CN105044154A - Material defect infrared thermal imaging detection and targeted elimination method in laser metal forming - Google Patents
Material defect infrared thermal imaging detection and targeted elimination method in laser metal forming Download PDFInfo
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- CN105044154A CN105044154A CN201510378421.2A CN201510378421A CN105044154A CN 105044154 A CN105044154 A CN 105044154A CN 201510378421 A CN201510378421 A CN 201510378421A CN 105044154 A CN105044154 A CN 105044154A
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Abstract
The invention discloses a material defect infrared thermal imaging detection and targeted elimination method in laser metal forming. In laser metal forming, after layers with fixed interlayers are produced, a workbench is controlled by a computer to move in the horizontal direction at a constant speed, thus an infrared thermal imaging detection lens can move in the horizontal direction above the imaging plane and carries out non-contact scanning and photo-taking by utilizing the residual heat of metal parts, and then the infrared thermal imaging detection images are analyzed online to calculate the coordinate azimuth of the metal forming plane. The computer control laser beams to target-melt the detected defects so as to eliminate the defects; after laser re-melting, an infrared thermal imaging detector is used to re-examine the metal forming surface to confirm the defect elimination effect. The provided method solves the problems that the defects on micro materials cannot be detected online and eliminated, effectively improves the using performance and service safety of laser formed metal parts, and reduces the risk of fatigue breakage.
Description
Technical field
The invention belongs to laser metal and increase material manufacturing technology field, be specifically related to material defect infrared thermal imaging in a kind of laser metal forming and detect and target removing method.
Background technology
The manufacture of laser metal increasing material is commonly called as laser metal 3D and prints, also known as laser metal forming.Because laser metal increases the process that material manufacture process is a multiple physical field coupling, in forming process, temperature variation is violent, easily occur the small material defect such as crackle, bubble, slag inclusion, interlayer hole, nodularization in formation of parts, the range of size of material defect is usually from tens microns to hundreds of micron.Material defect in metal parts may affect the usability of part on the one hand; On the other hand, even if do not affect usability at the part initial stage of being on active service, but under the long term of alternate load, the tiny flaw such as crackle can be expanded gradually, finally likely causes fatigue break accident.Particularly at aerospace field, once there is the fatigue break accident of important meals parts, catastrophic consequence will be caused.At present both at home and abroad metal increases the research of material manufacturing defect Test and control, still mainly concentrates on and carries out on-line checkingi and FEEDBACK CONTROL to reduce in the physical dimension defect of part to molten bath physical parameter.For the small material defect such as crackle, bubble, also there is no effective on-line checkingi and removing method at present.
Summary of the invention
The object of this invention is to provide material defect infrared thermal imaging in a kind of laser metal forming to detect and target removing method, infrared thermal imaging detection technique is utilized in laser metal forming, detect the material defect on surface and nearly surface in metal forming online, and adopt laser target to eliminate defect to the method for remelting, solve prior art cannot carry out on-line checkingi and elimination problem to small material defect.
The technical scheme that the present invention takes is, in a kind of laser metal forming, material defect infrared thermal imaging detects and target removing method, implements according to following steps:
Step 1, in the side of laser formation machine powder-feeding nozzle, infrared thermal imaging detector is set, in laser metal forming, when often having made the number of plies of fixed intervals, suspend and make, control worktable by computing machine and at the uniform velocity move in the horizontal direction, make the camera lens of the infrared thermal imaging detector being fixed on powder-feeding nozzle side utilize the remaining temperature of metal parts, above shaping plane, in the horizontal direction non-contact scanning is carried out to metal forming surface, and taken pictures in metal forming surface; On-line analysis is carried out to the infrared thermal imaging detected image photographed, and calculates the planimetric coordinates orientation of defect in conjunction with the motion track of the relative worktable in optical center, and this planimetric coordinates orientation is fed back to computing machine;
Step 2, computing machine, according to the planimetric coordinates orientation of fault location, controls laser beam and carries out target remelting to eliminate defect to the defect detected; Again by infrared thermal imaging detector, metal forming surface is rechecked after target remelting terminates, if go back defectiveness to proceed laser target to remelting, if there is no defect, continue the making of lower one deck.
Step 1 carries out on-line analysis to the infrared thermal imaging detected image photographed, specifically implement according to following steps: be (m when the camera lens of infrared thermal imaging detector is taken pictures by the coordinate of the optical center of computing machine Real-time Feedback in shaping plane, n), metal forming surface coordinate initial point is positioned at the worktable lower left corner, the pixel initial point of infrared thermal imaging detected image is positioned at the image upper left corner, the horizontal range of pixel initial point distance optical center is respectively x and y, and the length dimension that each pixel represents in shaping plane is PL;
Each pixel of the BMP image of s × t pixel of at every turn taking pictures obtained can represent with the matrix RG of a s × t.The GetPixel function provided with vc++2010 obtains the rgb value of each pixel successively according to the pixel order in BMP image and judges, if the G value of rgb value of the pixel that the i-th row j arranges and B value are all higher than 220 in image, namely judge that this pixel is defect point, then by the (i of matrix RG, j) value of individual element composes 1, otherwise the value of (i, j) individual element of matrix RG composes 0.After all elements assignment in matrix RG completes, then to find out all values in matrix RG be the element of 1, according to the grid bearing (X, Y) of following formulae discovery defect on metal forming surface:
X＝m-x+i×PL，Y＝n-y-j×PL。
The present invention also has following characteristics:
Preferably, the number of plies of fixed intervals is 1-10 layer.
Preferably, laser metal increases the thickness in material manufacture is 0.02-0.2mm.
Preferably, the resolution of infrared thermal imaging detector is 384 × 288 pixels, and the camera lens of employing is 0.5 times of micro-lens.
Preferably, the distance on infrared thermal imaging detector lens and metal forming surface is 5-10cm.
Preferably, taken pictures as the every inswept 2-10cm of camera lens of infrared thermal imaging detector in metal forming surface
2take pictures once.
Preferably, laser target to the laser power of remelting be the 1-1.5 of laser metal forming power doubly.
The invention has the beneficial effects as follows: method of the present invention is in laser metal forming, make use of infrared thermal imaging detection technique, automatic on-line detects the material defect on metal forming surface and nearly surface, and adopt laser target to eliminate defect to the method for remelting, solve prior art cannot carry out on-line checkingi and elimination problem to small material defect.Method of the present invention can effectively improve the key mechanics performances such as the fatigue strength of Laser Fabricating Metal Components, for the usability and the service safety that improve Laser Fabricating Metal Components, the risk reducing fatigue break has great importance, at industrial fields such as Aero-Space, precision manufactureing, automobile makings, have broad application prospects.
Accompanying drawing explanation
Fig. 1 is the schematic flow sheet of the detection of material defect infrared thermal imaging and target removing method in laser metal forming of the present invention;
Fig. 2 is the schematic diagram that in the present invention, in laser metal forming, material defect infrared thermal imaging detects;
Fig. 3 is the schematic diagram that in the present invention, in laser metal forming, material defect target is eliminated.
In figure, 1. computing machine, 2. data line, 3. material defect, 4. infrared thermal imaging detector, 5. powder-feeding nozzle, 6. metal parts, 7. worktable, 8. laser beam.
Embodiment
Below in conjunction with the drawings and specific embodiments, the present invention is described in further detail.
The invention provides material defect infrared thermal imaging in a kind of laser metal forming to detect and target removing method, with reference to Fig. 1, is idiographic flow schematic diagram.
Step 1, in laser metal forming, when often having made the number of plies of fixed intervals, suspend and make, control worktable 7 by computing machine 1 at the uniform velocity to move in the horizontal direction, make the camera lens of the infrared thermal imaging detector 4 being fixed on powder-feeding nozzle 5 side carry out non-contact scanning along X, Y horizontal direction above the shaping plane of metal parts 6, detect the material defect 3 on profiled surface and nearly surface.By infrared thermal imaging detector lens, taken pictures in metal forming surface, and on-line analysis is carried out to infrared thermal imaging detected image, in detected image, namely the R value of rgb value and G value are all judged to be defect higher than the pixel of 220, the arithmetic system of computing machine 1 calculates the grid bearing of defect 3 in shaping plane according to the camera lens of infrared thermal imaging detector 4 relative to the grid bearing of defect pixel point in view picture figure in the motion track of worktable 7 and infrared thermal imaging detected image, and this planimetric coordinates orientation is fed back to the control system of computing machine 1 by data line 2.During infrared detection, the structure of each service part is shown in Fig. 2.
Step 2, controls laser beam 8 by the control system of computing machine 1 and carries out target remelting to eliminate defect to the defect 3 detected.Again rechecked by the shaping plane of camera lens 4 pairs of metal parts 6 of infrared thermal imaging detector after target remelting terminates, if go back defectiveness, proceed target and eliminate, if there is no defect, continue the making of lower one deck.During target elimination defect, the structure of each service part is shown in Fig. 3.
Step 1 carries out on-line analysis to the infrared thermal imaging detected image photographed, specifically implement according to following steps: be (m when the camera lens of infrared thermal imaging detector is taken pictures by the coordinate of the optical center of computing machine Real-time Feedback in shaping plane, n), metal forming surface coordinate initial point is positioned at the worktable lower left corner, the pixel initial point of infrared thermal imaging detected image is positioned at the image upper left corner, the horizontal range of pixel initial point distance optical center is respectively x and y, and the length dimension that each pixel represents in shaping plane is PL;
Whether each pixel of the BMP image of s × t pixel of at every turn taking pictures obtained is that defect can represent with the matrix RG of a s × t.The GetPixel function provided with vc++2010 obtains the rgb value of each pixel successively according to the pixel order in BMP image and judges, if the G value of rgb value of the pixel that the i-th row j arranges and B value are all higher than 220 in image, namely judge that this pixel is defect point, then by the (i of matrix RG, j) value of individual element composes 1, otherwise the value of (i, j) individual element of matrix RG composes 0.After all elements assignment in matrix RG completes, then to find out all values in matrix RG be the element of 1, according to the grid bearing (X, Y) of following formulae discovery defect on metal forming surface:
X＝m-x+i×PL，Y＝n-y-j×PL。
The number of plies of above-mentioned fixed intervals can be 1-10 layer.
The thickness that above-mentioned laser metal increases material manufacture can be 0.02-0.2mm.
Preferably, the resolution of infrared thermal imaging detector is 384 × 288 pixels, i.e. s=384, t=288, and the camera lens of employing is 0.5 times of micro-lens.The distance on infrared thermal imaging detector lens and metal forming surface can be 5-10cm.
Taken pictures as the every inswept 2-10cm of infrared thermal imaging detector lens in metal forming surface
2take pictures once.
Preferably, laser target to the laser power of remelting be the 1-1.5 of laser metal forming power doubly.
Embodiment
Make by Laser Melting Deposition forming technology the TA15 titanium alloy rectangular parallelepiped that length, width and height are 100 × 30 × 50mm, the workpiece lower left corner (x, y) grid bearing in shaping plane is (100mm, 100mm).The forming parameters adopted is: laser power 300W, sweep velocity 10mm/s, powder feeding rate 4.9g/min, laser spot diameter 0.5mm, and thickness is 0.1mm, overlapping rate 40%, and scan mode is reciprocating scanning.When making this material, adopt method of the present invention to carry out material defect on-line checkingi and target elimination, concrete steps are as follows:
Step 1,5 layers are often made, suspend and make, control worktable 7 by computing machine 1 at the uniform velocity to move in the horizontal direction with the speed of 20mm/s, make the camera lens of the infrared thermal imaging detector 4 being fixed on powder-feeding nozzle 5 side carry out the reciprocating scanning of noncontact along X, Y horizontal direction as shown in the figure above shaping plane, detect the material defect on profiled surface and nearly surface.The running parameter of the infrared thermal imaging detector that the present embodiment uses is: resolution 384 × 288 pixel, heat sensitivity≤± 0.05 DEG C, maximum frame rate 80hz, adopts 0.5 times of micro-lens, and the distance of distance of camera lens metal parts 6 profiled surface of infrared thermal imaging detector 4 is 5cm.The every inswept 2cm of camera lens of infrared thermal imaging detector 4
2suspend and move and take pictures once, the infrared thermal imaging detected image that on-line analysis photographs, the R value of the rgb value of pixel and G value are all judged to be material defect higher than the place of 220.The present embodiment carries out on-line analysis to infrared thermal imaging detected image after having made the 10th layer, and calculate the planimetric coordinates orientation of defect in conjunction with the motion track of the relative worktable 7 in optical center of infrared thermal imaging detector 4, and this planimetric coordinates orientation is fed back to computing machine 1.
The circular of grid bearing is as follows: shaping flat areal coordinate initial point is positioned at the worktable lower left corner, the infrared thermal imaging pixel initial point of BMP image generated of taking pictures is positioned at the image upper left corner, the horizontal range of distance optical center, the infrared thermal imaging shot region upper left corner (this respective pixel initial point) is: x is to 10mm, y to 5mm.The length dimension that each pixel represents in shaping plane is 0.0425mm.Whether each pixel of the BMP image of 384 × 288 obtained pixels of at every turn taking pictures is that defect can represent with the matrix RG of 384 × 288.The GetPixel function utilizing vc++2010 to provide obtains the rgb value of each pixel successively according to the pixel order in BMP image and judges, if the G value of rgb value of the pixel that the i-th row j arranges and B value are all higher than 220 in image, namely judge that this pixel is defect point, then by the (i of matrix RG, j) value of individual element composes 1, otherwise the value of (i, j) individual element of matrix RG composes 0.After all elements assignment in matrix RG completes, then to find out all values in matrix RG be the element of 1, to fall vacant the grid bearing be trapped in shaping plane according to these elements position calculation in a matrix.Such as, find RG (87,99), RG (88,99) in the present embodiment, the value of RG (265,147) is 1, show to have detected 3 defect points.The coordinate of optical center in shaping plane of the infrared thermal imaging detector 4 of this computer-chronograph feedback is (120.00mm, 115.00mm), RG (87,99) the x coordinate that the actual coordinate value of corresponding defect is is 120.00mm – 10mm+87 × 0.0425, and y coordinate is that (each pixel is equivalent to the actual range of 0.0425mm in 115.00 – 5mm-99 × 0.0425; The 10mm that calculating x coordinate time deducts and the 5mm that calculating y coordinate time deducts is the optical center of infrared thermal imaging detector 4 and the coordinate difference in the shot region upper left corner), result of calculation is RG (87,99) actual coordinate of the defect point represented is (113.70mm, 120.79mm).The coordinate figure that in like manner can calculate two other defect point is respectively (113.74mm, 120.79mm), (121.26mm, 103.75mm).The line number of RG (87,99), RG (88,99) two elements is adjacent and row are number identical in a matrix, and therefore in fact these two points constitute a larger defect.By data line, the planimetric coordinates orientation of 3 defect points is fed back to computing machine 1.
Step 2, controls laser beam 8 by computing machine 1 and moves to each fault location successively, carry out target remelting respectively to each defect.Laser power 300W during remelting, laser spot diameter 0.5mm, during defect repair, hot spot stops the remelting time is 0.1s.Again by the camera lens of infrared thermal imaging detector 4, metal forming surface is rechecked after 3 whole target remeltings of defect point terminate, do not find defect, continue the making of lower one deck.
Claims (8)
1. in laser metal forming, material defect infrared thermal imaging detects and a target removing method, it is characterized in that, implements according to following steps:
Step 1, in the side of laser formation machine powder-feeding nozzle, infrared thermal imaging detector is set, in laser metal forming, when often having made the number of plies of fixed intervals, suspend and make, control worktable by computing machine and at the uniform velocity move in the horizontal direction, make the camera lens of the infrared thermal imaging detector being fixed on powder-feeding nozzle side utilize the remaining temperature of metal parts, above shaping plane, in the horizontal direction non-contact scanning is carried out to metal forming surface, and taken pictures in metal forming surface; On-line analysis is carried out to the infrared thermal imaging detected image photographed, and calculates the grid bearing of defect on metal forming surface in conjunction with the motion track of the relative worktable in optical center, and this grid bearing is fed back to computing machine;
Step 2, computing machine, according to the planimetric coordinates orientation of fault location, controls laser beam and carries out target remelting to eliminate defect to the defect detected; Again by infrared thermal imaging detector, metal forming surface is rechecked after target remelting terminates, if go back defectiveness to proceed laser target to remelting, if there is no defect, continue the making of lower one deck.
2. in laser metal forming according to claim 1, material defect infrared thermal imaging detects and target removing method, it is characterized in that, described in step 1, on-line analysis is carried out to the infrared thermal imaging detected image photographed, specifically implement according to following steps: when the camera lens of infrared thermal imaging detector is taken pictures, the coordinate of optical center in shaping plane is (m, n), metal forming surface coordinate initial point is positioned at the worktable lower left corner, the pixel initial point of infrared thermal imaging detected image is positioned at the image upper left corner, the horizontal range of pixel initial point distance optical center is respectively x and y, the length dimension that each pixel represents in shaping plane is PL,
Each pixel of the BMP image of s × t pixel of at every turn taking pictures obtained represents with the matrix RG of a s × t, concrete grammar is: the rgb value obtaining each pixel with GetPixel function according to the pixel order in BMP image successively, if the G value of rgb value of the pixel that the i-th row j arranges and B value are all higher than 220 in image, then this pixel is defect point, and then by the (i of matrix RG, j) value of individual element composes 1, otherwise this pixel is not defect point, and (the i of then matrix RG, j) value of individual element composes 0, after all elements assignment in matrix RG completes, finding out all values in matrix RG is the element of 1, utilize following formulae discovery defect at the grid bearing (X on metal forming surface, Y):
X=m-x+i×PL，Y=n-y-j×PL。
3. in laser metal forming according to claim 1, material defect infrared thermal imaging detects and target removing method, and it is characterized in that, the number of plies of fixed intervals described in step 1 is 1-10 layer.
4. in laser metal forming according to claim 1, material defect infrared thermal imaging detects and target removing method, it is characterized in that, the thickness that laser metal described in step 1 increases in material manufacture is 0.02-0.2mm.
5. in a kind of laser metal forming according to claim 1, material defect infrared thermal imaging detects and target removing method, it is characterized in that, the resolution of infrared thermal imaging detector described in step 1 is 384 × 288 pixels, and the camera lens of employing is 0.5 times of micro-lens.
6. in a kind of laser metal forming according to claim 1, material defect infrared thermal imaging detects and target removing method, and it is characterized in that, the camera lens of infrared thermal imaging detector described in step 1 and the distance on metal forming surface are 5-10cm.
7. in a kind of laser metal forming according to claim 1, material defect infrared thermal imaging detects and target removing method, it is characterized in that, takes pictures as the every inswept 2-10cm of camera lens of described infrared thermal imaging detector described in step 1 to metal forming surface
2take pictures once.
8. in a kind of laser metal forming according to claim 1, material defect infrared thermal imaging detects and target removing method, it is characterized in that, laser target described in step 2 to the laser power of remelting be the 1-1.5 of laser metal forming power doubly.
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| CN111790910B (en) * | 2020-07-07 | 2021-09-28 | 南京理工大学 | Method for feeding back and adjusting defects of fused forming part of laser powder bed |
| CN112557445B (en) * | 2020-11-17 | 2022-04-12 | 华中科技大学 | Defect online detection method, device and system based on additive manufacturing |
| CN112557445A (en) * | 2020-11-17 | 2021-03-26 | 华中科技大学 | Defect online detection method, device and system based on additive manufacturing |
| CN113042749A (en) * | 2021-03-10 | 2021-06-29 | 南京理工大学 | Method for eliminating formation defect of melting near surface layer of laser powder bed in real time |
| CN113042749B (en) * | 2021-03-10 | 2022-07-12 | 南京理工大学 | Method for eliminating formation defect of melting near surface layer of laser powder bed in real time |
| CN113500213A (en) * | 2021-06-15 | 2021-10-15 | 南京航空航天大学 | Method and device for reducing internal pore defects of selective laser melting formed part |
| CN113523304A (en) * | 2021-06-15 | 2021-10-22 | 南京航空航天大学 | Method and device for reducing internal pore defects of selective laser melting formed part |
| CN113828779A (en) * | 2021-09-27 | 2021-12-24 | 吉林大学 | Laser repairing method for surface defects of high-entropy alloy prepared by powder metallurgy method |
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