1、The Science of Advanced Materials Processing and Manufacturing 先进材料制备科学与技术,王华明北京航空航天大学 材料学院激光材料制备与成形实验室82317102 ,Processing and Manufacturing of Advanced Materials 先进材料制备科学与技术,王华明北京航空航天大学 材料学院激光材料制备与成形实验室82317102 ,The Four Elements of MSE,Processing/Synthesis,Structure,Properties:Mechanical Function
2、al,Performance,制备成形/合成,结构（成分）,性能,服役性能（性能/价格比）,The Role of Materials Processing in MSE,净重438吨的三峡电站不锈钢水轮机叶轮铸件（制备与成形：合金冶炼铸造热处理焊接）,材料合成、制备与成形（Materials Processing）在MSE中的地位和作用核心支柱,基本手段和方法 合成制备新材料 发现新材料 提高现有材料性能 零件成形制造材料制备新工艺新料料,材料制备与成形的内涵,材料制备与成形科学 The Science (Fundamentals) of Materials Processing and M
3、anufacturing材料制备与成形技术 The Technology of Materials Processing and Manufacturing材料组织性能/服役性能合成/制备工艺相互关系 Relationship of Materials Design Structure Properties Performance - Processing & Manufacturing材料加工过程控制及自动化 Process Control and Automation of Materials Processing,All Processes and Procedures which, t
4、hrough intelligent utilizations of Fundamentals of MSE and related disciplines, and various existing or new technologies or special environments, etc Synthesize or fabricate materials, Change or Control the internal structures (macro -or microstructure, atomic arrangements, distribution of elements,
5、 energy states, etc ) of materials for Designed or Tailored mechanical or functional properties of materials, Alter the properties of materials Form, shape and manufacture materials and components while forming or changing materials internal structures or properties, etc,What Is Materials Processing
6、?,Some Representative Examples of Materials Processing MethodsSolidification Processing (Melting, Casting, Welding) Thermal Processing (Heat Treating, Sintering, etc) Mechanical Processing (Cold forming & rolling, etc )Thermal Mechanical ProcessingElectro-magnetic Materials ProcessingBiological Mate
7、rials ProcessingHigh Energy Density Beam Materials Processing,Materials Surface ProcessingVacuum Materials Processing,Space or Micro-gravity Materials ProcessingCombustion Synthesisetc.,Driving Force :Social and Military Requirements for Better Materials（需求牵引！） Interests and Curiosity in Novel Mater
8、ialsetc Horse Power: Understanding and Intelligent Utilization of Fundamentals of Materials Science Innovation or Improvement of Current Materials Processing Technologies Intelligent Utilization of New or Innovative Technologiesetc,Horse Power 1:Understanding and Intelligent or Creative Utilizations
9、 of Fundamentals of Materials Science,Horse Power 1:Understanding and Intelligent or Creative Utilizations of Fundamentals of Materials Science,Theoretical Study on Nucleation of Metal Casting and the Development of the OCC Process,Separation of Crystals from Mold Walls Crystal Shower from Top Melt
10、Free SurfaceFragments of Dendrite Arms due to Melt ConvectionEndogenous Nucleation due to Constitutional Undercooling,.,Cooling Water Spray,Heated Mold,Ohno Continuous Casting (OCC) ProcessMold Temperature Higher Than the Alloy LiquidusNo Nucleation on Mold Wall;No Contact of Solidified Metal With t
11、he 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.,Horse Power 1:Understanding and Intelligent or Creative Utilizations of Fundamentals of Materi
12、als Science,拓朴密堆相 Topologically Close-Packed （TCP ） Phases,CN 12 (14, 15, 16)间隙全部为四面体间隙无八面体间隙原子间结合力很强共价键高硬度、高耐磨、高耐蚀等,TCP相的结构及TCP相金属间化合物耐磨合金涂层新材料：,1.高硬度： 优异的磨料磨损及粘着磨损性能2. 原子间结合力强、共价键与金属键共存， 难于发生金属粘着、粘着磨损性能 极好、摩擦系数很低、摩擦学相容性 高温组织稳定性与性能稳定性优异,3. 金属键仍占相当比例 保证涂层/金属基材间可实现冶金结合4. 存在广阔的合金化与多相平衡空间 可灵活地进行合金化，对组织
13、、性能与制备工艺进行灵活设计与控制！,Hexagonal MgZn2 Type (hP12) Laves Phase,MgZn2中A、B原子的分布和双原子堆垛方式,Laser Clad Mo2Ni3Si/NiSi IMC CoatingDry Sliding Wear Resistance,(),Wear mass loss of laser clad Mo2Ni3Si/NiSi coating under high-temperature sliding wear test conditions,Worn surface of 1Cr18Ni9Ti and laser clad Mo2Ni3
14、Si/NiSi coating after sliding wear tests at 600 for 60 min,Horse Power 1:Understanding and Intelligent or Creative Utilizations of Fundamentals of Materials Science,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年中国十大科技新闻（位列
15、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 the surface layer. The subsequent nitriding kinetics were greatly enhanced, so that the nitriding tempera
16、ture 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 nanomaterials in improving traditional processing techniques.,热激活过程Thermal Activation Process,Activation Energy(Ener
17、gy Barrier),Metastable State,Stable State,Vacancy Mechanism: Diffusion of Substitutional Solute Atoms空位机制：置换式溶质原子（置换式原子的扩散就是空位的反向运动）,位错、层错、晶界、相界、表面,面缺陷(晶界、相界、表面): 溶质原子扩散的快速通道,晶内、晶界及表面扩散系数,一、空位 Vacancies 一种热力学稳定的晶体缺陷,晶体热力学：N个晶格结点、n个空位，空位浓度Cv=n/N DG=nUv-T(nDSv+DSc) 空位: 系统自由能增加nUv（ Uv：空位形成自由能） 空位: 组态熵D
18、Sc及振动熵DSv增加系统自由能降低,空位对合金组织及性能控制的重要性,物理及电子学性质（密度、电学、电子学性能）原子扩散的基本（最重要）方式 对合金固态相变过程(形核、长大；时效)及固态相变组织具有决定性影响； 对合金扩散控制的热加工工艺(如渗金属、烧结等)组织具有决定性影响； 对合金力学性能特别是高温力学性能具有决定性影响（强度、塑性、耐蚀、氧化）,获得非平衡空位(过饱和空位)的方法,高温淬火(Quenching)：通过极端手段把高温下的平衡空位快速“冷冻”固定到室温 快速凝固；固溶处理：过饱和固溶体（固溶强化）、过饱和空位（固溶后时效热处理工艺要求的原因）！强烈塑性变形:表面喷丸强化表面
19、纳米化 高能粒子辐照：中子辐照等(同时产生自间隙原子），材料性能严重脆化！,2003年中国十大科技新闻之一 对纯铁进行表面纳米化处理，在几十微米厚的表面层中获得纳米晶组织。然后利用常规气体氮化处理在300 oC保温9小时后成功地实现了表面氮化，获得10微米厚的氮化物层，而未经处理的纯铁在同样条件下几乎无氮化物形成。性能测试结果表明在300 oC下形成的表面氮化层具有很高的硬度、耐磨性和耐腐蚀性。这一结果证明铁的表面氮化温度可以利用表面纳米化技术而大幅度下降，从而使表面氮化技术的适用面(材料和工件种类)大大拓宽。同时也说明通过表面纳米化技术可以实现材料表 面结构选择性化学反应。这一成果再次显示纳
20、米技术对传统产业技术的升级改造具有重要的推动作用。,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年中国十大科技新闻（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
21、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 lower than conventional nitriding temperatures (above 500C). This enhanced processing method de
22、monstrates the technological significance of nanomaterials in improving traditional processing techniques.,Horse Power 1:Understanding and Intelligent or Creative Utilizations of Fundamentals of Materials Science,16 April 2004, Vol.306, SCIENCE,密排晶体结构中原子的堆垛Atomic Stacking in Close Packed Crystals,On
23、e Dimensional Closest Packing: Closest Packed Crystallographic Direction,2. Two Dimensional Closest Packing Closest Packed Crystallographic Planes,密排晶体结构中原子的堆垛Atomic Stacking in Close Packed Crystals,2. Two Dimensional Closest Packing Closest Packed Crystallographic Planes,3. Three-Dimensional Close
24、st Stacking of Closest Packed Atomic Planes,Stacking SitesStacking Sequence,Stacking Sequence: A-B-A-B-HCP Crystal Structure,A,B,Stacking Sequence: A-B-C-A-B-CFCC Crystal Structure,B,C,B,Stacking Fault,A 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 Fault,Twin,堆垛层
25、错与孪晶Stacking Fault and Twins,The Nature of a Twin BoundaryA Perfect Coherent Interface,Growth Twins in Nano-crystalline Metals,Before Twining After Twining,Twin Plane,Twining Direction,Crystal Growth via Twins StepsGrowth Twins,纳米生长孪晶强化超高强度和高导电性铜,孪晶界是一种低能共格界面，能有效阻位错运动，可起到与普通晶界相似的强化作用。共格孪晶界对电子的散射能力极小
26、，其电阻值比普通晶界的电阻低一个数量级。 引入大量孪晶界（即制备出高密度纳米尺寸生长孪晶）可以大幅度提高材料的强度而对其电导特性无明显影响,Strong Blockage of a Twin Interface to Dislocation Movement,16 April 2004, Vol.306, SCIENCE,Horse Power 2:Improvements and Innovations of Current Materials Processing Technologies or Processes,Horse Power 3:Acute Perception and In
27、telligent Utilizations of Emerging or New Technologies!,Application of Laser in Materials Processing,LASER MATERIALS PROCESSING,Laser: Light Amplification by Stimulated Emission of RadiationCharacteristics of Laser:Nearly Coherent Nearly MonochromaticHigh DirectionalityHigh Energy Density,Applicatio
28、ns of Lasers in Materials Processing,LASER MATERIALS PROCESSING,Laser Materials Processing,Laser Surface Processing Laser Phase Transformation Hardening; Laser Surface Melting; Laser Surface Alloying; Laser Cladding; Laser Shock Processing; Laser Thin Films Depositions, etcLaser Welding, Laser Cutti
29、ng, 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 “激光材料制备、加工与成形制造科学与技术” 新兴交叉学科,加热/冷却；固态相变；熔化/凝固；蒸发沉积；消融；消融沉积；冲击波；光、热化学反应与核反应等,LASER MATERIALS S
30、URFACE PROCESSING,Surface Engineered Tribological Components(涂层材料与涂层技术),材,复,料,合,材料A,材料 B,力学性能：强韧性,表面性能,表面工程：零件性能最优化,表面涂层,零件本体,Solid-State LASER MATERIALS PROCESSINGTransformation HardeningLaser Shock ProcessingLaser Bending （forming),激光表面淬火 Laser Surface Hardening 金属零件及模具表面强化方法之一,主要作用表面硬度耐磨性与寿命疲劳、接触
31、疲劳与热疲劳寿命.,例：汽车弹簧及齿轮激光淬火表面强化,Rapid Solidification LASER MATERIALS PROCESSING,Effects of Rapid Solidification Processing on Structure of Metallic Materials,Refinement of Grain Size and Microstructure (PDAS, SDAS, Eutectic Colony Size and Spacing, Porosity, etc)Extension of Solubility Limits Formation
32、of New Metastable PhasesFormation of Quasi-Crystalline and Amorphous Phases (Metallic Glass)Suppression of Solidification Segregation,激光表面熔化/快速凝固Rapid Solidification Laser Surface Processing,主要作用耐磨性耐蚀性耐氧化性疲劳热疲劳其它表面性能.,例：大型拉丝模具激光表面熔化强化：使用寿命由12天提高到1年半以上,激光表面合金化 Laser Surface Alloying,主要作用耐磨性耐蚀性耐氧化性疲劳热
33、疲劳其它表面性能.,例：钛合金零件激光表面合金化，制备Ti5Si3/Ti高耐磨表面合金层，耐磨性提高100余倍！,Ti5Si3,Ti5Si3/Ti Composite Coatings High Quality Metallurguical Bonding,Ti5Si3/b-Ti,Ti-6Al-4V,例：钛合金零件激光表面合金化，制备Ti5Si3/Ti高耐磨表面合金层，耐磨性提高100余倍！,Melt Pool,LASER CLADDING: an Advanced Surface Technology Synthesis of Advanced Coating Materials Fabri
34、cation of High-Quality Metallurgical Coatings,基材涂层梯度过渡区,W/W5Si3 Refractory Metal Silicides Matrix in-situ Composites (W/ W5Si3),W,W5Si3,LASER MATERIALS PROCESSING AND MANUFACTURING,钛合金加强框,投影面积5.53 m2,投影面积：5.53 m2模锻件重：2976 Kg 零件重量：143.8 Kg材料利用率：4.83机加工时间：6月,投影面积5.53 m2,飞机钛合金结构件制造流程,飞机大型复杂钛合金结构件的成形制造:
35、,投影面积5.53 m2,模锻件：2976 Kg 零件： 143.8 Kg材料利用率：4.83机加工时间：6月,大型或超大型锻、铸工业基础设施 工序多、成本很高、周期很长,毛坯模锻件： 3000 磅机加工后零件：200 磅材料利用率： 6.67生产周期： 12 月,全致密快速凝固组织：高性能 近净成形：材料利用率高 无需毛坯、模具、锻铸设施 机械加工量小、周期短、成本低,激光熔化沉积制造：原理及优点,根据零件CAD模型，通过激光熔化沉积，一步实现零件的“近终成形”制造：材料制备/零件近终成形一体化,激光熔化沉积成形：材料技术特点：,材料设计材料制备高性能复杂零件近净成形一步完成（一体化）；根据
36、零件不同部位的工作条件与特殊性能要求，实现多材料梯度复合金属材料零件的直接快速成形；难熔、难加工、高活性、易污染、高纯净、高性能金属材料制备及零件快速近净成形。,无需大型或超大型铸锻工业设施；无需零件毛坯、锻压模具；材料利用率高、机加工量小、机加工时间短；制造成本低 、生产周期短；“超常”快速反应能力与高度的柔性（我们两例）,尤其适合于国防装备大型复杂钛合金结构件的短周期、低成本、快速成形制造！,激光熔化沉积成形：制造技术独特优点,思路：快速成形零件毛坯少量机械加工,DMD工艺进行材料设计,根据理论计算制造的Ni-Cr负热膨胀系数零件,DMD工艺进行材料设计,根据理论计算制造的Ni-Cr负热膨
37、胀系数零件,主要内容,先进材料制备科学与技术概论先进材料凝固制备成形科学与技术 先进金属基复合材料制备科学与技术 先进材料激光制备、加工与成形科学与技术先进材料特种连接与成形科学技术 纳米材料制备科学与技术 先进材料制备加工新技术进展评述,课程目的,了解先进材料制备的科学基础与先进材料制备技术的基本原理，认识材料科学“材料加工制备工艺-材料组织结构-材料性能”三要素中“材料加工制备技术的突出作用及“新工艺”与“新材料”的关系，熟悉通过材料先进制备技术发展高性能新材料的基本思路。,授课形式及目标,授课形式： 专题讲座以点带面（无教材）课程目标： 研究思路 研究方法 创新启示,考核方式,笔试 课程报告,XX材料及其制备技术研究进展评述必须有自己的评述，不少于8000汉字，至少包括以下内容：,前言（背景、原理、主要问题等）国内外研究进展及评述结论参考文献,先进材料制备科学与技术课程报告题目及要求,DMLS工艺制造的样件,DMLS工艺制造的样件,
