微细激光增材制造高强铝合金毛细芯结构成形工艺及毛细功能研究

doi:10.3901/JME.260079

摘要/Abstract

摘要： 针对高强铝合金毛细芯结构的高精度成形及传质功能需求，研究了常规激光粉末床熔融(Conventional laser powder bed fusion，c-LPBF)与微细激光粉末床熔融(Micro laser powder bed fusion，μ-LPBF)成形高强铝合金微特征结构的成形性与毛细性能。μ-LPBF成形高强铝合金结构的极限尺寸约为86 μm，缺陷等效直径集中于25～40 μm，平均缺陷体积和球形度分别为9.99×10^-6 mm³、0.76；远优于c-LPBF工艺(缺陷等效直径50～100 μm，球形度降至0.48)，且在200 μm以下结构展现出优异的尺寸精度与缺陷抑制能力。基于数值模型揭示了颗粒飞溅和剥蚀行为的演化机制，c-LPBF因强金属蒸汽羽流导致粉末飞溅速度超过10 m/s、剥蚀带宽度为821～932 μm；而μ-LPBF因蒸汽扰动减弱，飞溅速度降至5 m/s以下、剥蚀带宽度缩小至159～239 μm，工艺稳定性显著提升。μ-LPBF结构获得了更高的毛细压差-渗透率乘积(ΔP_capK=16.08×10^-8 N)与毛细因子(K/R_eff=1.16 μm)，展现出更均衡的综合传质性能，为热控结构的优化设计与一体化成形提供了参考。

关键词: 激光增材制造, 微米级激光粉末床熔融, 高强铝合金, 毛细结构

Abstract: To address the high-precision and mass-transfer of high-strength aluminum alloy capillary wick structures, this study investigates the printability and capillary performance of micro-featured structures fabricated via conventional laser powder bed fusion (c-LPBF) versus micro laser powder bed fusion (μ-LPBF). The μ-LPBF process achieved a structural resolution limit of ~86 μm, with defect equivalent diameter ranging from 25-40 μm, average defect volume of 9.99×10^-6 mm³, and sphericity of 0.76. These results significantly surpass c-LPBF performance (defect equivalent diameters: 50-100 μm; sphericity: 0.48), demonstrating superior dimensional accuracy and defect suppression capability for sub-200 μm features. Numerical simulation revealed the evolution mechanisms of particle splashing and denudation behavior: Strong metallic vapor plumes of c-LPBF induced powder splashing velocities up to 10 m/s and denudation zone widths of 821-932 μm. In contrast, μ-LPBF’s attenuated vapor disturbance reduced splashing velocities below 5 m/s and narrowed denudation zones to 159-239 μm, markedly enhancing process stability. The μ-LPBF-fabricated structures exhibited enhanced capillary metrics, including a higher capillary pressure-permeability product (ΔP_capK=16.08×10^-8 N) and capillary factor (K/R_eff=1.16 μm), indicating balanced comprehensive mass transfer performance. It provides a theoretical foundation for optimized design and integrated manufacturing of thermal management structures.

Key words: laser additive manufacturing, micro laser powder bed fusion, high-strength aluminum alloy, capillary structure

中图分类号:

V261

刘贺, 顾冬冬, 李林轩, 裴斌, 周优优. 微细激光增材制造高强铝合金毛细芯结构成形工艺及毛细功能研究[J]. 机械工程学报, 2026, 62(3): 190-202.

LIU He, GU Dongdong, LI Linxuan, PEI Bin, ZHOU Youyou. Process and Capillary Performance of High-strength Aluminum Micro-structures Fabricated by Micro Laser Powder Bed Fusion[J]. Journal of Mechanical Engineering, 2026, 62(3): 190-202.

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