目的 研究Inconel 625合金CMT电弧熔丝增材过程中的显微组织演变与元素偏析行为,为优化工艺与提升构件性能提供理论指导。方法 采用有限元法计算电弧熔丝增材制造过程中的温度场分布,提取不同沉积层的温度梯度与冷却速度并引入相场模型,模拟微观组织演变及元素偏析行为,最终通过实验验证模型有效性。结果 随着沉积层数的增加,热累积效应显著增强,熔池最高温度从第1层的2 595.15 K升至第7层的2 877.15 K,温度梯度由307.9 K/mm降至101.1 K/mm,冷却速度从537.5 K/s降至176.4 K/s。枝晶生长经历4个阶段：平面晶、界面失稳、竞争生长与稳定生长。随着温度梯度与冷却速度降低,枝晶逐渐粗化,一次枝晶臂间距从28.0 μm增至38.9 μm,二次枝晶发育增强,元素偏析加剧,模拟结果与实验数据吻合。Nb元素在枝晶间富集,形成块状或链状分布的Laves相,分布于基体γ相中。实验测得基体γ相中Nb元素的质量分数约为2.64%,Laves相中Nb元素的质量分数约为22.0%;模拟结果预测Laves相中Nb元素质量分数约为24.38%,基体γ相中Nb元素质量分数约为1.95%,实验数据验证了模拟结果的准确性。结论 在Inconel 625合金CMT电弧熔丝增材制造过程中,热累积效应导致温度梯度与冷却速度下降,进而引起枝晶粗化和元素偏析。因此,通过调控工艺参数改变冷却速度,是抑制有害相析出、优化材料性能的关键。
Abstract
The work aims to explore the microstructural evolution and element segregation behavior during the CMT arc wire additive manufacturing process of Inconel 625 alloy, to provide theoretical guidance for optimizing processing parameters and enhancing component performance. The finite element method was employed to calculate the temperature field distribution during the arc wire additive manufacturing process. Temperature gradients and cooling rates at different deposition layers were extracted and integrated into a phase-field model to simulate the microstructural evolution and element segregation behavior. The accuracy of the simulation results was confirmed through experimental observations. As the number of deposition layers increased, the effects of thermal accumulation became more pronounced. The maximum molten pool temperature escalated from 2 595.15 K (Layer 1) to 2 877.15 K (Layer 7), while the temperature gradient and the cooling rate decreased from 307.9 K/mm to 101.1 K/mm and from 537.5 K/s to 176.4 K/s, respectively. Dendrite growth was observed in four stages: planar crystal, interfacial instability, competitive growth, and stable growth. As the temperature gradient and cooling rate decreased, dendritic structures progressively coarsened. The primary dendrite arm spacing expanded from 28.0 μm to 38.9 μm, with an increase in secondary dendrite development. The simulation results aligned well with the experimental data. Nb elements, enriched between dendrites, formed blocky or chain-like Laves phases distributed within the γ-phase matrix. Experimental measurements indicated an Nb content of approximately 2.64 wt% in the γ matrix and 22.0 wt% in Laves phases, while simulations predicted 1.95 wt% in the γ matrix and 24.38 wt% in Laves phases, thereby validating the precision of the simulation model. In conclusion, during the CMT arc wire additive manufacturing of Inconel 625 alloy, thermal accumulation reduces temperature gradients and cooling rates, resulting in dendritic coarsening and element segregation.
关键词
相场模拟 /
CMT电弧熔丝增材 /
枝晶间距 /
组织演变 /
元素偏析
Key words
phase-field simulation /
CMT arc wire additive manufacturing /
dendritic spacing /
microstructural evolution /
elemental segregation
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基金
国家自然科学基金（51705218）; 湖北省教育厅科学研究计划指导性项目（B2024073）; 博士科研启动基金（BK202303）; 湖北省科技人才服务企业项目（2025DJB012）; 2018年湖北省高等学校优秀中青年科技创新团队计划项目“高性能汽车粉末冶金零件关键制备技术研究及应用”（T201811）
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