选择性激光熔化制备难熔高熵合金研究进展

朱恩; 杨宝震; 张登科; 张微; 李婉秋; 虞飞标

doi:10.16490/j.cnki.issn.1001-3660.2025.16.003

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表面技术 ›› 2025, Vol. 54 ›› Issue (16) : 39-59. DOI: 10.16490/j.cnki.issn.1001-3660.2025.16.003

研究综述

选择性激光熔化制备难熔高熵合金研究进展

朱恩¹, 杨宝震^1,*, 张登科¹, 张微¹, 李婉秋², 虞飞标¹

作者信息 +

Research Progress on Selective Laser Melting of Refractory High-entropy Alloys

ZHU En¹, YANG Baozhen^1,*, ZHANG Dengke¹, ZHANG Wei¹, LI Wanqiu², YU Feibiao¹

Author information +

文章历史 +

摘要

旨在系统梳理选择性激光熔化（SLM）技术在难熔高熵合金（RHEAs）制备领域的研究现状,明确工艺参数-微观结构-性能之间的关联机制。揭示SLM技术解决传统铸造RHEAs晶粒粗大、成分偏析等问题的有效性,并探讨其在工程应用中的关键瓶颈与发展前景。研究表明：SLM技术通过极端非平衡凝固实现了RHEAs的微观结构创新,其独特的晶粒细化效应和原位纳米强化机制为开发高性能RHEAs提供了新途径。通过统计分析近年国际权威文献中SLM制备RHEAs的工艺参数,系统研究能量密度对难熔高熵合金致密度、缺陷特征及元素分布的影响规律。结合文献中电子背散射衍射（EBSD）和透射电镜（TEM）等表征,阐明快速凝固条件下亚稳态相形成机制,定量分析晶粒细化与力学性能提升的对应关系。进一步阐明了如NbC、TiC等纳米析出相通过晶界钉扎效应抑制晶粒粗化及提高材料抗氧化性能的机理。然而,尽管SLM-RHEAs在复杂构件成形方面展现出显著优势,但残余应力分布不均及成分均匀性控制仍是制约其工业化应用的核心瓶颈。最后展望了其在生物医用植入物和航空航天部件等领域的潜力。

Abstract

Refractory high-entropy alloys (RHEAs), composed of multiple principal elements with high melting points, have garnered significant attention for their exceptional mechanical strength, oxidation resistance, and thermal stability, making them ideal candidates for extreme-environment applications in aerospace, nuclear energy, and biomedical engineering. Currently, conventional RHEA preparation processes such as arc melting, powder metallurgy and magnetron sputtering have certain limitations in practical applications. Specifically, arc melting is limited by a low cooling rate (10⁰-10² K/s), which is prone to inducing macroscopic segregation, coarse grains (grain size >100 μm) and shrinkage defects. While powder metallurgy can achieve compositional homogeneity through mechanical alloying, the long-time high-temperature holding time of the conventional sintering process triggers abnormal coarsening of brittle intermetallic compounds (e.g., σ-phase, Laves-phase). Magnetron sputtering, as a physical vapour-phase deposition technique, can prepare nano-crystalline/amorphous structures with a homogeneous distribution of compositions, but it is difficult to obtain direct access to the nanocrystalline/amorphous structure due to the low deposition rate and the finite forming dimensions. Selective laser melting (SLM), an advanced additive manufacturing technique, addresses these challenges through ultrahigh cooling rates (10³-10⁵ K/s) and precise layer-by-layer fabrication, enabling unprecedented control over microstructural refinement and property enhancement. The work aims to comprehensively examine recent advancements in SLM-processed RHEAs, focusing on process-microstructure-property relationships, defect mitigation strategies, and industrial applications, while identifying critical challenges and future research directions.
Key findings highlight that SLM achieves remarkable grain refinement, reducing average grain sizes from >200 μm in cast alloys to <20 μm, with further reductions to 10.6 μm through microalloying (e.g., 0.5at.% C in NbMoTaW). Energy density, governed by laser power, scan speed, and layer thickness, critically affects relative density and porosity. Advanced characterization via EBSD and TEM reveals metastable phase formation and in-situ nano-precipitates (e.g., NbC, TiC), which enhances mechanical properties through grain boundary pinning and dislocation interaction. For instance, SLM-fabricated VNbMoTaW alloys exhibit compressive strengths of 993.84 MPa at 1 000 ℃, retaining 62.2% of their room-temperature strength, while NbMoTaW-0.5C demonstrates a 43.3% increase in yield strength (1 391 MPa) and improved ductility (6.9% strain).
The rapid solidification inherent to SLM suppresses elemental segregation, promoting homogeneous microstructures and dense oxide layers (e.g., Nb₂O₅, Ta₂O₅) that enhance corrosion resistance. Electrochemical tests reveal corrosion current densities as low as 8.716×10^-11 A/cm² for SLM-processed NbMoTaW in 3.5% NaCl, surpassing 316L stainless steel. High-temperature oxidation resistance is further bolstered by ternary oxides (e.g., Ta₁₆W₁₈O₉₄) formed at elevated energy densities (>150 J/mm³), effectively inhibiting oxygen diffusion. Biomedical applications leverage SLM's design flexibility to fabricate porous TiNbTaZrMo implants with tunable Young's modulus (6.71-16.21 GPa), mimicking bone trabeculae to mitigate stress shielding. Osteoblast adhesion and actin filament development on these alloys rival pure titanium, underscoring their biocompatibility.
Despite these advancements, SLM-processed RHEAs face challenges including residual stress (up to 380 MPa at 400 mm/s scan speed), microcracks, and compositional heterogeneity. Residual stress is mitigated by optimizing scan strategies (e.g., stripe vs. chessboard patterns) and post-processing techniques like hot isostatic pressing (HIP), which reduces porosity by 60%. Crack initiation is suppressed through compositional adjustments (e.g., 1at.% C additions to limit oxygen segregation) and adaptive parameter tuning. For example, lowering scan speeds to 600 mm/s reduces surface roughness and transforms long cracks into isolated micropores.
Industrial applications demonstrate SLM's capability to produce complex geometries such as turbine blades, lattice structures, and gradient components. Case studies include lightweight WNbMoTa turbine blades with high strength-to-weight ratios and Ta-rich RHEAs for nuclear reactor cladding, capitalizing on their irradiation resistance. Future research must prioritize defect control through in-situ monitoring, compositional uniformity via machine learning-driven alloy design, and performance validation under extreme conditions (e.g., >1 200 ℃ oxidation, neutron irradiation). Multi-scale simulations (phase-field and molecular dynamics) are essential to decode melt pool dynamics, while hybrid processes (e.g., laser remelting) could enhance surface functionality.
In conclusion, SLM represents a transformative approach to RHEA manufacturing, offering unmatched microstructural control and performance optimization. By bridging laboratory innovation and industrial demands, this technology unlocks new possibilities for high-performance materials in extreme environments. Collaborative efforts in process refinement, computational modeling, and interdisciplinary integration will be pivotal to advancing SLM-processed RHEAs toward widespread commercialization.

导出引用

朱恩, 杨宝震, 张登科, 张微, 李婉秋, 虞飞标. 选择性激光熔化制备难熔高熵合金研究进展[J]. 表面技术. 2025, 54(16): 39-59 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.16.003

ZHU En, YANG Baozhen, ZHANG Dengke, ZHANG Wei, LI Wanqiu, YU Feibiao. Research Progress on Selective Laser Melting of Refractory High-entropy Alloys[J]. Surface Technology. 2025, 54(16): 39-59 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.16.003

中图分类号： TF841

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