CN111151748A - On-line monitoring method for manufacturing ceramic-containing reinforced phase composite material by using laser additive - Google Patents
On-line monitoring method for manufacturing ceramic-containing reinforced phase composite material by using laser additive Download PDFInfo
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- CN111151748A CN111151748A CN201911423458.7A CN201911423458A CN111151748A CN 111151748 A CN111151748 A CN 111151748A CN 201911423458 A CN201911423458 A CN 201911423458A CN 111151748 A CN111151748 A CN 111151748A
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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
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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
- B22F10/10—Formation of a green body
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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
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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
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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
- 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
- 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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- 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
Abstract
The invention discloses an online monitoring method for manufacturing a ceramic-reinforced phase-containing composite material by using laser additive, which comprises the following steps: s10, performing a laser additive manufacturing experiment by changing different laser parameter combinations, and simultaneously recording a molten pool thermal history curve and molten pool residence time to obtain the highest molten pool temperature; s20, carrying out test experiments on the obtained samples, thereby determining the optimal laser parameter combination and the corresponding molten pool residence time and molten pool highest temperature data, and storing the data in the system as reference data; and S30, in the laser additive manufacturing verification or production, when the relation among the molten pool residence time, the molten pool maximum temperature and the laser parameter does not accord with the reference data, changing the laser parameter according to the reference data so as to enable the laser parameter, the molten pool thermal history curve and the molten pool residence time to accord with the reference data. The method can realize the purposes of on-line monitoring and control, changes post-detection as a matter of business, and has far-reaching practical significance for developing green manufacturing, intelligent manufacturing and additive manufacturing.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to an online monitoring method for manufacturing a composite material containing a ceramic reinforcing phase by using a laser additive.
Background
The laser additive manufacturing process is different from the traditional material reduction manufacturing process, the traditional material reduction manufacturing process adopts detection methods such as X-ray, ultrasonic and the like to determine whether the material is qualified or not after casting, forging and processing, and the unqualified product is scrapped or remedied by methods such as welding and the like. However, laser additive manufacturing is produced by layer-by-layer superposition, which is like building covering, and when building covering (in the equivalent additive manufacturing process), if defects cannot be found, huge loss is brought, so that online monitoring is very important, and the quality monitoring of monitoring and control is obviously different from that of the traditional manufacturing method.
For additive manufacturing, typically, each laser scan can melt and resolidify several layers of powder, typically 20 μm to several mm thick. After each laser shot, additional powder is scraped off the work area (dusting) or a new powder is fed directly (dusting) to melt, and the process is repeated until a solid three-dimensional (3D) part is built. Each "build" process contains thousands of layers, thus taking hours, tens to hundreds of hours, per run. Tens of identical or different parts may be produced each time a "build".
The metal-based ceramic phase-containing material integrates the advantages of high strength, good toughness, strong plastic deformation capability, good comprehensive mechanical property of metal, high hardness and high wear resistance of a ceramic strengthening phase, so that a ceramic-metal composite layer with a certain thickness can be formed on the working surface of a wear-resistant part, the composite layer bears wear, and the metal matrix plays a bearing role. The local compounding mode can improve the wear resistance of the wear-resistant part and ensure the integral toughness of the wear-resistant part. When the ceramic particles are selected, the ceramic particle strengthening phase is a main wear-resistant phase in the composite material, the matrix can be effectively protected only by having higher hardness and melting point than the matrix, and meanwhile, the ceramic particles and the matrix have good interface bonding performance, so that the ceramic particles cannot fall off integrally in the service process. In order to meet the requirements, when the ceramic phase is manufactured by the laser additive manufacturing method, the ceramic particles and the metal matrix must have a certain degree of interfacial bonding energy, so that the prepared composite material has the best service performance. The ceramic and metal are combined mainly in three conditions, one is that interface binding energy is hardly generated, the ceramic particles are only mechanically combined like gems inlaid in gold and silver, and the ceramic reinforced phase is easy to peel off and fails early in the service process of the composite material. The second is that the ceramic and the metal have proper interface bonding energy, and the ceramic and the metal matrix are metallurgically bonded and have optimal service performance. The third is that the interfacial bonding energy of the ceramic reinforcing phase with the metal is too large, i.e. the interfacial bonding energy of the ceramic reinforcing phase with the metal (metallurgical bonding) is too large, and the properties of the ceramic itself are damaged, and the properties of the resulting composite material are better than the first case, but not desirable, because the situation is equivalent to making unnecessary money. Maximization of value is not achieved. Considering the above issues together, particularly those parts that are critical to the structure, a significant challenge to the widespread use of additive manufacturing techniques is the qualification of the finished product and how to qualify it. Recently, some reports on additive manufacturing have called for on-line, closed-loop process control and sensors to ensure the quality, consistency and reproducibility of additive manufacturing. On-line quality monitoring is beneficial to reduce waste, which would eliminate testing or destructive testing that is typically done after construction (modification to a component). The traditional ceramic coating is manufactured without on-line monitoring and is inspected afterwards, and once unqualified ceramic coating is found, huge waste is caused. Therefore, the on-line monitoring of the preparation of composite materials containing ceramic reinforcing phases is imminent.
With the rapid development of the industries such as metallurgical machinery, petrochemical industry, cement, ships, aerospace, rail transit and the like, the requirement on the additive manufacturing quality is higher and higher under the influence of the price reduction and the improvement of the automation degree of laser equipment, and the existing quality detection method cannot meet the actual requirements of the laser additive manufacturing quality and the automation of the existing manufacturing industry. Therefore, there is a need to design an online monitoring method for laser additive manufacturing. In summary, how to effectively solve the problems that the quality requirements of laser additive manufacturing are difficult to meet and the like is a problem that needs to be solved urgently by those skilled in the art at present.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a stable and reliable online monitoring method for manufacturing a composite material containing a ceramic reinforcing phase by using a laser additive, which can be monitored in real time. The technical scheme is as follows:
an on-line monitoring method for manufacturing a ceramic reinforcing phase-containing composite material by using laser additive comprises the following steps:
s10, performing a laser additive manufacturing experiment by changing different laser parameter combinations, and simultaneously recording a molten pool thermal history curve and molten pool residence time to obtain the highest molten pool temperature;
s20, carrying out test experiments on the obtained samples, thereby determining the optimal laser parameter combination and the corresponding molten pool residence time and molten pool highest temperature data, and storing the data in the system as reference data;
and S30, in the laser additive manufacturing verification or production, when the relation among the molten pool residence time, the molten pool maximum temperature and the laser parameter does not accord with the reference data, changing the laser parameter according to the reference data so as to enable the laser parameter, the molten pool thermal history curve and the molten pool residence time to accord with the reference data.
As a further improvement of the present invention, the step S10 specifically includes:
respectively fixing any two of laser power P, laser scanning speed V and powder feeding rate Mp, changing the other one to perform a test and recording a molten pool thermal history curve and molten pool residence time, and obtaining powder heating, melting and gasifying, solidification starting, corresponding time and the highest temperature of a molten pool according to the thermal history curve;
or, respectively fixing any two of the laser power P, the laser scanning speed V and the powder spreading thickness, changing the other one to perform a test and recording a molten pool heat history curve and a molten pool residence time, and obtaining the time for heating, melting and gasifying, starting solidification and corresponding cooling of the powder and the highest temperature of the molten pool according to the heat history curve.
As a further improvement of the present invention, the step S20 specifically includes:
selecting a sample which is colored and has no air holes or cracks, observing the sample by naked eyes, carrying out metallographic phase analysis, scanning electron microscope analysis, hardness test, frictional wear test and impact test on the sample of which the forming quality meets the use requirement, obtaining the optimal combination of good combination of the ceramic phase and the metal matrix and the frictional wear performance and the impact toughness meeting the use requirement after the experiment to determine the laser processing technological parameters, and storing the technological parameters in a system as the technological parameters for formal production or verification processing.
As a further improvement of the invention, the laser parameters include laser power and scanning speed.
As a further improvement of the invention, the laser power and the scanning speed are adjusted in accordance with a laser power detector.
As a further improvement of the invention, the thermal history of the bath is recorded using an infrared pyrometer.
The invention has the beneficial effects that:
the on-line monitoring method for manufacturing the ceramic-containing reinforced phase composite material by the laser additive comprises the steps of collecting a molten pool thermal history curve and molten pool residence time in real time; when the collected thermal history curve of the molten pool (the highest temperature of the molten pool) and the characteristics of the residence time of the molten pool do not accord with the pre-stored relations between the laser power P (scanning speed) and the highest temperature of the molten pool as well as the residence time of the molten pool, the laser power P (scanning speed) is adjusted according to the relation between the laser power P (scanning speed) and the highest temperature of the molten pool as well as the residence time of the molten pool, so that the collected highest temperature of the molten pool and the residence time of the molten pool all accord with the pre-stored corresponding relations between the laser power P (scanning speed) and the highest. Therefore, the purpose of on-line monitoring and control is achieved, the post-detection is changed into the pre-prediction, and the method has far-reaching practical significance for developing green manufacturing, intelligent manufacturing and additive manufacturing. Meanwhile, the defects that destructive detection is difficult to operate and loss is huge after the fact can be avoided.
The foregoing description is only an overview of the technical solutions of the present invention, and in order to make the technical means of the present invention more clearly understood, the present invention may be implemented in accordance with the content of the description, and in order to make the above and other objects, features, and advantages of the present invention more clearly understood, the following preferred embodiments are described in detail with reference to the accompanying drawings.
Drawings
Fig. 1 is a flow chart of an on-line monitoring method for laser additive manufacturing of a ceramic reinforcing phase-containing composite material according to an embodiment of the present invention.
Detailed Description
The present invention is further described below in conjunction with the following figures and specific examples so that those skilled in the art may better understand the present invention and practice it, but the examples are not intended to limit the present invention.
Example one
As shown in fig. 1, an on-line monitoring method for laser additive manufacturing of a ceramic-containing reinforcing phase composite material includes the following steps:
s10, performing a laser additive manufacturing experiment by changing different laser parameter combinations, and simultaneously recording a molten pool thermal history curve and molten pool residence time to obtain the highest molten pool temperature;
wherein the laser parameters include laser power and scanning speed. The laser power and scanning speed are adjusted according to a laser power detector. The thermal history of the bath was recorded using an infrared pyrometer.
Step S10 specifically includes:
respectively fixing any two of laser power P, laser scanning speed V and powder feeding rate Mp, changing the other one to perform a test and recording a molten pool thermal history curve and molten pool residence time, and obtaining powder heating, melting and gasifying, solidification starting, corresponding time and the highest temperature of a molten pool according to the thermal history curve;
or, respectively fixing any two of the laser power P, the laser scanning speed V and the powder spreading thickness, changing the other one to perform a test and recording a molten pool heat history curve and a molten pool residence time, and obtaining the time for heating, melting and gasifying, starting solidification and corresponding cooling of the powder and the highest temperature of the molten pool according to the heat history curve.
More specifically, step S10 includes:
s11, fixing the laser scanning speed (V500 mm-1) Carrying out experiments by changing different laser powers (P is 300-1200W) according to the laser powder spreading thickness (tp is 30 mu m, the laser spot D is 200 mu m and the laser defocusing amount F is 0, keeping the existing parameters of the equipment unchanged in the whole processing process, and recording a molten pool thermal history curve and the molten pool highest temperature by adopting a temperature recorder to obtain the molten pool highest temperature and the molten pool dwell time under different laser powers;
s12, fixing laser power (P is 400W) and powder spreading thickness (tp is 30 mu m), and changing laser scanning speed (V is 500-1900 mm-1) Carrying out a series of experiments to obtain the data of the temperature of the molten pool under the conditions of different scanning speeds;
s13, fixing laser power (P is 400W) and laser scanning speed (700mm. S-1), and changing powder spreading thickness (powder spreading mode is selected here, powder speed tp is 20-40 μmin-1) Obtaining a series of powder feeding rate, a molten pool thermal history curve and molten pool residence time;
s20, carrying out test experiments on the obtained samples, thereby determining the optimal laser parameter combination and the corresponding molten pool residence time and molten pool highest temperature data, and storing the data in the system as reference data;
step S20 specifically includes:
selecting a sample which is colored and has no air holes or cracks, observing the sample by naked eyes, carrying out metallographic phase analysis, scanning electron microscope analysis, hardness test, frictional wear test and impact test on the sample of which the forming quality meets the use requirement, obtaining the optimal combination of good combination of the ceramic phase and the metal matrix and the frictional wear performance and the impact toughness meeting the use requirement after the experiment to determine the laser processing technological parameters, and storing the technological parameters in a system as the technological parameters for formal production or verification processing.
If the fluctuation of the highest temperature of the molten pool or the residence time of the molten pool exceeds the data stored in the system in the monitoring process, the system preferentially selects the parameter combination which can realize the change and reach the expected data fastest in the process of the online monitoring because the laser power (or the scanning speed) is selected as the change control quantity. When laser additive manufacturing is carried out by adopting the laser power, the scanning speed and the powder spreading thickness stored in the system, the measured highest temperature of the molten pool or the residence time of the molten pool fluctuates, and the laser power (scanning speed) is correspondingly adjusted to the laser power (scanning speed) corresponding to the laser power (scanning speed) in the system for processing, so as to ensure that the laser power (scanning speed) corresponds to the highest temperature of the molten pool (or the residence time of the molten pool).
More specifically, step S20 is performed after step S11 to obtain an effective relational expression T1, step S20 is performed after step S12 to obtain an effective relational expression T2, step S20 is performed after step S13 to obtain an effective relational expression T3, and the effective relational expressions T1, T2 and T3 are arranged together to determine a relational expression T4 of the laser power P variation and the molten pool temperature and CT three-dimensional data.
And S30, in the laser additive manufacturing verification or production, when the relation among the molten pool residence time, the molten pool maximum temperature and the laser parameter does not accord with the reference data, changing the laser parameter according to the reference data so as to enable the laser parameter, the molten pool thermal history curve and the molten pool residence time to accord with the reference data.
Wherein, the relation T4 is adopted to carry out the online monitoring of the laser additive manufacturing on the actual workpiece. If the fluctuation of the highest temperature of the molten pool or the residence time of the molten pool exceeds the data stored in the system in the monitoring process, the system preferentially selects the parameter combination which can realize the change and reach the expected data fastest in the online monitoring process because the laser power (or the scanning speed) is selected as the change control quantity. When laser additive manufacturing is carried out by adopting the laser power, the scanning speed and the powder spreading thickness stored in the system, the measured highest temperature of the molten pool or the residence time of the molten pool fluctuates, and the laser power (scanning speed) is correspondingly adjusted to the laser power (scanning speed) corresponding to the laser power (scanning speed) in the system for processing, so as to ensure that the laser power (scanning speed) corresponds to the highest temperature of the molten pool (or the residence time of the molten pool).
The invention provides an on-line monitoring method for manufacturing a composite material containing a ceramic reinforcing phase by a laser additive, which comprises the steps of optimizing process parameters, carrying out analysis and calculation on a data curve measured by a test sample to obtain the most appropriate laser processing parameters, using the parameters as actually measured data, carrying out calculation and analysis, and comparing whether effective molten pool temperature and CT three-dimensional data meet the pre-stored standard or not so as to achieve the purpose of on-line monitoring and control. The method has the advantages of good controllability and high processing efficiency, can be better applied to manufacturing occasions needing cladding and longer working time in the fields of ships, rail transit, mechanical manufacturing and the like, better adapts to flexible manufacturing environment, and has more profound practical significance.
The above embodiments are merely preferred embodiments for fully illustrating the present invention, and the scope of the present invention is not limited thereto. The equivalent substitution or change made by the technical personnel in the technical field on the basis of the invention is all within the protection scope of the invention. The protection scope of the invention is subject to the claims.
Claims (6)
1. An on-line monitoring method for manufacturing a ceramic reinforcing phase-containing composite material by using laser additive is characterized by comprising the following steps:
s10, performing a laser additive manufacturing experiment by changing different laser parameter combinations, and simultaneously recording a molten pool thermal history curve and molten pool residence time to obtain the highest molten pool temperature;
s20, carrying out test experiments on the obtained samples, thereby determining the optimal laser parameter combination and the corresponding molten pool residence time and molten pool highest temperature data, and storing the data in the system as reference data;
and S30, in the laser additive manufacturing verification or production, when the relation among the molten pool residence time, the molten pool maximum temperature and the laser parameter does not accord with the reference data, changing the laser parameter according to the reference data so as to enable the laser parameter, the molten pool thermal history curve and the molten pool residence time to accord with the reference data.
2. The on-line monitoring method for laser additive manufacturing of a ceramic-containing reinforcing phase composite material according to claim 1, wherein the step S10 specifically includes:
respectively fixing any two of laser power P, laser scanning speed V and powder feeding rate Mp, changing the other one to perform a test and recording a molten pool thermal history curve and molten pool residence time, and obtaining powder heating, melting and gasifying, solidification starting, corresponding time and the highest temperature of a molten pool according to the thermal history curve;
or, respectively fixing any two of the laser power P, the laser scanning speed V and the powder spreading thickness, changing the other one to perform a test and recording a molten pool heat history curve and a molten pool residence time, and obtaining the time for heating, melting and gasifying, starting solidification and corresponding cooling of the powder and the highest temperature of the molten pool according to the heat history curve.
3. The on-line monitoring method for laser additive manufacturing of a ceramic-containing reinforcing phase composite material according to claim 2, wherein the step S20 specifically includes:
selecting a sample which is colored and has no air holes or cracks, observing the sample by naked eyes, carrying out metallographic phase analysis, scanning electron microscope analysis, hardness test, frictional wear test and impact test on the sample of which the forming quality meets the use requirement, obtaining the optimal combination of good combination of the ceramic phase and the metal matrix and the frictional wear performance and the impact toughness meeting the use requirement after the experiment to determine the laser processing technological parameters, and storing the technological parameters in a system as the technological parameters for formal production or verification processing.
4. The method of online monitoring of laser additive manufacturing of a ceramic reinforcing phase containing composite material of claim 1, wherein the laser parameters include laser power and scan speed.
5. The method of online monitoring of laser additive manufacturing of a ceramic reinforcing phase containing composite material of claim 4, wherein the laser power and scanning speed are adjusted according to a laser power detector.
6. The method of on-line monitoring for laser additive manufacturing of a composite material containing a ceramic reinforcing phase according to claim 1, wherein the thermal history of the melt pool is recorded using an infrared pyrometer.
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