=1146031591421210625, issueId=1212410683682099946, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1243195808502366442, tenantId=1146029695717560320, journalId=1146031591421210625, issueId=1212410683682099946, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null, downloadFileDto=null}, startPage=87, endPage=101, ext={EN=ArticleExt(id=1212410691617723280, articleId=1212410690581730161, tenantId=1146029695717560320, journalId=1146031591421210625, language=EN, title=Recycling of superalloy powders for selective laser melting, columnId=1150494644690366681, journalTitle=Science & Technology Review, columnName=Papers, runingTitle=null, highlight=null, articleAbstract=

Selective laser melting (SLM), as a prominent metal additive manufacturing technology, has achieved industrial applications in aerospace, biomedical, and energy sectors due to its near−net−shape forming capability and ability to fabricate complex structures. Superalloys, owing to their excellent high−temperature strength, oxidation resistance, and creep performance, are the preferred materials for SLM−fabricated heat−resistant components. However, the unmelted powder generated during SLM undergoes degradation (including thermal cycling, oxidation, and particle size distribution alterations), posing significant challenges to its efficient recycling and reconditioning, which constitutes a critical bottleneck for sustainable industrial development. This article is centered on the research progress concerning the recycling of superalloy powders during selective laser melting (SLM). It systematically analyzes the evolution of physical and chemical characteristics of powders throughout the recycling process, elucidates the impact of recycled powders on the formation of defects and mechanical properties of printed parts. As the number of recycling cycles increases, satellite particles and irregular granules appear on the powder surface, leading to an increase in surface roughness, along with a continuous rise in oxygen content. Additionally, the recycled powder results in an increased defect density in the fabricated parts, manifested as a higher prevalence of unmelted pores and micropores, while the mechanical properties exhibit complex variations. Technological breakthroughs and application cases in efficient recycling and reconditioning methods were summarized. Furthermore, it proposes future research priorities and development directions in this field.

, authors=null, authorsList=Liming TAN, Jin LÜ, Yi ZHANG, Zi WANG, Xin MA, Hailong ZHANG, Yiwei LUO, Juncheng WANG, Jie SU, Jinrong WEN, Lan HUANG, Feng LIU, authorCompany=null, correspAuthors=Lan HUANG, authorNote=null, correspAuthorsNote=null, copyrightStatement=All rights reserved. Unauthorized reproduction is prohibited., copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, fund=null), CN=ArticleExt(id=1212410697967898705, articleId=1212410690581730161, tenantId=1146029695717560320, journalId=1146031591421210625, language=CN, title=激光选区熔融高温合金粉末的循环利用, columnId=1146540929516700224, journalTitle=科技导报, columnName=研究论文, runingTitle=null, highlight=null, articleAbstract=

激光选区熔融作为金属增材制造技术的典型代表,凭借其近净成形能力和复杂结构制造优势,在航空航天、生物医疗及能源领域获得了产业化应用。高温合金因其优异的高温强度、抗氧化性及蠕变性能,成为激光选区熔融技术制备耐高温部件的首选材料。然而,激光选区熔融过程中产生的未熔化粉末在经历热循环、氧化及粒径分布变化后性能下降,其高效循环利用困难,成为制约产业可持续发展的关键瓶颈。围绕高温合金粉末在激光选区熔融过程中循环利用的研究进展,系统分析循环过程中粉末物理化学特性的演化规律,阐明循环粉末对成形件缺陷形成与力学性能的影响。随着循环次数增加,粉末表面出现卫星粉和不规则颗粒,导致表面粗糙度增加,同时氧含量持续上升。此外,循环粉末导致成形件缺陷密度增加,表现为未熔孔隙和微孔增多,力学性能呈现复杂变化。综述高效回收与再生方法的技术突破与应用案例,并展望了该领域未来的研究重点与发展方向。

, authors=

谭黎明,副研究员,研究方向为数据驱动高温合金和涂层材料高效设计、制造(铸造、粉末冶金、涂层、增材制造)及其服役行为,电子信箱:

, authorsList=谭黎明, 吕金, 张毅, 王子, 马鑫, 张海龙, 罗一苇, 王俊程, 苏捷, 文锦溶, 黄岚, 刘锋, authorCompany=null, correspAuthors=黄岚, authorNote=null, correspAuthorsNote=
黄岚(通信作者),教授,研究方向为融合大数据、机器学习、高通量试验和模拟计算等方式加速新型高温合金材料的开发,结合传统粉末冶金工艺和增材制造开展材料制备,电子信箱:
, copyrightStatement=版权所有,未经授权,不得转载。, copyrightOwner=《科技导报》编辑部, extLink=null, articleAbsUrl=null, sourceXml=E8niS5lZwLnAp+f00Ia0Hg==, magXml=E8niS5lZwLnAp+f00Ia0Hg==, pdfUrl=null, pdf=tfrtORi+O1hQuuDZBUymhw==, pdfFileSize=6599551, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=c2HV65H2umGdgHNx4Fyp2Q==, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=v5ZFjiAw3w7Vv1eebZorfw==, mapNumber=null, fund=null)}, authors=[Author(id=1242146121632527178, tenantId=1146029695717560320, journalId=1146031591421210625, articleId=1212410690581730161, orderNo=0, firstName=null, middleName=null, lastName=null, nameCn=null, orcid=null, stid=null, country=null, authorPic=null, dead=0, email=limingtan@csu.edu.cn, emailSecond=null, emailThird=null, correspondingAuthor=0, authorType=1, ext={EN=AuthorExt(id=1242146121716413261, tenantId=1146029695717560320, journalId=1146031591421210625, articleId=1212410690581730161, authorId=1242146121632527178, language=EN, stringName=Liming TAN, firstName=Liming, middleName=null, lastName=TAN, prefix=null, suffix=null, authorComment=null, nameInitials=null, affiliation=null, department=null, xref=1, 2, address=1 Institute of Powder Metallurgy, Central South University, Changsha 410083, China
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谭黎明,副研究员,研究方向为数据驱动高温合金和涂层材料高效设计、制造(铸造、粉末冶金、涂层、增材制造)及其服役行为,电子信箱:

"}, bioImg=null, bioContent=

谭黎明,副研究员,研究方向为数据驱动高温合金和涂层材料高效设计、制造(铸造、粉末冶金、涂层、增材制造)及其服役行为,电子信箱:

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(a) 单次填装粉末循环使用 (b) 每次成形补充原始粉末策略 (c) 隔离递减消耗策略

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制粉
工艺
原材料 细粉
收得率
球形度/% 空心
粉率
生产效率/
[kg·(8 h)−1]
生产
成本
优点 缺点
VIGA 铸锭、棒材 中等 大于80 约200  制备效率高,成本低  存在卫星粉、空心粉、非金属杂质等
EIGA 棒材 中等 大于80 约200  粒径分布广,非金属杂质少  有空心粉和卫星粉
PREP 棒材 大于90 几乎没有 200~400 很高  球形度高,无卫星粉和空心粉  粉末粒径较大,细粉收得率低
PA 丝材 大于85 小于200  细粉收得率高,少卫星粉  原材料昂贵,存在空心粉
), ArticleFig(id=1242146129530401720, tenantId=1146029695717560320, journalId=1146031591421210625, articleId=1212410690581730161, language=CN, label=表1, caption=

4种常见的制粉方法比较

, figureFileSmall=null, figureFileBig=null, tableContent=
制粉
工艺
原材料 细粉
收得率
球形度/% 空心
粉率
生产效率/
[kg·(8 h)−1]
生产
成本
优点 缺点
VIGA 铸锭、棒材 中等 大于80 约200  制备效率高,成本低  存在卫星粉、空心粉、非金属杂质等
EIGA 棒材 中等 大于80 约200  粒径分布广,非金属杂质少  有空心粉和卫星粉
PREP 棒材 大于90 几乎没有 200~400 很高  球形度高,无卫星粉和空心粉  粉末粒径较大,细粉收得率低
PA 丝材 大于85 小于200  细粉收得率高,少卫星粉  原材料昂贵,存在空心粉
), ArticleFig(id=1242146129610093498, tenantId=1146029695717560320, journalId=1146031591421210625, articleId=1212410690581730161, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
性能指标 性能变化 主导机制 参考文献
室温强度 上升 位错密度累积 [72]
高温强度 上升 固溶原子滞留
(Nb/Mo未析出)
[75]
伸长率 下降 氧化物晶界偏聚 [69]
蠕变性能 650℃时下降,
700℃时上升
温度−缺陷交互作用 [72]
), ArticleFig(id=1242146129673008060, tenantId=1146029695717560320, journalId=1146031591421210625, articleId=1212410690581730161, language=CN, label=表2, caption=

粉末循环使用对样品力学性能的影响

, figureFileSmall=null, figureFileBig=null, tableContent=
性能指标 性能变化 主导机制 参考文献
室温强度 上升 位错密度累积 [72]
高温强度 上升 固溶原子滞留
(Nb/Mo未析出)
[75]
伸长率 下降 氧化物晶界偏聚 [69]
蠕变性能 650℃时下降,
700℃时上升
温度−缺陷交互作用 [72]
), ArticleFig(id=1242146129735922621, tenantId=1146029695717560320, journalId=1146031591421210625, articleId=1212410690581730161, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
分类 国内标准 国外标准
高温合金粉末  GB/T 43484—2023《增材制造 激光粉末床熔融用高温合金粉末》;中关村材料创新联盟发布的《TCSTM 01268—2024 增材制造用高温合金粉末》团体标准  ASTM F3049 《Standard Guide for Characterizing Properties of Metal Powders Used for Additive Manufacturing Processes》;ISO/ASTM 52904 《Additive manufacturing — Process characteristics and performance — Practice for metal powder bed fusion process to meet critical applications》
检测与评价  GB/T 35022—2018《增材制造 主要特性和测试方法零件和粉末原材料》;GB/T 350291—2018《增材制造 工艺分类及原材料》  ASTM F3055−14a 《Standard Specification for Additive Manufacturing Nickel Alloy (UNS N07718) with Powder Bed Fusion》;ASTM F3056−14(2021)《Standard Specification for Additive Manufacturing Nickel Alloy (UNS N06625) with Powder Bed Fusion》
回收再利用  GB/T 44194—2024《增材制造 金属粉末再利用技术规范》  ASTM F3456−19《Standard Guide for Powder Reuse Schema in Powder Bed Fusion Processes for Medical Applications for Additive Manufacturing Feedstock Materials》
), ArticleFig(id=1242146129794642878, tenantId=1146029695717560320, journalId=1146031591421210625, articleId=1212410690581730161, language=CN, label=表3, caption=

国内外AM用粉末标准对比与分析

, figureFileSmall=null, figureFileBig=null, tableContent=
分类 国内标准 国外标准
高温合金粉末  GB/T 43484—2023《增材制造 激光粉末床熔融用高温合金粉末》;中关村材料创新联盟发布的《TCSTM 01268—2024 增材制造用高温合金粉末》团体标准  ASTM F3049 《Standard Guide for Characterizing Properties of Metal Powders Used for Additive Manufacturing Processes》;ISO/ASTM 52904 《Additive manufacturing — Process characteristics and performance — Practice for metal powder bed fusion process to meet critical applications》
检测与评价  GB/T 35022—2018《增材制造 主要特性和测试方法零件和粉末原材料》;GB/T 350291—2018《增材制造 工艺分类及原材料》  ASTM F3055−14a 《Standard Specification for Additive Manufacturing Nickel Alloy (UNS N07718) with Powder Bed Fusion》;ASTM F3056−14(2021)《Standard Specification for Additive Manufacturing Nickel Alloy (UNS N06625) with Powder Bed Fusion》
回收再利用  GB/T 44194—2024《增材制造 金属粉末再利用技术规范》  ASTM F3456−19《Standard Guide for Powder Reuse Schema in Powder Bed Fusion Processes for Medical Applications for Additive Manufacturing Feedstock Materials》
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激光选区熔融高温合金粉末的循环利用
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谭黎明 1, 2 , 吕金 1, 2 , 张毅 3 , 王子 1, 2 , 马鑫 3 , 张海龙 3 , 罗一苇 1, 2 , 王俊程 1, 2 , 苏捷 1, 2 , 文锦溶 4 , 黄岚 1, 2, * , 刘锋 1, 2
科技导报 | 研究论文 2025,43(21): 87-101
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激光选区熔融高温合金粉末的循环利用
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谭黎明,副研究员,研究方向为数据驱动高温合金和涂层材料高效设计、制造(铸造、粉末冶金、涂层、增材制造)及其服役行为,电子信箱:

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谭黎明,副研究员,研究方向为数据驱动高温合金和涂层材料高效设计、制造(铸造、粉末冶金、涂层、增材制造)及其服役行为,电子信箱:

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谭黎明1, 2 , 吕金1, 2, 张毅3, 王子1, 2, 马鑫3, 张海龙3, 罗一苇1, 2, 王俊程1, 2, 苏捷1, 2, 文锦溶4, 黄岚1, 2, * , 刘锋1, 2
作者信息
  • 1 中南大学粉末冶金研究院,长沙 410083
  • 2 中南大学粉末冶金全国重点实验室,长沙 410083
  • 3 中国航发南方工业有限公司,株洲 412002
  • 4 普利(宁波)新材料科技有限公司,宁波 315000
通讯作者:
黄岚(通信作者),教授,研究方向为融合大数据、机器学习、高通量试验和模拟计算等方式加速新型高温合金材料的开发,结合传统粉末冶金工艺和增材制造开展材料制备,电子信箱:
Recycling of superalloy powders for selective laser melting
Liming TAN1, 2 , Jin LÜ1, 2, Yi ZHANG3, Zi WANG1, 2, Xin MA3, Hailong ZHANG3, Yiwei LUO1, 2, Juncheng WANG1, 2, Jie SU1, 2, Jinrong WEN4, Lan HUANG1, 2, * , Feng LIU1, 2
Affiliations
  • 1 Institute of Powder Metallurgy, Central South University, Changsha 410083, China
  • 2 National Key Laboratory of Powder Metallurgy, Central South University, Changsha 410083, China
  • 3 AECC South Industry Company Limited, Zhuzhou 412002, China
  • 4 Puli (Ningbo) New Material Technology Co., Ltd., Ningbo 315000, China
出版时间: 2025-11-13 doi: 10.3981/j.issn.1000-7857.2025.06.00043
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激光选区熔融作为金属增材制造技术的典型代表,凭借其近净成形能力和复杂结构制造优势,在航空航天、生物医疗及能源领域获得了产业化应用。高温合金因其优异的高温强度、抗氧化性及蠕变性能,成为激光选区熔融技术制备耐高温部件的首选材料。然而,激光选区熔融过程中产生的未熔化粉末在经历热循环、氧化及粒径分布变化后性能下降,其高效循环利用困难,成为制约产业可持续发展的关键瓶颈。围绕高温合金粉末在激光选区熔融过程中循环利用的研究进展,系统分析循环过程中粉末物理化学特性的演化规律,阐明循环粉末对成形件缺陷形成与力学性能的影响。随着循环次数增加,粉末表面出现卫星粉和不规则颗粒,导致表面粗糙度增加,同时氧含量持续上升。此外,循环粉末导致成形件缺陷密度增加,表现为未熔孔隙和微孔增多,力学性能呈现复杂变化。综述高效回收与再生方法的技术突破与应用案例,并展望了该领域未来的研究重点与发展方向。

激光选区熔融  /  高温合金  /  粉末循环  /  热循环  /  粉末物理化学特性

Selective laser melting (SLM), as a prominent metal additive manufacturing technology, has achieved industrial applications in aerospace, biomedical, and energy sectors due to its near−net−shape forming capability and ability to fabricate complex structures. Superalloys, owing to their excellent high−temperature strength, oxidation resistance, and creep performance, are the preferred materials for SLM−fabricated heat−resistant components. However, the unmelted powder generated during SLM undergoes degradation (including thermal cycling, oxidation, and particle size distribution alterations), posing significant challenges to its efficient recycling and reconditioning, which constitutes a critical bottleneck for sustainable industrial development. This article is centered on the research progress concerning the recycling of superalloy powders during selective laser melting (SLM). It systematically analyzes the evolution of physical and chemical characteristics of powders throughout the recycling process, elucidates the impact of recycled powders on the formation of defects and mechanical properties of printed parts. As the number of recycling cycles increases, satellite particles and irregular granules appear on the powder surface, leading to an increase in surface roughness, along with a continuous rise in oxygen content. Additionally, the recycled powder results in an increased defect density in the fabricated parts, manifested as a higher prevalence of unmelted pores and micropores, while the mechanical properties exhibit complex variations. Technological breakthroughs and application cases in efficient recycling and reconditioning methods were summarized. Furthermore, it proposes future research priorities and development directions in this field.

selective laser melting  /  high−temperature alloys  /  powder recycling  /  thermal cycling  /  physical and chemical characteristics of powders
谭黎明, 吕金, 张毅, 王子, 马鑫, 张海龙, 罗一苇, 王俊程, 苏捷, 文锦溶, 黄岚, 刘锋. 激光选区熔融高温合金粉末的循环利用. 科技导报, 2025 , 43 (21) : 87 -101 . DOI: 10.3981/j.issn.1000-7857.2025.06.00043
Liming TAN, Jin LÜ, Yi ZHANG, Zi WANG, Xin MA, Hailong ZHANG, Yiwei LUO, Juncheng WANG, Jie SU, Jinrong WEN, Lan HUANG, Feng LIU. Recycling of superalloy powders for selective laser melting[J]. Science & Technology Review, 2025 , 43 (21) : 87 -101 . DOI: 10.3981/j.issn.1000-7857.2025.06.00043
激光选区熔融(selective laser melting,SLM)作为金属增材制造(additive manufacturing, AM)技术的典型代表,凭借其逐层叠加、近净成形的特点,在航空航天、生物医疗及能源领域实现了复杂结构部件的定制化生产,推动了制造业的革新[13]。该技术通过高能激光束选择性熔化金属粉末床,逐层构建三维实体,突破了传统AM对几何复杂性的限制,尤其适用于高性能高温合金部件的制备[47]。例如,在航空发动机热端部件和燃气轮机叶片等耐高温场景中,镍基高温合金因优异的高温强度、抗氧化性及蠕变性能被广泛采用,而对于此类构型复杂的零件,SLM技术由于其高设计自由度和高精度的特点展现出显著优势[89]。然而,SLM过程中未熔化的粉末经历多次热循环、氧化及机械应力作用,导致其物理化学特性显著退化,包括粒径分布宽化、氧含量累积、卫星粉增多及流动性下降等现象,直接制约了粉末的循环利用率和工艺经济性[10]。AM过程中,粉末的循环使用可以通过筛分、混合、干燥等步骤实现,以提高材料利用率并降低生产成本,而回收再制粉则涉及对使用后的粉末进行回收、分类、预处理和净化等工艺,以确保其性能符合AM的要求。这2个阶段相辅相成,共同构成了高温合金粉末循环利用的技术体系。
据统计,SLM成型过程中仅有5%~30%的粉末被完全熔化,剩余粉末若未经有效回收,不仅造成高昂的原材料浪费,还会因粉末氧化和污染引发批次稳定性问题[1112]。例如,IN718等镍基合金粉末在反复使用后,氧含量上升,引发晶界脆化并降低零件的力学性能[1314]。此外,粉末粒径分布的变化(如细粉比例增加)会降低铺粉均匀性,导致熔池不稳定和零件内部缺陷[1517]。这些挑战使得高温合金粉末的循环利用成为SLM技术规模化应用的瓶颈,亟须系统性研究其退化机制与再生策略。
金属粉末是AM制备高致密、高性能高温合金部件的关键材料。不同的AM工艺,例如SLM、电子束熔化(electron beam melting,EBM)和激光同轴粉末进料(laser coaxial powder feeding,LCPF)等,对颗粒尺寸和形态等特性有特定的要求[1820]。制备金属粉末的主要方法有机械破碎法、雾化法、还原法、电解法、氢化脱氢法等。其中,雾化法中的气雾化法、等离子旋转电极雾化法(plasma rotating electrode process,PREP)和等离子雾化法可制备球形金属粉末,且粉末的化学成分均匀、氧含量低、球形度高,尤其适用于AM制造[2122]
PREP是将高温等离子枪作为热源,利用等离子弧将高速旋转的金属棒料熔化,并利用离心力将熔融金属甩出,形成微小液滴,最终在保护气氛的冷却下凝固成金属粉末的一种技术[2325]
真空感应熔炼气雾化(vacuum induction−melting gas atomization,VIGA)的基本原理是合金在真空室的坩埚中完成熔化、精炼和脱气过程,精炼完成的金属液倾倒进入预热中间包系统,金属液通过导流进入雾化器;随后金属液流被高压气体破碎、分散形成金属液滴进入雾化室,在飞行过程中球化、凝固形成金属粉末落入下方收集罐。气雾化的雾化介质为气体。为了减少雾化过程中粉末的氧化和杂质的引入,通常采用惰性气体(氩气或氮气)作为雾化介质[2629]
电极感应熔炼气雾化法(electrode induction−melting inert gas atomization,EIGA)是一种通过耦合电极感应熔炼技术与高压气体雾化工艺制备金属粉末的先进方法。其核心原理是利用电磁感应加热使金属电极棒端部快速熔化形成熔滴,随后通过高压惰性气体对液态金属进行高速冲击,使其破碎并快速凝固为球形微细粉末。该技术避免了传统雾化过程中坩埚对熔融金属的污染,特别适用于制备高纯度、高活性(如钛合金、高温合金)及易氧化金属粉末。所制粉末具有粒径分布窄、球形度高、流动性好等特点,广泛应用于AM、热喷涂、粉末冶金等领域,在航空航天和生物医用材料制备中展现出显著优势[3031]。EIGA通过无坩埚感应熔炼技术直接熔化预制合金棒材形成熔滴,并利用超音速惰性气体雾化,省去传统熔炼与导流环节,简化了设备结构,进而降低能耗,同时避免了耐火材料接触导致的非金属夹杂污染[32]
等离子火炬雾化技术(plasma atomization,PA)以金属丝材为原材料,利用等离子火炬产生的聚焦等离子射流将金属丝材熔化,形成微小金属粉末,由于采用非接触式雾化过程,因此可减少氧化,获得高纯度的金属粉末[33]。金属丝材进入雾化区内被聚焦等离子火焰加热熔化、蒸发成为饱和金属蒸气,随后通过气流实现淬火,金属蒸气发生快速团聚、形核、长大,最终获得特定粒径分布的金属粉末。目前等离子火炬雾化法已成功应用在Ti、Ni等金属粉末的生产,与其他雾化制粉技术相比,PA技术的优势在于其制得的粉末纯净度高,氧含量较低;金属熔滴的凝固速率减慢,从而获得高球形度的金属粉末;金属粉末粒径分布较窄,且具有高球形度和低杂质含量的特性[34]
这些技术各有优缺点(表1[3539])。PREP法凭借高速旋转电极的离心破碎机制,在惰性环境中制得超高纯净度粉末,但细粉收率极低且成本居高,专用于航空航天钛/高温合金等严苛纯度领域;VIGA法通过真空感应熔炼耦合高压气雾化,实现多材料(铁/镍/钴基)规模化生产,细粉收率高,成本可控,但易引入陶瓷夹杂且流动性较差,成为不锈钢/模具钢工业级应用的优选;EIGA法采用无坩埚电极熔炼雾化,规避污染风险,对高活性金属兼容性强,细粉收得率高,但粒径控制不稳易生卫星粉;而PA法以等离子流粉碎金属丝材,实现难熔金属(钨/钼)高效球化,细粉收得率突出,却受限于丝材预加工成本及氧含量问题。
目前研究较多的AM用高温合金粉末有IN718、IN625、GH3536等[4043]。本文将从高温合金粉末在SLM中的特性演变规律、循环利用对零件力学性能与微观组织的影响、高效低耗回收技术开发以及全生命周期评价等维度,综述该领域的最新进展,并针对粉末−工艺−性能协同调控、智能化回收系统开发等方向提出展望,以期为推动SLM技术的绿色可持续发展提供理论支撑。
AM用粉末材料的性能指标众多,相互之间的关系如图1所示。粉末重复使用最为理想的情况是回收粉末(或原始粉末和回收粉末的混合物)的物理、化学性能与原始粉末无显著差异,且成形件性能与原始粉末制件相比也没有明显差异。但是,这部分未熔化凝固为零件的金属粉末与热源进行了一系列动态热交互作用,每次成形均会造成部分粉末质量变化,其物理、化学特性不可避免地在重复循环使用中发生一定变化。
高温合金粉末在SLM循环利用过程中,因经历多次热循环、氧化及机械应力作用,其物理性能(包括颗粒形貌、氧含量、流动性及粒径分布等)呈现退化趋势。这些退化不仅影响粉末的工艺适应性,还会导致零件内部缺陷与性能衰减。SLM循环过程中,未熔化的粉末颗粒因反复受热(局部温度可达800~1200℃)发生表面张力驱动的球化效应,同时伴随氧化层形成,导致球形度下降和流动性劣化[4447]
热诱导的表面张力驱动球化效应与熔池飞溅物附着共同作用,导致卫星粉数量显著增加,宋巍等[48]研究发现,GH4169合金粉末在SLM成形过程中,随着使用次数的增加,卫星粉明显增多,合金粉末的流动性由0次的14.85 s/(50 g)增加到13次的18.62 s/(50 g)。粉末不同循环使用次数下的表面显微组织如图2[48]所示。此外,在其他参数相同的情况下,随着循环使用次数的增加,粉末直径增大,不规则粉末增多,粗糙度增加,这是由于粉末床预热过程中的温度升高引起的,高温会将粉末床中粉末轻微烧结在一起,在后续回收中部分粉末会难以分离[49]
在循环过程中细粉通过熔池边缘聚合粗化及小颗粒优先熔融消耗,导致粒径分布向粗端偏移。Ardila等[50]研究了IN718粉末在重复利用后粉末性能变化,粉末的显微组织及粒径变化如图3所示,其中在第7次重复利用后,粉末粒度分布略微粗化。
粉末床预热高温引发轻微烧结,使回收时颗粒难以分离,进一步加剧形貌不规则化。在Cordova等[51]的研究中,通过新旧粉混合的方式将IN718粉末重复利用了38次,在38次循环使用后,可以观察到粉末出现伸长和卫星粉形成,且材料的球形度在38次重复利用后下降了约7%,此外,重复使用的粉末具有更高的导电性。Rock等[52]通过连续10次循环使用IN718合金粉末(未补充新粉)发现,粉末重复回收导致粒径分布宽化、氧含量累积及室温下磁性上升,同时流动性下降。Sendino等[53]进一步观察到IN718循环粉末的颗粒形貌发生变异(如卫星粉附着及表面不规则化),筛分实验中大于40 μm的粗颗粒占比由80%提升至90%,表面粗糙度由5.9 μm升至6.6 μm,内部孔隙率由1%升高至1.14%,最终劣化粉末流动特性。
综合而言,高温合金粉末在循环使用中呈现粒径分布宽化与氧含量增加的趋势,其中粒径变化幅度因合金类型和循环次数而异;流动性呈现“先升后降”的特性——初期因细粉减少及颗粒氧化而短暂优化,后期因异形大颗粒与小颗粒的相互作用加剧流动阻力,降低流动性。
IN718粉末的合金化成分具有较好的热稳定性,可以经历多次重复使用循环,而不会发生合金成分的明显变化。Nandwana等[54]回收再利用了6次IN718高温合金粉末。在循环周期内,重复使用的粉末中的合金成分没有发生显著变化,在重复使用6次后,元素成分仍在合金特定要求范围内。但O质量分数由0.014%增加到0.022%,而C、N、H等其他元素的变化不明显。
高温合金粉末在SLM循环使用过程中,粉末在熔池附近经历局部高温,引发活性元素氧化,形成稳定的氧化物层。Gruber等[55]发现多次重复利用的IN718粉末中O含量略有增加(在14个循环周期后,O质量分数由0.0146%增加到0.0266%)。同时,会生成一种富Al和O的纳米颗粒并附着于粉末颗粒表面,这可能是由于Al在粉末颗粒表面的选择性氧化。同时,粉末中的N含量在整个循环周期中保持稳定。使用这种重复使用的粉末打印的样品显示出更多富含氧化物的区域,这可能会对零件的结构完整性产生不利影响[56]。在另一项研究中,Gruber等[57]对SLM过程中4种状态的IN718粉末(新粉、循环粉末、溢出粉和飞溅粉)在形态、流动性和物理化学性质方面进行了表征。研究表明,经过20次循环使用后的粉末及AM过程中产生的飞溅粉末中的O含量明显增加,且在一些飞溅颗粒中发现了Al2O3斑点,如图4[57]所示。这使得飞溅粉末表现出更高的激光吸收率,从而影响成形质量。
重复使用的高温合金粉末中成分的变化似乎仅限于O含量的增加,而其他元素,如C、N、H的变化则是微乎其微。Lee等[58]研究发现,在SLM中重复使用IN718粉末会增加粒度和O含量,导致形态改变。与原始粉末(质量分数为0.0081%)相比,再利用粉末(循环10次)的O质量分数增加至0.02%,Al和Ti 元素含量随粉末重复使用次数的增加变化较小,粉末中的Al、Ti、O和N元素的成分变化如图5[58]所示。Paccou等[59]系统研究了IN718合金粉末的循环再利用可行性。研究发现,经过多次生产循环后,O含量虽呈现轻微上升趋势,但仍在标准范围以内。郭雨萌等[60]研究表明,GH3536粉末在循环20次后,化学成分无明显变化,仅O和N元素含量略微增加。
高温合金中的Ni、Cr、Al、Fe和Ti等元素在氧气存在下极易形成氧化物,这可能造成NiO、Cr2O3、Al2O3、FeO/Fe2O3或TiO/TiO2等氧化物的形成。其中,Al2O3形成的Gibbs自由能是这些氧化物中最低的,使其具有最高的稳定性[61]。因此,Al2O3与高温合金中的其他氧化物相比更容易在粉末及构件内形成。虽然Cr元素与Al元素相比,对O的亲和力较低,但它的形成在动力学上是有利的,特别是考虑到它在IN718合金中的含量较高。高温合金粉末O含量的升高会导致原始颗粒边界缺陷(PPBs)的形成[62],从而对力学性能产生不利影响。
在SLM工艺中,对于不同的AM工艺和不同类型的粉末,其性能的变化也是不同的。例如,等离子雾化粉末(PA)相较于气雾化粉末(GA)表现出显著优势[63]:PA粉末颗粒球形度更高、比表面积更小,且熔滴表面张力更低,有利于熔池稳定成形;同时,其氧化速率较低,能够有效抑制打印过程中由氧渗透引发的冶金缺陷。
在高功率激光加工中,吸收率[64]可以表示为
$ A=(8{\epsilon }_{0}\omega {\rho }')^{\tfrac{1}{2}} $
其中
$ \omega ={2{\text{π}} {\mathrm{c}}}/{\lambda } $
式中,A为吸收率;λ为光波波长,m;c为光速,m/s;ε0为真空中的介电常数,F/m;$\rho' $为材料的电阻率,Ω·m;$ \omega $为角速度,rad/s。
由式(1)可知,材料的吸收率主要受激光的波长、材料的光学常数影响。低激光吸收率会使得其在成形过程中不能获取足够的激光输入能量,粉体无法充分熔化,熔池湿润性较差,加工过程中容易出现严重的气孔与球化缺陷,造成最终成形零件不够致密、性能差;而且加工过程中被反射的激光可能会损伤打印设备的硬件。研究表明,粉末粒径、球形度及表面氧化状态会显著影响激光吸收率[65]
颗粒尺寸对激光吸收有重要影响,Yang等[66]通过射线衍射法研究了粉末颗粒尺寸与激光吸收之间的关系,研究发现,粉末的激光吸收率与颗粒大小呈负相关(图6)。随着粉末粒径由10 μm增加到60 μm,粉末床吸收率由0.222下降至0.123。Balbaa等[67]的研究也得出了类似的结论,使用漫反射光谱法测量发现,细粉末的激光吸收率比粗粉末高13%。
金属粉末的几何形态也会对激光吸收率造成一定影响,严深平等[65]测量了常用的几种金属在球状颗粒和块状下的激光吸收率,研究发现,球形颗粒表面光滑的结构特性促进了入射激光的多重反射效应,从而提升了能量耦合效率;同时规则球形颗粒在粉末床中可实现更均匀的密堆积状态,减少光路空隙造成的能量损失,因此吸收率也增加。基于此,在实际SLM加工过程中,普遍采用接近球形的金属粉末。
金属粉末的表面氧化物也会影响粉末颗粒的激光吸收率,Doğu等[68]研究了IN939合金在SLM过程中原始粉末与飞溅粉末的激光吸收率变化及其影响。通过对比分析发现,飞溅粉末表面因高温氧化形成Al2O3层,导致其颜色变为棕色调,并在400~900 nm波长范围内反射率显著降低,表明光吸收率提升。X射线光电子能谱技术(XPS)分析进一步证实飞溅粉末表面碳含量减少、氧含量增加,氧化层增强了光吸收特性。
综合上述因素,高温合金粉末在循环使用过程中,激光吸收率随循环次数的增加呈现非线性演化规律。在循环初期,粉末表面氧化层逐渐增厚,如Gruber等[57]在IN718循环粉末中观察到的富Al2O3纳米颗粒的形成,导致激光吸收率小幅上升,这与Doğu等[68]报道的飞溅粉末因氧化而提升吸收率的结论一致。然而,随着循环次数进一步增加,粉末形貌发生退化,包括卫星粉比例升高、表面粗糙度增大及球形度降低,这些变化会削弱多重反射效应,从而降低激光能量耦合效率。同时,循环过程中的粒径分布向粗端偏移也会进一步降低吸收率。因此,在长期循环中,形貌劣化和粒径粗化效应将逐渐抵消甚至超过氧化带来的增益,导致吸收率整体呈下降趋势。当循环次数达到一定阈值时,粉末性能的退化可能引发熔池不稳定性和成形缺陷,需通过粉末再生技术或补充新粉来维持工艺稳定性。
高温合金粉末循环利用会影响合金构件的性能。He等[69]研究表明,采用循环粉末制备的Hastelloy X合金孔隙率达1.47%,明显高于原始粉末成形件(0.82%),原始粉末和循环粉末制备的构件均呈现典型非平衡凝固特征,晶粒取向和核平均错向(kernel average misorientation,KAM)分析表明,循环粉末未显著改变晶粒尺寸或取向分布,但循环粉末构件表面粗糙度更高,主要源于不规则粉末颗粒和打印过程中缺陷的累积。
重复使用IN718或IN738粉末时,其宏观晶粒结构(如晶粒尺寸、γ基体连续性、γ'析出相形貌)未发生明显变化[59,7071]。Bhowmik等[72]研究发现,采用原始粉末和重复粉末打印的IN718样品显示出连续的γ基体和花形γ′沉淀,以及相似的纹理和晶粒尺寸,粉末反极图(inverse pole figure,IPF)如图7(a)和(c)[72]所示。然而,亚微观尺度的位错密度和再结晶行为存在明显差异,采用重复使用粉末制备的IN718样品的KAM高于未使用的粉末,如图7(b)和(d)所示,这可能意味着位错密度的增加。相关研究表明[58],在SLM工艺中,IN718随着循环次数的增加,再结晶率从89.6%下降到82.7%,这可能是因为多次循环导致粉末反复经历局部高温,引发氧化诱导的晶界钉扎效应,同时氧渗透促使活性元素在晶界偏聚,产生拖拽力共同压制了再结晶形核动力,导致再结晶率下降。
Yi等[70]通过X射线CT结果发现,重复使用的IN718粉末可以增加孔隙的球形度和零件的孔隙度,这是因为在重复使用的IN718粉末中,大颗粒内部存在被困气体[73]。对于哈氏合金,使用回收粉末制造的Hastelloy X合金的孔隙率为1.47%,明显高于使用原始粉末制备的零件。然而,在由原始粉末和回收粉末制成的Hastelloy X合金中仅观察到晶粒尺寸略有不同[69]
重复使用的IN718粉末进行打印时,硬度有一定的降低[74]。例如,Gruber等[57]发现,采用重复使用的IN718粉末制备的样品硬度从334HV略微下降到329HV。Choi等[75]研究发现,使用原始和重复使用的IN718粉末制备的样品具有几乎相同的极限抗拉强度、屈服强度和伸长率。然而,对于高温拉伸性能,重复使用的IN718粉末制备的样品具有更高的屈服强度和极限抗拉强度,但延展性略低,这可能是因为重复使用的粉末样品中,溶质原子(如Nb、Mo)更倾向于保留在γ基体中,而非被析出相(如δ相或碳化物)吸收。这导致在高温拉伸时,溶质原子与位错的相互作用更强。He等[69]研究发现,使用6次循环后的Hastelloy X回收粉末制备的样品塑性降低了20.8%。
热处理后的IN718样品的高温拉伸性能如图8[72]所示,前3次粉末重复使用循环可以提高屈服强度和极限抗拉强度,并保持伸长率。而在650℃时,由于扩散速率的增加,氧化铝对位错运动的阻滞作用减弱,导致屈服强度和极限抗拉强度几乎不变。使用循环粉末制备的Hastelloy合金的抗拉强度((753±8) MPa)和伸长率(11.1%)略低于原始样品的抗拉强度((780±7) MPa)和伸长率(14.2%),这是由于使用循环粉末打印的样品中存在明显的缺陷[69]。对于GH3536合金,有研究表明循环次数对SLM成形件的抗拉强度、屈服强度和伸长率均无显著影响,横向制备试棒强度更高,纵向试棒塑性更好,但粉末循环未导致性能劣化,验证了GH3536粉末在AM中的可重复利用性[60]
研究发现,用原粉末制备的样品在550℃和650℃时具有更好的蠕变性能,然而,在700℃测试时,观察到相反的趋势如图9[72]所示。这种机制可能是由于用重复使用的粉末制成的合金含有更多的可用位错,可以很容易地激活以适应蠕变应变。然而,在700℃时,较高的位错含量阻碍了扩散过程,从而增加了蠕变寿命[72]
在疲劳性能方面,Paccou等[59]研究发现,当塑性振幅较小(∆εp/2 = 0.00004)时,用循环粉末打印IN718的疲劳寿命略有降低,但这种差异甚至小于相同参数下制备的不同部件的差异。此外,Chen等[71]发现,重复使用IN738粉末会降低构件的疲劳寿命。总体上,粉末循环使用对样品力学性能的影响如表2所示。
此外,尽管高温合金牌号差异导致循环粉末的具体响应各异,但仍存在一些共性规律。循环过程中粉末氧含量普遍上升,形成Al2O3/Cr2O3等晶界氧化物,导致塑性及疲劳性能下降。高循环次数下位错密度显著增加,通过钉扎晶界和阻碍滑移,部分抵消强度损失。孔隙率变化则因合金而异,但均通过改变应力集中系数与裂纹萌生点密度,影响材料的疲劳极限与断裂韧性。
根据Thomas等[76]对AM经济性成本研究的系统性分析,AM零件的总成本Cp可定义为
$ \mathit{C} _{ \mathrm{p}} = \mathit{C} _{ \mathrm{m}} + \mathit{C} _{ \mathrm{e}} + \mathit{C} _{ \mathrm{i}} + \mathit{C} _{ \mathrm{c}} + \mathit{C} _{ \mathrm{0}} + \mathit{C} _{ \mathrm{w}} $
式中,Cm为材料成本,Ce为设备成本,Ci为清洁和设置机器的劳动力成本,Cc为能源成本,Co为正常业务运营的间接成本,Cw为包括故障部件在内的浪费成本。
Hopkinson等[77]用下式表示AM的部分成本
$ \mathit{C} _{ \mathrm{p}} = \mathit{P} _{ \mathrm{m}} ( \mathit{M} _{ \mathrm{f}} + \mathit{M} _{ \mathrm{u}} )+ \mathit{P} _{ \mathrm{i}} \mathit{t} $
式中,Pm为材料价格,Mf为熔融粉末的质量,Mu为未熔融粉末的质量,Pi为间接成本率,t为打印时间。
在AM过程中直接使用原始粉末将显著提升材料成本系数Cm及单件材料用量Mu,导致AM总成本Cp大幅上升。可见,未熔粉末的循环利用是降低AM成本的重要路径。高温合金粉末的回收与再生方法的核心在于通过物理、化学或热力学手段恢复粉末的形貌特征、流动性能及化学成分稳定性。研究表明,高温合金粉末在多次循环使用过程中易出现粒径分布偏移、氧含量累积及非球形颗粒比例上升等问题,这促使研究者开发了如等离子球化、粉末表面改性等复合再生技术[7880]
粉末再利用的方法主要有3种,如图10[81]所示。第一种方法称为单批次回收,在每次循环过程后不添加任何原始粉末,并在每个周期后对粉末进行筛分以去除烧结团聚物或变形的粉末。单批次粉末可以重复使用,直到它的各项特征参数不满足使用要求或直到剩余的粉末不足以完成下一批样品的制备。粉末性能的降低因素包括粉末成分、密度、孔隙率、形态、流动性和粒径分布变窄的变化。
第二种方法称为多次更新法,其中使用过的粉末在每次循环后与一定量的原始粉末混合。与单批次回收方法相比,这种方法能够使AM过程中节省粉末成本,减少了粉末浪费,原始粉末的掺入能够缓解性能退化,有效延长原料粉末的使用寿命。
第三种策略是前2种策略的综合应用。在前若干次AM过程中不添加新的粉末,仅使用经筛分处理的再利用粉末。经过3次工艺后,通过添加原始粉末补偿损耗粉末。该策略通过定期“刷新”粉末批次,借助原始粉末的补充提升整体粉末性能。
然而,当使用多次更新方法时,因为粉末中添加了不同批次的原始粉末,粉末的可追溯性也随之消失,这在航空航天和生物医学等可追溯性至关重要的行业中是不可取的。同时,如果回收粉末和原始粉末之间没有进行适当的配合,只能部分解决粉末的不均匀性,且随着用于制造周期次数的增加,混合粉末中一小部分性能会急剧恶化,这对制件的性能是致命的。为了避免这种现象的发生,Lutter–Günther等[82]提出了一种新的粉末再利用策略,他们认为需要将粉末分批储存管理,以获得回收粉末可追溯的历史信息,然后将相同年限的废旧粉末混合使用,以控制在重复使用过程中的粉末变化。
初次筛分粒径较大的颗粒,可以极大地提高粉末循环利用的寿命,但是仍然存在残留的飞溅物无法去除的问题,这些氧化和扭曲的飞溅物存在会导致循环粉末性能的退化[8384]。有研究表明,等离子体球化可以改变金属粉末的理化性质[85]。该工艺可以明显提高粉末颗粒的球形度、粉末的流动性和密度,甚至可以降低氧含量。在还原气氛下对Mo−40Re粉末进行等离子体球化,导致氧质量分数由1.3%显著降低至0.04%[86]。刘佳伟等[87]采用机械合金化及等离子球化处理制备出TiCp/GH3536复合粉末,经过球化处理后复合粉末的球形度和粒度分布均匀性得到改善,空隙率下降5.8%。Garboczi等[88]通过电感耦合等离子体(inductively coupled plasma,ICP)球化工艺来修复循环使用的IN718粉末,使用氩气作为载气,经过球化处理后粉末的松装密度和振实密度均升高,氧质量分数由0.03%降低至0.016%,使循环粉末满足SLM工艺要求。
图11为等离子体球化利用电感耦合使氩气电离[89],电离的氩气可以与其他气体如氦、氮、氢、氧或空气混合以产生惰性、还原性或氧化性气氛。将粉末轴推向等离子体区(约11000 K),使颗粒全部或部分熔化。当颗粒在反应器中向下移动时,它们由于表面张力而变成球形,并在到达粉末收集室之前凝固。等离子体球化处理通过熔化对颗粒产生致密化作用,并通过蒸发表面杂质产生净化作用。
粉末的进料速率对粉末的物理性能有很大的影响。Massard等[90]研究发现,在进料速率较小时,细颗粒总蒸发量较大,会使粉末转向更大的颗粒。同时外层颗粒的蒸发,使粉末倾向于转变为更细的颗粒。随着进料速率增大,颗粒更容易碰撞融合成更大的颗粒,如图12[90]所示。
为突破粉末循环利用的瓶颈,表面改性技术成为优化粉末性能、延长服役周期的关键研究方向。通过物理、化学或复合手段对循环粉末进行表面处理,可有效去除表面氧化物、修复形貌缺陷并抑制二次污染,从而恢复甚至提升粉末的打印性能[9193]
Lim等[94]通过酸处理对IN718粉末进行表面改性,显著改善了粉末的流动性,酸蚀作用使粉末表面粗糙度增加,表面能降低,改性后的IN718表面接触角达到129°。Lee等[95]提出了一种金属粉末表面改性工艺,称为表面改性和增强移植(surface modification and augmented reinforcement transplantation,SMART),该工艺可以对不规则粉末进行球化、表面改性或合金化,SMART工艺的原理示意如图13[95]所示。粉体粒度应具有双峰分布,且较大的粉末颗粒充当磨球而较小的粉末通过碰撞变形,形成球形颗粒,可以精确快速地控制粉末特性,因此SMART工艺的产品是球形核壳粉末,这是传统机械合金化无法获得的。
采用SMART工艺,可以使增强元素或颗粒均匀分布在粉末表面,更有利于AM零件机械性能的均匀化。Lee等[95]通过SMART改性方法在IN625中引入质量分数10%TiCp particles(TiCps)使得IN625在保持较好的流动性情况下提高了激光吸收率和球形度,并减少了缺陷的形成,提高了打印制件的力学性能。SMART工艺作为一种新型的粉末改性方法,有望改善粉末的形貌和成分,降低金属AM材料的制造成本,促进金属AM的快速发展。
在高温合金粉末的循环利用过程中,粉末再生技术并非简单的“重新生产”,而是一种通过等离子球化、粉末表面改性等工艺手段,将加工过程中产生的废料转化为高质量粉末材料的先进制造方式。这种技术不仅能够有效降低资源消耗,还能显著提升材料性能和降低成本。然而,尽管粉末再生技术在成本控制方面具有显著优势,但其经济性也受到多种因素的影响。例如,传统等离子球化技术受限于设备成本高、单机产量小、耗电耗气量大等因素,长期被认为是一种高成本的技术,通常局限于科研或航空航天等超高端领域。因此,在评估粉末再生技术的经济性时,需综合考虑原材料价格、能源消耗、设备投入、工艺复杂度以及市场供需等多方面因素。
国内外AM用高温合金粉末的标准存在明显差异。如表3所示,国内虽然已发布部分相关标准,但缺乏统一性和系统性,且在技术要求、制备工艺及循环使用等方面仍需完善。相比之下,国外标准体系更为成熟,能够更好地支持产业化发展。因此,亟须从系统行业数据出发,形成有效的粉末循环方法和标准,以解决当前高温合金粉末循环标准化不足的问题。
近年来,随着AM技术的快速发展,特别是SLM技术在航空航天和高性能材料制造领域的应用日益广泛。SLM技术在实现复杂结构设计和快速制造方面展现出巨大优势。然而,由于高成本的原材料消耗以及对环境的影响,粉末循环利用成为SLM过程中一个重要的研究方向。EBM因其铺粉−激光选区熔化的工艺特点,面临相似的粉末热循环、氧化及机械应力问题。对于其他增材工艺,如DED、LENS因粉末利用率高且粉末经历单次热循环,退化程度显著降低。
本文选取高温合金粉末作为分析对象,回顾了粉末再利用对粉末特性和打印件性能演变的影响,得出以下结论:(1) SLM循环过程中,未熔化的高温合金粉末经历热循环、氧化和机械应力作用,导致物理化学性能退化,包括粉末平均粒径增大、球形度下降、粗糙度增加进而导致流动性劣化。粉末回收利用对粉末中合金成分影响不大,但氧含量逐渐增加,并在粉末表面形成Al2O3氧化相。(2) SLM工艺中高温合金粉末的循环使用对构件的显微组织未产生明显改变,但粉末反复回收会导致颗粒表面氧化加剧和流动性降低,进而影响成形质量,主要变现为孔隙率增加,部分区域出现未熔合缺陷。(3) 为了保证AM产品的质量并延长重复使用粉末的寿命,必须在每次操作前准确评估粉末特性并相应调整工艺参数。采用再生技术和混合再利用策略,可以提升粉末的可重复使用性,同时保证最终产品质量和降低成本。
基于上述研究不足与突破点,亟须通过材料创新、工艺革新、标准建设的协同突破:(1) 在粉末特性方面,未来研究需聚焦于合金成分创新与制备工艺优化,例如通过集成计算材料学和人工智能算法实现材料性能的精准预测,设计定制化合金配方,通过Al/Ti含量优化,抑制选择性氧化。同时,探索高纯度、细粒度及球形度粉末的制备技术,如雾化、等离子球化等工艺,以提高流动性和成形性能,提高循环再利用粉末的性能。(2) 针对粉末反复回收导致颗粒表面氧化加剧和流动性降低的问题,需提升回收效率,突破现有技术瓶颈。例如,针对AM产生的废粉,可通过粗/细粉混合压块、保护气氛烧结及熔炼工艺实现再生,使氧含量降低,达到新料标准。等离子球化技术可改善回收粉末的形貌与流动性,尤其适用于高熔点合金。此外,需开发低成本的粉末还原再处理工艺,解决杂质累积、元素烧蚀等问题。同时还应关注能耗与成本平衡,例如通过优化分选技术和流程自动化降低回收成本。(3) 针对人工检测滞后性以及不同合金粉末循环后性能变化的差异性,需要建立标准化的表征方法和高温合金粉末回收标准。此外,为准确描述SLM技术用粉末的各项性能,应运用原位检测技术尽可能复现粉末在成形过程中的实际状态。当前传统的粉末质量评估仍依赖于成形后的人工检测,而通过集成传感器与人工智能(AI)算法,可实现对粉末粒度分布、颗粒形貌、化学成分及氧化程度的实时监控。这不仅能保障回收粉末的质量,还可通过数据驱动优化工艺窗口,提升粉末重复使用效率。
综上所述,研发并突破粉末循环再生技术,深化氧含量控制与形貌恢复机制研究,构建覆盖“回收—再生—质控—应用”全链条的标准体系,建立一个集粉末制备工艺优化、低能耗再生工艺、粉末特性原位表征及构件全生命周期性能验证于一体的粉末循环再利用系统,为AM产业的绿色化发展与资源利用率提升注入持续动能。
  • 中国航发集团产学研合作项目(HFZL2022CXY029)
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2025年第43卷第21期
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doi: 10.3981/j.issn.1000-7857.2025.06.00043
  • 接收时间:2025-06-10
  • 首发时间:2025-12-29
  • 出版时间:2025-11-13
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  • 收稿日期:2025-06-10
  • 修回日期:2025-08-05
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中国航发集团产学研合作项目(HFZL2022CXY029)
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    1 中南大学粉末冶金研究院,长沙 410083
    2 中南大学粉末冶金全国重点实验室,长沙 410083
    3 中国航发南方工业有限公司,株洲 412002
    4 普利(宁波)新材料科技有限公司,宁波 315000

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黄岚(通信作者),教授,研究方向为融合大数据、机器学习、高通量试验和模拟计算等方式加速新型高温合金材料的开发,结合传统粉末冶金工艺和增材制造开展材料制备,电子信箱:
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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