CN111965171A - Method for preparing functionally graded material based on closed-loop joint measurement and control system - Google Patents
Method for preparing functionally graded material based on closed-loop joint measurement and control system Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 29
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- 239000000843 powder Substances 0.000 claims abstract description 43
- 238000001816 cooling Methods 0.000 claims abstract description 27
- 238000004519 manufacturing process Methods 0.000 claims abstract description 26
- 239000000654 additive Substances 0.000 claims abstract description 23
- 230000000996 additive effect Effects 0.000 claims abstract description 23
- 229910052751 metal Inorganic materials 0.000 claims abstract description 15
- 239000002184 metal Substances 0.000 claims abstract description 15
- 238000001228 spectrum Methods 0.000 claims abstract description 15
- 238000012545 processing Methods 0.000 claims abstract description 12
- 238000002360 preparation method Methods 0.000 claims abstract description 9
- 238000001514 detection method Methods 0.000 claims abstract description 8
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- 238000004458 analytical method Methods 0.000 claims description 2
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- 230000004069 differentiation Effects 0.000 claims 1
- 230000010354 integration Effects 0.000 claims 1
- 238000005516 engineering process Methods 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- 238000011088 calibration curve Methods 0.000 description 4
- 238000013480 data collection Methods 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
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- 229910052804 chromium Inorganic materials 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
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- 239000010936 titanium Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 239000013070 direct material Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/62—Systems in which the material investigated is excited whereby it emits light or causes a change in wavelength of the incident light
- G01N21/71—Systems in which the material investigated is excited whereby it emits light or causes a change in wavelength of the incident light thermally excited
- G01N21/73—Systems in which the material investigated is excited whereby it emits light or causes a change in wavelength of the incident light thermally excited using plasma burners or torches
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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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- G—PHYSICS
- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
- G01J5/0003—Radiation pyrometry, e.g. infrared or optical thermometry for sensing the radiant heat transfer of samples, e.g. emittance meter
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
- G01J2005/0077—Imaging
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Abstract
The invention relates to the field of laser additive manufacturing and functional gradient materials, in particular to a method for preparing a functional gradient material based on a closed-loop combined measurement and control system. And the spectrometer is used for measuring plasma spectrum signals in the metal additive manufacturing process in real time and calibrating elements, and the acquired data is transmitted to the PC (personal computer) end for classified storage and processing in the next step. And shooting and analyzing a thermal image of the material during preparation by using an infrared camera to obtain the cooling rate of the metal material, and summarizing, summarizing and prejudging the processed data by combining a fuzzy PID algorithm so as to control the laser power, the powder feeding speed and the scanning speed. The method can carry out on-line detection and real-time calibration on the content of the element in the metal additive manufacturing process, and avoid errors caused by destructive detection. And correcting the process parameters according to the measured cooling rate to avoid the deformation problem caused by heat accumulation.
Description
Technical Field
The invention relates to the field of laser additive manufacturing and functional gradient materials, in particular to a method for preparing a functional gradient material based on a closed-loop combined measurement and control system.
Background
Laser additive manufacturing technology is an emerging technology developed in the middle of the 80's 20 th century, and has attracted much attention because of its ability to rapidly and accurately manufacture structural members having complex shapes. The laser additive manufacturing adopts a layer-by-layer surfacing mode to manufacture a compact metal component, has the outstanding characteristics of low manufacturing cost and high forming efficiency, and shows obvious advantages in the rapid forming technology of large-size and complex parts, thereby having wide application prospects in the fields of aerospace, automobiles, ships and the like.
In the aerospace field, a single alloy cannot meet local functional requirements, and the components need to ensure mechanical and metallurgical properties and realize light weight, so the concept of a functional gradient material is developed at the same time. In the preparation process of the functional gradient material, in order to avoid the defect conditions (cracks, air holes, peeling and the like) caused by direct material increase of different materials, related scholars propose methods of changing a scanning path, preheating in advance and the like, and the methods do not realize nondestructive detection and process control, cannot predict the forming state of a sample in advance and cannot ensure the forming quality and efficiency of a workpiece.
Disclosure of Invention
In order to solve the problems, the invention provides a method for preparing a functional gradient material based on a closed-loop joint measurement and control system, which is characterized by comprising the following steps of: aiming at the difficult problem of preparing the functional gradient material, the plasma spectrum signal in the metal additive manufacturing process is measured in real time and element calibration is carried out through a spectrometer, and the acquired data is transmitted to a PC (personal computer) end for further classified storage and processing. And shooting and analyzing a thermal image of the material during preparation by using an infrared camera to obtain the cooling rate of the metal material, and summarizing, summarizing and prejudging the processed data by combining a fuzzy PID algorithm so as to control the laser power, the powder feeding speed and the scanning speed. The method can carry out on-line detection and real-time calibration on the content of the element in the metal additive manufacturing process, and avoid errors caused by destructive detection. And correcting process parameters according to the measured cooling rate, so that the deformation problem caused by heat accumulation is avoided, and the method has important significance for preparing the gradient material with good functionality.
The technical scheme adopted by the invention comprises the following specific steps:
1) the spectrometer is placed on one side of a laser additive manufacturing and processing platform, and the optical fiber is aligned to a workpiece and used for element calibration in the material preparation process. The infrared camera is fixed on the same side of the spectrometer by a tripod and is aligned with the workpiece so as to shoot a thermal imaging picture of the sample in real time. The spectrometer and the infrared camera are connected to the PC terminal through the USB interface.
2) And compiling a software part of the closed-loop joint measurement and control system. And a real-time data acquisition control system is established at the PC end and comprises a data processing and PID control system. The data acquisition system comprises data acquisition, data recording and data storage. The PID control system comprises a proportional link, an integral link and a differential link.
3) Presetting technological parameters of laser additive manufacturing through numerical control equipment, mixing various powders required by preparing the functional gradient material in a powder mixer, adjusting a processing platform to a starting point, and waiting for printing.
4) In the additive manufacturing process, a spectrometer is used for measuring plasma spectrum signals in the metal additive manufacturing process in real time, the relative intensity of plasma corresponding to each element in a plasma spectrum curve chart is combined to determine the content of each element in a workpiece, when the content of one element is too high, the powder feeding speed of the powder feeder is properly reduced, the powder feeding speed of the other powder is increased, and the conditions of generating cracks and air hole defects are reduced.
5) The method comprises the steps of transmitting the relative intensity data of each element plasma collected by a spectrometer to a real-time data collection control system at a PC (personal computer) end, storing element content appearing in each collection process in the real-time data collection control system in a classified mode, dividing the element content into main elements and impurity elements, calibrating and summarizing the elements after the element components are determined, and drawing an element content curve graph.
6) The thermal image of the material during preparation is shot by an infrared camera, the temperature field distribution data obtained by shooting is imported into a PC terminal for analysis, the cooling rate of the metal is calculated, the relation between the temperature of a molten pool and the cooling rate is obtained, and the pictures are sorted according to the defect and defect types and are respectively stored by drawing a gray distribution curve.
7) The PID controller is used for adjusting and prejudging the deviation between the given value and the actual output value of the cooling rate, so that the laser power, the powder feeding speed and the scanning speed are controlled, and the conditions of sample edge collapse and deformation caused by high heat accumulation temperature are avoided.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings needed to be used in the examples or the description of the prior art will be briefly described below.
FIG. 1 is a flow chart of a method for preparing a functionally graded material based on a closed-loop joint measurement and control system.
Fig. 2 is a structural diagram of a closed-loop joint measurement and control system.
Fig. 3 is a graph of a plasma spectrum.
FIG. 4 is a plot of elemental content calibration.
Fig. 5 is a temperature real-time distribution diagram.
FIG. 6 is a graph of bath temperature versus cooling rate.
FIG. 7 is an electron microscope contrast image showing the presence or absence of crack defects during the additive manufacturing process.
In the above figures: 1: argon gas; 2: a powder mixer; 3: a laser additive manufacturing apparatus; 4: an optical fiber; 5: an optical bench; 6: a spectrometer; 7: a PC terminal; 8: an infrared camera; 9: a workpiece; 10: a processing platform; 11: and (5) numerical control equipment.
Detailed Description
The following detailed description of the present invention will be made with reference to the accompanying drawings and examples, but the present invention should not be limited to the examples.
This example used a TC4 substrate of 150mm × 150mm × 15mm specification, and the mixed powders were TC4 (particle size 100-.
Examples
1) And building a hardware part of a closed-loop joint measurement and control system. The spectrum selected by the embodiment is purchased from oceanographic companies, the model of the spectrum is Maya2000Pro series, and the element calibration part of the closed-loop combined measurement and control system mainly comprises an optical fiber 4, an optical bench 5 and a spectrometer 6. The spectrometer is placed on one side of a laser additive manufacturing platform and is respectively connected to an optical fiber 4, an optical bench 5 and a PC (personal computer) end 7 through three interfaces, one end of the optical fiber is connected to the interface of the spectrometer, and the other end of the optical fiber is fixed through a nut of the optical bench and is aligned to a workpiece for element calibration in the material preparation process.
2) The infrared camera 8 used in this embodiment is available from the very auspicious technologies ltd of Wuxi, Inc. and is model number LT7-P series. The infrared camera 8 is placed on the processing platform 10 and fixed on one side of the workpiece 9 by a tripod so as to take a thermal imaging picture of the sample in real time.
3) And compiling a software part of the closed-loop joint measurement and control system. And a real-time data acquisition control system is established on the PC terminal 7 and comprises a data acquisition system and a PID control system. The data acquisition system comprises data acquisition, data recording and data storage. The PID control system comprises a proportional link, an integral link and a differential link.
4) A coaxial powder feeding metal printer 3 is selected for carrying out a cladding experiment, the model is LMD 8060, and the experiment is carried out by Nanjing Kouchi light laser technology company Limited. Presetting the technological parameters of laser additive manufacturing through a numerical control device 11: the lapping rate is 50%, the diameter of a light spot is 3mm, the thickness of the layer is 0.7mm, the laser power is 1500W, the scanning speed is 600mm/min, the powder feeding speed of a 316L powder feeding barrel is 0.5r/min, the powder feeding speed of a TC4 powder feeding barrel is 0.5r/min, and the scanning speed and the powder feeding speed can be automatically adjusted according to the requirements of the workpiece 9. Mixing TC4 powder and 316L powder required by preparing a functional gradient material into a powder mixer 2, filling inert gas argon 1 into the powder mixer 2 to prevent the powder from generating oxidation reaction at high temperature, adjusting a processing platform to a starting point, and waiting for printing a workpiece 9.
5) In the laser additive manufacturing process, the spectrum radiated by the plasma is collected through the spectrometer 6, the collected spectrum data is drawn into a plasma spectrum curve graph, and the plasma spectrum curve graph is transmitted to the real-time data collection control system of the PC end 7. On the basis of collecting plasma intensity curves of different elements, the content of each element is collected into a graph to form an element content calibration curve. When the powder of the printed workpiece is mixed powder of 316L and TC4, the element content calibration curve shows that the main elements in the workpiece are Ti, Fe and the impurity elements such as Al, Cr, V and Ni are less, while the plasma spectrum curve shows that the plasma relative intensity of the Ti, Fe and Cr elements is the highest, and the experimental result is mainly based on the element content calibration curve, as shown in FIG. 3 and FIG. 4. When the iron element exceeds the titanium element in the material increase process, a brittle compound is formed between the dissimilar alloys to cause the defects of cracks and air holes, the powder feeding speed of the 316L powder feeding barrel is properly reduced, and the powder feeding speed of the TC4 powder feeding barrel is increased, so that the content proportion is controlled, and the defects are reduced.
6) The thermal image of the material as it was prepared was taken with an infrared camera 8 and the real-time temperature field profile was taken in real time after each layer was printed as shown in fig. 5. The pictures are led into a PC end 7 to be analyzed, the cooling rate of the metal is calculated according to the picture data and the scanning speed in the material increase process, and the cooling rate meets the following requirements:
cp (t) is a cooling rate (DEG C/t), DeltaT (t) is a temperature difference (DEG C), Deltat is a time difference(s), Tm (T) is an instantaneous bath temperature (DEG C), Tn (T) is a cooled bath temperature (DEG C), and n tau is a delay time (t), and a relation curve between the bath temperature and the cooling rate is obtained by using real-time temperature distribution data at a plurality of times and the cooling rate obtained by calculation, as shown in FIG. 6.
7) The measured picture data is transmitted to a real-time data acquisition control system of the PC terminal 7, a gray distribution curve is drawn, and the picture is divided into four categories, namely, a defect-free picture, a crack defect, a hole defect and a peeling defect. And after classification, data are transmitted to a PID controller, the cooling rate calculated by a temperature field distribution diagram on the surface of the workpiece without cracks is set as a given value in the PID controller, the cooling rate calculated by the temperature field distribution diagram shot by an infrared camera in each printing process is set as an actual output value, the PID adjusts the deviation formed by the given value and the actual output value, limits the variation range of the cooling rate and gives a prejudgment, and sends an instruction to an actuator through the controller.
8) In this example, the initial test parameters were set as: the lapping rate is 50%, the diameter of a light spot is 3mm, the thickness of a layer is 0.7mm, the laser power is 1500W, the scanning speed is 600mm/min, the powder feeding speed of a 316L powder feeding barrel is 0.5r/min, the powder feeding speed of a TC4 powder feeding barrel is 0.5r/min, the powder feeding speed and the laser power of a powder mixing barrel are continuously adjusted in the material increase process by combining an element content calibration curve and a relation graph of the temperature of a molten pool and the cooling rate, and the optimal process parameters are finally determined: the laser power is 1600W, the powder feeding speed of the TC4 powder feeding barrel is adjusted to be 0.9r/min, the powder feeding speed of the 316L powder feeding barrel is adjusted to be 0.1r/min, the scanning speed is 700mm/min, and other parameters are unchanged.
The closed-loop joint measurement and control method adopting real-time measurement and regulation control realizes online monitoring and real-time control of workpiece quality, avoids defect detection after material increase is finished, saves time cost, simultaneously ensures the forming quality of the workpiece, reduces the phenomena of sample edge collapse and deformation caused by high heat accumulation temperature and metal brittle compounds caused by improper powder content proportion, and reduces the phenomena of cracks, air holes and even peeling, as shown in figure 7.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
Claims (4)
1. A method for preparing a functional gradient material based on a closed-loop combined measurement and control system is characterized in that a spectrometer is used for carrying out real-time measurement and element calibration on plasma spectrum signals in a metal additive manufacturing process, and collected data are transmitted to a PC (personal computer) end for carrying out classification storage and processing of the next step; the method comprises the following steps of shooting and analyzing a thermal image of a material during preparation by using an infrared camera to obtain the cooling rate of the metal material, summarizing and prejudging processed data by combining a fuzzy PID algorithm, so as to control laser power, powder feeding speed and scanning speed, carrying out online detection and real-time calibration on the content of elements in the metal additive manufacturing process, avoiding errors caused by destructive detection, correcting process parameters according to the measured cooling rate, and avoiding the deformation problem caused by heat accumulation, and specifically comprises the following steps:
1) placing a spectrometer on one side of a laser additive manufacturing and processing platform, and aligning an optical fiber to a workpiece for element calibration in the material preparation process; the infrared camera is fixed on the same side of the spectrometer by a tripod and is aligned with the workpiece so as to shoot a thermal imaging picture of a sample in real time, and the spectrometer and the infrared camera are connected to a PC (personal computer) end through USB (universal serial bus) interfaces;
2) compiling a closed-loop joint measurement and control system software part; establishing a real-time data acquisition control system at a PC (personal computer) end, wherein the real-time data acquisition control system comprises a data processing and PID (proportion integration differentiation) control system; the data acquisition system comprises data acquisition, data recording and data storage; the PID control system comprises a proportional link, an integral link and a differential link;
3) presetting technological parameters for laser additive manufacturing through numerical control equipment, mixing various powders required for preparing the functional gradient material in a powder mixer, adjusting a processing platform to a starting point, and waiting for printing;
4) in the laser additive manufacturing process, a spectrometer is used for measuring plasma spectrum signals in the metal additive manufacturing process in real time, the relative intensity of plasma corresponding to each element in a plasma spectrum curve chart is combined to determine the content of each element in a workpiece, when the content of one element is too high, the powder feeding speed of the powder feeder is properly reduced, the powder feeding speed of the other powder is increased, and the conditions of generating cracks and air hole defects are reduced;
5) transmitting the collected plasma relative intensity data of each element to a real-time data acquisition control system of a PC (personal computer) end, storing the element content appearing in each acquisition process in the real-time data acquisition control system in a classified manner, and classifying, analyzing and controlling the element content into main elements and impurity elements;
6) shooting a thermal image of the material during preparation by using an infrared camera, importing the temperature field distribution data obtained by shooting into a PC (personal computer) terminal for analysis, calculating the cooling rate of metal to obtain the relation between the temperature of a molten pool and the cooling rate, and sorting and storing pictures according to the defect-free and defect types by drawing a gray distribution curve;
7) the PID controller is used for adjusting and prejudging the deviation between the given value and the actual output value of the cooling rate, so that the laser power, the powder feeding speed and the scanning speed are controlled, and the conditions of sample edge collapse and deformation caused by high heat accumulation temperature are avoided.
2. The method for preparing the functionally graded material based on the closed-loop joint measurement and control system as claimed in claim 1, wherein in the step (6), the cooling rate of the metal satisfies the following conditions:
cp (t) is a cooling rate (DEG C/t), Delta T (t) is a temperature difference (DEG C), Delta (t) is a time difference(s), Tm (T) is an instantaneous molten pool temperature (DEG C), Tn (T) is a molten pool temperature (DEG C) after cooling, and n tau is a delay time (t).
3. The method for preparing a functionally graded material based on the closed-loop joint measurement and control system as claimed in claim 1, wherein the spectrometer is connected to the optical fiber, the optical bench and the PC end through three interfaces, respectively, one end of the optical fiber is connected to the interface of the spectrometer, and the other end of the optical fiber is fixed through a nut of the optical bench to be aligned with the workpiece.
4. The method for preparing a functionally graded material based on the closed-loop joint measurement and control system as claimed in claim 1, wherein in the step (6), the measured picture data is transmitted to a real-time data acquisition control system at the PC end, a gray distribution curve is drawn, and the picture is divided into four categories, namely, no defect, crack defect, hole defect and peeling defect; and after classification, transmitting the data to a PID controller, setting the cooling rate calculated by the temperature field distribution diagram of the surface of the workpiece without crack generation as a given value in the PID controller, and setting the cooling rate calculated by the temperature field distribution diagram shot by an infrared camera in each printing process as an actual output value.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| 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 |
| CN115922066A (en) * | 2022-12-27 | 2023-04-07 | 中国重汽集团济南动力有限公司 | Welding penetration control method and system based on real-time coaxial visual monitoring |
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