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2024 Vol. 29, No. 6
Published: 2024-12-15
Engineering and Technology
Theoretical Research
Review
Review
423
3D printing of continuous fiber reinforced ceramic matrix composites: research development and challenges
LI Zengchan, WANG Wenqing, WANG Gang, HE Rujie
DOI: 10.19976/j.cnki.43-1448/TF.2024068
Continuous fiber reinforced ceramic matrix composites (CFRCMCs) exhibit low density, high strength, excellent high-temperature stability and chemical stability, which are of significant application in various fields including aerospace, nuclear industry, chemical engineering, and transportation. In recent years, the evolution of 3D printing technology has provided an innovative approach for the shaping of complex and irregular CFRCMCs preforms. However, 3D printing of CFRCMCs remains in its infancy with significant challenges in forming equipment, processes, and principles. Hence, a summary and analysis of the research progress and challenges of the 3D printing of CFRCMCs are of significant value. Firstly, this paper briefly introduces 3D printing technologies; then, research progresses in 3D printing of CFRCMCs, including thermoplastic raw material-based fused deposition modeling 3D printing, aqueous slurry-based direct ink writing 3D printing, mechanically-assisted direct ink writing 3D printing, and photosensitive slurry-based vat photopolymerization 3D printing, are summarized; finally, the challenges in 3D printing of CFRCMCs are analyzed from fiber-ceramic interfaces, defect characterization and control, ceramization and densification, automation and intelligent manufacturing, structural and functional integration, 4D printing, self-healing, and standards. It is hoped that this review will provide some references and guidance for basic scientific and key technological research related to CFRCMCs 3D printing.
2024 Vol. 29 (6): 423-448 [
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86
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449
Research status and development trends of binder jetting printing technology
QIAN Yuhang, LUO Xia, CHEN Jingyu, FAN Zhou, HUANG Bensheng, ZHANG Liang, HUANG Ruo, ZHANG Weizheng
DOI: 10.19976/j.cnki.43-1448/TF.2024077
Binder jetting (BJ) is an additive manufacturing technology that involves jetting liquid binder onto the layers of powder materials to selectively bond the powder and form a shape, then followed by densification processing. In recent years, BJ technology has received widespread attention and research due to its high efficiency, low cost, and wide range of applicable materials. During the BJ process, factors such as powder characteristics, binder and its interactions with the powder bed, as well as printing parameters, have crucial impacts on the quality and performance of the green body. Additionally, the sintering process is one of the key factors affecting the quality of the final component. This study summarizes the influencing factors of BJ printing and proposes the use of machine learning to assist in predicting the green body quality and sintering shrinkage, enabling shape and property control. Currently, BJ technology is being promoted in industries such as automotive and medical devices. In the future,the key to the large-scale application of BJ technology lies in improving the quality and precision of the green body, enhancing the bonding strength between the binder and the body, and optimizing the post-processing techniques.
2024 Vol. 29 (6): 449-463 [
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80
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Theoretical Research
464
Crystal plasticity simulation studying the effects of cold rolling deformation and heat treatment on the texture and planar anisotropy of 7085 aluminum alloy
TAN Xin, ZHANG Zhichen, TANG Sai, XIAO Daihong, LIU Wensheng
DOI: 10.19976/j.cnki.43-1448/TF.2024075
The effects of cold rolling deformation and heat treatment on texture composition and plastic strain ratio
r
of 7085 aluminum alloy were investigated by XRD, EBSD, and tensile experiments combined with crystal plasticity simulation. The effects of five ideal textures on average plastic strain ratio and planar anisotropy index |Δ
r
| were analyzed. The results show that when the deformation increases from 50% to 80% during cold rolling, the volume fraction of S texture increases the most (10.9%), the volume fraction of Copper texture increases the least (2.9%), and the recrystallization texture changes little. After heat treatment, the Brass, S, and Copper textures of the alloys are weakened, when the deformation amount is 80%, the S texture decreases the most (15.9%) and the Copper texture decreases the least (2.4%); the Cube texture increases, and the larger the deformation is, the more significant the increase is; the Goss texture change is not obvious. The |Δ
r
| value of cold-rolled alloy is higher than that of aged alloy; with the increase of cold rolling deformation, the value of cold rolled alloy increases gradually, the value of aged alloy decreases gradually, and the |Δ
r
| value increases gradually. Rolled texture Δ
r
<0 while recrystallization texture Δ
r
>0. The Goss texture mainly provides resistance to deformation in the 90° direction, while the Cube texture has little difference in r value in the three directions.
2024 Vol. 29 (6): 464-476 [
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55
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Engineering and Technology
477
Effect of fiber quality ratio on the properties of fiber porous ceramic composites
MO Chen, XIANG Yang, LUO Meng, PENG Zhihang, WEN Jin, LIU Ping, LI Hailong
DOI: 10.19976/j.cnki.43-1448/TF.2024072
Fiber porous ceramic composites are widely used in the field of thermal protection for aircraft due to their low density, low thermal conductivity, and relatively high compressive strength. This study used oxide fibers to prepare efficient thermal insulation materials, and prepared fiber porous ceramic composites with different fiber mass ratios (aluminosilicate and ultrafine quartz fibers) at different sintering temperatures. The influences of fiber mass ratio on the microstructure and macroscopic properties of the composites were investigated. X-ray computed tomography (X-CT) technology was introduced to achieve non-destructive characterization of the microstructure of composites. The interactive threshold analysis of the structure and the reconstruction of the fiber distribution were carried out by 3D reconstruction software, and fiber orientations were simulated using fiber tracking analysis. The results show that when the sintering temperature is relatively low (900-1 000 ℃), as the content of aluminosilicate fibers increases, the density of the composites increases, and the porosity is less affected, the compressive strength of the composites gradually decreases. When the sintering temperature is 900 ℃ and the mass fraction of aluminosilicate fibers is 20%, the compressive strength of the composites is 1.99 MPa; when the mass fraction increases to 45%, the compressive strength decreases to 0.80 MPa. When the sintering temperature is 1 200 ℃, significant damage occurrs to the strength of both fibers, resulting in a decrease in the compressive strength of the composites. The fiber distribution is not uniform in the micro area, and there are large pores in some areas, which are weak areas of strength and prone to failure.
2024 Vol. 29 (6): 477-485 [
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54
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486
Effects of WC content on microstructure and properties of Co-based alloy composite cladding layers
SU Liang, TONG Yonggang, HU Yongle, FANG Jingzhong, WANG Kaiming, WU Pengfei
DOI: 10.19976/j.cnki.43-1448/TF.2024073
To explore the effects of WC content on the microstructures and high temperature tribological behavior of Co-based alloy composite cladding layers, WC/Co-based alloy cladding layers with different WC contents were prepared by plasma cladding process. The microstructures, hardness, and friction and wear properties of the composite cladding layers were systematically investigated. The results show that the microstructure of the cladding layer is composed of cellular, columnar, and dendritic crystal zones when the content of WC is low. As the WC content increasing, a large number of irregularly shaped fine (Co,W)C carbides and undissolved WC particles are formed inside the composite cladding layer, which significantly improves the hardness and friction and wear properties of the composite cladding layers. The microhardness of the composite cladding layer is enhanced with the increase of WC content, showing the best hardness of 752 with the WC mass fraction of 40%, which is 76% higher than that of the cladding layer without WC. The WC reinforced composite cladding layers exhibit excellent wear resistance. The friction factor decreases first then increases, and then decreases again, and the wear volume loss decrease firstly and then increase with the increase of WC content. The cladding layer with WC mass fraction of 20% shows the best high temperature wear performance, of which the average friction factor at 600 ℃ is 0.235, and the wear volume loss is 25.13×10
8
μm
3
, the wear forms are oxidative wear and fatigue wear.
2024 Vol. 29 (6): 486-495 [
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74
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496
Microstructure and mechanical properties of high strength Al-Mg-Sc-Er-Zr alloy fabricated by laser powder bed fusion
WANG Yangbo, LI Ruidi, ZHI Shengxing, YUAN Tiechui, KE Linda, HOU Yaping
DOI: 10.19976/j.cnki.43-1448/TF.2024071
Al-Mg-Sc-Zr alloy fabricated by laser powder bed fusion (LPBF) technology is not easy to crack and has good mechanical properties. However, Sc is expensive, it is necessary to find some elements that can replace Sc. This article used gas atomized powder as raw material and prepared Al-Mg-Sc-Er-Zr alloy by LPBF technology. Density was measured using hydrostatic balance and defects were observed using a metallographic microscope to optimize laser process parameters; the hardness was measured using a Vickers hardness tester and tensile tests were conducted using a universal mechanical testing machine to optimize the aging process parameters; scanning electron microscope and transmission electron microscope were used to characterize the alloy structure and study its strengthening mechanism. The results indicate that the optimized LPBF process parameters are: laser power of 300 W, scanning speed of 900 mm/s; the optimized aging process parameters are: aging temperature of 325 ℃ and aging time of 4 h. Al-Mg-Sc-Er-Zr alloy prepared by LPBF exhibits a typical bimodal grain structure, with fine equiaxed grains at the boundary of the melt pool and coarse columnar grains inside the melt pool. After aging treatment at 325 ℃/4 h, the tensile strength of the alloy reaches 565 MPa, the yield strength reaches 520 MPa, the elongation rate is 14.5%, and the hardness (HV) increase from 118 before aging to 163. Mg2Si particles and nano Al3(Sc,Zr) particles formed after aging treatment can synergistically nail grain boundaries and improve alloy strength.
2024 Vol. 29 (6): 496-504 [
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67
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505
Preparation of porous graphene/SiC-based composite by direct ink write 3D printing
TANG Run, LIU Hongjun, LI Yajun, LI Yamin
DOI: 10.19976/j.cnki.43-1448/TF.2024074
Graphene/SiC
p
/PCS slurry was prepared using graphene and SiC powder (SiC
p
) as fillers and polycarbosilane (PCS) as ceramic precursor, and then the porous lightweight conductive graphene/SiC-based composite was prepared by direct ink write 3D printing and high temperature pyrolysis method. The influences of slurry composition and printing process on 3D printing formability were investigated, and the microstructure and properties of composite were characterized. The results show that the formability of the extruded filament is suitable for printing when the slurry viscosity is about 32.0 Pa·s by controlling the solid content, graphene content in graphene/SiC
p
composite powder, and dispersant content. When the printing speed is 360 mm/min and the layer height is 0.48 mm, the formability of the lattic grid structure for 3D printing is optimal. After heating the printed green body at 1 100 ℃ for 2 h, PCS is pyrolyzed into ceramics, the average compressive strength and conductivity of the composite are 11 MPa and 8 S/m, respectively. This study provides a new pathway for the preparation of porous graphene/SiC-based composite.
2024 Vol. 29 (6): 505-513 [
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52
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514
Preparation and properties of Cr
3
C
2
-doped Ni-P-PTFE chemical composite coating
WANG Jiangang, XU Meiqi, WANG Xue, SUN Yihan, WANG Yujiang
DOI: 10.19976/j.cnki.43-1448/TF.2024083
To enhance the corrosion resistance and hardness of the surface of medical device components based on ferritic stainless steel, this study employed a chemical composite plating method to prepare
x
Cr
3
C
2
/Ni-P-PTFE (polytetrafluoroethylene) coatings on the surface of ferritic stainless steel. The influences of Cr
3
C
2
mass concentrations (10, 15, 20 g/L) on the hardness, surface morphology, phase composition, and corrosion resistance of the Ni-P-PTFE chemical composite plating coatings before and after heat treatment were investigated. The results indicate that the incorporation of Cr
3
C
2
particles at a certain mass concentration results in a smoother and more even surface of the Ni-P-PTFE coating, reducing surface roughness while enhancing hardness and corrosion resistance. When the Cr
3
C
2
mass concentration is 15 g/L, the Ni-P-PTFE-Cr
3
C
2
coating exhibits a uniform and smooth surface with the lowest roughness and a hardness (HV
0.1
) of 354; the surface corrosion current density decreases from 0.05 μA/cm2 to 0.02 μA/cm2, representing a 60% reduction and indicating superior corrosion resistance; after heat treatment (300 ℃, 2 h), due to the precipitation of Ni3P hard phase and Ni phase in the coating, the hardness (HV0.1) reaches 527, representing an increase of approximately 49%. The Ni-P-PTFE-Cr3C2 coating effectively improves the performance of the steel substrate used in medical device components.
2024 Vol. 29 (6): 514-521 [
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51
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