Densification behavior of gas and water atomized 316L stainless steel powder during selective laser melting

The densification during selective laser melting (SLM) process is an important factor determining the final application of SLM-part. In the present work, the densifications under different processing conditions were investigated and the densification mechanisms were elucidated. It was found that the higher laser power, lower scan speed, narrower hatch spacing and thinner layer thickness could enable a much smoother melting surface and consequently a higher densification.The gas atomized powder possessed better densification than water atomized powder, due to the lower oxygen content and higher packing density of gas atomized powder. A large number of regular-shaped pores can be generated at a wider hatch spacing, even if the scanning track is continuous and wetted very well. The densification mechanisms were addressed and the methods for building dense metal parts were also proposed as follows: inhibiting the balling phenomenon, increasing the overlap ratio of scanning tracks and reducing the micro-cracks.     

Impact mechanism of gas temperature in metal powder production via gas atomization

This paper aims at studying the influence mechanism of gas temperatures(300 K, 400 K, 500 K, and 600 K) on gas atomization by simulating the integral atomization process of the close-coupled nozzle in vacuum induction gas atomization(VIGA). The primary atomization is simulated by the volume of fluid(VOF) approach, and the second atomization is studied by the discrete phase model(DPM) combined with the instability breakage model. The results show that, at an increased gas temperature, the influences of gas–liquid contact angle and gas temperature in the recirculation zone on the primary atomization are virtually negligible. However, increasing the gas temperature will increase the gas–liquid relative velocity near the recirculation zone and decrease the melt film thickness, which are the main reasons for the reduced mass median diameter(MMD, d50) of primary atomized droplets. During the secondary atomization, increasing the gas temperature from 300 K to 600 K results in an increase in the droplet dispersion angle, which is beneficial to the formation of spherical metal powder. In addition, increasing the gas temperature, the positive effect of gas–liquid relative velocity increase on droplets refinement overweighs the negative influence of the GMR decrease, resulting in the reduced MMD and diameter distribution interval. From the analysis of the atomization mechanism, the increase in atomization efficiency caused by increasing the temperature of the atomizing gas, including primary atomization and secondary atomization, is mainly due to the increase in the gas drag force difference between the inner and outer sides of the annular liquid film.     

316L不锈钢粉末光纤激光选区熔化特性

采用自行研制的光纤激光选区熔化快速成型设备,研究了选区激光熔化316L不锈钢粉末工艺参数、能量输入与样件致密度、表面形貌之间的关系以及微观组织特征。结果表明：扫描速度对成型效果影响最为显著;样件致密度随着激光能量密度提高有逐渐增大的趋势;能量密度作为选区激光熔化工艺的技术指标具有可操作性;表面形貌由激光功率与扫描速度比值所决定。深入探讨了能量输入、熔化凝固行为、激光功率与扫描速度比值与样件致密度、表面形貌的关系。结果表明：选区激光熔化凝固组织层内、层间熔合处为弧形,且为冶金结合,金相组织主要由柱状晶与等轴晶组成,层内靠近熔合线周围是柱状晶,而层间靠近熔合线附近主要是细小等轴晶,晶粒直径为1 μm左右。     

316L不锈钢粉末光纤激光选区熔化特性

采用自行研制的光纤激光选区熔化快速成型设备,研究了选区激光熔化316L不锈钢粉末工艺参数、能量输入与样件致密度、表面形貌之间的关系以及微观组织特征。结果表明:扫描速度对成型效果影响最为显著;样件致密度随着激光能量密度提高有逐渐增大的趋势;能量密度作为选区激光熔化工艺的技术指标具有可操作性;表面形貌由激光功率与扫描速度比值所决定。深入探讨了能量输入、熔化凝固行为、激光功率与扫描速度比值与样件致密度、表面形貌的关系。结果表明:选区激光熔化凝固组织层内、层间熔合处为弧形,且为冶金结合,金相组织主要由柱状晶与等轴晶组成,层内靠近熔合线周围是柱状晶,而层间靠近熔合线附近主要是细小等轴晶,晶粒直径为1μm左右。     

Process mapping of laser surface modification of AISI 316L stainless steel for biomedical applications

A 1.5-kW CO₂ laser in pulsed mode at 3 kHz was used to investigate the effects of varied laser process parameters and resulting morphology of AISI 316L stainless steel. Irradiance and residence time were varied between 7.9 to 23.6 MW/cm² and 50 to 167 μs, respectively. A strong correlation between irradiance, residence time, depth of processing and roughness of processed steel was established. The high depth of altered microstructure and increased roughness were linked to higher levels of both irradiance and residence times. Energy fluence and surface temperature models were used to predict levels of melting occurring on the surface through the analysis of roughness and depth of the region processed. Microstructural images captured by the SEM revealed significant grain structure changes at higher irradiances, but due to increased residence times, limited to the laser in use, the hardness values were not improved.     

电极感应熔化气雾化制粉技术中非限制式喷嘴雾化过程模拟

电极感应熔化气雾化(electrode induction melting gas atomization, EIGA)是一种制备超洁净无夹杂物的先进制粉技术,本文以粉末高温合金的氩气雾化过程为研究示例,对现有用于实际生产的国内某厂家提供的EIGA用非限制式喷嘴进行建模,采用商用计算流体力学软件FLUENT,分布采用欧拉-欧拉VOF(volume of fluid)多相流方法与欧拉-拉格朗日DPM (discrete phase model)离散相方法,对非限制式环缝喷嘴主雾化与二次雾化过程进行了数值模拟.通过对主雾化过程中多相流大涡模拟速度流场,主雾化过程中不同阶段高温熔体云图模拟以及二次雾化过程中TAB (Taylor analogy breakup)模型速度流场及TAB模型粒度分布的模拟研究,实现了对EIGA制粉技术中非限制式喷嘴雾化过程的全过程模拟,并预测了雾化后的粉末粒度分布.在此基础上,采用本文模拟使用的非限制式环缝喷嘴,设定与模拟条件一致(进气压力4 MPa,液流直径约4 mm)的实验条件,制备的粉末大部分颗粒的直径大小在100μm左右,该实验结果与模拟得到的粉末直径D50=100μm大小一致,进一步验证了模拟数据的合理性.该方法也适用于非限制式喷嘴里,其他金属或合金的雾化过的模拟研究.     

High strain rate deformation microstructures of stainless steel 316L by cold spraying and explosive powder compaction

Cold spraying is a new coating technique in which dense, tightly bonded coatings form only due to the high kinetic energy of impinging particles of the spray powder. These particles are still in the solid state during impact. Explosive powder compaction is a technique where powder is consolidated by a shock wave. In the shock front the powder is deformed under high strain rates, which under suitable conditions results in high-strength bonding of the particles. Thus, the microstructural features obtained by both techniques should be similar. This study correlates the microstructure of cold-sprayed 316L austenitic steel coatings in comparison to the microstructure of 316L samples obtained by explosive compaction. The results provide insight into the prevailing local deformation mechanisms, as well as into the physical background of observed phase transformations. PACS 81.15.Rs; 61.72.Ff; 62.50.+p; 64.60.My; 64.70.Kb     

拉瓦尔喷嘴的气流线质量及密度分析

喷气负载是高功率Z箍缩的主要负载之一。应用一维等熵压缩气体动力学,分析了“强光一号”加速器拉瓦尔喷嘴的基本物理过程,获得了拉瓦尔喷嘴出口处气流的马赫数,Ma=4.6,并对其进行了修正,修正值为3.5。利用由雪耙模型导出的Z箍缩聚爆时间表达式,并结合“强光一号”Z箍缩实验结果,修正了由一维等熵气体动力学得到的喷嘴气流线质量表达式。最后根据已知气流的线质量40 μg/cm ,利用B-T模型初步估算了喷嘴的气流密度分布。估算结果为：在轴向2.5~40 mm,径向0~15 mm的区域内,气体分子密度基本在1016～1017/cm3,且在轴向2 cm内基本形成空心的气体壳层结构。     

Consecutive induction melting of nickel-based superalloy in electrode induction gas atomization

The crucible-free electrode induction melting gas atomization(EIGA) technology is an advanced technology for preparing ultra-clean nickel-based superalloy powders. One of the key issues for fabricating powders with high quality and yield is the consecutive induction melting of a superalloy electrode. The coupling of a superalloy electrode and coil,frequency, output power, and heat conduction are investigated to improve the controllable electrode induction melting process. Numerical simulation results show that when the coil frequency is 400 kHz, the output power is 100 kW, superalloy liquid flow with a diameter of about 5 mm is not consecutive. When the coil frequency is reduced to 40 kHz, the output power is 120 kW, superalloy liquid flow is consecutive, and its diameter is about 7 mm.     

316L不锈钢在静态液态锂中的腐蚀行为研究

利用脉冲激光诱导击穿光谱仪(LIBS)结合SEM、EDX和维氏硬度(HV)等分析手段,分析了316L不锈钢在350℃的液态锂中静态腐蚀500h后的腐蚀特性。微观形貌分析表明：样品存在较明显的晶间腐蚀,其腐蚀层厚度约为2.7μm。硬度分析表明：腐蚀后表面硬度值约HV234.72,约是腐蚀前硬度值的0.78倍。LIBS组分分析表明：经液态锂腐蚀后的样品表面Ni、Cr等元素含量相对减少;在被腐蚀区域Li元素含量随激光击打深度的增加而减少,而Ni、Cr等元素含量与之近似呈成正比递增;母材区Li元素的渗透深度约3.5μm,约是焊缝区的0.6倍。     

Electrophoretic deposition of PVA coated hydroxyapatite on 316L stainless steel

Polyvinyl alcohol (PVA) coated hydroxyapatite was deposited onto a 316L stainless steel substrate by electrophoretic deposition. Deposition was carried out in a methanol suspension at pH 5.5 using a graphite rod as an anode. Parameters such as PVA concentration, deposition voltage and time were optimized to achieve a homogeneous, crack-free adhesive coating. Techniques such as X-ray diffraction and Fourier transform infrared spectroscopy were used to study the phase composition of the coated materials and the stability of hydroxyapatite in the presence of PVA.     

液态金属锂对于316L不锈钢焊接件的腐蚀行为研究

通过失重法结合SEM、金相分析等手段,研究了含焊缝的316L 不锈钢试样在350°C、0.15MPa 液态锂中500h 的静态腐蚀,并采用LIBS 结合台阶仪表征液态锂的渗入深度。结果表明,锂对含焊缝的316L 不锈钢样式的平均腐蚀速率为99.8mg·m^-2·h^-1;腐蚀深度为6.4μm;渗入深度在316L 不锈钢焊缝处为8.6μm,在母材处为4.8μm。在焊缝处锂对材料有明显的晶间腐蚀。     

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利用脉冲激光诱导击穿光谱仪(LIBS)结合SEM、EDX和维氏硬度(HV)等分析手段,分析了316L不锈钢在350℃的液态锂中静态腐蚀500h后的腐蚀特性.微观形貌分析表明:样品存在较明显的晶间腐蚀,其腐蚀层厚度约为2.7μm.硬度分析表明:腐蚀后表面硬度值约HV234.72,约是腐蚀前硬度值的0.78倍.LIBS组分分析表明:经液态锂腐蚀后的样品表面Ni、Cr等元素含量相对减少;在被腐蚀区域Li元素含量随激光击打深度的增加而减少,而Ni、Cr等元素含量与之近似呈成正比递增;母材区Li元素的渗透深度约3.5μm,约是焊缝区的0.6倍.     

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通过失重法结合SEM、金相分析等手段,研究了含焊缝的316L不锈钢试样在350°C、0.15MPa液态锂中500h的静态腐蚀,并采用LIBS结合台阶仪表征液态锂的渗入深度。结果表明,锂对含焊缝的316L不锈钢样式的平均腐蚀速率为99.8mg·m?2·h?1;腐蚀深度为6.4μm;渗入深度在316L不锈钢焊缝处为8.6μm,在母材处为4.8μm。在焊缝处锂对材料有明显的晶间腐蚀。     

测量喷气Z箍缩负载的气流马赫数

利用双压力传感器的方法测量了喷气Z箍缩负载的气流马赫数。测量得到的气流马赫数最高可达到4.25,它和定常计算的结果4.8很接近,这表明可以用定常计算来估算喷气Z箍缩中超声速喷嘴产生的气流马赫数。     

Global nonequilibrium energy criterion for predicting strength of 316L stainless steel under complex loadings:Theoretical modeling and experimental validation

Classical strength criteria are developed based on some empirical assumptions and have been widely used in engineering to predict material strength owing to their simplicity. In some cases, however, considerable discrepancies arise between classicalstrength-criteria-based theoretical predictions and experimental results. Recently, a global nonequilibrium thermodynamics model has made important progress over classical models without resorting to any empirical assumptions. A prominent advance of this rational energy model is that it straightforwardly determines the dissipation energy density function, which is pertinent to inherent material ductility, through simple uniaxial and equi-biaxial tensions. In this study, a brief introduction of the nonequilibrium energy model was followed by systematic experimental investigation to determine the dissipation energy function and predict the material strength of pristine 316 L stainless steel-commonly used in engineering-under complex loadings. The results indicated that the strength contours predicted by the nonequilibrium energy criterion for complex loadings are consistent with the experimental results obtained for biaxial tension, implying that the nonequilibrium thermodynamics model is both reasonable and reliable. The prediction error was presumed to be induced by the anisotropy of the 316 L stainless steel sheets.     

测量喷气Z箍缩负载的气流马赫数

 利用双压力传感器的方法测量了喷气Z箍缩负载的气流马赫数。测量得到的气流马赫数最高可达到4.25，它和定常计算的结果4.8很接近，这表明可以用定常计算来估算喷气Z箍缩中超声速喷嘴产生的气流马赫数。     

Electron stimulated desorption of H3O from 316L stainless steel

Surface ions generated by electron stimulated desorption from mass spectrometer ion source grids are frequently observed, but often misidentified. For example, in the case of mass 19, the source is often assumed to be surface fluorine, but since the metal oxide on grid surfaces has been shown to form water and hydroxides, a more compelling case can be made for the formation of hydronium. Further, fluorine is strongly electronegative, so it is rarely generated as a positive ion. A commonly used metal for ion source grids is 316L stainless steel. Thermal vacuum processing by bakeout or radiation heating from the filament typically alters the surface composition to predominantly Cr₂O₃. X-ray photoelectron spectral shoulders on the O 1s and Cr 2p_3/2 peaks can be attributed to adsorbed water and hydroxides, the intensity of which can be substantially increased by hydrogen dosing. On the other hand, the sub-peak intensities are substantially reduced by heating and/or by electron bombardment. Electron bombardment diode measurements show an initial work function increase corresponding to predominant hydrogen desorption (H₂) and a subsequent work function decrease corresponding to predominant oxygen desorption (CO). The fraction of hydroxide concentration on the surface was determined from X-ray photoelectron spectroscopy and from the deconvolution of temperature desorption spectra. Electron stimulated desorption yields from the surface show unambiguous H₃O⁺ peaks that can be significantly increased by hydrogen dosing. Time of flight secondary ion mass spectrometry sputter yields show small signals of H₃O⁺, as well as its constituents (H⁺, O⁺ and OH⁺) and a small amount of fluorine as F⁻, but no F⁺ or F⁺ complexes (HF⁺, etc.). An electron stimulated desorption cross-section of σ⁺ ∼ 1.4 × 10⁻²⁰ cm² was determined for H₃O⁺ from 316L stainless steel for hydrogen residing in surface chromium hydroxide.     

Collagen immobilization on 316L stainless steel surface with cathodic deposition of calcium phosphate

Collagen fibril/(calcium phosphate and carbonate) composite coatings on 316L stainless steel were developed with a cathodic deposition technique. The response of SaOS-2 osteoblast-like cells to the collagen/calcium salt-coated 316L steel was investigated. The collagen fibrils were self-assembled on the 316L steel surface and immobilized by their partial incorporation into a calcium salt layer electrodeposited cathodically in Hanks’ solution. The amount of calcium salt depended on the applied cathodic potential. The mineralization of collagen fibrils was observed. The collagen coverage localized and the composition of calcium salts varied on the same specimen. Such non-uniform surfaces affected the cell response. The observed outlines of cell bodies and nuclei on the thin collagen coating were clearer than those on the thick collagen coating in most cases. The collagen coating did not significantly influence the mean viability of cells on the whole specimen surface. Interestingly, the alkaline phosphatase activity per cell on the collagen/calcium salt-coated specimens was higher than that on the as-received specimen. It was revealed that cathodic deposition is an effective technique to immobilize collagen fibrils on a 316L steel surface.     

Surface characterisation and electrochemical behaviour of porous titanium dioxide coated 316L stainless steel for orthopaedic applications

Porous titanium dioxide was coated on surgical grade 316L stainless steel (SS) and its role on the corrosion protection and enhanced biocompatibility of the materials was studied. X-ray diffraction analysis (XRD), atomic force microscopy (AFM), Fourier transform infrared (FTIR) spectroscopy, scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDAX) were carried out to characterise the surface morphology and also to understand the structure of the as synthesised coating on the substrates. The corrosion behaviour of titanium dioxide coated samples in simulated body fluid was evaluated using polarisation and impedance spectroscopy studies. The results reveal that the titanium dioxide coated 316L SS exhibit a higher corrosion resistance than the uncoated 316L SS. The titanium dioxide coated surface is porous, uniform and also it acts as a barrier layer to metallic substrate and the porous titanium dioxide coating induces the formation of hydroxyapatite layer on the metal surface.