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Chao Wang, Lilin Wang, Zhennan Wang, Xin Lin, Geng Liu, and Jie Su, Thermodynamics formation of oxides in L-PBF processed aluminum-deoxidized maraging steel and their effects on toughness, Int. J. Miner. Metall. Mater., (2026). https://doi.org/10.1007/s12613-025-3223-6
Chao Wang, Lilin Wang, Zhennan Wang, Xin Lin, Geng Liu, and Jie Su, Thermodynamics formation of oxides in L-PBF processed aluminum-deoxidized maraging steel and their effects on toughness, Int. J. Miner. Metall. Mater., (2026). https://doi.org/10.1007/s12613-025-3223-6
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激光粉末床熔融成形铝脱氧马氏体时效钢中氧化物的形成热力学及其对韧性的影响

摘要: 马氏体时效钢是一类兼具超高强度与良好韧性的高强钢,其性能对杂质元素,尤其是氧含量十分敏感。在激光粉末床熔融(L-PBF)增材制造过程中,粉末中的氧元素易形成氧化物夹杂,从而影响材料的力学性能。本文以铝脱氧马氏体时效钢为研究对象,选用两种氧含量不同的粉末:真空感应气雾化(VIGA)粉末(0.034wt% O)和等离子旋转电极法(PREP)粉末(0.016wt% O),系统研究了粉末氧含量对L-PBF成形材料中氧化物特征及其低温韧性的影响。结果表明,PREP试样中形成的Al2O3氧化物尺寸更细小且分布更弥散,其平均尺寸为(37 ± 11)nm,数量密度为7.6 × 1018 m−3;相比之下,VIGA试样中氧化物尺寸较大,为(59 ± 28)nm,数量密度为6.5 ×1018 m−3。由于氧化物尺寸及分布特征的差异,PREP试样表现出更优异的冲击韧性,其室温和−196°C低温冲击吸收功分别达到138 J和65 J,较VIGA试样分别提高53.3%和47.8%。进一步分析表明,较低的氧含量降低了氧化物的形核温度并减小了形核能垒,从而促进细小弥散氧化物的形成。基于L-PBF熔池快速热循环特征,建立了氧化物形核与演化的热力学模型,实现了不同氧含量条件下纳米氧化物尺寸及数量密度演化的预测。研究结果为增材制造马氏体时效钢的氧含量控制与粉末设计提供了理论依据。

 

Thermodynamics formation of oxides in L-PBF processed aluminum-deoxidized maraging steel and their effects on toughness

Abstract: Maraging steels are ultrahigh-strength, low-carbon steels requiring strict control of impurity elements to ensure optimal strength and toughness. This study aims to elucidate the role of oxygen content in controlling oxide inclusions and cryogenic toughness in laser powder bed fusion (L-PBF) fabricated maraging steels. Two types of powders were used: vacuum induction gas atomization (VIGA) powder with 0.034wt% oxygen and plasma rotating electrode process (PREP) powder with 0.016wt% oxygen. The PREP deposit exhibited finer and more dispersed Al2O3 inclusions (average size: (37 ± 11) nm; number density: 7.6 × 1018 m−3) compared to the VIGA deposit ((59 ± 28) nm; 6.5 × 1018 m−3). As a result, the PREP specimens demonstrated significantly improved impact toughness—138 J at 23°C and 65 J at −196°C—representing 53.3% and 47.8% increase over the VIGA specimens, respectively. This difference is due to the lower oxygen content in PREP, leading to lower-temperature nucleation with a reduced nucleation barrier. In addition to quantitatively evaluating the oxygen inclusion–toughness relationship, a thermodynamic model was developed to capture the nucleation and evolution of nanoscale oxides under the rapid thermal cycles characteristic of the L-PBF molten pool, which enables prediction of the size and number density evolution of oxide inclusions under different oxygen levels. These findings offer insights for oxygen-level control and powder design strategies in additive manufacturing of maraging steels.

 

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