目的 解决增材制造GH4169合金表面球化缺陷难以高效、高精度去除的难题,提升增材制造件表面质量与服役性能。方法 采用飞秒激光器在氩气气氛下对带有球化缺陷的增材制造GH4169试样进行表面球化缺陷去除实验;基于正交实验设计,研究激光功率、轨迹重叠率LO、光斑重叠率PO及光斑大小df对去除效率与表面质量的影响规律,并结合多手段表征与有限元仿真分析烧蚀机制。结果 当激光功率30 W、LO=50％、PO=80％、离焦量≤90 µm时,球化缺陷的去除步长达4.65 μm且围球化缺陷凹槽式烧蚀损伤最小;累计20次扫描后球化缺陷高度由153.8 μm降至20.5 μm,基本完成缺陷去除;烧蚀过程中由于球化结构扰动作用形成围缺陷凹槽,深度约9 μm。飞秒激光烧蚀有效清除了表面氧化膜,表面O含量（质量分数）由6.67％降至5.58％,Ni、Ti、Cr含量（质量分数）变化<1％;表面硬度从364HV提升至409HV,增幅达12.3％;表面润湿接触角由96.7°降低至82.5°,润湿性显著改善。理论仿真表明,球化结构衍射导致激光能量在球化缺陷边缘能量集中、电场强度呈波纹放射状分布,从而形成了围缺陷凹槽烧蚀。结论 飞秒激光烧蚀可针对增材制造GH4169表面球化缺陷实现高效率、高精度的定点去除,同步改善表面硬度与润湿性,对基体成分影响小,为增材制造在线修复提供了可靠技术路径。
Abstract
GH4169 nickel-based superalloy is widely used in aerospace and other high-end fields; however, selective-laser-melted (SLM) parts frequently exhibit spheroidization defects that severely degrade surface quality and service performance. Conventional post-treatments such as mechanical machining or electropolishing suffer from low efficiency and limited adaptability. The work aims to propose a femtosecond laser spot ablation method to eradicate these spheroidization defects on SLM-GH4169 surfaces, systematically investigate the influences of laser power, pulse/track overlap ratios and defocus distance on removal efficiency, and employ multi-scale characterizations in combination with numerical simulations to unveil the light-field disturbance mechanisms induced by defect topography.
Specimens were fabricated on an RS450D metal 3D printer under as-built conditions, presenting spheroidization defects with an average height of 78.4 µm. Ablation was performed with an OR-30-IR femtosecond laser under an argon atmosphere. A orthogonal array was employed to optimize laser power, track overlap (LO), pulse overlap (PO) and defocus distance (z), to balance the removal rate against surface quality. Pre- and post-processing topographies, chemistries, hardness and wettability were systematically characterized by laser-scanning confocal microscopy (LSCM), SEM, EDS, XRD, XPS, Vickers micro-indentation and contact-angle goniometry.
Optimal removal was achieved at 30 W, LO =50%, PO =80% and defocus ≤ 90 µm, yielding a maximum removal step of 4.65 µm with minimal peripheral trenching. After 20 passes, the defect height decreased from 153.8 µm to 20.5 µm, indicating complete elimination. A circumferential groove of about 9 µm deep was formed simultaneously, attributed to diffraction of the incident light by the spheroidal topography. COMSOL transient-thermal analyses revealed localized energy concentration at the defect periphery, with temperatures exceeding 2 000 K that drove collateral ablation. FDTD simulations further showed a ripple-like, radial intensity distribution within a 50 µm annulus around the defect, creating electromagnetic hot-spots responsible for the observed trench.
Compositional analyses indicated that surface oxygen decreased from 6.67wt.% to 5.58wt.% after femtosecond ablation, whereas Ni, Ti and Cr varied by <1wt.%, evidencing minimal alteration of the substrate chemistry. XPS confirmed effective removal of the native Al2O3 scale. Vickers hardness rose from 364HV to 409HV (+12.3%) within the processed zone; concomitant XRD peak shifts of the γ phase toward higher 2θ suggested lattice contraction and/or micro-strain. Wettability measurements showed a decrease in water-contact angle from 96.7° to 82.5°, restoring a hydrophilic surface favorable for subsequent machining or coating adhesion.
In summary, femtosecond laser ablation enables efficient and high-precision elimination of spheroidization defects on GH4169 surfaces while concurrently enhancing surface hardness and wettability, with negligible modification of the bulk composition. The structural disturbance of the incident optical field by the defect topography is identified as the primary mechanism driving the formation of the peripheral trench. This approach offers a reliable laser-subtractive route for in-situ repair and performance enhancement of additively manufactured components, exhibiting excellent scalability and industrial applicability. In the future, integrating in-line monitoring and closed-loop control is expected to further enhance repair accuracy and efficiency. The technology also holds promise for defect remediation in other additively manufactured materials such as titanium alloys and tool steels.
关键词
GH4169合金 /
球化缺陷 /
飞秒激光去除 /
光场扰动 /
增材制造
Key words
GH4169 alloy /
spheroidization defects /
femtosecond laser removal /
light field disturbance /
additive manufacturing
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基金
国家重点研发计划项目（2023YFB4606000）; 浙江省“尖兵”“领雁”研发攻关项目（2023C01051）; 浙江省属高校基本科研业务费专项资金（RF-C2022001）
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