CN103134599A - Method and system for real-time monitoring of molten bath state in direct molding process of laser metal - Google Patents
Method and system for real-time monitoring of molten bath state in direct molding process of laser metal Download PDFInfo
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Abstract
The invention discloses a method for real-time monitoring of a molten bath state in the direct molding process of laser metal. The method comprises a first step of obtaining monochrome radiation images in at least two directions of the molten bath and heat affecting areas of the molten bath in the direct molding process of the laser metal, a second step of actually measuring a temperature value of the molten bath or at least one point of places near to the molten bath to enable the temperature value to serve as a reference temperature, a third step of carrying out real-time processing on the collected radiation images and converting the monochrome radiation images to a grey-scale map, and a fourth step of carrying out temperature calibration on the grey-scale map by utilizing of the reference temperature, obtaining temperature values of points in the images according to a gray value-temperature value corresponding relation and establishing a three-dimensional shape and a temperature field of the molten bath and the heat affecting areas of the molten bath. The invention further discloses a system for real-time monitoring of the molten bath state in the direct molding process of the laser metal. According to the monitoring method and the system, the molten bath state can be monitored in a real time mode accurately, reliably and fully in the direct molding process of the laser metal.
Description
Technical field
The present invention relates to metal laser direct-forming process monitoring technical field, is status real time monitor method and system in molten bath in a kind of metal laser direct-forming.
Background technology
The metal laser direct-forming technology is a branch of high-power laser beam to be focused on surface of the work form the molten bath, metal powder is formed cladding layer by the coaxial molten bath of sending into, according to given route back and forth scanning laser beam produce layer by layer the new technology of metal parts entity by line.The Laser Direct Deposition technology has the mould of need not, the complex configuration part that can be shaped, can carry out to refractory metal the advantage such as directly manufacturing, be directly to make fast at present the most rising new manufacture in all multi-methods, have a wide range of applications in fields such as Aeronautics and Astronautics, automobiles.
In metal laser direct-forming, inside, molten bath exists strong convection current, heat transfer, transport phenomenon, is the interactional critical area of laser and metal powder.On macroscopic view, the molten bath state can be characterized by melting pool shape and size, bath temperature, molten bath and the characteristic parameters such as near temperature field, molten bath cooldown rate thereof.The processes such as the metallurgy in molten bath state and forming technology, crystallization, phase transformation have close contacting, and the stability of molten bath state in technological process directly has influence on dimensional accuracy and the mechanical property of metal laser direct-forming part.Therefore, be the key of controlling metal laser direct-forming technique to the Real-Time Monitoring of molten bath state.
Summary of the invention
The purpose of this invention is to provide a kind of can be accurately, reliably, all sidedly in the metal laser direct-forming process to the method for molten bath status real time monitor, diagnose and FEEDBACK CONTROL carrying out the Laser Direct Deposition process by this method.
In a kind of metal laser direct-forming provided by the invention, molten bath status real time monitor method is:
1) obtain monochromatic radiation image on the both direction at least of molten bath in metal laser direct-forming and heat-affected zone thereof by image sensing;
2) survey molten bath in described metal laser direct-forming by infrared measurement of temperature or near it temperature value of at least one point as the reference temperature;
3) radiation image that collects is processed in real time, the monochromatic radiation image transitions is become gray-scale map, and extract the characteristic parameter of melting pool shape and size;
4) utilize reference temperature equity gray-scale map to carry out temperature calibration, obtain the temperature value of each point in image according to gray-scale value-temperature value corresponding relation, set up thus 3D shape and the temperature field of molten bath and heat-affected zone thereof;
Described gray-scale value-temperature value relation is as follows:
Wherein: T represents the surface temperature in molten bath, and G represents the gray-scale value in the monochromatic radiation image, λ
0The corresponding centre wavelength of the expression monochromatic radiation image that gathers, C
2Be the Planck second radiation constant, M is to the electric current of CCD-grayvalue transition coefficient, photoelectric conversion factors, time shutter, emergent pupil diameter, as the relevant definite value of the coefficients such as square focal length, transmissivity of optical system, spectral response functions.
Preferably, described step 1) in, image sensing gathers the crater image on both direction at least, and one of them gathers Top-Side Pool Image, a collection molten bath side image.
Preferably, the reference temperature point that described step 2), infrared measurement of temperature is measured is positioned among described Top-Side Pool Image or side image.
In a kind of metal laser direct-forming of the present invention, molten bath state real-time detecting system comprises:
Image sensing cell is for the monochromatic radiation image on the both direction at least that obtains metal laser direct-forming molten bath and heat-affected zone thereof;
The infrared measurement of temperature unit, survey molten bath in described metal laser direct-forming or near it temperature value of at least one point as the reference temperature;
Graphics processing unit gathers described monochromatic radiation image and processes in real time, and the monochromatic radiation image transitions is become gray-scale map, and extracts the characteristic parameter of melting pool shape and size; Recycling reference temperature equity gray-scale map carries out temperature calibration, obtains the temperature value of each point in image according to gray-scale value-temperature value corresponding relation, sets up thus 3D shape and the temperature field of molten bath and heat-affected zone thereof;
Described gray-scale value-temperature value relation is as follows:
Wherein: T represents the surface temperature in molten bath, and G represents the gray-scale value in the monochromatic radiation image, λ
0The corresponding centre wavelength of the expression monochromatic radiation image that gathers, C
2Be the Planck second radiation constant, M is to the electric current of CCD-grayvalue transition coefficient, photoelectric conversion factors, time shutter, emergent pupil diameter, as the relevant definite value of the coefficients such as square focal length, transmissivity of optical system, spectral response functions.
Preferably, described image sensing cell comprises: video camera, image pick-up card, filter system, described video camera gather the monochromatic radiation image of molten bath and heat-affected zone thereof by filter system, and send described image processing system to by described image pick-up card.
Preferably, described infrared measurement of temperature unit is infrared thermometer.
Monitoring method of the present invention and system can be accurately, reliably, all sidedly in the metal laser direct-forming process to the molten bath status real time monitor, for technical foundation has been established in the closed-loop control that further realizes the metal laser direct-forming process.
Description of drawings
Fig. 1 metal laser direct-forming molten bath real-time monitoring system for state schematic diagram;
Front, Fig. 2 metal laser direct-forming process molten bath monochrome image;
Fig. 2 (a) original image;
Fig. 2 (b) reference temperature point position view;
The real-time processing flow chart of Fig. 3 metal laser direct-forming molten bath status image;
The positive processing procedure image in Fig. 4 metal laser direct-forming process molten bath;
Fig. 4 (a) bianry image;
Image after Fig. 4 (b) closed operation;
Image after Fig. 4 (c) rim detection;
Fig. 4 (d) characteristic dimension is extracted schematic diagram;
Front, Fig. 5 metal laser direct-forming process molten bath temperature distribution image.
Embodiment
Below in conjunction with accompanying drawing, the present invention is described in further detail:
As shown in Figure 1, this embodiment adopts the metal laser direct-forming of coaxial powder-feeding mode, and laser beam and powder interact, and successively scanning, form wallboard 3 in substrate 2, and substrate 2 is placed on worktable 1.Detection system comprises: image sensing cell, infrared measurement of temperature unit and graphics processing unit.Image sensing cell adopts has infrared thermometer 8, and this infrared thermometer 8 has infrared measurement of temperature instrument probe 4.Image sensing cell filter system 6, video camera 7 and image pick-up card 9.Graphics processing unit is computing machine 10.In embodiments of the present invention, each unit is specifically:
As shown in Figure 1, add filter system 6 before video camera 7, form image collecting device, two identical image collecting devices of this system disposition, be fixed on laser head and feeding head 5, gather respectively the monochromatic radiation image on front, molten bath and side, molten bath both direction, the view data that collects is delivered to control computer 10 through image pick-up card 9, carries out image processing and analysis.Infrared measurement of temperature instrument probe 4 is fixed on laser head and feeding head 5, becomes 15～30 ° of angles with it, measures in real time the surface temperature of molten bath or near its heat-affected zone as the reference temperature, and reference temperature point is in the field range of video camera 7.Infrared thermometer 8 is connected with computing machine 10 by the RS485 interface, and the surface temperature data that Real-time Measuring is got send software demonstration and temperature correction to.
In the present embodiment, shaping matrix 2 is 316 stainless steels, and size of foundation base is 80mm * 40mm * 20mm, and the shaping powder is 316 powder of stainless steel.Experiment adopting process parameter is: power 300W, and defocusing amount 9mm, floor height 0.15mm, 100 layers of the shaping numbers of plies, laser scanning speed 3mm/s, preheating scan cycle number of times 30, powder feeding rate 0.72g/min, reference temperature point is at distance laser spot 2mm place.
In metal laser direct-forming of the present invention, molten bath status real time monitor method specifically comprises the steps:
(1) obtain monochromatic radiation image on the both direction at least of molten bath in metal laser direct-forming and heat-affected zone thereof by image sensing cell;
In the metal laser direct-forming process, on substrate 2 surfaces, metal material melts rapidly, evaporates and even ionizes due to the high power laser light radiation, also produces plasma when forming the molten bath above the molten bath.The radiation of plasma and the reflection of material for laser light gather crater image to video camera 7 and form larger interference, easily produce the situation of CCD electric current output saturation.Before the filter system 6 that the present invention adopts is prepended to video camera 7 camera lenses, by the combined lens in filter system 6, radiant light from metal laser direct-forming processes zone is decayed and filtering, not only filtering photo plasma radiation and laser reflection intense laser interfere but also solved the problem of CCD electric current output saturation, make video camera 7 collect molten bath and heat-affected zone thereof monochromatic radiation image clearly.
In this embodiment, filter system 6 has two groups with video camera 7, be fixed in laser head on feeding head, the monochromatic radiation image of front, molten bath and side, molten bath in difference Real-time Collection metal laser direct-forming, the image that collects is stored among computing machine 10 with document form by image pick-up card 9, processes and the temperature calibration program for the image of subsequent step.
Fig. 2 (a) is depicted as the positive monochromatic radiation image in the molten bath that collects in this embodiment, and for sake of convenience, the image processing process of follow-up (2)-(4) step is all described as an example of this image example.
(2) survey molten bath in metal laser direct-forming by infrared measurement of temperature or near it temperature value of at least one point as the reference temperature;
The metal laser direct-forming process is the interaction process of laser, metal powder and the material of a complexity, infrared measurement of temperature is applied to the metal laser direct-forming process as contactless thermometry, just requires that infrared measurement of temperature device temperature measurement range is wide, spatial resolution is high, fast response time, antijamming capability be strong.In this embodiment, the IGA740-LO type optical fiber type high speed infrared temperature measurer 8 of employing Mikron company is as infrared measurement of temperature equipment, temperature-measuring range 500-2500 ℃, response times 6 μ s, wherein the built-in laser filter of LVO25 type standard probe 4 is got rid of on-the-spot laser emission interference.
LVO25 type standard probe 4 is fixed on laser head and feeding head, and alignment distance laser spot 2mm place namely gathers the surface temperature of this point as the reference temperature.Infrared thermometer 8 in the metal laser direct-forming process Real-time Collection to reference temperature value be sent to computing machine 10, for follow-up temperature calibration program.
Fig. 2 (b) is depicted as the position of the surface temperature reference point of high speed infrared temperature measurer 8 collections.
(3) process in real time by 10 pairs of radiation images that collect of computing machine, the monochromatic radiation image transitions is become gray-scale map, and extract the characteristic parameter of melting pool shape and size;
In this embodiment, image is processed in real time by the C++ program based on the Windows operating system design in computing machine 10 and is realized.Program circuit as shown in Figure 3.
For single acquisition to the monochromatic radiation image be handled as follows:
A) image filtering.The employing field method of average is carried out image filtering, the noise in the filtering image.
B) generate gray level image.Because adopt the CF8/5MX type industry B/W camera of KAPPA company in this embodiment, the gray level image that can directly collect.
C) Threshold segmentation is bianry image.Based on the characteristics of crater image, adopt the thresholding method of varimax that the molten bath object is extracted from the background of image.
D) edge detection algorithm extracts melt tank edge.Due to metal laser direct-forming, fall into unfused powder in the molten bath, form noise spot in the molten bath in bianry image, to extracting melt tank edge, extract the characteristic dimension in molten bath and bring interference.Therefore, first image is carried out closed operation here, remove noise, extract melt tank edge with the Roberts edge detection operator afterwards.
E) calculate area, the length in molten bath.In this embodiment, utilize bianry image to calculate the pool size characteristic parameter by edge detection algorithm in program take pixel as unit.In Top-Side Pool Image, calculate molten bath area, length and width, in the side image in molten bath, calculate the height in molten bath.
Image in image processing process as shown in Figure 4.
(4) utilize reference temperature to carry out temperature calibration to gray-scale map, try to achieve the temperature value of each point in image according to gray-scale value in radiation theory-temperature value corresponding relation;
This step is completed by program as shown in Figure 3 equally.
Utilizing reference temperature is that this scaling method is a kind of real-time scaling method to the outstanding feature that gray-scale map carries out temperature calibration.In the prior aries such as dual wavelength infrared image two-color thermometry, usually adopt blackbody radiation to carry out temperature calibration, this scaling method process is complicated, and cost is high, needs to complete staking-out work before carrying out the metal laser direct-forming process monitoring.Scaling method of the present invention adopts reference temperature that the gray-scale map of synchronization is demarcated, and real-time is good, and accuracy is high.
Described gray-scale value-temperature value relation is as follows:
Wherein: T represents the surface temperature in molten bath, and G represents the gray-scale value in the monochromatic radiation image, λ
0The corresponding centre wavelength of the expression monochromatic radiation image that gathers, C
2Be the Planck second radiation constant, M is to the electric current of CCD-grayvalue transition coefficient, photoelectric conversion factors, time shutter, emergent pupil diameter, as the relevant definite value of the coefficients such as square focal length, transmissivity of optical system, spectral response functions.
The process that calculate in gray-scale map temperature calibration and temperature field is as follows:
A) the interior average gray value of reference point scope that calculates as shown in Figure 2 is G;
B) with the phase that gathers the monochromatic radiation image in the same time, read the temperature value T that infrared thermometer records;
C) with the gray-scale value G in upper two steps and temperature value T substitution gray scale temperature relation, calculate the definite value M in formula;
D) with the gray-scale value G of all points of the monochromatic radiation image that collects
ijGray scale temperature relation formula in substitution following formula monochromatic radiation image calculates the temperature value T that points all in the monochromatic radiation image represents
ij
G wherein
ijThe gray-scale value of each pixel in expression monochromatic radiation image, T
ijThe temperature value of expression corresponding pixel points representative, λ
0The corresponding centre wavelength of the expression monochromatic radiation image that gathers, C
2Be the Planck second radiation constant, M is at c) definite value that obtains in the step.
(5) according to melting pool shape obtained above and dimensional data, image temperature data, set up 3D shape and the temperature field of molten bath and heat-affected zone thereof.
In this embodiment, video camera is taken the monochromatic radiation image of front, molten bath and side, molten bath both direction, suppose that the molten bath is identical two sides, and do smoothing processing on the 3rd direction, the data and the temperature field that utilize the both direction epigraph to process, 3D shape and the temperature field of reconstruction molten bath and heat-affected zone thereof.Be income effect figure as shown in Figure 6.
Claims (6)
1. molten bath status real time monitor method in a metal laser direct-forming, comprise the steps:
1) obtain monochromatic radiation image on the both direction at least of molten bath in metal laser direct-forming and heat-affected zone thereof by image sensing;
2) survey molten bath in described metal laser direct-forming by infrared measurement of temperature or near it temperature value of at least one point as the reference temperature;
3) radiation image that collects is processed in real time, the monochromatic radiation image transitions is become gray-scale map, and extract the characteristic parameter of melting pool shape and size;
4) utilize reference temperature equity gray-scale map to carry out temperature calibration, obtain the temperature value of each point in image according to gray-scale value-temperature value corresponding relation, set up thus 3D shape and the temperature field of molten bath and heat-affected zone thereof;
Described gray-scale value-temperature value relation is as follows:
Wherein: T represents the surface temperature in molten bath, and G represents the gray-scale value in the monochromatic radiation image, λ
0The corresponding centre wavelength of the expression monochromatic radiation image that gathers, C
2Be the Planck second radiation constant, M is to the electric current of CCD-grayvalue transition coefficient, photoelectric conversion factors, time shutter, emergent pupil diameter, as the relevant definite value of the coefficients such as square focal length, transmissivity of optical system, spectral response functions.
2. the method for claim 1, is characterized in that, described step 1) in image sensing gather crater image on both direction at least, one of them gathers Top-Side Pool Image, a collection molten bath side image.
3. method as claimed in claim 2, is characterized in that, described step 2) in the reference temperature point measured of infrared measurement of temperature be positioned among described Top-Side Pool Image or side image.
4. molten bath real-time detection device for state in a metal laser direct-forming, is characterized in that, comprising:
Image sensing cell is for the monochromatic radiation image on the both direction at least that obtains metal laser direct-forming molten bath and heat-affected zone thereof;
The infrared measurement of temperature unit, survey molten bath in described metal laser direct-forming or near it temperature value of at least one point as the reference temperature;
Graphics processing unit gathers described monochromatic radiation image and processes in real time, and the monochromatic radiation image transitions is become gray-scale map, and extracts the characteristic parameter of melting pool shape and size; Recycling reference temperature equity gray-scale map carries out temperature calibration, obtains the temperature value of each point in image according to gray-scale value-temperature value corresponding relation, sets up thus 3D shape and the temperature field of molten bath and heat-affected zone thereof;
Described gray-scale value-temperature value relation is as follows:
Wherein: T represents the surface temperature in molten bath, and G represents the gray-scale value in the monochromatic radiation image, λ
0The corresponding centre wavelength of the expression monochromatic radiation image that gathers, C
2Be the Planck second radiation constant, M is to the electric current of CCD-grayvalue transition coefficient, photoelectric conversion factors, time shutter, emergent pupil diameter, as the relevant definite value of the coefficients such as square focal length, transmissivity of optical system, spectral response functions.
5. system as claimed in claim 4, it is characterized in that, described image sensing cell comprises: video camera, image pick-up card, filter system, described video camera gathers the monochromatic radiation image of molten bath and heat-affected zone thereof by filter system, and sends described image processing system to by described image pick-up card.
6. system as claimed in claim 4, is characterized in that, described infrared measurement of temperature unit is infrared thermometer.
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