增材制造金属材料典型缺陷研究进展

Research progress of typical defects in additive manufactured metallic materials

摘要

增材制造是一种通过逐层沉积材料实现三维实体制备的近净成形技术，因其在制造复杂结构金属零件方面具有独特优势，已在航空航天、生物医疗和高端模具等关键领域获得广泛应用。然而，增材制造特有的成形过程也带来了与传统制造方法不同的缺陷特征，这些问题严重制约了成形零件的服役可靠性，成为该技术亟须解决的核心问题之一。本文系统总结了中国航发增材制造技术创新中心在增材制造金属材料缺陷方面的研究成果，重点阐述了孔洞、未熔合、夹杂及裂纹等典型缺陷的形貌特征、形成机制及其对力学性能的影响规律，并进一步分析了热等静压处理对缺陷闭合及力学性能的改善作用。针对当前研究存在的不足，本文建议从揭示缺陷形成机理与工艺映射关系、开发增材制造专用金属材料、建立面向零件服役要求的缺陷验收标准和研究智能化在线监测与闭环控制技术等方面开展研究，以进一步推动该领域的进步。

Abstract

Additive manufacturing is a near-net shaping technology that builds three-dimensional solid parts by depositing material layer by layer. It offers unique advantages in producing metal parts with complex structures. As a result，it has been widely used in key fields such as aerospace， biomedical and high-end mold manufacturing. However， the unique forming process of additive manufacturing introduces defect characteristics that differ from those in traditional manufacturing methods. These issues severely affect the service reliability of the formed parts and have become a critical challenge for the technology. This paper systematically summarizes the research findings of AECC Additive Manufacturing Technology Innovation Center on defects in additively manufactured metal materials. It focuses on the morphological features，formation mechanisms and effects on mechanical properties of typical defects such as holes， lack of fusion， inclusions and cracks. The paper also analyzes the role of hot isostatic pressing in closing defects and improving mechanical properties. To address current research gaps， it suggests further studies in several areas. These include revealing the relationship between defect formation mechanisms and process parameters，developing metal materials specifically for additive manufacturing，establishing defect acceptance standards based on part service requirements，and advancing intelligent online monitoring and closed-loop control technologies. These efforts aim to promote further progress of additive manufacturing.

关键词

增材制造 / 缺陷 / 孔洞 / 未熔合 / 夹杂 / 裂纹

Key words

additive manufacturing / defect / hole / lack of fusion / inclusion / crack

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基金资助

工业和信息化部新材料重大专项项目(2025 ZD0609800)