Effect of interlayer spacing on the microstructure and mechanical properties of 2219 aluminum alloy by rod feed additive friction stir deposition
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摘要:
为了提高航天高强韧2219-T8铝合金的固相增材制造性能，采用搅拌摩擦沉积工艺分别制备了层间距为1 mm，1.5 mm和2 mm的单道多层沉积件，分析了层间距对沉积件微观组织和力学性能的影响. 结果表明，层间距从2 mm 减小到1 mm 时，沉积件的致密无缺陷区域从24.5 mm扩大到33 mm，材料结合更加充分；同时沉积件的晶粒明显细化，平均晶粒尺寸从 3.69 μm 减小到 2.27 μm；沉积件的硬度没有明显变化，整体上硬度梯度增大，但均质性更好；沉积件构建方向的抗拉强度和断后伸长率分别提高了26 MPa和3%，而纵向的力学性能变化不大. 当层间距为1 mm时，沉积件表现出最优的材料性能，屈服强度达122 MPa，抗拉强度达207 MPa，断后伸长率达7%，平均硬度达75.6 HV.
Abstract:In order to improve the solid phase additive manufacturing performance of aerospace high strength and toughness 2219-T8 aluminum alloy, single-channel multi-layer deposition parts with interlayer spacing of 1 mm, 1.5 mm and 2 mm were prepared by friction stir deposition process in this study. The effects of interlayer spacing on the microstructure and mechanical properties of the deposited parts were analyzed. The results show that when the interlayer spacing was reduced from 2 mm to 1 mm, the dense defect-free area of the deposited part was expanded from 24.5 mm to 33 mm, and the material bonding was more sufficient. At the same time, the grains of the deposited parts were obviously refined, and the average grain size was reduced from 3.69 μm to 2.27 μm. The hardness of the deposited parts did not change significantly, and the overall hardness gradient increased, but the homogeneity was better. The tensile strength and elongation of the deposited parts in the construction direction increased by 26 MPa and 3 %, respectively, while the longitudinal mechanical properties did not change much. When the interlayer spacing was 1 mm, the deposited parts show the best material properties, the yield strength was 122 MPa, the tensile strength was 207 MPa, the elongation after fracture was 7%, and the average hardness was 75.6 HV.
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图 5 拉伸试样示意图(mm)
Figure 5. Diagram of tensile specimen. (a) traverse direction specimen; (b) build direction specimen
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图 6 沉积层宏观形貌
Figure 6. Macroscopic morphology of sedimentary layer. (a) 1 mm; (b) 1.5 mm; (c) 2 mm; (d) deposition layer defects
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图 7 微观组织及晶粒尺寸分布
Figure 7. Microstructure and grain size distribution. (a) 1 mm interlayer spacing; (b) 1.5 mm interlayer spacing; (c) 2 mm interlayer spacing
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图 8 2219-T8母材SEM表征结果
Figure 8. SEM characterization results of 2219-T8 substrate. (a) low magnification SEM morphology; (b) high magnification SEM morphology; (c) EDS analysis results of coarse second phase; (d) EDS analysis results of fine second phase
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图 9 沉积层SEM表征结果
Figure 9. SEM characterization results of the deposition layer. (a) low magnification SEM morphology; (b) high magnification SEM morphology; (c) EDS analysis results of coarse second phase; (d) EDS analysis results of fine second phase
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图 10 不同层间距沉积层的显微硬度云图
Figure 10. Microhardness cloud diagram of deposited layers with different interlayer spacing. (a) 1 mm-top; (b) 1 mm-middle; (c) 1 mm-low; (d) 1.5 mm-top; (e) 1.5 mm-middle; (f) 1.5 mm-low; (g) 2 mm-top; (h) 2 mm-middle; (i) 2 mm-low
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图 11 拉伸试验结果(纵向)
Figure 11. Tensile test results of deposits with different layer spacings (longitudinal direction)
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图 12 拉伸试验结果(构建方向)
Figure 12. Tensile test results of deposits with different layer spacings (build direction)
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图 13 构建方向不同层间距拉伸试样的断口形貌
Figure 13. The fracture morphology of the tensile specimens in the building direction under different interlayer spacings. (a) 1 mm; (b) 1.5 mm; (c) 2 mm
表 1 铝合金的化学成分(质量分数，%)
Table 1 Chemical composition of 2219 aluminium ally
Cu Mn Si Zr Fe Mg Zn V Ti Al 5.8 ~ 6.8 0.2 ~ 0.4 ≤0.2 0.10 ~ 0.25 ≤0.3 0.04 0.1 0.05 ~ 0.15 0.02 ~ 0.10 余量 
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表 2 试验具体工艺参数
Table 2 Test the specific process parameters
层间距
s/mm转速
n/(r·min−1)横移速度
v1/(mm·min−1)送料速度
v2/(mm·min−1)1 450 280 120 1.5 450 280 140 2 450 300 195
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表 3 不同方向和层间距沉积层的力学性能
Table 3 Mechanical properties of deposited layers with different directions and interlayer spacings
试样 屈服强度
RP0.2/MPa抗拉强度
Rm/MPa断后伸长率
A(%)1 mm纵向 153.3 288.3 17.3 1.5 mm纵向 150.0 282.0 17.0 2 mm纵向 162.3 269.2 15.6 1 mm构建方向 122.0 207.3 7.0 1.5 mm构建方向 130.0 207.5 7.2 2 mm构建方向 138.3 181.0 4.2
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