CN111266577A - 3D printing quality computer online monitoring method - Google Patents
3D printing quality computer online monitoring method Download PDFInfo
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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Abstract
A3D printing quality computer on-line monitoring method includes that in a multi-element powder synchronous powder feeding laser 3D printing process, a CCD camera is used for collecting laser molten pool temperature data in real time and uploading the laser molten pool temperature data to a computer, the laser molten pool temperature data is compared with standard temperature data prestored by the computer, and working parameters are adjusted in real time, the working parameters are at least one of laser power, scanning speed or powder feeding speed, and the standard temperature data prestored by the computer are established according to a synchronous powder feeding laser 3D printing simulation experiment of premixed or pre-alloyed powder with the same element proportion as that of multi-element powder conveyed by a different cylinder. The invention adopts relatively ideal and stable simulation conditions, so that the standard data more conforms to the actual cladding requirement, the misjudgment and overshoot proportion when the printing parameters are regulated and controlled in real time is greatly reduced, the sintering defects in cladding are reduced, and the quality of the finished piece is improved.
Description
Technical Field
The invention relates to the technical field of 3D printing, in particular to a computer online monitoring method for 3D printing quality.
Background
In recent years, the 3D printing technology has played an important role in manufacturing special functional materials, for example, domestic and foreign enterprises, colleges and universities and research institutions increasingly use the 3D printing technology to prepare multi-metal or alloy functional gradient materials used in the electronic industry, and obtain mechanical, thermal, magnetic and other properties that cannot be achieved by the conventional technology, and meanwhile, the 3D printing technology has incomparable advantages in development period and manufacturing efficiency, which greatly promotes the progress of industry and technology.
Based on the characteristics of 3D printing layer-by-layer generated parts, the online monitoring and control of printing quality based on molten pool detection are the current research focus, according to the difference of energy source and raw material supply mode, the 3D printing technology has a plurality of types, synchronous powder feeding laser 3D printing is one of the common types, the technology directly feeds metal powder into a laser processing point on line to generate products layer by layer, when printing materials with component gradient, a multi-element powder different-cylinder synchronous powder feeding mode is adopted, different metal or nonmetal components are respectively loaded into different powder feeding cylinders, the online blending of the components of each gradient layer is indirectly realized by adjusting the powder feeding ratio of each powder feeding cylinder, the technology can be seen in Chinese patent 201710229361.7, the technology utilizes a coaxial powder feeding laser 3D printing method to prepare tungsten copper alloy components with the required component gradient change along with the increase of the number of printing layers, the multi-element powder different-cylinder synchronous powder feeding process can be said to promote the step of industrial production of the gradient functional material. Different element powders are required to be mixed on line when the multi-element powder is synchronously fed by the different cylinders, so that the phenomenon of uneven powder mixing or discharging error caused by the instability of carrier gas and the structural defects of a powder nozzle exists with high probability, the thermal fluctuation of a molten pool is more obvious than that of a common powder supply mode under relatively stable laser energy, and the problems of high misjudgment rate or overshoot and the like can occur when the printing parameters are regulated and controlled in real time based on the online detection of the molten pool in the prior art.
Disclosure of Invention
In order to solve the problems, the invention provides a 3D printing quality computer online monitoring method, standard temperature data is established according to a synchronous powder feeding laser 3D printing simulation experiment of premixed or pre-alloyed powder with the same element proportion as that of multi-element powder conveyed by a special cylinder, the temperature data of a laser melting pool is collected in real time in the 3D printing process of multi-element powder synchronous powder feeding laser, and compared with the standard temperature data, because a material state and stable simulation conditions which are relatively more ideal than those of the actual printing process are adopted, the standard data more accord with the actual cladding requirements, the misjudgment and the overshoot proportion when the printing parameters are regulated and controlled in real time are greatly reduced, the sintering defects during cladding are reduced, and the quality of a finished piece is improved.
The technical scheme of the invention is as follows:
A3D printing quality computer on-line monitoring method is characterized in that in the process of adopting multi-element powder synchronous powder feeding laser 3D printing through a different cylinder, a CCD camera is adopted to collect laser molten pool temperature data in real time and upload the laser molten pool temperature data to a computer, and the laser molten pool temperature data is compared with standard temperature data prestored in the computer and work parameters are adjusted in real time.
According to the 3D printing quality computer online monitoring method, the working parameter is at least one of laser power, scanning speed or powder feeding speed.
According to the 3D printing quality computer online monitoring method, the standard temperature data prestored by the computer is established according to the synchronous powder feeding laser 3D printing simulation experiment of the premixed or prealloyed powder with the same element proportion as the multi-element powder conveyed by the different cylinder, and the establishing method comprises the following steps:
(1) establishing a layer height L for each grade of gradient functional material to be printed1、L2、……、LNAnd the number of printing layers M corresponding to each level of layer height1、M2、……、MNWherein N is a positive integer greater than or equal to 2;
(2) preparing premixed or prealloyed powder with the same element proportion according to the element proportion of the multi-element powder set in each grade of gradient;
(3) under the same printing atmosphere (protective gas pressure and oxygen content) set in the multi-element powder different-cylinder synchronous powder feeding laser 3D printing, adopting the premixed or prealloyed powder prepared in the step (2), carrying out synchronous powder feeding laser 3D printing according to the layer height corresponding to each level of gradient set in the step (1) and the printing layer number corresponding to each level of layer height, and acquiring laser molten pool temperature data in real time by adopting a CCD (charge coupled device) camera and uploading the laser molten pool temperature data to a computer when each layer is printed;
(4) and the computer converts and processes the received laser molten pool temperature data to obtain standard temperature data.
According to the above 3D printing quality computer online monitoring method, after the step (4), the method further comprises the steps of: (5) and (4) carrying out slicing and metallographic analysis on the printed gradient functional material, and evaluating the printing quality.
According to the 3D printing quality computer online monitoring method, the steps (3) - (5) are repeated, and the temperature data corresponding to the printing sample with the best printing quality is selected as standard data.
According to the 3D printing quality computer online monitoring method, in the 3D printing process, a thermodetector is used for measuring the fixed-point temperature of the substrate or the printing completion part close to the current layer, and temperature data are recorded.
According to the 3D printing quality computer online monitoring method, the fixed point temperature measurement adopts a multi-point measurement mode.
According to the 3D printing quality computer online monitoring method, when the pre-mixed or pre-alloyed powder is adopted for synchronous powder feeding laser 3D printing to collect standard temperature data, a thermodetector is used for carrying out fixed-point temperature measurement on the substrate or a printing completion part close to the current layer, temperature data is recorded, and when printing is suspended due to the fact that powder in a powder cylinder is replaced, the substrate or the printing completion part close to the current layer is heated to recover the working temperature.
According to the 3D printing quality computer online monitoring method, when the multi-element powder is adopted for the different-cylinder synchronous powder feeding laser 3D printing, the thermometers are used for measuring the fixed-point temperature of the substrate or the printing completion part close to the current layer, the measured data are uploaded to the computer, the measured data are compared with the corresponding temperature data prestored by the computer, and the real-time temperature is adjusted.
According to the 3D printing quality computer online monitoring method, the CCD camera and the synchronous powder feeding laser 3D printing head move synchronously.
The invention can obtain the following technical effects:
1. the invention provides a 3D printing quality computer on-line monitoring method, which establishes standard temperature data according to a synchronous powder feeding laser 3D printing simulation experiment of premixed or prealloyed powder with the same proportion as that of elements of multi-element powder conveyed by a special cylinder, collects the temperature data of a laser molten pool in real time in the 3D printing process of multi-element powder synchronous powder feeding laser and compares the temperature data with the standard temperature data, and because relatively ideal and stable simulation conditions are adopted, the standard data better meets the actual cladding requirement, the misjudgment and overshoot proportion when the printing parameters are regulated and controlled in real time are greatly reduced, the temperature control in the actual state is more accurate, the temperature field is more uniform, the obtained workpiece has more uniform tissue, fewer sintering defects and the quality of the workpiece is greatly improved;
2. the invention provides a 3D printing quality computer on-line monitoring method, which strictly ensures the consistency of the simulation state and the printing parameter condition, the printing atmosphere condition and the component thermal influence condition in the actually adopted multi-element powder different-cylinder synchronous powder feeding laser 3D printing, particularly when the pre-mixed or pre-alloyed powder is adopted to carry out synchronous powder feeding laser 3D printing to acquire standard temperature data (simulation state) and when the multi-element powder is adopted to carry out different-cylinder synchronous powder feeding laser 3D printing (actual state), the method comprises the steps of measuring the fixed point temperature of a substrate or a printing completion part close to a current layer, on one hand, avoiding the change of a component heat influence condition caused by replacing a powder cylinder or powder in the powder cylinder in a simulation state through temperature compensation, and on the other hand, reducing the error between the component heat influence condition and the simulation state in an actual state through temperature compensation;
3. according to the 3D printing quality computer online monitoring method provided by the invention, the utilized controls and programs can adopt mature schemes in the prior art, the method is simple and reliable, the CCD camera and the synchronous powder feeding laser 3D printing head move synchronously, the laser molten pool live data are accurately captured, the computer accurately adjusts the laser power according to a built-in PID algorithm, the embedded substrate heating device can well realize temperature regulation and sensing, the optical pyrometer with the preprocessor realizes good communication with the computer, the multipoint temperature measurement can effectively avoid temperature overshoot, and errors are reduced.
Drawings
Fig. 1 is a schematic diagram of a 3D printing quality computer online monitoring method according to embodiment 1 of the present invention.
Fig. 2 is a gradient composition diagram of a 3D printing target product according to each embodiment of the present invention.
Fig. 3 is a schematic diagram of standard temperature data acquisition in a 3D printing quality computer online monitoring method according to embodiment 1 of the present invention.
Fig. 4 is a schematic diagram of standard temperature data acquisition in a 3D printing quality computer online monitoring method according to embodiment 2 of the present invention.
Fig. 5 is a schematic diagram of a 3D printing quality computer online monitoring method according to embodiment 2 of the present invention.
In the figure:
1-synchronous powder feeding laser 3D printing head, 2-substrate, 3-workpiece (printing completion part), 4-laser melting pool, 5-powder cylinder, 6-CCD camera, 7-laser controller, 8-computer, 9-substrate heating device, 10-thermodetector, 101-first gradient layer, 102-second gradient layer, 103-third gradient layer, 104-fourth gradient layer and 105-fifth gradient layer.
Detailed Description
Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings.
Example 1
A3D printing quality computer on-line monitoring method, in the 3D printing process of adopting multi-element powder different-cylinder synchronous powder feeding laser as shown in figure 1, adopting CCD camera 6 to collect the temperature data of laser melting bath 4 in real time and upload the data to computer 8, comparing the data with the standard temperature data pre-stored by computer 8 and adjusting the working parameters in real time, when the multi-element powder different-cylinder synchronous powder feeding laser 3D is printed for constructing the gradient functional material, because the composition of the metal element is changed, and the laser processing energy is mainly used for heating the metal powder to melt or sinter the metal powder, when the gradient change of the metal element composition is larger, the laser processing energy is also changed according to the metal element composition of the current gradient layer, therefore, the working parameters mainly refer to the laser power, when the laser power is relatively constant, the scanning speed or the powder feeding speed can be adjusted, therefore, the scanning speed or the powder feeding speed may also be used as variables.
In order to solve the problems proposed by the present application, the standard temperature data pre-stored by the computer 8 in this embodiment is established according to the simulation experiment of synchronous powder feeding laser 3D printing of premixed or pre-alloyed powder with the same element proportion as that of multi-element powder conveyed by a different cylinder, fig. 2 first exemplarily shows the gradient composition of a 3D printing target product aimed at in this embodiment, the base metal of the product 3 to be printed in this embodiment includes two types, i.e., a and B, and includes, starting from the bottom layer, a first gradient layer 101, a second gradient layer 102, a third gradient layer 103, a fourth gradient layer 104, and a fifth gradient layer 105, the mass fraction of the base metal a in each gradient layer is 100%, 75%, 50%, 25%, and 0%, and the mass fraction of the base metal B in each corresponding gradient layer is 0%, 25%, 50%, 75%, and 100%, respectively.
As the base metals A and B, there may be mentioned, for example, Ti-Al, Fe-Al, Ti-Ni, Al-Ni, Fe-Cu, W-Cu and the like.
As shown in fig. 3, the standard temperature data pre-stored by the computer 8 is established according to the synchronous powder feeding laser 3D printing simulation experiment of the premixed or pre-alloyed powder with the same element proportion as the multi-element powder delivered by the different cylinders, and the establishing method is as follows:
(1) establishing a layer height L for each grade of gradient functional material to be printed1、L2、……、LNAnd the number of printing layers M corresponding to each level of layer height1、M2、……、MNWherein N is a positive integer greater than or equal to 2, and when the target product 3 shown in fig. 2 is printed, N is 5;
(2) the simultaneous powder feeding laser 3D printing simulation experiment was performed to prepare pre-mixed or pre-alloyed powder of the same elemental ratio according to the elemental ratio of the multi-element powder set in each step of the gradient, as shown in fig. 3, by providing five powder cartridges 5 in total, two of the powder cartridges 5 being used to supply 100% of the base metal a and 100% of the base metal B, respectively, and the other three powder cartridges 5 being used to supply pre-mixed or pre-alloyed powder of the composition group of 75% a + 25% B, 50% a + 50% B, 25% a + 75% B, respectively;
(3) under the same printing atmosphere (protective gas pressure and oxygen content) set in the multi-element powder different-cylinder synchronous powder feeding laser 3D printing shown in the figure 1, adopting the premixed or pre-alloyed powder prepared in the step (2), carrying out synchronous powder feeding laser 3D printing according to the layer height corresponding to each grade of gradient set in the step (1) and the printing layer number corresponding to each grade of layer height, and adopting a CCD (charge coupled device) camera 6 to collect temperature data of a laser molten pool 4 in real time and upload the temperature data to a computer 8 when each layer is printed;
(4) and the computer 8 converts and processes the received temperature data of the laser melting pool 4 to obtain standard temperature data.
The collection of the standard data should be the data that is most advantageous for obtaining the best print quality and the required performance, and therefore, after said step (4), the method further comprises the steps of: (5) and (3) carrying out slicing and metallographic analysis on the printed gradient functional material, evaluating the printing quality, wherein in addition to checking whether the generated phase meets the expectation and checking the uniformity of the product structure, according to specific application, the required mechanical property or thermal property, magnetic property and the like also need to be quantitatively evaluated, preferably, repeating the steps (3) to (5), and selecting the temperature data corresponding to the printing sample with the best printing quality as standard data.
The principle of collecting standard temperature data and the principle of adjusting working parameters (laser power) according to the standard temperature data in the actual process of synchronously feeding powder by adopting multi-element powder in a different cylinder in a 3D printing mode are mature, the CCD camera 6 provides laser molten pool live data for the computer 8 based on thermal image capturing, the computer 8 processes original image data to establish molten pool temperature field data related to a scanning path, and timely adjusts the working parameter (laser power) according to the built-in PID algorithm, as another important improvement to the prior art, as shown in fig. 1 and 3, the CCD camera 6 of the present invention is disposed coaxially with the synchronized powder feeding laser 3D print head 1, the synchronous movement of the CCD camera 6 and the synchronous powder feeding laser 3D printing head 1 is realized, the live data of a laser melting pool can be captured more accurately, and the control system is greatly simplified.
In the embodiment, because relatively ideal material states and stable simulation conditions are adopted, standard data are more in line with actual cladding requirements, when materials such as Ti-Ni and W-Cu are verified, the actual measurement temperature field data and the adjustment response amplitude of laser power in the actual laser 3D printing process are observed and analyzed in a multi-element powder different-cylinder synchronous powder feeding mode, the method is more accurate in temperature control, more uniform in temperature field, lower in misjudgment and overshoot proportion during real-time regulation and control, and more uniform in composition and less in sintering defects when the obtained workpiece is observed in a tissue mode.
Example 2
The method mainly ensures that the simulation state is highly consistent with the printing parameter conditions, the printing atmosphere conditions and the component heat influence conditions in the actually adopted multi-element powder-feeding laser 3D printing synchronously by using the different cylinders, the main control printing parameters in the two states can be accurately controlled, and can be automatically adjusted in an external interference mode when the printing atmosphere conditions change greatly, but the component heat influence conditions are formed passively, on one hand, the high-energy laser beam is used for forming the finished piece, the real-time temperature of the whole finished piece, particularly the temperature of a just finished part, is an important influence factor, the temperature of a key part of the finished piece has the largest influence on the cladding quality except the laser energy directly irradiated to a molten pool, particularly for the finished piece with a small size or a thin thickness, the laser energy has a great influence on the temperature of the finished part of the finished piece and even a substrate, on the other hand, in the simulation state of the invention, if the gradient formation of the product is complicated due to the gradient function, the number of powder cylinders 5 prepared in advance for conveying premixed or prealloyed powder is increased, and pipelines and control programs are added to the corresponding powder conveying system, and the problem can be solved by replacing one or more powder cylinders 5 or replacing the powder component composition in the powder cylinder 5, but the problem brings about a new problem that the printing is suspended due to the replacement of the powder cylinder 5 or the replacement of the powder in the powder cylinder 5, the thermal influence condition of a component mainly based on the temperature of the critical part is greatly changed, and the situation appears in the simulation state and generally does not appear in the actually adopted multi-element powder synchronous powder-feeding laser 3D printing with different cylinders, this can lead to inconsistencies between the simulated and actual conditions and a distortion in the effectiveness of the standard temperature acquisition.
The above-mentioned situation is explained by referring to fig. 4, and as shown in fig. 4, it is obvious that the system for performing the simultaneous powder feeding laser 3D printing simulation experiment is provided with only four powder cartridges 5, but also a 3D printing object product having a five-step composition gradient as shown in fig. 2 is simulated, if first 100% base metal a and 100% base metal B are supplied by two of the powder cartridges 5, respectively, and premixed or prealloyed powder having composition groups of 75% a + 25% B and 50% a + 50% B is supplied by the other two powder cartridges 5, the printing process is interrupted before a gradient layer having composition of 25% a + 75% B is printed, the powder cartridges 5 are replaced or the powder composition in one of the powder cartridges 5 is replaced with the composition of 25% a + 75% B, so that the heat affected condition of the component mainly based on the critical site temperature in the stage is largely changed, to cope with this influence, as shown in fig. 4 and 5, when performing synchronous powder feeding laser 3D printing using premixed or prealloyed powder to collect standard temperature data (simulation state) and when performing asynchronous powder feeding laser 3D printing using multi-element powder (actual state), the thermometer 10 is used to perform fixed point temperature measurement on the substrate 2 or a printing completion part close to a current layer and record temperature data, when performing synchronous powder feeding laser 3D printing using premixed or prealloyed powder to collect standard temperature data, the thermometer 10 is used to perform fixed point temperature measurement on the substrate 2 or a printing completion part close to a current layer and record temperature data, and when printing is suspended due to replacement of powder in the powder cylinder 5, the substrate 2 or the printing completion part close to the current layer is returned to operating temperature by heating the substrate 2, when multi-element powder is adopted for carrying out different-cylinder synchronous powder feeding laser 3D printing, a thermodetector 10 is utilized to carry out fixed-point temperature measurement on the substrate 2 or a printing completion part close to the current layer and upload measurement data to a computer 8, comparison is carried out with corresponding temperature data prestored by the computer 8 and real-time temperature is adjusted, and according to the deviation direction, the adjustment on the real-time temperature can adopt a mode of prolonging interlayer printing switching time or a mode of heating the substrate 2.
The heating of the substrate 2 and the temperature measurement by the temperature measuring instrument 10 mentioned in the embodiment belong to the existing mature technology, the embedded substrate heating device 9 shown in fig. 4 and fig. 5 can well realize the temperature regulation and sensing, the temperature measuring instrument 10 can select the optical high temperature instrument with the preprocessor to realize the reliable communication with the computer 8, the fixed point temperature measurement preferably adopts a multipoint measurement mode, the temperature overshoot can be effectively avoided, and the error is reduced.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention.
Claims (10)
1. A3D printing quality computer on-line monitoring method is characterized in that in the process of adopting multi-element powder different-cylinder synchronous powder feeding laser 3D printing, a CCD camera is adopted to collect laser molten pool temperature data in real time and upload the laser molten pool temperature data to a computer, and the laser molten pool temperature data is compared with standard temperature data prestored by the computer and work parameters are adjusted in real time.
2. The 3D printing quality computer online monitoring method according to claim 1, wherein the working parameter is at least one of laser power, scanning speed or powder feeding speed.
3. The 3D printing quality computer online monitoring method according to claim 1, wherein the standard temperature data pre-stored by the computer is established according to a synchronous powder feeding laser 3D printing simulation experiment of premixed or pre-alloyed powder with the same proportion of multi-element powder elements conveyed by a special cylinder, and the establishment method comprises the following steps:
(1) establishing a layer height L for each grade of gradient functional material to be printed1、L2、……、LNAnd the number of printing layers M corresponding to each level of layer height1、M2、……、MNWherein N is a positive integer greater than or equal to 2;
(2) preparing premixed or prealloyed powder with the same element proportion according to the element proportion of the multi-element powder set in each grade of gradient;
(3) under the same printing atmosphere (protective gas pressure and oxygen content) set in the multi-element powder different-cylinder synchronous powder feeding laser 3D printing, adopting the premixed or prealloyed powder prepared in the step (2), carrying out synchronous powder feeding laser 3D printing according to the layer height corresponding to each level of gradient set in the step (1) and the printing layer number corresponding to each level of layer height, and acquiring laser molten pool temperature data in real time by adopting a CCD (charge coupled device) camera and uploading the laser molten pool temperature data to a computer when each layer is printed;
(4) and the computer converts and processes the received laser molten pool temperature data to obtain standard temperature data.
4. The 3D printing quality computer online monitoring method according to claim 3, characterized by further comprising, after the step (4), the steps of: (5) and (4) carrying out slicing and metallographic analysis on the printed gradient functional material, and evaluating the printing quality.
5. The 3D printing quality computer online monitoring method according to claim 4, wherein the steps (3) - (5) are repeated, and the temperature data corresponding to the printing sample with the best printing quality is selected as standard data.
6. The 3D printing quality computer online monitoring method according to claim 3, characterized in that in the 3D printing process, a thermodetector is also used to measure the fixed-point temperature of the substrate or the printing completion part close to the current layer, and record the temperature data.
7. The 3D printing quality computer online monitoring method according to claim 6, wherein the fixed point temperature measurement is a multi-point measurement.
8. The 3D printing quality computer online monitoring method according to claim 6, characterized in that when the pre-mixed or pre-alloyed powder is adopted for synchronous powder feeding laser 3D printing to collect standard temperature data, a thermodetector is used for measuring the fixed point temperature of the substrate or the printing completion part close to the current layer, and recording the temperature data, and when the printing is suspended due to the replacement of powder in the powder cylinder, the substrate or the printing completion part close to the current layer is heated to recover the working temperature.
9. The method for on-line monitoring the 3D printing quality by the computer according to claim 8, wherein when the multi-element powder is adopted for the laser 3D printing of the different-cylinder synchronous powder feeding, the thermometers are used for measuring the fixed-point temperature of the substrate or the printing completion part close to the current layer and uploading the measured data to the computer, and the measured data is compared with the corresponding temperature data prestored by the computer and the real-time temperature is adjusted.
10. The 3D printing quality computer online monitoring method according to any one of claims 1-9, wherein the CCD camera moves synchronously with the synchronous powder feeding laser 3D printing head.
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| CN111965171A (en) * | 2020-07-22 | 2020-11-20 | 江苏大学 | Method for preparing functionally graded material based on closed-loop joint measurement and control system |
| CN112517926A (en) * | 2020-11-30 | 2021-03-19 | 江苏海宇机械有限公司 | Method for regulating and controlling temperature gradient of molten pool in laser cladding process |
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