目的 针对聚变堆第一壁关键候选材料碳化锆弥散强化钨合金（W-0.5wt.% ZrC,WZC）存在的加工难、热损伤敏感问题,探究磨料水射流（AWJ）切割WZC的冲蚀机理及低热损伤预加工适用性。方法 开展后混合AWJ与电火花线切割（WEDM）的对比试验,并补充10°倾斜入射试验考察局部冲蚀形貌。结合扫描电子显微镜（SEM）和能谱分析（EDS）表征切割表面、横截面损伤和元素分布。基于全因子切割实验与光滑粒子流体动力学耦合有限元法（SPH-FEM）构建数值模型,研究射流粒子动力学行为与材料去除机制。结果 WEDM加工表面存在明显的再铸层与微裂纹网络等热损伤特征,EDS显示表面元素组成偏离WZC基体。AWJ切割表面在SEM观察下未发现再铸层和热诱导微裂纹,在抑制热损伤方面具有明显优势,元素变化主要表现为局部分散磨料残留。AWJ宏观切割面呈上塑下脆的分层特征,上部受高能粒子垂直冲击以微切削塑性去除为主,下部因动能耗散转变为解理断裂为主的脆性去除。仿真揭示了切缝内的正交动量转化机制,进给方向的粒子速度振荡导致了微观表面的多向交错耕犁痕迹。10°前倾或侧倾未改变“上塑下脆”的基本去除规律。结论 AWJ凭借冷态切割特性可避免钨基材料的热损伤缺陷,适合作为WZC板材冷态下料和低热损伤预加工手段。切割表面的光滑区/粗糙区分层、拖尾纹和切缝锥度主要源于射流能量随深度衰减及其与进给运动的耦合作用。由于AWJ侧壁仍存在粗糙区、拖尾纹和局部解理剥落,尚不宜直接作为偏滤器复杂曲面构件的终加工方法,后续需结合精密修整工序。
Abstract
The work aims to investigate the erosion mechanism and low-thermal-damage pre-machining applicability of post-mixed abrasive water jet (AWJ) cutting for zirconium-carbide dispersion-strengthened tungsten (W-0.5wt% ZrC, WZC), a candidate plasma-facing material for fusion reactors. Cutting experiments were performed on hot-rolled WZC plates with a thickness of 12 mm and a width of 20 mm via a self-built CNC post-mixed AWJ system with 80-mesh garnet abrasives. A two-factor three-level full factorial design was adopted at a fixed standoff distance of 3 mm, with jet pressures of 320, 350 and 380 MPa and feed rates of 15, 10 and 5 mm·min-1. Wire electrical discharge machining (WEDM) was used as a reference process. The representative AWJ condition of 380 MPa and 10 mm·min-1 was selected for mechanism-level analysis, and additional 10° forward-tilt and lateral-tilt cutting tests were conducted to examine oblique-incidence effects. Surface morphology, cross-sectional damage and elemental distribution were characterized by SEM and EDS.
A coupled smoothed particle hydrodynamics-finite element method (SPH-FEM) model was established in LS-DYNA to interpret particle dynamics, kerf formation and depth-dependent material removal. WZC was described by a Johnson-Cook constitutive model coupled with the Grüneisen equation of state, while element failure was implemented through an equivalent plastic-strain erosion criterion. Water and abrasive phases were represented by SPH particles defined with *MAT_NULL and EOS-Grüneisen, and their coupling with the solid target was realized via *CONTACT_ERODING_NODES_TO_SURFACE. Considering post-mixing energy loss and abrasive acceleration, the jet exit velocity was set to 0.8 of the theoretical waterjet velocity, namely 697.42 m·s-1 at 380 MPa. Grid and particle-size verification led to an SPH spacing of 1.25 × 10-4 m and a refined FEM mesh size of 0.15 mm.
The WEDM surface appeared macroscopically smooth but contained a discontinuous recast layer, redeposited droplets and dense micro-crack networks, and cross-sectional observations confirmed a thermally affected modified layer with cracks extending toward the substrate. EDS further showed that the WEDM-machined surface composition deviated from the WZC matrix owing to melting, oxidation and resolidification. By contrast, AWJ produced a cold-cut surface without a continuous recast layer or thermally induced micro-cracks in the SEM observation range. The detected non-matrix elements were mainly attributed to locally dispersed garnet residues. The AWJ kerf wall exhibited clear smooth-rough stratification, with the smooth zone occupying approximately 42% of the cut surface. In the rough zone, backward-curving striations developed with theincreasing erosion depth. The average angle between the terminal tangents of three fitted drag-tail striations and the erosion direction was 8.73°. SEM observations at erosion depths of 2, 6, and 10 mm further showed a gradual transition from dense overlapping micro-cutting and micro-plowing grooves to enlarged cleavage facets, river patterns, and fan- or tongue-shaped fracture features. This indicated a depth-dependent change in the removal mode, from plastic-dominated removal in the upper region to cleavage-controlled brittle removal in the lower region.
The simulation reproduced crater initiation, particle rebound, secondary impacts and an upper-wide/lower-narrow kerf.The predicted lag-trajectory angle of approximately 9.1° agreed well with the measured drag-tail angle of 8.73°. Mechanistically, vertical particle kinetic energy attenuated nonlinearly with depth, including stagnation-zone damping that reduced particle velocity by up to about one third.Meanwhile, orthogonal momentum conversion transformed the blocked vertical jet into a wall jet, causing oscillatory feed-direction particle motion and multi-directional plowing traces. The 10° tilted-incidence tests did not change the fundamental "plastic upper/brittle lower" removal law, but altered groove orientation, lateral asymmetry and abrasive-residue distribution. Therefore, AWJ is suitable for cold blanking and low-thermal-damage pre-machining of WZC plates. However, because rough zones, drag-tail striations and local cleavage spalling remain on the sidewall, AWJ should be combined with precision finishing rather than used directly as the final machining process for complex divertor surfaces.
关键词
碳化锆弥散强化钨合金 /
磨料水射流 /
冲蚀机理 /
表面完整性 /
SPH-FEM耦合 /
微观形貌 /
解理断裂
Key words
W-ZrC alloy /
abrasive water jet /
erosion mechanism /
surface integrity /
SPH-FEM coupling /
micro-morphology /
cleavage fracture
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] SADIK-ZADA E R, GATTO A, WEIßNICHT Y. Back to the Future: Revisiting the Perspectives on Nuclear Fusion and Juxtaposition to Existing Energy Sources[J]. Energy, 2024, 290: 129150.
[2] SONG Y T, ZOU X L, GONG X Z, et al. Realization of Thousand-Second Improved Confinement Plasma with Super I-Mode in Tokamak EAST[J]. Science Advances, 2023, 9(1): eabq5273.
[3] WANG S K, CHUILON B, BARTH A, et al.Consideration of Tungsten Recrystallization in Plasma Facing Components Design[J]. Fusion Engineering and Design, 2024, 200: 114162.
[4] JIANG S, CHEN L, LI W H, et al.Evolution of Tungsten Degradation under Different Cyclic ELM-Like High Heat Flux Plasma[J]. Journal of Nuclear Materials, 2024, 588: 154762.
[5] CHRISTENSEN M, WIMMER E, GILBERT M R, et al.Atomistic Modelling of Tritium Thermodynamics and Kinetics in Tungsten and Its Oxides[J]. Nuclear Materials and Energy, 2024, 38: 101611.
[6] WANG K, XI Y, ZAN X, et al.Failure Analysis of Damaged Tungsten Monoblock Components of Upper Divertor Outer Target in EAST Fusion Device[J]. Nuclear Engineering and Technology, 2024, 56(6): 2307-2316.
[7] LANG E, SCHAMIS H, MADDEN N, et al.Recrystallization Suppression through Dispersion-Strengthening of Tungsten[J]. Journal of Nuclear Materials, 2021, 545: 152613.
[8] YANG R, XIE Z M, LIU R, et al.Enhanced Strength and Thermal Stability of Tungsten Alloys by the Dispersion of Nanoscale Potassium Bubbles and ZrC Particles[J]. Journal of Nuclear Materials, 2025, 613: 155863.
[9] LIN Q Q, CAO L, HAN L, et al.Thermal Strain Test and Analysis of the W-ZrC Mono-Block Mock-up[J]. Fusion Engineering and Design, 2024, 200: 114188.
[10] GAO X N, HAO Z H, MA R L, et al.Crack Suppression in Laser Powder Bed Fusion of Tungsten Alloy by Using a Spherical W-ZrC Composite Powder[J]. Journal of Alloys and Compounds, 2025, 1037: 182247.
[11] 王慧, 丁晨师, 谢卓明, 等. 放电等离子烧结制备W-ZrC/HfC-Re合金的力学性能和热稳定性研究[J]. 稀有金属材料与工程, 2024, 53(5): 1321-1331.
WANG H, DING C S, XIE Z M, et al.Mechanical Properties and Thermal Stability of W-ZrC/HfC-Re Alloys Fabricated by Spark Plasma Sintering[J]. Rare Metal Materials and Engineering, 2024, 53(5): 1321-1331.
[12] SREEJITH S, PRIYADARSHINI A, CHAGANTI P K, et al.Effect of Machining Operations on Mechanical Properties, Surface Integrity and Corrosion Resistance of Tungsten Heavy Alloy[J]. Materials Today Communications, 2023, 37: 106930.
[13] MOURALOVA K, BENES L, PROKES T, et al.Analysis of the Machinability of Different Types of Sintered Carbides with WEDM in both Water and Oil Baths[J]. The International Journal of Advanced Manufacturing Technology, 2023, 125(5): 2705-2715.
[14] SIRELI E, ORHON N, SIRELI G K.Effects of Wire- Electro Discharge Machining Process on Surface Integrity of WC-10Co Alloy[J]. International Journal of Refractory Metals and Hard Materials, 2017, 64: 190-199.
[15] 王军, 景延延, 杜鑫豪, 等. 磨料水射流加工技术研究现状及展望[J]. 机械工程学报, 2025, 61(9): 46-77.
WANG J, JING Y Y, DU X H, et al.Abrasive Waterjet Machining—State of the Art and Future Perspectives[J]. Journal of Mechanical Engineering, 2025, 61(9): 46-77.
[16] HASHISH M.Abrasive Waterjet Machining[J]. Materials, 2024, 17(13): 3273.
[17] WANG Y, ZHANG X, ZHOU Z, et al.Study on Cutting First Wall Tungsten Material for Fusion Reactor by Premixed Abrasive Jet[J]. Nuclear Fusion and Plasma Physics, 2021, 41(1): 85-90.
[18] WANG Y, WANG L, ZHANG X Y, et al.Cutting of Tungsten Plate for Fusion Device via Pre-Mixed Abrasive Water Jet[J]. Fusion Engineering and Design, 2020, 159: 111790.
[19] WANG Y, WANG L, ZHANG X Y.Modeling of Processing Parameters for the Cutting of Rolled Tungsten Plates via Abrasive Water Jet[J]. AIP Advances, 2022, 12(9): 095103.
[20] LI M J, SU T, LIN X C.Improving Surface Striation and Kerf Taper of Hybrid Al/CFRP Stacks Using Dual-Pass Abrasive Waterjet Slotting Strategy[J]. The International Journal of Advanced Manufacturing Technology, 2024, 130(11): 5763-5776.
[21] QIAN Y N, LI Y Z, WAN L, et al.High-Quality Cutting Method for Complex Surfaces Using Abrasive Waterjet: Take Kerf Taper Angle as Example[J]. The International Journal of Advanced Manufacturing Technology, 2025, 140(3): 1981-1997.
[22] 汪明明. 多尺度界面结构W-ZrC合金的微结构和性能调控研究[D]. 合肥: 中国科学技术大学, 2021.
WANG M M.Study on Microstructure and Property Regulation of W-ZrC Alloy with Multiscale Interface Structure[D]. Hefei: University of Science and Technology of China, 2021.
[23] 李鹏飞, 范景莲, 章曼, 等. ZrC增强细晶钨的高温性能和高热负荷冲击损伤行为[J]. 稀有金属材料与工程, 2019, 48(2): 517-523.
LI P F, FAN J L, ZHANG M, et al.High Temperature Properties and High Heat Flux Shock Damage Behavior of Fine Grain Tungsten Reinforced by ZrC Particles[J]. Rare Metal Materials and Engineering, 2019, 48(2): 517-523.
[24] XIE Z M, LIU R, MIAO S, et al.High Thermal Shock Resistance of the Hot Rolled and Swaged Bulk W-ZrC Alloys[J]. Journal of Nuclear Materials, 2016, 469: 209-216.
[25] GAO J, WANG Y, et al.Study on Cutting Surface Quality of Potassium-Tungsten Using Premixed Abrasive-Water Jet[J]. AIP Advances, 2025, 15(9): 095006.
[26] ALKAHLAN B, TABBAKH T, KURDI A, et al.Formation and Characterization of the Recast Layer Formed on Inconel 718 during Wire Electro Discharge Machining[J]. Materials, 2023, 16(3): 930.
[27] ZHAO W, GUO C W.Topography and Microstructure of the Cutting Surface Machined with Abrasive Waterjet[J]. The International Journal of Advanced Manufacturing Technology, 2014, 73(5): 941-947.
[28] BRANDSTÄTTER M, WÖHRLE A, KAUFELD M, et al. The Quantitative Evaluation of the Cutting Surface Quality Levels in Abrasive Water Jet Cutting by Measurement of the Representative Striation Mark Displacement[J]. The International Journal of Advanced Manufacturing Technology, 2022, 120(3): 1625-1642.
[29] LI S Q, WU Y D, SUN X Y, et al.Penetration Behavior and Configuration Design of Long-Rod Projectiles under Damage Regulation[J]. Journal of Materials Science, 2026, 61(20): 14404-14424.
[30] WU Q, XU W X, ZHANG L C.Machining of Particulate- Reinforced Metal Matrix Composites: An Investigation into the Chip Formation and Subsurface Damage[J]. Journal of Materials Processing Technology, 2019, 274: 116315.
[31] XU J Y, EL MANSORI M.Cutting Modeling of Hybrid CFRP/Ti Composite with Induced Damage Analysis[J]. Materials, 2016, 9(1): 22.
[32] GOBIVEL K, VIJAYSEKAR K S.Assessment of Johnson-Cook Material Constitutive Parameters in Finite Element Simulation of Machining Al-SiC Metal Matrix Composite[J]. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2023, 45(11): 567.
[33] LI Y M, ZHANG H, YUAN M N.Based on Genetic Algorithm to Analyze the Anti-Penetration Properties and Optimize the Structure of Ti-Al3Ti-Al Laminated Composites[J]. Frontiers in Materials, 2022, 9: 806020.
[34] ZHOU Q, FENG J R, CHEN P W.Numerical and Experimental Studies on the Explosive Welding of Tungsten Foil to Copper[J]. Materials, 2017, 10(9): 984.
[35] 米建宇, 黄飞, 李树清, 等. 基于SPH-FEM耦合算法的后混合磨料水射流冲击破岩数值模拟研究[J]. 振动与冲击, 2021, 40(16): 132-139.
MI J Y, HUANG F, LI S Q, et al.Numerical Simulation of Rock Breaking by Rear-Mixed Abrasive Water Jet Based on an SPH-FEM Coupling Algorithm[J]. Journal of Vibration and Shock, 2021, 40(16): 132-139.
[36] THONGKAEW K, WANG J, YEOH G H.Impact Characteristics and Stagnation Formation on a Solid Surface by a Supersonic Abrasive Waterjet[J]. International Journal of Extreme Manufacturing, 2019, 1(4): 045004.
[37] NOURAEI H, KOWSARI K, SAMAREH B, et al.Calibrated CFD Erosion Modeling of Abrasive Slurry Jet Micro-Machining of Channels in Ductile Materials[J]. Journal of Manufacturing Processes, 2016, 23: 90-101.
[38] KOWSARI K, NOURAEI H, SAMAREH B, et al.CFD-Aided Prediction of the Shape of Abrasive Slurry Jet Micro-Machined Channels in Sintered Ceramics[J]. Ceramics International, 2016, 42(6): 7030-7042.
基金
先进制造技术山西省重点实验室开放基金（XJZZ202401）; 安徽省教育厅安徽高校自然科学研究项目（2024AH050380）
PDF(11831 KB)
渝公网安备 50010702501715号 渝ICP备15012534号-3
