1、 Processing and Manufacturing of Advanced Materials 先進(jìn)材料制備科學(xué)與技術(shù)王華明、湯海波北京航空航天大學(xué) 材料學(xué)院大型金屬構(gòu)件增材制造國家工程實(shí)驗(yàn)室82317102 82339691 PART IIntroduction and Fundamentals of Advanced Materials Processing and Manufacturing 第一部分先進(jìn)材料制備科學(xué)與技術(shù)基礎(chǔ)The Four Elements of MSEProcessing/SynthesisStructureProperties:Mechanical Fun

2、ctionalPerformance制備成形/合成結(jié)構(gòu)（成分）性能服役性能（性能/價(jià)格比）PerformancePropertiesStructureMat. DesignProcessing &ManufacturingThe Role of Materials Processing in MSEBEIHANG UNIVERSITY凈重438噸的三峽電站不銹鋼水輪機(jī)葉輪鑄件（制備與成形：合金冶煉鑄造熱處理焊接）三峽電站大型水輪機(jī)不銹鋼葉輪（從加拿大進(jìn)口：價(jià)格950萬美元/個(gè)）大型核電部件的熱處理百萬千瓦超超臨界汽輪機(jī)低壓轉(zhuǎn)子大型構(gòu)件淬火材料合成、制備與成形（Materials Process

3、ing）在MSE中的地位和作用核心支柱 基本手段和方法 合成制備新材料 發(fā)現(xiàn)新材料 提高現(xiàn)有材料性能 零件成形制造材料制備新工藝新料料材料制備與成形的內(nèi)涵材料制備與成形科學(xué) The Science (Fundamentals) of Materials Processing and Manufacturing材料制備與成形技術(shù) The Technology of Materials Processing and Manufacturing材料組織性能/服役性能合成/制備工藝相互關(guān)系 Relationship of Materials Design Structure Properties Pe

4、rformance - Processing & Manufacturing材料加工過程控制及自動(dòng)化 Process Control and Automation of Materials ProcessingAll Processes and Procedures which, through intelligent utilizations of Fundamentals of MSE and related disciplines, and various existing or new technologies or special environments, etc Synthesi

5、ze or fabricate materials, Change or Control the internal structures (macro -or microstructure, atomic arrangements, distribution of elements, energy states, etc ) of materials for Designed or Tailored mechanical or functional properties of materials, Alter the properties of materials Form, shape an

6、d manufacture materials and components while forming or changing materials internal structures or properties, etcWhat Is Materials Processing? Some Representative Examples of Materials Processing MethodsSolidification Processing (Melting, Casting, Welding) Thermal Processing (Heat Treating, Sinterin

7、g, etc) Mechanical Processing (Cold forming & rolling, etc )Thermal Mechanical ProcessingElectro-magnetic Materials ProcessingBiological Materials ProcessingHigh Energy Density Beam Materials Processing,Materials Surface ProcessingVacuum Materials Processing,Space or Micro-gravity Materials Processi

8、ngCombustion Synthesisetc. Driving Force :Social and Military Requirements for Better Materials（需求牽引?。?Interests and Curiosity in Novel Materialsetc Horse Power: Understanding and Intelligent Utilization of Fundamentals of Materials Science Innovation or Improvement of Current Materials Processing T

9、echnologies Intelligent Utilization of New or Innovative TechnologiesetcHorse Power 1:Understanding and Intelligent or Creative Utilizations of Fundamentals of Materials ScienceBEIHANG UNIVERSITYe.g. Unidirectional Solidification ProcessingPreferred Orientation and Competition in Crystal GrowthDS Co

10、lumnar Grain and Single-Crystal Turbine Blades定向凝固單晶鎳基高溫合金渦輪葉片定向凝固單晶鎳基高溫合金渦輪葉片Horse Power 1:Understanding and Intelligent or Creative Utilizations of Fundamentals of Materials ScienceBEIHANG UNIVERSITYTheoretical Study on Nucleation of Metal Casting and the Development of the OCC Process BEIHANG UNI

11、VERSITYSeparation of Crystals from Mold Walls Crystal Shower from Top Melt Free SurfaceFragments of Dendrite Arms due to Melt ConvectionEndogenous Nucleation due to Constitutional Undercooling,.BEIHANG UNIVERSITYCooling Water SprayHeated MoldOhno Continuous Casting (OCC) ProcessMold Temperature High

12、er Than the Alloy LiquidusNo Nucleation on Mold Wall;No Contact of Solidified Metal With the Mold WallVery Smooth Surface;Solidification Starts from Interior No Central Shrinkage and SegregationFully Directionally Solidified or Single-Crystal Wires, Bares, Shaped Parts or Multi-Metal Materials. Hors

13、e Power 1:Understanding and Intelligent or Creative Utilizations of Fundamentals of Materials Science激光材料制備與成形實(shí)驗(yàn)室BEIHANG UNIVERSITY Laboratory of Laser Materials Processing and Surface Engineering拓樸密堆相 Topologically Close-Packed （TCP ） Phases CN 12 (14, 15, 16)間隙全部為四面體間隙無八面體間隙原子間結(jié)合力很強(qiáng)共價(jià)鍵高硬度、高耐磨、高耐蝕等

14、TCP相的結(jié)構(gòu)及TCP相金屬間化合物耐磨合金涂層新材料：1.高硬度： 優(yōu)異的磨料磨損及粘著磨損性能2. 原子間結(jié)合力強(qiáng)、共價(jià)鍵與金屬鍵共存， 難于發(fā)生金屬粘著、粘著磨損性能 極好、摩擦系數(shù)很低、摩擦學(xué)相容性 高溫組織穩(wěn)定性與性能穩(wěn)定性優(yōu)異3. 金屬鍵仍占相當(dāng)比例 保證涂層/金屬基材間可實(shí)現(xiàn)冶金結(jié)合4. 存在廣闊的合金化與多相平衡空間 可靈活地進(jìn)行合金化，對(duì)組織、性能與制備工藝進(jìn)行靈活設(shè)計(jì)與控制！Hexagonal MgZn2 Type (hP12) Laves PhaseMgZn2中A、B原子的分布和雙原子堆垛方式 Laser Clad Mo2Ni3Si/NiSi IMC CoatingDry

15、 Sliding Wear Resistance激光材料加工與表面工程 實(shí)驗(yàn)室BEIHANG UNIVERSITY Laboratory of Laser Materials Processing and Surface Engineering()Wear mass loss of laser clad Mo2Ni3Si/NiSi coating under high-temperature sliding wear test conditions激光材料加工與表面工程 實(shí)驗(yàn)室BEIHANG UNIVERSITY Laboratory of Laser Materials Processing

16、 and Surface EngineeringWorn surface of 1Cr18Ni9Ti and laser clad Mo2Ni3Si/NiSi coating after sliding wear tests at 600 for 60 minBEIHANG UNIVERSITYHorse Power 1:Understanding and Intelligent or Creative Utilizations of Fundamentals of Materials ScienceBEIHANG UNIVERSITYNitriding Iron at Lower Tempe

17、ratures W. P. Tong, N. R. Tao, Z. B. Wang, J. Lu, K. Lu* Science 299 (2003)5607, 686-688. 2003年中國十大科技新聞（位列第二）Microstructure in the surface layer of a pure iron plate was refined at the nanometer scale by a surface mechanical attrition treatment that generates repetitive severe plastic deformation of

18、 the surface layer. The subsequent nitriding kinetics were greatly enhanced, so that the nitriding temperature could be as low as 300C, which is much lower than conventional nitriding temperatures (above 500C). This enhanced processing method demonstrates the technological significance of nanomateri

19、als in improving traditional processing techniques.熱激活過程Thermal Activation ProcessActivation Energy(Energy Barrier)Metastable StateStable StateVacancy Mechanism: Diffusion of Substitutional Solute Atoms空位機(jī)制：置換式溶質(zhì)原子（置換式原子的擴(kuò)散就是空位的反向運(yùn)動(dòng)）位錯(cuò)、層錯(cuò)、晶界、相界、表面面缺陷(晶界、相界、表面): 溶質(zhì)原子擴(kuò)散的快速通道晶內(nèi)、晶界及表面擴(kuò)散系數(shù)一、空位 Vacancies

20、一種熱力學(xué)穩(wěn)定的晶體缺陷晶體熱力學(xué)：N個(gè)晶格結(jié)點(diǎn)、n個(gè)空位，空位濃度Cv=n/N DG=nUv-T(nDSv+DSc) 空位: 系統(tǒng)自由能增加nUv（ Uv：空位形成自由能） 空位: 組態(tài)熵DSc及振動(dòng)熵DSv增加系統(tǒng)自由能降低空位對(duì)合金組織及性能控制的重要性物理及電子學(xué)性質(zhì)（密度、電學(xué)、電子學(xué)性能）原子擴(kuò)散的基本（最重要）方式 對(duì)合金固態(tài)相變過程(形核、長(zhǎng)大；時(shí)效)及固態(tài)相變組織具有決定性影響； 對(duì)合金擴(kuò)散控制的熱加工工藝(如滲金屬、燒結(jié)等)組織具有決定性影響； 對(duì)合金力學(xué)性能特別是高溫力學(xué)性能具有決定性影響（強(qiáng)度、塑性、耐蝕、氧化）獲得非平衡空位(過飽和空位)的方法高溫淬火(Quenchi

21、ng)：通過極端手段把高溫下的平衡空位快速“冷凍”固定到室溫 快速凝固；固溶處理：過飽和固溶體（固溶強(qiáng)化）、過飽和空位（固溶后時(shí)效熱處理工藝要求的原因）！強(qiáng)烈塑性變形:表面噴丸強(qiáng)化表面納米化 高能粒子輻照：中子輻照等(同時(shí)產(chǎn)生自間隙原子），材料性能嚴(yán)重脆化！2003年中國十大科技新聞之一 對(duì)純鐵進(jìn)行表面納米化處理，在幾十微米厚的表面層中獲得納米晶組織。然后利用常規(guī)氣體氮化處理在300 oC保溫9小時(shí)后成功地實(shí)現(xiàn)了表面氮化，獲得10微米厚的氮化物層，而未經(jīng)處理的純鐵在同樣條件下幾乎無氮化物形成。性能測(cè)試結(jié)果表明在300 oC下形成的表面氮化層具有很高的硬度、耐磨性和耐腐蝕性。這一結(jié)果證明鐵的表面

22、氮化溫度可以利用表面納米化技術(shù)而大幅度下降，從而使表面氮化技術(shù)的適用面(材料和工件種類)大大拓寬。同時(shí)也說明通過表面納米化技術(shù)可以實(shí)現(xiàn)材料表 面結(jié)構(gòu)選擇性化學(xué)反應(yīng)。這一成果再次顯示納米技術(shù)對(duì)傳統(tǒng)產(chǎn)業(yè)技術(shù)的升級(jí)改造具有重要的推動(dòng)作用。 Nitriding Iron at Lower Temperatures W. P. Tong, N. R. Tao, Z. B. Wang, J. Lu, K. Lu* Science 299 (2003)5607, 686-688. 2003年中國十大科技新聞（位列第二）Microstructure in the surface layer of a pure

23、 iron plate was refined at the nanometer scale by a surface mechanical attrition treatment that generates repetitive severe plastic deformation of the surface layer. The subsequent nitriding kinetics were greatly enhanced, so that the nitriding temperature could be as low as 300C, which is much lowe

24、r than conventional nitriding temperatures (above 500C). This enhanced processing method demonstrates the technological significance of nanomaterials in improving traditional processing techniques.Horse Power 1:Understanding and Intelligent or Creative Utilizations of Fundamentals of Materials Scien

25、ce激光材料制備與成形實(shí)驗(yàn)室BEIHANG UNIVERSITY Laboratory of Laser Materials Processing and Surface Engineering16 April 2004, Vol.306, SCIENCE密排晶體結(jié)構(gòu)中原子的堆垛Atomic Stacking in Close Packed CrystalsOne Dimensional Closest Packing: Closest Packed Crystallographic Direction2. Two Dimensional Closest Packing Closest Pac

26、ked Crystallographic Planes密排晶體結(jié)構(gòu)中原子的堆垛Atomic Stacking in Close Packed Crystals2. Two Dimensional Closest Packing Closest Packed Crystallographic Planes3. Three-Dimensional Closest Stacking of Closest Packed Atomic PlanesStacking SitesStacking SequenceStacking Sequence: A-B-A-B-HCP Crystal Structure

27、ABStacking Sequence: A-B-C-A-B-CFCC Crystal StructureBCStacking FaultBA B C A B C A B C A B C A B C C A B C A B C A BA B C A C A B C A B C A B C Stacking FaultTwin堆垛層錯(cuò)與孿晶Stacking Fault and TwinsThe Nature of a Twin BoundaryA Perfect Coherent InterfaceGrowth Twins in Nano-crystalline MetalsBefore Twi

28、ning After TwiningTwin PlaneTwining DirectionCrystal Growth via Twins StepsGrowth Twins納米生長(zhǎng)孿晶強(qiáng)化超高強(qiáng)度和高導(dǎo)電性銅 孿晶界是一種低能共格界面，能有效阻礙位錯(cuò)運(yùn)動(dòng)，可起到與普通晶界相似的強(qiáng)化作用。共格孿晶界對(duì)電子的散射能力極小，其電阻值比普通晶界的電阻低一個(gè)數(shù)量級(jí)。 引入大量孿晶界（即制備出高密度納米尺寸生長(zhǎng)孿晶）可以大幅度提高材料的強(qiáng)度而對(duì)其電導(dǎo)特性無明顯影響 Strong Blockage of a Twin Interface to Dislocation Movement 16 April 2

29、004, Vol.306, SCIENCEHorse Power 1:Understanding and Intelligent or Creative Utilizations of Fundamentals of Materials Science激光材料制備與成形實(shí)驗(yàn)室BEIHANG UNIVERSITY Laboratory of Laser Materials Processing and Surface Engineering實(shí)例之二對(duì)“小平面晶體液固界面結(jié)構(gòu)與生長(zhǎng)機(jī)制轉(zhuǎn)化”經(jīng)典凝固理論的再認(rèn)識(shí)（講授本科生課程金屬學(xué)原理的“收獲”之一）（很長(zhǎng)時(shí)間的積累、很久的思考）光滑界面粗糙界面

30、當(dāng)DT DTc時(shí)， DTc側(cè)向生長(zhǎng)連續(xù)生長(zhǎng)小平面晶體著名的凝固理論 有關(guān)小面晶體經(jīng)典凝固理論 “隨凝固冷卻速度增加，液/固界面結(jié)構(gòu)將由原子尺度光滑向原子尺度粗糙轉(zhuǎn)變、生長(zhǎng)機(jī)制由側(cè)向生長(zhǎng)向連續(xù)生長(zhǎng)機(jī)制轉(zhuǎn)變”的經(jīng)典凝固理論“著名推論” ，迄今只在Si等非典型小面晶體中得到實(shí)驗(yàn)證實(shí)。對(duì) “高Jackson因子小面晶體”是否具有普遍適用性，一直缺乏實(shí)驗(yàn)及理論依據(jù)。101105 K/s范圍內(nèi)，發(fā)現(xiàn)TiC經(jīng)典小面晶體生長(zhǎng)新形態(tài)及演化規(guī)律，發(fā)現(xiàn)“原子尺度光滑的液/固界面及其臺(tái)階側(cè)向生長(zhǎng)機(jī)制”基本特征均不隨凝固冷卻速度的改變而變化！(a)(b)光滑界面 粗糙界面？當(dāng)DT DTc時(shí)，DTc側(cè)向生長(zhǎng)連續(xù)生長(zhǎng)？經(jīng)典

31、小面晶體凝固理論有關(guān)“隨凝固冷卻速度增加，液/固界面結(jié)構(gòu)由光滑向粗糙轉(zhuǎn)變、生長(zhǎng)機(jī)制由側(cè)向生長(zhǎng)向連續(xù)生長(zhǎng)轉(zhuǎn)變”的著名推論，對(duì)高Jackson因子小面晶體不具普遍意義!SCI研究論文收錄10余篇陳瑤獲全國百篇優(yōu)秀博士論文提名獎(jiǎng)Horse Power 2:Improvements and Innovations of Current Materials Processing Technologies or ProcessesBEIHANG UNIVERSITYHorse Power 3:Acute Perception and Intelligent Utilizations of Emerging

32、 or New Technologies!BEIHANG UNIVERSITYApplication of Laser in Materials ProcessingLASER MATERIALS PROCESSINGBEIHANG UNIVERSITYLaser: Light Amplification by Stimulated Emission of RadiationCharacteristics of Laser:Nearly Coherent Nearly MonochromaticHigh DirectionalityHigh Energy Density BEIHANG UNI

33、VERSITYApplications of Lasers in Materials ProcessingLASER MATERIALS PROCESSINGLaser Materials ProcessingLaser Surface Processing Laser Phase Transformation Hardening; Laser Surface Melting; Laser Surface Alloying; Laser Cladding; Laser Shock Processing; Laser Thin Films Depositions, etcLaser Weldin

34、g, Laser Cutting, Laser Forming; Laser Micro-Machining and Nano-FabricationsLaser Ablations for Thin Films DepositionLaser Rapid Manufacturing of High-Performance Metallic Components.LASER and LASER MATERIALS PROCESSING “激光材料制備、加工與成形制造科學(xué)與技術(shù)” 新興交叉學(xué)科加熱/冷卻；固態(tài)相變；熔化/凝固；蒸發(fā)沉積；消融；消融沉積；沖擊波；光、熱化學(xué)反應(yīng)與核反應(yīng)等BEIHAN

35、G UNIVERSITYLASER MATERIALS SURFACE PROCESSINGBEIHANG UNIVERSITYSurface Engineered Tribological Components(涂層材料與涂層技術(shù))材復(fù)料合材料A材料 B力學(xué)性能：強(qiáng)韌性表面性能表面工程：零件性能最優(yōu)化表面涂層零件本體BEIHANG UNIVERSITYSolid-State LASER MATERIALS PROCESSINGTransformation HardeningLaser Shock ProcessingLaser Bending （forming)BEIHANG UNIVERS

36、ITY激光表面淬火 Laser Surface Hardening 金屬零件及模具表面強(qiáng)化方法之一激光束加熱相變區(qū)Shielding GasScan Direction表面硬化層 主要作用表面硬度耐磨性與壽命疲勞、接觸疲勞與熱疲勞壽命.BEIHANG UNIVERSITY例：汽車彈簧及齒輪激光淬火表面強(qiáng)化BEIHANG UNIVERSITY激光材料制備與成形實(shí)驗(yàn)室 PROMAN Laboratory of Laser Materials Processing and ManufacturingRapid Solidification LASER MATERIALS PROCESSINGBEIH

37、ANG UNIVERSITYEffects of Rapid Solidification Processing on Structure of Metallic MaterialsRefinement of Grain Size and Microstructure (PDAS, SDAS, Eutectic Colony Size and Spacing, Porosity, etc)Extension of Solubility Limits Formation of New Metastable PhasesFormation of Quasi-Crystalline and Amor

38、phous Phases (Metallic Glass)Suppression of Solidification SegregationBEIHANG UNIVERSITY激光表面熔化/快速凝固Rapid Solidification Laser Surface ProcessingLaser Beam激光熔池Shielding GasScan Direction激光重熔層主要作用耐磨性耐蝕性耐氧化性疲勞熱疲勞其它表面性能.BEIHANG UNIVERSITY例：大型拉絲模具激光表面熔化強(qiáng)化：使用壽命由12天提高到1年半以上BEIHANG UNIVERSITY激光表面合金化 Laser Surface AlloyingLaser Beam合金熔池合金粉末Scan Direction表面合金層主要作用耐磨性耐蝕性耐氧化性疲勞熱疲勞其它表面性能.BEIHANG UNIVERSITY例：鈦合金零