激光定向能量沉积制造A131 EH36/AISI 1045双金属结构性能研究 
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Directed energy deposition (DED) not only inherits the high degree of freedom of the additive manufacturing technology, but also features a flexible material deployment. It can flexibly switch material types during the manufacturing process and precisely adjust the proportion of dissimilar powders, which enables high-efficiency manufacturing of large-scale multi-material parts. However, although the entire multi-material part can be easily fabricated using the DED process, the cost is relatively high when fabricating regular parts. A promising proposal is to manufacture regular parts using the traditional processes and fabricate complex parts using the DED process. By this, the purpose for improving efficiency and reducing manufacturing costs can be achieved while maintaining part performance. In this study, A131 EH36 steel is deposited on a commercial AISI 1045 steel using the DED process to verify the feasibility of a bimetallic structure by the hybrid DED and conventional processes as well as to reveal the interfacical binding mechanism. Furthermore, the effect of heat treatment on microstructure and mechanical properties of the bimetallic structure is also investigated. This research aims to explore a new way to improve the DED efficiency, reduce the costs, and provide theoretical and data supports for making full use of the performances of multiple materials.
The materials used in this study are the A131 EH36 powder and the AISI 1045 steel sheet. DED is used to deposit A131 EH36 on the AISI 1045 substrate. Quenching and tempering are performed to study the effect of heat treatment. Metallographic microscope and scanning electron microscope (SEM) are used for microstructural observation and fracture morphology observation. The elements are detected by an energy dispersive spectrometer. The porosity is determined using the image processing software (ImageJ). A Vickers microhardness tester is used to measure microhardness on the as-built and heat-treated samples. Quasi-static uniaxial tensile tests are conducted on a universal testing machine. The cutting experiment is done on an ULG-100 ultra-precision turning system equipped with a dynamometer. The surface roughness and groove morphology are measured and obtained using a laser confocal microscope.
A ~0.5 mm wide interface region with good metallurgical quality is obtained in the A131 EH36/AISI 1045 bimetallic structure (Fig. 5). The microstructure of the interfacical region in the as-built sample includes refinement zones, coarsening zones, dual heat-affected zones, and heat-affected zones (Fig. 6). Although the morphologies are different, they interfit with each other and are replaced by homogenized structures after heat treatment. The average hardness of as-built A131 EH36 is (297.1±20.1)HV, higher than (182.0±11.7) HV of AISI 1045. The hardness in the interfacical region increases gradually along the building direction due to the excellent interfacial fusion (Fig. 8). The inhomogeneous microstructure of the DED A131 EH36 steel causes the hardness to vary between 262 HV and 308 HV. However, it becomes uniform and decreases by ~37.2% to (186.5±6.0)HV after heat treatment. Since the tensile strength of the A131 EH36 steel is up to (970.5±10.9) MPa, the as-built strength of the bimetallic structure is close to that of the AISI 1045 steel (lower one, Fig. 10). After heat treatment, the strength of the A131 EH36 steel decreases significantly and is lower than that of the AISI 1045. Therefore, the tensile strength and yield strength of the bimetallic structure become close to those of the A131 EH36 steel, reaching (671.3±5.6) MPa and(572.8±8.4) MPa, respectively. Both the as-built and heat-treated bimetallic structures show ductile fractures with the fracture positions far away from the interfacial region (Fig. 9). During the cutting process, the maximum and average cutting forces in the FX and FZ directions decreases by 64.1% and 61.1%, respectively, when cutting from A131 EH36 to AISI 1045 (Fig. 14). In addition, the surface roughness after ultra-precision machining is reduced from (111.8±13.6) nm in the AISI 1045 to (107.0±10.4) nm in the A131 EH36 regions (Fig. 15).
In the present study, the A131 EH36/AISI 1045 bimetallic structure is successfully fabricated by the hybrid DED and conventional processes. At the interface of the bimetallic structure, a transition zone of about 0.5 mm wide with good metallurgical quality is obtained without large cracks and unfused defects. The interface consists of microstructural refinement zones, coarsening zones, dual heat-affected zones, and heat-affected zones. The hardness in the interfacial region increases gradually along the building direction. The tensile strength, yield strength, and elongation of the as-built bimetallic structure are (629.0±1.1) MPa, (471.4±9.2)MPa, and 17.9%, respectively, which increase slightly to (671.3±5.6) MPa, (572.8±8.4)MPa and 22.1% after heat treatment. The as-built bimetallic structure is easier to cut than the heat-treated counterpart. When cutting from the AISI 1045 to the A131 EH36 regions, the cutting force decreases significantly with the maximum reduction of 64.1%. In addition, the surface roughness of the ultra-precision machining face decreases from(111.8±13.6) nm in the AISI 1045 region to (107.0±10.4) nm in the A131 EH36 region.
1 引言
定向能量沉积(DED)是一种高成型效率的热门增材制造工艺，其使用聚焦的热能(例如激光、电子束或等离子弧等)在沉积时熔化材料来实现零件的逐层堆积制造，可以实现大尺寸复杂结构件的高效率制造[1-2]。其中，激光作为高能量密度的清洁能源，成为了DED系统中最常用的能源之一[3]，并被广泛应用于各种金属零件的制造中。Sciammarella等[4]采用激光DED工艺制造了316L不锈钢零件，并研究了工艺参数对微观组织与相应硬度的影响，发现该工艺可以获得孔隙率低、微观组织精细且硬度不低于锻造件的316L零件。Li等[5]对激光DED制造的NI718合金的微观组织和力学性能进行了研究，并报道了零件沿着成型方向的微观组织、硬度和强度的不均匀分布。此外，Tan等[6]以及Hamilton等[7]也分别对Ti6Al4V和NiTi合金的激光DED制造进行了研究。
此外，DED技术不仅继承了增材制造技术的高自由度能力，而且具有灵活的材料调配特性，可以实现打印过程中材料的灵活切换以及异种粉末含量的精细调配，进而实现大尺寸多材料零件的高效率制造。而采用传统焊接、粉末冶金等方法将异种材料结合起来制造多材料零件的工艺则缺乏效率和灵活性[8]。因此，DED增材制造技术将为新型多材料零件的制造提供一种新的且有前景的解决方案[9]。近年来，采用该技术直接制造多材料零件的研究也越来越多。Muller等[10]研究了功能梯度材料的定向能量沉积过程的建模与工艺控制，提出了多材料零件从数字形式到实体的详细制造步骤，但没有对异种材料的结合机制与性能开展研究。Chen等[11]实现了IN625和SS316L双金属结构材料的增材制造，并发现在SS316L上打印IN625可以有效抑制界面区裂纹的产生。Carroll等[12]通过调整IN625和SS304L合金的粉末配比，验证了梯度零件定向能量沉积制造的可行性，同时发现靠近SS304L一侧的微米级第二相颗粒是引起微裂纹的根源。Reichardt等[13]采用激光定向能量沉积制造了Ti-6Al-4V和304L不锈钢梯度组件，并发现脆性的FeTi金属间化合物以及Fe-V-Cr相是引起组件裂纹的原因。Zhang等[14]将AlSi12合金沉积到已经成型的SS316L不锈钢上，获得了抗压强度达到(299.4±22.1)MPa的双金属结构。同时，由于FeAl3相的存在，界面区域的显微硬度高达(834.2±107.1)HV0.1。Onuike等[15]通过在激光定向能量沉积过程中添加碳化钒作为中间层的方式，成功获得了无裂纹的IN718/Ti64双金属结构。
虽然采用DED技术可以轻松制造整个多材料零件，但在制造具有部分规则形状的多材料零件时，整个过程的制造成本会相对增加。而采用传统方法与DED工艺结合的方式，分别制造规则的部分和复杂的结构部分，则可以在保持零件性能的前提下显著提高整体的效率并降低制造成本。近年来，已有部分学者对此开展研究。例如，Pan等[16]通过将具有高强度和耐腐蚀性的IN625合金沉积在传统制造的块状铜合金基体上，获得了具有优异综合性能的双金属材料，其热扩散速率比纯IN625合金高～100%。Onuike等[17]通过添加IN718和GRCop-84合金含量(质量分数)各50%的预混合粉末，在传统IN718基体上沉积了GRCop-84合金，获得的双金属结构的热扩散率和导电率比纯IN718合金分别提高了250%和300%。Cortina等[18]通过在AISI 1045基体上沉积AISI H13工具钢，获得了综合性能优良的双金属结构热冲压模具，实验结果表明，在保证其力学性能良好的情况下，该新型模具的冲压周期与传统的纯AISI H13钢模具相比降低了44.5%，显著提高了产品的生产效率。
A131 EH36是一种低碳低合金钢，具有强度和塑性的完美结合，以及较高的韧性和优良的可焊接性，特别适用于大型结构件的制造。然而，对于形状简单的大型结构件，增材制造技术的优势无法充分发挥。而在规则的传统件上采用DED增材制造技术制造具有特定几何结构的功能组件对降低增材制造大尺寸多材料零件的成本、提高整体制造效率以及扩大其应用范围具有重要意义。其中，DED成型的结构与传统方法制造的零件之间的良好界面结合特征以及优异的力学性能则是实现该目标的前提。本文采用优化的工艺参数将A131 EH36钢沉积到商业的AISI 1045基体上以获得具有双材料特性的多材料结构。对两种材料的界面结合特征、微观组织演变、力学性能以及切削响应进行了深入的研究和分析，验证了在传统金属件上激光定向能量沉积制造双金属零件的可行性。同时对另一部分制造的双金属样品进行热处理，以探索其对其微观结构特征与力学性能的影响。该研究不仅为提高增材制造效率和降低制造成本提供了新的方式，而且为充分利用异种材料的力学特性，提高成型组件的综合性能提供了理论和数据支撑。
2 材料与方法
2.1 实验材料及样品准备
本实验中的传统制造件是由蒂森克虏伯材料服务有限公司(德国)提供的轧制的AISI 1045钢，其尺寸为200 mm×200 mm ×20 mm (长×宽×高)。使用的 A131 EH36 钢的粉末颗粒形貌如
图 1. 粉末的SEM形貌和双金属结构。(a)A131 EH36钢的粉末形貌；(b)激光定向能量沉积双金属零件示意图和拉伸样品尺寸
Fig. 1. SEM morphology of powder and bimetallic structure. (a) Powder morphology of A131 EH36 steel; (b) schematic of DED bimetallic part and size of tensile sample
表 1. A131 EH36 和 AISI 1045 钢的主要化学成分(质量分数，%)
Table 1. Main chemical compositions of A131 EH36 and AISI 1045 steels(mass fraction，%)
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2.2 微观组织与界面特征表征
用电火花线切割机分别切取热处理前和热处理后的单材料区域以及包含界面区域的10 mm×10 mm×10 mm的方形样品。使用碳化硅砂纸对上述样品进行机械打磨，然后采用粒径为1.0 μm的氧化铝悬浮液进行抛光处理。使用乙醇清洗后，采用配制好的金相腐蚀液(4 mL HNO3＋100 mL C2H5OH)对单材料和界面区进行时间为10 s的刻蚀，然后分别用LEICA DM 2500 M金相显微镜和JEOL JSM-5500LV扫描电子显微镜进行微观组织观察。拉伸测试后的样品的界面区的微观组织形貌同样采用上述方法进行刻蚀和观察。材料的元素组成采用SEM配备的能量色散谱仪(EDS)进行检测。样品界面区域的孔隙率采用图像处理软件(ImageJ)进行测定。在测量前，对样品进行打磨抛光后轻刻蚀3 s以显示界面区。
2.3 力学性能与切削响应测试
使用SHIMADZU 显微维氏硬度计测量热处理前和热处理后界面区域及单材料区域的一系列点的硬度，相邻两个测量点的间距为100 μm。设备的加载力设置为200 g，保持时间设置为15 s。为评价双金属结构的拉伸性能，使用电火花线切割机沿着成型方向对直接成型和热处理后的样品进行薄板拉伸试样的制备。拉伸样品总长度为40 mm，标距长度为12 mm，厚度为3 mm，宽度为4 mm。同时为了对比单材料的性能，分别在相应的单材料区切取同样尺寸的拉伸样品。进行磨抛和超声清洗后，在INSTRON 8501万能材料试验机上以0.5 mm/min的拉伸速度进行室温准静态单轴拉伸测试。每组样品分别拉伸三个样品，获取拉伸强度和断后延伸率，并取平均值以降低误差。拉伸后的断口形貌采用JEOL JSM-5500LV扫描电子显微镜观察。
切削响应测试在配备测力仪的东芝生产的ULG-100超精密车削系统上通过微量正交切削的方式进行。在进行微量切削实验前，包含界面区域的10 mm×10 mm×10 mm的方形样品首先在超精密加工中心上进行切平处理以获得平滑均匀的表面，其切削参数为：主轴转速 1500 r/min，径向进给速度 5 mm/min，切削深度1 μm，并使用油雾进行冷却和润滑。在微量切削实验中，保持Y轴不动，X轴为立方氮化硼(CBN)刀具切削方向，其速度设置为50 mm/min，Z 轴为切削深度进给方向，其切削深度设置为5 μm，整个过程中不添加冷却液。对于直接沉积制造和热处理后的双金属结构样品，其切削方向均为从AISI 1045区域延伸到A131 EH36区域。采用OLYMPUS LEXT OLS5000 激光共聚焦显微镜测量切削后的样品表面粗糙度和正交切削的沟槽形貌，多次测量后取平均值以降低测量误差。
3 分析与讨论
3.1 微观组织分析
图 2. 定向能量沉积制造的A131 EH36钢的微观组织形貌。(a)低倍光学形貌；(b)～(f)不同区域的SEM形貌
Fig. 2. Microscopic morphologies of DED A131 EH36 steel. (a) Low-magnification optical image; (b)(f) SEM images of different regions
图 3. 轧制的AISI 1045钢的原始显微组织形貌。(a)低倍光学组织形貌；(b)～(d)高倍SEM图
Fig. 3. Original microscopic morphologies of rolled AISI 1045 steel. (a) Low-magnification optical image; (b)(d) high-magnification SEM images
铁素体和珠光体的形貌与分布可以在
图 4. 热处理后的微观组织形貌。(a)～(c)定向能量沉积A131 EH36钢；(d)～(f)轧制的AISI 1045钢
Fig. 4. Microscopic morphologies after heat treatment. (a)(c) DED A131 EH36 steel; (d)(f) rolled AISI 1045 steel
3.2 界面结合特征
良好的界面冶金结合质量是保证混合制造双金属结构优良性能的关键。
图 5. A131 EH36/AISI 1045双金属结构的光学微观组织形貌。(a)热处理前；(b)热处理后；热处理前界面区附近的孔隙(c)分布和(d)形貌
Fig. 5. Optical microscopic morphologies of A131 EH36/AISI 1045 bimetallic part. (a) Before heat treatment; (b) after heat treatment; (c) distribution and (d) morphology of pore at interface before heat treatment
图 6. A131 EH36/AISI 1045双金属结构界面区的显微组织形貌。(a)界面区形貌；(b)～(f)对应于图6 (a)中的5个位置的微观组织形貌
Fig. 6. Interfacial microscopic morphologies of A131 EH36/AISI 1045 bimetallic part. (a) Interfacial morphology; (b)(f) microscopic morphologies corresponding to five positions in Fig. 6(a)
图 7. 热处理后界面区的显微组织形貌。(a)(b)低倍光学图；(c)(d)高倍SEM图
Fig. 7. Interfacial microscopic morphologies after heat treatment. (a)(b) Low-magnification optical images; (c)(d) high-magnification SEM images
3.3 力学性能
图 8. 定向能量沉积的A131 EH36/AISI 1045双金属结构的显微硬度。(a)热处理前后沿着界面的维氏硬度分布；(b)直接能量沉积态A131 EH36的组织与硬度；(c)原始AISI 1045的组织与硬度
Fig. 8. Microhardnesses of A131 EH36/AISI 1045 bimetallic structure by DED. (a) Vickers microhardness distributions along interface before and after heat treatment; (b) hardness and microstructure of DED A131 EH36; (c) hardness and microstructure of original AISI 1045
热处理前后单材料和双金属结构的工程应力-应变曲线及断后过渡区界面形貌如
图 9. 单种材料和双金属材料的拉伸应力-应变曲线及双金属结构断裂位置图。(a)(c)热处理前；(b)(d)热处理后
Fig. 9. Engineering stress-strain curves of single and bimetallic parts and fracture location images of bimetallic part. (a) (c) Before heat treatment; (b) (d) after heat treatment
图 10. 热处理前后的单种材料和双金属结构材料的力学拉伸测试结果
Fig. 10. Tensile test results of single and bimetallic parts before and after heat treatment
3.4 断口形貌分析
图 11. 热处理前单种材料和双金属结构材料的拉伸断口形貌。(a)(a1)(a2) A131 EH36；(b)(b1)(b2)双金属结构；(c)(c1)(c2)AISI 1045
Fig. 11. Tensile fracture morphologies of single and bimetallic parts before heat treatment. (a)(a1)(a2) A131 EH36; (b)(b1)(b2) bimetallic part; (c)(c1)(c2) AISI 1045
热处理后的单种材料和双金属结构材料的断口形貌如
图 12. 热处理后单种材料和双金属结构材料的拉伸断口形貌。(a)(a1)(a2) A131 EH36；(b)(b1)(b2)双金属结构；(c)(c1)(c2)AISI 1045
Fig. 12. Tensile fracture morphologies of single and bimetallic parts after heat treatment. (a)(a1)(a2) A131 EH36; (b)(b1)(b2) bimetallic part; (c)(c1)(c2) AISI 1045
图 13. A131 EH36断口中的球形缺陷及元素检测点位置。(a)大尺寸球颗粒；(b)小尺寸球颗粒
Fig. 13. Ball-like defects and locations for element detection in A131 EH36. (a) Large-size ball-like particles; (b) small-size ball-like particles
表 2. 图13 中球形缺陷的化学成分(质量分数，%)
Table 2. Chemical compositions of ball-like defects in Fig. 13( mass fraction, %)
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3.5 微量切削响应分析
微量切削实验是在配备三向测力仪的超精密车床上进行的。切削深度只有5 μm，因此，微量切削实验可以很好地反应出微区材料的变形特点和行为。而切削过程从另一个角度看也可以认为是工件的微区材料在高刚度刀具的作用下发生高应变率变形的过程[27]，因此本实验可以用来探索双金属结构中单材料区和界面区材料的高应变响应，并以切削力和切削表面质量的形式进行表达。此外，也可以给未来通过切削加工来提高增材制造多材料金属零件表面质量的研究和应用提供参考。
图 15. 从AISI 1045钢切削到A131 EH36区域时的平面和沟槽形貌：(a)热处理前，(b)热处理后
Fig. 15. Machined surface and groove morphologies from AISI 1045 steel to A131 EH36 steel. (a) Before heat treatment; (b) after heat treatment
4 结论
对激光定向能量沉积制造的A131 EH36/AISI 1045双金属结构的界面结合性能开展深入研究，并对比了热处理对其微观组织演变、力学性能及切削响应的影响，探索了增材制造异种材料的界面结合机制，揭示了高能束场下熔池内材料的熔合与凝固特征。主要得到如下研究结果。
1) 在AISI 1045和A131 EH36的结合面处，获得了大约0.5 mm宽、冶金质量良好的过渡区，无裂纹和未熔合缺陷的产生。仅在界面靠近A131 EH36钢一侧观察到少量尺寸小于5 μm的聚集性孔隙，但总体孔隙率低于0.5%。界面结合处由组织细化区、组织粗化区、双重热影响区和热影响区组成。
2) 直接沉积态A131 EH36的硬度[(297.1±20.1)HV]明显高于轧制的AISI 1045[(182.0±11.7)HV]，过渡区中的硬度沿着成型方向逐渐均匀增加。热处理后，A131 EH36的硬度降低了约37.2%，与热处理后的AISI 1045的硬度接近[(183.5±2.5)HV]。
3) 直接沉积态的双金属结构的拉伸强度和屈服强度分别为(629.0±1.1)MPa和(471.4±9.2)MPa，断后延伸率为17.9%。热处理后，双金属结构的拉伸强度和屈服强度分别达到了(671.3±5.6)MPa和(572.8±8.4)MPa，且断后延伸率也达到了22.1%，均高于直接成型状态。
4) 直接沉积的双金属结构材料比热处理态更容易切削，从AISI 1045区域切削到A131 EH36区域时，切削力经历了明显的下降过程，最大可降低64.1%。此外，超精加工后的表面粗糙度从AISI 1045区域的(111.8±13.6)nm降低到A131 EH36区域的(107.0±10.4)nm，整体切削表面质量较为均匀。
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Article Outline
白玉超, 王迪, 李朝将. 激光定向能量沉积制造A131 EH36/AISI 1045双金属结构性能研究[J]. 中国激光, 2022, 49(14): 1402304. Yuchao Bai, Di Wang, Chaojiang Li. Research on A131 EH36/AISI 1045 Bimetallic Material Fabricated by Laser Directed Energy Deposition[J]. Chinese Journal of Lasers, 2022, 49(14): 1402304.
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