High Sphericity Titanium-based Composite Powder Fabrication and Selective Laser Melting

doi:10.3901/JME.2025.13.429

Abstract

Abstract: Selective laser melting technology (SLM) is widely used in the fabrication of new composites materials because of its controllable composition of powder raw materials. At the same time, based on the demand for the uniformity and flatness of the powder bed, the powder material used is required to have a specific high sphericity and a mismatch distribution of the powder particle size. High-energy ball milling technology is used to manufacture Ti-6Al-4V/TiB₂ composite powder by three different mixing processes of dry ball milling, wet ball milling and hollow mixing powder in argon atmosphere. The action mechanism of grinding ball, strengthening phase and matrix powder under different media and different processes is studied. It is found that the best mixing process for keeping good ball shape and mixing uniformity of the composite powder is that the rotating speed is 230 r/min, the milling time is 24 hours, and the hollow powder mixing without grinding ball. Through the analysis of the dynamic force relationship and energy accumulation of grinding ball, Ti-6Al-4V and TiB₂ particles, the stress welding mechanism makes a strong bond between the reinforcing phase and the matrix powder under the impact of high energy grinding ball, but the huge energy accumulation causes serious deformation of the spherical powder. The new hollow mixing technology proposed in this thesis ensures the sphericity of Ti-6Al-4V powder while forming a strong pinning effect between the reinforcing phase and the powder, finally, an important powder base for the fabrication of high-quality block Ti-6Al-4V/TiB₂ composites is successfully prepared. Bulk titanium-based composite materials by using the SLM technology and the optimal mixing and preparation process of the composite powders. The relationship between density, structure and mechanical properties is studied.

Key words: grinding ball, titanium composite powder, powder sphericity, selective laser melting, relative density

CLC Number:

V261
TB331

ZHAO Shuo, GUO Meng, REN Yuhang, XIE Yilian, YANG Guang, WANG Xiangming. High Sphericity Titanium-based Composite Powder Fabrication and Selective Laser Melting[J]. Journal of Mechanical Engineering, 2025, 61(13): 429-439.

References

[1] LIU Y， YANG Y，MAI S，et al. Investigation into spatter behavior during selective laser melting of AISI 316L stainless steel powder[J]. Mater Des，2015，87：797-806.
[2] KRUTH J P，FROYEN L，Van VAERENBERGH J，et al. Selective laser melting of iron-based powder[J]. J Mater Process Technol，2004，149(1-3)： 616-22.
[3] KRUTH J P，LEVY G，KLOCKE F，et al. Consolidation phenomena in laser and powder-bed based layered manufacturing[J]. CIRP Annals，2007，56(2)：730-59.
[4] SHI Q，GU D，XIA M，et al. Effects of laser processing parameters on thermal behavior and melting/solidification mechanism during selective laser melting of TiC/Inconel 718 composites[J]. Optics & Laser Technology，2016，(84) 9-22.
[5] MUNIR K S，ZHENG Y F，ZHANG D L，et al.Microstructure and mechanical properties of carbon nanotubes reinforced titanium matrix composites fabricated via spark plasma sintering[J]. Materials Science and Engineering：A，2017，688：505-523．
[6] 高超峰. 激光选区熔化成形TiN/AlSi10Mg复合材料组织性能与强韧化机理[D]. 广州：华南理工大学，2021. GAO Chaofeng. Organization properties and toughening mechanism of TiN/AlSi10Mg composites formed by laser selective zone melting [D]. Guangzhou：South China University of Technology，2021.
[7] 张衬新. 增材制造用钛合金粉末的制备现状[J].有色冶金设计与研究，2023，44(4)：15-18. ZHANG Chenxin. Current status of preparation of titanium alloy powder for additive manufacturing[J]. Nonferrous Metallurgy Design and Research，2023，44(4)：15-18.
[8] 王永清. 镁基纳米复合材料的制备、改性及其储氢性能研究[D]. 南宁：广西大学，2021. Wang Yongqing. Preparation and modification of magnesium-based nanocomposites and their hydrogen storage properties [D]. Nanning： Guangxi University，2021.
[9] 董树成. 混合元素法制备Ti-6Al-4V合金致密过程分析及力学性能研究[D]. 长春：吉林大学，2023. DONG Shucheng. Analysis of densification process and mechanical properties of Ti-6Al-4V alloy prepared by mixed element method[D]. Changchun：Jilin University，2023.
[10] ZHOU W，SUN X，KIKUCHI K，et al. Carbon nanotubes as a unique agent to fabricate nanoceramic/metal composite powders for additive manufacturing[J]. Mater Des，2018，(137) 276-85.
[11] TAN H，HAO D，AL-HAMDANI K，et al. Direct metal deposition of TiB2/AlSi10Mg composites using satellited powders[J]. Mater Lett，2018，(214) 123-6.
[12] 江鸿翔，宋岩，赵雷，等. 气体雾化法制备TiB2/Al复合材料粉末及其组织演变[J]. 粉末冶金技术，2022，40(1)：33-39. JIANG Hongxiang，SONG Yan，ZHAO Lei et al. Preparation of TiB2/Al composite powders by gas atomization and their tissue evolution[J]. Powder Metallurgy Technology，2022，40(1)：33-39.
[13] 王仪凌，孙崇锋，白亚平，等. 机械合金化Fe-Mn-Al-C低密度钢合金粉末的烧结特性[J]. 西安工业大学学报，2023，43(5)：484-494. WANG Yiling，SUN Chongfeng，BAI Yaping，et al. Sintering characteristics of mechanically alloyed Fe-Mn-Al-C low-density steel alloy powder[J]. Journal of Xi'an University of Technology，2023，43(5)：484-494.
[14] VAIDYA M，MURALIKRISHNA G M，MURTY B S. High-entropy alloys by mechanical alloying：A review[J]. Journal of Materials Research，2019，34(5)：664-686.
[15] 曹遴，陈彪，郭柏松，等. 碳纳米管增强铝基复合材料分散方法研究进展[J]. 精密成形工程，2021，13(3)：9-24. CAO Lin，CHEN Biao，GUO Baisong et al. Research progress on dispersion method of carbon nanotube reinforced aluminum matrix composites[J]. Precision Molding Engineering，2021，13(3)：9-24.
[16] PEREZ-BUSTAMANTE R，PEREZ-BUSTAMANTE F，ESTRADA-GUEL，et al. Effect of milling time and CNT concentration on hardness of CNT/Al2024 composites produced by mechanical alloying[J]. Materials Characterization，2013，75：13-19.
[17] ABKOWITZ S，ABKOWITZ S M，FISHER H，et al. CermeTidiscontinuously reinforced Ti-matrix composites：Manufacturing，properties，and applications[J]. JOM，2004，56(5)：37-41．
[18] LEE W H，SEONG J G，YOON Y H，et al. Synthesis of TiC reinforced Ti matrix composites by spark plasma sintering and electric discharge sintering：A comparative assessment of microstructural and mechanical properties[J]. Ceramics International，2019，45(7)：8108-8114．
[19] MA F C，WANG C H，LIU P，et al. Microstructure and mechanical properties of Ti matrix composite reinforced with 5vol.%TiC after various thermo-mechanical treatments[J]. Journal of Alloys and Compounds，2018，758：78-84
[20] WANG Xu，DUAN Junbiao，SONG Kexing，et al. Microstructure，mechanical properties and arc erosion behavior of CuW composites prepared by high energy ball milling and spark plasma sintering[J]. International Journal of Refractory Metals and Hard Materials，2024，119：106523，
[21] MINET K，SAHARAN A，LOESSER A，et al. Additive manufacturing for the aerospace industry superalloys，powders，process monitoring in additive manufacturing[M]. Netherlands：Elsevier，2019.
[22] 葛庆. 选区激光熔化钛基复材介观热力学行为与工艺优化研究[D]. 南京：南京航空航天大学，2023. GE Qing. Study on mesoscopic thermodynamic behavior and process optimization of selected zone laser melting of titanium-based composites [D]. Nanjing：Nanjing University of Aeronautics and Astronautics，2023.
[23] 赵金猛. 激光选区熔化Ti-6Al-4V成形工艺与组织性能研究[D]. 上海：上海第二工业大学，2021. ZHAO Jinmeng. Research on forming process and organizational properties of Ti-6Al-4V by laser selective zone melting [D]. Shanghai：Shanghai Second University of Technology，2021.
[24] MAGINI M，IASONNA A. Energy transfer in mechanical alloying (overview)[J]. The Japan Institute of Metals，1995，36(2)：122-133.
[25] 朱云天，杜开平，沈婕，等. 激光能量密度对选区激光熔化(SLM)制品性能的影响及其机理研究[J]. 热喷涂技术，2017，9(2)：35-41. ZHU Yuntian，DU Kaiping，SHEN Jie，et al. Effect of laser energy density on the properties of selected zone laser melting (SLM) products and its mechanism[J]. Thermal Spraying Technology，2017，9(2)：35-41.
[26] WU Wenjie，GAO Chaofeng，LIU Zhongqiang，et al. Laser powder bed fusion of crack-free TiN/Al7075 composites with enhanced mechanical properties [J]. Materials letters，2021，128625.
[27] MARIUS S. KNIEPS，WILLIAM J，et al. n-situ alloying in powder bed fusion：The role of powder morphology[J]. Materials Science & Engineering A，807(2021)140849.
[28] PAN Deng，LI Shufeng，LIU Lei，et al. Enhanced strength and ductility of nano-TiBw-reinforced titanium matrix composites fabricated by electron beam powder bed fusion using Ti6Al4V–TiBw composite powder[J]. Additive Manufacturing，2022，50：102519.
[29] 宋亢. 选区激光熔化SiCp/AlSi10Mg复合材料的组织及性能研究[D]. 西安：西安工业大学，2022. SONG Kang. Study on the organization and propertiesof selected zone laser melting SiCp/AlSi10Mg composites[D]. Xi'an：Xi'an University of Technology，2022.
[30] 杨宇. 激光选区熔化制备Ti/SiC复合材料样品的缺陷形成机制及性能调控研究[D]. 武汉：华中科技大学，2022. YANG Yu. Study on defect formation mechanism andproperty regulation of Ti/SiC composite samples prepared by laser selective zone melting [D]. Wuhan：Huazhong University of Science and Technology，2022.
[31] CAI C ，HE S ，LI L ，et al. In-situ TiB/Ti-6Al-4V composites with a tailored architecture produced by hot isostatic pressing：Microstructure evolution，enhanced tensile properties and strengthening mechanisms[J]. Composites Part B Engineering，2019，164：546-558.
[32] 朱立洋. TiBw/Ti-6Al-4V复合材料多向锻造与热处理工艺研究[D]. 哈尔滨：哈尔滨工业大学，2018. ZHU Liyang. Research on multidirectional forging andheat treatment process of TiBw/Ti-6Al-4V composites[D]. Harbin：Harbin Institute of Technology，2018.