CN107671288B - Additive manufacturing device and method - Google Patents
Additive manufacturing device and method Download PDFInfo
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- CN107671288B CN107671288B CN201710917246.9A CN201710917246A CN107671288B CN 107671288 B CN107671288 B CN 107671288B CN 201710917246 A CN201710917246 A CN 201710917246A CN 107671288 B CN107671288 B CN 107671288B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
- B22F10/368—Temperature or temperature gradient, e.g. temperature of the melt pool
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/10—Auxiliary heating means
- B22F12/17—Auxiliary heating means to heat the build chamber or platform
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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Abstract
The invention provides an additive manufacturing device and method. The device provided by the invention is characterized by comprising the following components: a material increase processing part; a high-speed imaging unit comprising: the camera moves synchronously with the additive processing head to obtain material image information; infrared temperature measurement portion contains: the temperature measuring head and the additive processing head move synchronously to obtain material temperature distribution information; an optical measuring part for detecting the surface defect and the forming size of the material to obtain detection information; an internal defect detecting section comprising: a probe head and a probe analyzer; the post-processing part is used for processing and processing the defective area of the material in a corresponding post-processing mode to eliminate the defect; the post-processing mode comprises the following steps: at least one of mechanical rolling, laser shock peening, and friction stir processing; and the control part controls the operation of the parts, acquires various information, determines the defect processing area, the post-processing path and the post-processing mode based on the information, and controls the post-processing part to perform corresponding post-processing.
Description
Technical Field
The invention belongs to the field of additive manufacturing of metal materials, and particularly relates to an additive manufacturing device and a method for additive manufacturing by adopting the device.
Background
The additive manufacturing technology is a technology for realizing rapid forming manufacturing by utilizing a discrete accumulation principle according to a product three-dimensional model, can directly manufacture complex parts of various materials, and has wide industrial application prospect. However, the additive manufacturing has the characteristics of high temperature of a molten pool, rapid solidification and large temperature gradient, which can cause higher residual stress and metallurgical defects to be formed inside a formed workpiece, cause deformation, reduce mechanical properties, particularly fatigue properties, and influence service performance. The phenomenon is particularly prominent in the manufacturing process of complex and large-sized components, is a main technical bottleneck faced by the additive manufacturing technology of materials such as metal and the like, and hinders the industrial application of the metal additive manufacturing technology. Most of the existing technologies for solving the problems are focused on the optimization of process parameters, and the process optimization has certain improvement effect and cannot solve the problems fundamentally. Direct measurement of defects and real-time elimination of defects directly improve the performance of components, which is a fundamental solution to such problems.
The defect distribution condition is monitored in real time through online nondestructive testing, reference is provided for optimizing subsequent processes, and the method is an important way for improving the processing quality. The existing defect measurement technologies are more, such as an X-ray nondestructive testing technology, a neutron diffraction testing technology, an ultrasonic testing technology and the like, but the existing defect measurement technologies are less applied to the additive manufacturing process, and are mostly offline measurement. The only few online additive monitoring technologies (201710418485. X, 201610436562. X) are only limited to judging whether defects exist, and no clear technical route exists for the subsequent elimination of the existing defects. The material increase manufacturing cost is high, and the sample with defects is basically equal to scrap, so that after the defects are detected, a post-processing method is adopted to eliminate the defects, and the method is a fundamental way for improving the material increase manufacturing quality and manufacturing qualified parts.
201010147632.2 combines a mechanical rolling process with plasma arc additive manufacturing, applies mechanical contact force directly on the deposit to improve stress and deformation and precisely control the topography of the deposit. The technology has the advantage of low cost, but can not generate obvious strengthening effect on materials. The short pulse laser shock peening technology can generate a processing hardened layer and induce residual compressive stress on the surface of an acting component, the acting depth can reach several millimeters, and meanwhile, the derived dynamic strain aging effect enables high-density dislocation and precipitated phase to be generated inside the material to form pinning dislocation, so that the mechanical property of the material is improved. Because the action range of the laser beam is small, the processing method has the characteristics of accurate processing position and small action range. 201610661086.1 has been proposed to apply this technique in selective laser Sintering (SLM). However, the two technologies do not treat the local area where the defect exists, but integrally treat the whole deposition layer, so that the processing time is greatly prolonged, and the efficiency of additive manufacturing is greatly reduced. In addition, a friction stir processing technique derived from friction stir welding is used to generate thermoplastic flow by stirring, inhibit interface defects such as pores and cracks, form recrystallization, refine grain size, and improve mechanical properties. When a stirring head with a larger size is adopted, the technology has large processing area and relatively higher processing efficiency. Therefore, the mechanical rolling, laser shock strengthening and surface stirring treatment technologies can be used for optimizing the forming and structure performance of the metal component, and improving the surface hardness, wear resistance, corrosion resistance and fatigue life of the component. The above technologies are independently developed, and methods and equipment for organically applying a defect detection technology, a laser shock peening technology or a surface stirring friction technology to additive manufacturing and selectively performing post-treatment on local regions of defects do not exist.
Disclosure of Invention
The present invention has been made to solve the above problems, and an object of the present invention is to provide an efficient high-quality additive manufacturing apparatus and a method for additive manufacturing using the same.
In order to achieve the above object, the present invention adopts the following aspects.
< additive manufacturing apparatus >
The present invention provides an additive manufacturing apparatus, characterized by comprising: an additive processing portion comprising: the high-energy beam generator generates high-energy beams which are transmitted to the additive machining head, the additive machining head moves according to a set movement path, and materials to be machined are melted to sinter and prepare a deposition layer; a high-speed imaging unit comprising: the camera and the additive processing head synchronously move to shoot images of the material processing forming condition to obtain material image information; infrared temperature measurement portion contains: the temperature measuring head and the additive processing head synchronously move to detect the temperature distribution condition of the material to obtain the temperature distribution information of the material; a drive section including: the three-dimensional motion mechanism comprises a first mechanical arm, a second mechanical arm and a three-dimensional motion mechanism; the front end of the first mechanical arm is used for installing the additive machining head, the camera and the temperature measuring head and driving the additive machining head, the camera and the temperature measuring head to move synchronously; an optical measuring part for detecting the surface defect and the forming size of the material to obtain detection information; an internal defect detecting section comprising: the detector head is close to the sediment layer for surface scanning, and the detector analyzes and determines the type and position of the defect in the sediment layer according to the scanning condition of the detector head; the moving end of the three-dimensional moving mechanism is used for mounting the detecting head and driving the detecting head to move; the post-processing part is used for processing the material defect area by adopting a corresponding post-processing mode and comprises the following steps: the post-processing head can move to be close to the upper surface of the material defect area and gradually carry out defect elimination processing on the material defect area; the post-processing mode comprises the following steps: at least one post-treatment mode of mechanical rolling treatment, laser shock strengthening treatment and stirring friction processing treatment; the front end of the second mechanical arm is used for installing the post-processing head and driving the post-processing head to move; the control part is used for controlling the operation of the material adding processing part, the high-speed shooting part, the infrared temperature measuring part, the first mechanical arm, the optical measuring part and the internal defect detecting part, acquiring material image information, material temperature distribution information, detection information, defect type and position information, judging whether defects exist or not and whether the defects can be eliminated or not based on the information, determining a defect processing area, a post-processing path and a post-processing mode corresponding to each area under the condition that the defects can be eliminated, controlling the post-processing part to follow the corresponding post-processing path and processing each defect processing area by adopting the corresponding post-processing mode; in the case of the presence of unerasable defects, the process is stopped and an alarm is given.
The additive manufacturing apparatus according to the present invention may further include: the control section lets the tester input the material type of the material to be processed, and determines the post-processing manner based on the material type as follows: in the case that the material type belongs to metal material and the width of the deposition layer is more than 2mm, a mechanical rolling processing mode is adopted to control a mechanical roller in the post-processing head to perform deposition layer treatmentUnder the condition that the material type belongs to a high-strength metal material, a laser shock strengthening treatment mode is adopted to control a restraint layer of a laser shock head in a post-treatment processing head to cover a flat deposition layer, a laser beam penetrates through the restraint layer to generate plasma shock waves to shock the deposition layer, so that the material is plastically deformed, the pore defects and the stress concentration in the deposition layer are eliminated, the material of the deposition layer is strengthened, the walking speed range of the laser shock head is 0.5-5m/min, and the laser power density is 0.5 ~ GW/cm2Under the condition that the material type belongs to a low-strength nonferrous metal material, a stirring friction processing mode is adopted, a stirring head in a post-processing head is controlled to stir the material, the defects of internal geometric shapes are eliminated, the rotating speed of the stirring head is 1500 ~ 2000 rpm for aluminum alloy/magnesium alloy, 2000 ~ 3000 rpm for copper alloy, and the stirring depth is equal to the depth of a deposition layer, and under other conditions, a mechanical rolling processing mode is selected.
The additive manufacturing apparatus according to the present invention may further include: under the condition of adopting a friction stir processing mode, when the thickness of a deposition layer is less than 5mm, the processing walking speed of the stirring head is not more than 0.8m/min for the aluminum alloy magnesium alloy material, and the processing walking speed of the stirring head is not more than 0.5m/min for the copper alloy material.
The additive manufacturing apparatus according to the present invention may further include: under the conditions that the defects of a deposition layer cannot be eliminated by adopting a mechanical rolling mode, the flatness error of the upper surface of the deposition layer is more than 1mm, and the material is titanium alloy, high-strength steel or high-temperature alloy, a laser shock strengthening treatment mode is further adopted; and under the condition that the defects of the deposition layer cannot be eliminated by adopting a mechanical rolling mode, the flatness error of the upper surface of the deposition layer is more than 1mm, and the material is aluminum alloy, magnesium alloy or copper alloy, a stirring friction processing mode is further adopted.
The additive manufacturing apparatus according to the present invention may further include: the control section determines the defect processing area and the post-processing path as follows: in the case that the material defect is a plurality of defects or a single defect distributed in a local cluster shape, the diameter d of the smallest circumference containing all the defects of the local area is used for representing the characteristic size of the defect area, the defect processing area is the area contained by the circle, the post-processing path is a spiral line with the largest diameter d around the area, and the scanning starting position is the central point of the spiral line; in the case where the material defect is a multi-defect distributed in a chain shape, the length l and the width w of a long strip region covering all the defects in the local region are used to represent the characteristic size of the defect region, the defect processing region is the long strip region, the post-processing path is the long strip region, and the scanning start position is one of the end points of the long strip region.
The additive manufacturing apparatus according to the present invention may further include: the control part controls each part to carry out sintering, detection and post-treatment of the subsequent deposition layer under the condition of no defect.
The additive manufacturing apparatus according to the present invention may further include: after one or more settled layers are sintered, the control part controls the additive machining head, the high-speed camera part and the infrared temperature measuring part to stop working, and further controls the first mechanical arm to move the additive machining head, the camera and the temperature measuring head to the outside of a sintering working area; after the detection is finished, the control part controls the detection head to stop working and controls the three-dimensional motion mechanism to move the detection head to the outside of the sintering working area for resetting; and the control part also controls the post-processing part to stop working after all the defects are processed, and controls the second mechanical arm to move the post-processing head to the outside of the sintering working area for resetting.
The additive manufacturing apparatus according to the present invention may further include: the control part controls each part to circularly carry out sintering, detection and post-treatment of the deposition layer until the whole manufacturing process is finished.
The additive manufacturing apparatus according to the present invention may further include: the substrate bears a material to be processed, has a heating function, preheats a processing environment and inhibits stress concentration.
< additive manufacturing method >
The invention also provides an additive manufacturing method for additive manufacturing using additive manufacturing as claimed in any of claims 1 to 9, characterized in that:
transmitting the high-energy beam to an additive machining head by adopting a high-energy beam generator in the additive machining part, enabling the additive machining head to move according to a set movement path, and melting a material to be machined to prepare a deposition layer; the camera in the high-speed camera part and the additive processing head move synchronously to take images of the material processing and forming condition to obtain material image information; meanwhile, a temperature measuring head in the infrared temperature measuring part and the additive processing head move synchronously to detect the temperature distribution condition of the material to obtain the temperature distribution information of the material; detecting the surface defects and the forming sizes of the materials by adopting an optical measuring part to obtain detection information; driving a detecting head in the internal defect detecting part to be close to the sediment layer by adopting a three-dimensional motion mechanism for surface scanning, and analyzing and determining the type and the position of the defect in the sediment layer by adopting a detection analyzer according to the scanning condition of the detecting head; adopt post-processing portion to adopt corresponding post-processing mode to carry out processing to material defect area, include: driving the post-processing head to move to the upper surface close to the material defect area by adopting a second mechanical arm, and gradually carrying out defect elimination processing on the material defect area; the method comprises the following steps that a control part is adopted to control the operation of an additive processing part, a high-speed photographing part, an infrared temperature measuring part, a first mechanical arm, an optical measuring part and an internal defect detecting part, material image information, material temperature distribution information, detection information, defect type and position information are obtained, whether defects exist or not and whether the defects can be eliminated or not is judged based on the information, a defect processing area, a post-processing path and a post-processing mode corresponding to each area are determined under the condition that the defects can be eliminated, the post-processing part is controlled to follow the corresponding post-processing path, and the corresponding post-processing mode is adopted to process each defect processing area; in the case of the presence of unerasable defects, the process is stopped and an alarm is given.
Action and Effect of the invention
1) The invention realizes the online detection of defects, feedback control and selective post-treatment in the processing process, can ensure that the internal metallurgical defects and deformation of the processed component are controlled within a reasonable range, and greatly improves the finished product rate of the processed component;
2) according to the invention, selective mechanical rolling, laser shock strengthening or friction stir processing is carried out on the defect concentrated area of the additive deposition layer, so that the defects in the deposition layer are reduced or eliminated, the possibility of generation of defects, deformation and cracking of the component in the processing process is greatly reduced, the quality and the size precision of the component are ensured, meanwhile, due to the selective characteristic, the post-processing time is reduced, and the processing efficiency can be improved;
3) according to the invention, the additive deposition layer is subjected to real-time mechanical rolling, laser shock strengthening or friction stir processing, the plastic deformation generated by mechanical rolling is utilized to flatten the surface of the deposition layer, high-density dislocation is generated in the deposition layer by utilizing the dynamic strain aging effect of laser shock strengthening, the precipitation of a second strengthening phase is promoted, or the recrystallization effect of friction stir processing is utilized to refine grains, so that the mechanical performance of a processed component is improved.
Drawings
Fig. 1 is a block diagram of an additive manufacturing apparatus according to an embodiment of the present invention;
fig. 2 is a schematic structural diagram of an additive manufacturing apparatus according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of the scanning path of a clustered defect according to an embodiment of the present invention;
fig. 4 is a schematic diagram of scanning paths of chain-like distributed defects according to an embodiment of the present invention.
Detailed Description
The additive manufacturing apparatus and method according to the present invention will be described in detail below with reference to the accompanying drawings.
< example >
As shown in fig. 1, an additive manufacturing apparatus 100 includes: the device comprises a workbench 101, a substrate 102, an additive machining part 103, a high-speed photographing part 104, an infrared temperature measuring part 105, a driving part 106, an optical measuring part 107, an internal defect detecting part 108, a post-processing part 109 and a control part 110.
As shown in fig. 2, a substrate 102 is placed on a table 101, and is used for carrying a material to be processed, and has a heating function to preheat a processing environment and suppress stress concentration.
The additive processing portion 103 includes: a high energy beam generator 103a and an additive processing head 103 b. The high-energy beam generator 103a can generate a high-energy beam and transmit the high-energy beam to the additive processing head 103 b; the additive machining head 103b moves according to a set movement path, melts the material to be machined during the movement, and sinters to form a deposition layer S with a required shape and size. Here, the high-energy beam generator 103a may be a laser, an electron beam generating device, an arc power supply, a plasma arc power supply; correspondingly, the additive machining head 103b corresponds to a laser optical machining head, an electromagnetic lens, an arc welding gun and a plasma arc welding gun. In this embodiment, the additive processing head 103b further includes a device for filling material, such as a wire filling device or a powder feeding device.
The high-speed imaging unit 104 is for detecting a molten pool shape, and includes: a camera head 104a and an image processing transmitter. The camera 104a and the additive processing head 103b move synchronously to shoot images of the material processing and forming conditions; the image processing transmitter processes the shot data and transmits the processed material image information to the control section 110.
The infrared temperature measuring part 105 is used for detecting the temperature of a molten pool and comprises: temperature probe and processing transmitter. The temperature measuring head and the additive processing head 103b move synchronously to detect the temperature distribution condition of the material; the temperature processing transmitter processes the detected data and transmits the processed material temperature distribution information to the control part 110.
The driving unit 106 includes: a first robot arm 106a, a second robot arm 106b, and a three-dimensional motion mechanism 106 c. The first robot arm 106a and the second robot arm 106b are both mounted on the sides of the table 101, and both of them are capable of free movement at their front ends and cover the entire table 101. The three-dimensional movement mechanism 106c is mounted on the side of the table 101, and the movement end can freely move over the entire table 101.
The front end of the first mechanical arm 106a is used for installing the additive machining head 103b, the camera 104a and the temperature measuring head, and driving the additive machining head 103b, the camera 104a and the temperature measuring head to move synchronously.
The optical measuring section 107 is fixedly installed above the substrate 102 and faces the deposition layer S for performing detection of surface defects and formed dimensions of the material to obtain detection information.
The internal defect detecting unit 108 is for detecting internal defects of a material, and includes: a detection head 108a, a detection generator 108b, and a detection analysis transmitter. The detector head 108a performs a surface scan proximate the deposition layer S; the probe generator 108b transmits energy to the probe head 108 a; the probe analysis transmitter analyzes and determines the type and position of defects inside the deposited layer S based on the scanning conditions of the probe head 108a and transmits the defect type and position information to the control section 110. Here, the probe head 108a is an ultrasound or X-ray probe and, correspondingly, the probe generator 108b is an ultrasound or X-ray generator.
The moving end of the three-dimensional moving mechanism 106c is used for mounting the detecting head 108a and driving the detecting head 108a to move;
the post-processing part 109 is used for processing the material defect area by adopting a corresponding post-processing mode, and comprises: a post-processing head 109a and a post-processing device. The post-processing head 109a can move to close to the upper surface of the material defect area and perform post-processing on the material defect area step by step to eliminate defects, and in this embodiment, the post-processing head 109a includes: the three processing heads of the mechanical roller, the laser impact head and the stirring head are selected, and one processing head is selected according to a processing mode during each processing; the post-processing device is used for supplying energy to the post-processing head 109a and comprises a power supply, a pulse laser and a mechanical device; here, the post-processing method includes: at least one post-processing mode of mechanical rolling processing, laser shock strengthening processing and friction stir processing can be automatically switched.
The front end of the second robot arm 106b is used for mounting the post-processing head 109a and driving the post-processing head 109a to move;
the control part 110 is in communication connection with the additive processing part 103, the high-speed photographing part 104, the infrared temperature measuring part 105, the first mechanical arm 106a, the optical measuring part 107 and the internal defect detecting part 108, and is used for controlling the operations of the additive processing part 103, the high-speed photographing part 104, the infrared temperature measuring part 105, the first mechanical arm 106a, the optical measuring part 107 and the internal defect detecting part 108, acquiring material image information, material temperature distribution information, detection information, defect type and position information, judging whether defects exist or not and whether the defects can be eliminated or not based on the information, determining a defect processing area, a post-processing path and a post-processing mode corresponding to each area if the defects can be eliminated exist, controlling the post-processing part 109 to follow the corresponding post-processing path and process each defect processing area by; in the case of the presence of unerasable defects, the process is stopped and an alarm is given. In this embodiment, the control unit 110 is a computer, and is capable of displaying the processing status information in real time and allowing the operator to input or select corresponding information, that is, the control unit 110 can set the process parameters and the workflow of each device controlled by the control unit.
Based on the above structure, the method for performing additive manufacturing by using the additive manufacturing apparatus 100 includes:
(1) the high-energy beam generator 103a generates high-energy beams and transmits the energy to the additive processing head 103b, the additive processing head 103b melts materials to form a molten pool, the additive processing head 103b moves according to a set movement path under the drive of the first mechanical arm 106a, a deposition layer S is formed step by step, and deposition layers S of different shapes are obtained according to different movement paths;
(2) in the sintering process, the first mechanical arm 106a drives the camera 104a and the temperature measuring head to synchronously move along with the additive processing head 103b to perform molten pool movement, perform image shooting on the material processing forming condition to obtain material image information, and simultaneously, detect the temperature distribution condition of the material to obtain material temperature distribution information, and the information is fed back to the control part 110 by the image processing transmitter and the temperature processing transmitter;
(3) after one or more layers are sintered, the additive machining head 103b, the camera 104a and the temperature measuring head stop working and move out of the sintering working area along with the first mechanical arm 106 a;
(4) the optical measurement section 107 detects surface defects and a formed dimension, and feeds back the detected material temperature distribution information to the control section 110;
(5) the internal defect detecting part 108 starts to work, the detecting head 108a is close to the deposition layer S for surface scanning under the driving of the three-dimensional motion mechanism 106c, the detection analyzer analyzes and determines the defect type and position determination of the internal of the deposition layer S according to the scanning condition, and the information is fed back to the control part 110;
(6) after the detection is finished, the detection head 108a stops working and moves out of the sintering working area along with the three-dimensional motion mechanism 106 c;
(7) the control part 110 comprehensively analyzes the defect form and the specific position of the deposition layer S, and determines whether the defect can be eliminated according to the size and the number of the defects. If it is possible to eliminate, the defect position is determined, and the scan path (post-processing path), the scan range (defect processing area), and the post-processing method and process parameters of the post-processing head 109a are planned, thereby performing the post-processing step. If not, stopping processing and alarming. If no defect exists, the next layer is sintered. If the defect is a pore defect, when the size of the defect exceeds the effective working size of the post-processing head 109a, the defect is judged that the size cannot be eliminated, the processing is stopped, and an alarm is given; if the defects are small-sized pores or cracks and the like, carrying out the next post-treatment processing process;
(8) the control section 110 determines the optimal post-processing scan path and scan range: as shown in fig. 3, when the material defect is a local clustered multi-defect or a single defect, the diameter d of the smallest circle containing all the defects in the local area is used to represent the characteristic size of the defect area, the scanning area position is the area contained by the circle, the scanning path is a spiral line with the largest diameter d around the area, and the scanning starting position is the central point of the spiral line; as shown in fig. 4, in the multi-defects distributed in a chain manner, the length l and the width w of the strip-shaped region covering all the defects in the local region are used to represent the characteristic size of the defect region, the scanning region position is the strip-shaped region, the scanning path is the strip-shaped region, and the scanning start position is one of the end points of the strip-shaped region.
(9) The control section 110 determines the optimum post-processing method and process parameters according to the following classification:
the mechanical rolling technology is suitable for all metals and medium-sized and large-sized sedimentary layers S, such as sedimentary layers S with the width larger than 2mm, and the working process comprises the steps of applying mechanical force to the sedimentary surface by a mechanical roller to flatten the surface and compact the internal pore defects, wherein the parameters are selected from 1) the traveling speed range of a processing head is 0.5 ~ 5m/min, and 2) the pressing pressure of the processing head is dependent on the type of materials and generally larger than the yield strength of the materials;
the laser shock strengthening treatment technology comprises the steps of enabling a high-strength material such as titanium alloy, high-temperature alloy and high-strength steel to have a deposition layer S with the width smaller than 0.5mm, enabling a constraint layer of a laser shock head to cover and flatten the deposition layer S, enabling a pulse laser to work, enabling a laser beam to generate plasma shock waves through the constraint layer to shock the deposition layer S to enable the material to generate plastic deformation, eliminating pore defects and stress concentration in the deposition layer S and strengthening the deposition layer S material, and adopting the following process parameters of 1) the traveling speed range of a processing head to be 0.5 ~ 5m/min, 2) the laser energy parameter to be 0.5 ~ 5 GW/cm2；
l surface friction stir treatment technique: low strength non ferrous metal materials such as aluminum alloy, magnesium alloy, copper alloy are applicable to thick wall structure simultaneously, and if the sedimentary deposit S width is greater than 5mm, and surfacing, the parameter selection is as follows: 1) rotating speed of a stirring head: the aluminum alloy/magnesium alloy is 1500-; 2) stirring depth: completely depends on the depth of the deposition layer S, which is how much the depth of the deposition layer S is, and is generally less than 5mm in the technology;
3) the traveling speed of the processing head: depending on the depth of the deposit S and the type of material, in general, when the thickness of the deposit S is less than 5mm, the maximum thickness of the aluminum alloy magnesium alloy can reach 0.8m/min, and the maximum thickness of the copper alloy can reach 0.5 m/min;
l, compound post-processing mode:
a) the mechanical rolling and laser shock strengthening method comprises the following steps: mechanical rolling of titanium alloy, high-strength steel and high-temperature alloy can not eliminate all defects of a deposition layer S, the flatness error of the upper surface of the deposition layer S is larger than 1mm, and the machining process comprises mechanical rolling and laser impact;
b) the mechanical rolling and surface stirring friction treatment method comprises the following steps: aluminum alloy, magnesium alloy and copper alloy, wherein all defects of the deposition layer S cannot be eliminated by mechanical rolling, and the flatness error of the upper surface of the deposition layer S is more than 1 mm; the processing process is that mechanical rolling is firstly carried out, and then surface stirring and friction treatment are carried out;
(10) the post-treatment process comprises the following specific steps: the post-processing head 109a is driven by the second mechanical arm 106b to move to be close to the upper surface of the deposition layer S, the post-processing head 109a gradually scans and impacts the deposition layer S according to the scheme determined in the steps (8) and (9), post-processing is carried out until all the surfaces of the defect area of the deposition layer S are completely processed, and then the post-processing head 109a is reset along with the second mechanical arm 106 b;
(11) the additive machining head 103b moves to the position above the deposition layer S, the machining of the next deposition layer S is started, and the above processes are circulated until the machining is finished.
The foregoing description is intended to be illustrative rather than limiting, and it will be appreciated by those skilled in the art that changes may be made in this disclosure without departing from the spirit and scope of the disclosure as defined in the following claims, which are intended to be covered by the appended claims.
In the scheme, the online nondestructive detection technology and the selective post-processing method are introduced into the additive manufacturing process, and the novel additive manufacturing method and equipment are formed through organic combination, so that the problems of additive manufacturing defects and material performance are solved powerfully, meanwhile, the processing time is short, the technical bottleneck of metal additive manufacturing can be broken through, and high-quality and high-efficiency additive manufacturing is realized.
The above embodiments are merely illustrative of the technical solutions of the present invention. The additive manufacturing apparatus and method according to the present invention are not limited to the structures described in the above embodiments, but are subject to the scope defined by the claims. Any modification, or addition, or equivalent replacement by a person skilled in the art on the basis of this embodiment is within the scope of the invention as claimed.
Claims (7)
1. An additive manufacturing apparatus, comprising:
an additive processing portion comprising: the high-energy beam generator generates high-energy beams and transmits the high-energy beams to the additive machining head, and the additive machining head moves according to a set movement path and melts materials to be machined to sinter and prepare a deposition layer;
a high-speed imaging unit comprising: the camera moves synchronously with the additive processing head to shoot images of the material processing forming condition to obtain material image information;
infrared temperature measurement portion contains: the temperature measuring head moves synchronously with the additive processing head to detect the temperature distribution condition of the material and obtain the temperature distribution information of the material;
a drive section including: the three-dimensional motion mechanism comprises a first mechanical arm, a second mechanical arm and a three-dimensional motion mechanism; the front end of the first mechanical arm is used for installing the additive machining head, the camera and the temperature measuring head and driving the additive machining head, the camera and the temperature measuring head to move synchronously;
an optical measuring part for detecting the surface defect and the forming size of the material to obtain detection information;
an internal defect detecting section comprising: the detector head is close to the sedimentary deposit for surface scanning, and the detector analyzer analyzes and determines the defect type and position in the sedimentary deposit according to the scanning condition of the detector head;
the moving end of the three-dimensional moving mechanism is used for mounting the detecting head and driving the detecting head to move;
the post-processing part is used for processing the material defect area by adopting a corresponding post-processing mode and comprises the following steps: the post-processing head can move to be close to the upper surface of the material defect area and gradually carry out defect elimination processing on the material defect area; the aftertreatment processing head includes mechanical gyro wheel, laser impact head and stirring head, the aftertreatment mode includes: at least one post-treatment mode of mechanical rolling treatment, laser shock strengthening treatment and stirring friction processing treatment;
the front end of the second mechanical arm is used for installing the post-processing head and driving the post-processing head to move;
a control unit configured to control operations of the additive processing unit, the high-speed imaging unit, the infrared temperature measuring unit, the first robot, the optical measuring unit, and the internal defect detecting unit, to acquire the material image information, the material temperature distribution information, the detection information, and the defect type and position information, to determine whether or not a defect exists and whether or not the defect can be eliminated based on the information, to determine a defect processing area, a post-processing path and a post-processing method corresponding to each area, to control the post-processing unit to follow the corresponding post-processing path, and to process each defect processing area by using the corresponding post-processing method; in the case of the presence of unerasable defects, the process is stopped and an alarm is given.
2. The additive manufacturing apparatus of claim 1, wherein:
wherein the control section determines the defect processing area and the post-processing path as follows:
in the case that the material defect is a plurality of defects or a single defect distributed in a local cluster shape, the diameter d of the smallest circle containing all defects of the local area is used for representing the characteristic size of the defect area, the defect processing area is an area contained by the circle, the post-processing path is a spiral line with the largest diameter d around the area, and the scanning starting position is the central point of the spiral line;
in the case where the material defect is a multi-defect distributed in a chain shape, the characteristic size of the defect region is represented by the length l and the width w of an elongated region covering all the defects, the defect processing region is the elongated region, the post-processing path is the elongated region, and the scanning start position is one of the end points of the elongated region.
3. The additive manufacturing apparatus of claim 1, wherein:
wherein, the control part controls each part to carry out sintering, detection and post-treatment of the subsequent deposition layer under the condition of no defect.
4. An additive manufacturing apparatus according to claim 3, wherein:
after one or more deposited layers are sintered, the control part controls the additive processing head, the high-speed camera part and the infrared temperature measuring part to stop working, and further controls the first mechanical arm to move the additive processing head, the camera and the temperature measuring head out of a sintering working area;
after the detection is finished, the control part controls the detection head to stop working and controls the three-dimensional motion mechanism to move the detection head to the outside of a sintering working area for resetting;
the control part is used for controlling the post-processing part to stop working after all the defects are processed, and controlling the second mechanical arm to move the post-processing head to the outside of the sintering working area for resetting.
5. The additive manufacturing apparatus of claim 4, wherein:
wherein, the control part controls each part to circularly carry out sintering, detection and post-treatment of the deposition layer until the whole manufacturing process is finished.
6. The additive manufacturing apparatus of claim 1, further comprising:
the substrate bears a material to be processed, has a heating function, preheats a processing environment and inhibits stress concentration.
7. An additive manufacturing method for additive manufacturing using the additive manufacturing apparatus according to any one of claims 1 to 6, wherein:
transmitting a high-energy beam to an additive machining head by adopting a high-energy beam generator in the additive machining part, enabling the additive machining head to move according to a set movement path, and melting the material to be machined to prepare a deposition layer;
a camera in the high-speed camera part and the additive processing head move synchronously to shoot images of the material processing and forming condition to obtain material image information;
meanwhile, a temperature measuring head in the infrared temperature measuring part and the additive processing head move synchronously to detect the temperature distribution condition of the material to obtain the temperature distribution information of the material;
detecting the surface defects and the forming sizes of the materials by adopting an optical measuring part to obtain detection information;
driving a detecting head in an internal defect detecting part to be close to a sediment layer by adopting a three-dimensional motion mechanism for surface scanning, and analyzing and determining the type and the position of the defect in the sediment layer by adopting a detection analyzer according to the scanning condition of the detecting head;
adopt post-processing portion to adopt corresponding post-processing mode to carry out processing to material defect area, include: driving the post-processing head to move to the upper surface close to the material defect area by adopting a second mechanical arm, and gradually carrying out defect elimination processing on the material defect area;
controlling the operation of the material adding processing part, the high-speed photographing part, the infrared temperature measuring part, the first mechanical arm, the optical measuring part and the internal defect detecting part by using a control part, acquiring the material image information, the material temperature distribution information, the detection information, the defect type and the position information, judging whether defects exist or not and whether the defects can be eliminated or not based on the information, determining a defect processing area, a post-processing path and a post-processing mode corresponding to each area under the condition that the defects can be eliminated, controlling the post-processing part to follow the corresponding post-processing path, and processing each defect processing area by adopting the corresponding post-processing mode; in the case of the presence of unerasable defects, the process is stopped and an alarm is given.
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