激光粉末床熔融镍基高温合金中第二相演化机制与调控策略进展

doi:10.11900/0412.1961.2025.00209

金属学报

2026, Vol. 62

Issue (7): 1147-1162 DOI: 10.11900/0412.1961.2025.00209

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激光粉末床熔融镍基高温合金中第二相演化机制与调控策略进展

彭望君¹, 王长河², 杜大帆¹(

), 董安平¹(

), 陈彪³, 孙宝德¹

1 上海交通大学材料科学与工程学院上海市先进高温材料及其精密成形重点实验室上海 200240
2 上海工程技术大学材料科学与工程学院上海 201600
3 西北工业大学凝固技术全国重点实验室西安 710072

A Review on the Evolution Mechanisms and Regulation Strategies of Secondary Phases in Laser Powder Bed Fusion Nickel-Based Superalloys

PENG Wangjun¹, WANG Changhe², DU Dafan¹(

), DONG Anping¹(

), CHEN Biao³, SUN Baode¹

1 Shanghai Key Laboratory of Advanced High Temperature Materials and Precision Forming, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
2 School of Materials Science and Engineering, Shanghai University of Engineering Science, Shanghai 201600, China
3 State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi'an 710072, China

引用本文:

彭望君, 王长河, 杜大帆, 董安平, 陈彪, 孙宝德. 激光粉末床熔融镍基高温合金中第二相演化机制与调控策略进展[J]. 金属学报, 2026, 62(7): 1147-1162.
Wangjun PENG, Changhe WANG, Dafan DU, Anping DONG, Biao CHEN, Baode SUN. A Review on the Evolution Mechanisms and Regulation Strategies of Secondary Phases in Laser Powder Bed Fusion Nickel-Based Superalloys[J]. Acta Metall Sin, 2026, 62(7): 1147-1162.

全文: PDF(3250 KB) HTML

摘要:

激光粉末床熔融(LPBF)工艺凭借其高成形精度与复杂结构可制造性，为镍基高温合金带来新的组织设计范式，但其快速冷却与层间再加热导致第二相演化显著偏离传统工艺。本文系统总结了LPBF镍基合金中多类型第二相(γ′相、γ″相、拓扑密排(TCP)相、MC/M₂₃C₆碳化物及弥散氧化物)的形成和演化机制，构建了工艺参数→熔池→凝固亚结构→沉淀的因果框架，揭示了非平衡偏析和循环热历史引发的回溶、再析出与粗化序列，并阐明其在沿高度方向形成沉淀梯度中的作用。综合LPBF实验、后续热处理与多尺度模拟结果，归纳出稳定γ′/γ″相、抑制Laves/δ/TCP相的热处理窗口；指出碳化物与氧化物对晶界钉扎和高温稳定性的贡献及过度连续化导致的脆化风险；阐明γ′/γ″协同强化对蠕变/疲劳性能的提升以及γ″相向δ相转变的服役隐患。进一步讨论了热等静压、分级时效与扫描策略在沉淀相均匀化和缺陷控制中的协同作用。最后，提出了多相协同控制、跨尺度预测与过程-组织-性能一体化设计的关键挑战与发展路线。

关键词 ：镍基高温合金, 激光粉末床熔融, 热处理, 第二相, 演化机制

Abstract：

Laser powder bed fusion (LPBF) offers high forming precision and the ability to manufacture complex structures, providing a new paradigm for the microstructural design of nickel-based superalloys. However, the rapid cooling and interlayer reheating inherent to LPBF lead to significant deviations in the evolution of secondary phases compared with traditional processes. This study systematically reviews the formation and evolution mechanisms of various secondary phases (γ′ phase, γ″ phase, topologically close-packed (TCP) phase, MC/M₂₃C₆ carbides, and dispersed oxides) in LPBF-fabricated nickel-based alloys, and establishes a causal framework linking process parameters, melt pool behavior, solidification substructure, and precipitation. The study reveals that nonequilibrium segregation and cyclic thermal history induce dissolution, reprecipitation, coarsening sequences, and a precipitation gradient along the build direction. By integrating experimental, heat treatment, and multiscale simulation results, a heat treatment window is identified to stabilize γ′/γ″ phase and suppress Laves/δ/TCP phases. The contributions of carbides and oxides to grain boundary pinning and high-temperature stability, coupled with the risks of embrittlement associated with excessive coarsening, are discussed. The synergistic secondary effects of γ′/γ″ phase on creep and fatigue performance, along with the service risks arising from the transformation of γ″ phase into δ phase, are also elucidated. Furthermore, the cooperative effects of hot isostatic pressing, aging, and scanning strategies on precipitation homogenization and defect mitigation are examined. Finally, key challenges and future development paths in multiphase cooperative control, multiscale prediction, and integrated process-microstructure-property design are proposed.

Key words： nickel-based superalloy laser powder bed fusion (LPBF) heat treatment secondary phase evolution mechanism

收稿日期: 2025-07-29

ZTFLH:

TG132.3

基金资助:国家自然科学基金项目(52071205);凝固技术国家重点实验室开放课题项目(SKLSP202214)

通讯作者: 杜大帆，dafand@sjtu.edu.cn，主要从事高温合金精密铸造和增材制造研究；
董安平，apdong@sjtu.edu.cn，主要从事高温合金精密铸造和增材制造研究

作者简介: 彭望君，男，1991年生，博士

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https://www.ams.org.cn/CN/10.11900/0412.1961.2025.00209 或 https://www.ams.org.cn/CN/Y2026/V62/I7/1147

图1 激光粉末床熔融(LPBF)制造过程及第二相作用机制

图2 LPBF镍基高温合金第二相的形成与调控：形成路径示意图，相演变，及热处理调控[7,24,29,40]

表1 LPBF镍基高温合金的缺陷类型、成因及化学不均匀性(元素偏析)

图3 第二相形貌与分布特征[64,69,74,82,86]

图4 第二相分布和相演化规律[6,103~105]

图5 工艺参数-组织演化-性能响应三者之间的对应关系

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