CN113059159B - Additive manufacturing method for preventing directional solidification superalloy cracks - Google Patents
Additive manufacturing method for preventing directional solidification superalloy cracks Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 44
- 239000000654 additive Substances 0.000 title claims abstract description 41
- 230000000996 additive effect Effects 0.000 title claims abstract description 41
- 229910000601 superalloy Inorganic materials 0.000 title claims abstract description 17
- 238000007711 solidification Methods 0.000 title claims abstract description 7
- 230000008023 solidification Effects 0.000 title claims abstract description 7
- 238000010438 heat treatment Methods 0.000 claims abstract description 60
- 238000001816 cooling Methods 0.000 claims abstract description 46
- 238000005253 cladding Methods 0.000 claims abstract description 23
- 239000000758 substrate Substances 0.000 claims abstract description 20
- 238000004372 laser cladding Methods 0.000 claims abstract description 17
- 239000007788 liquid Substances 0.000 claims abstract description 15
- 239000000843 powder Substances 0.000 claims description 17
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 14
- 238000000034 method Methods 0.000 claims description 14
- 238000001514 detection method Methods 0.000 claims description 11
- 229910052782 aluminium Inorganic materials 0.000 claims description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 10
- 239000011888 foil Substances 0.000 claims description 10
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 8
- 229910052757 nitrogen Inorganic materials 0.000 claims description 7
- 239000002994 raw material Substances 0.000 claims description 5
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 4
- 239000007787 solid Substances 0.000 claims description 3
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- B22—CASTING; POWDER METALLURGY
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- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
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- 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
- 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
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
- B22F2007/068—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts repairing articles
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- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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Abstract
本发明公开了一种预防定向凝固高温合金裂纹的增材制造方法,包括冷却装置和加热装置,所述冷却装置和加热装置通过以下步骤应用在增材制造过程中:S1:增材制造:采用激光熔覆设备在基板上进行增材制造;S2:在线冷却和在线加热:冷却装置设置于热源前方并跟随热源对熔池前段实时冷却,所述加热装置设置于热源后侧并跟随热源对熔池后段实时加热。本发明加热装置跟在熔池的后方随着熔池同步移动,可以有效减缓熔池后段熔覆层的固态冷却速度,减少残余应力;冷却装置设置在熔池前段,并随着熔池同步移动,用于冷却熔池前段熔覆层的温度,使熔池固液界面的温度梯度足够大,促进定向晶的生成,提高凝固的定向性。
The invention discloses an additive manufacturing method for preventing directional solidification superalloy cracks, including a cooling device and a heating device, and the cooling device and the heating device are applied in the additive manufacturing process through the following steps: S1: additive manufacturing: using Laser cladding equipment performs additive manufacturing on the substrate; S2: online cooling and online heating: the cooling device is set in front of the heat source and follows the heat source to cool the front section of the molten pool in real time, and the heating device is set behind the heat source and follows the heat source to cool the molten pool. The back section of the pool is heated in real time. The heating device of the present invention follows the rear of the molten pool and moves synchronously with the molten pool, which can effectively slow down the solid-state cooling speed of the cladding layer in the rear section of the molten pool and reduce residual stress; the cooling device is arranged at the front section of the molten pool and is synchronized with the molten pool The movement is used to cool the temperature of the cladding layer in the front section of the molten pool, so that the temperature gradient of the solid-liquid interface of the molten pool is large enough to promote the formation of oriented crystals and improve the orientation of solidification.
Description
技术领域technical field
本发明涉及增材制造技术领域,特别涉及一种预防定向凝固高温合金裂纹的增材制造方法。The invention relates to the technical field of additive manufacturing, in particular to an additive manufacturing method for preventing directional solidification superalloy cracks.
背景技术Background technique
由于定向高温合金消除了叶片的横向晶界,纵向性能优异,耐高温性能更好,因此被广泛使用在进口温度更高的航空航天及燃气轮机涡轮叶片中。其相应的制备条件苛刻,必须同时满足热流垂直于晶体生长的固液界面单一方向和晶体生长的界面前的熔体中没有新的结晶核心并长大,保证正的温度梯度,进而制备成本跟高。Because the oriented superalloy eliminates the transverse grain boundary of the blade, has excellent longitudinal performance and better high temperature resistance, it is widely used in aerospace and gas turbine turbine blades with higher inlet temperature. The corresponding preparation conditions are harsh, and it must be satisfied that the heat flow is perpendicular to the single direction of the solid-liquid interface of crystal growth and that there are no new crystal cores in the melt before the crystal growth interface and grow up to ensure a positive temperature gradient. high.
而增材制造手段作为一种新的制造方法,可以实现服役损伤叶片的修复,也可以作为一种定向叶片的制备手段。在实际的激光熔覆制备该定向高温合金中通常面临两个难题,其一为DZ125、MarM247、CM247LC等定向凝固高温合金在激光修复过程中由于存在较大的应力,极易开裂;其二为材料的定向性问题,特别是打印部件高度比较高的时候,热累积较大,导致外延生长性变差,无法保证定向性。As a new manufacturing method, the additive manufacturing method can realize the repair of damaged blades in service, and can also be used as a preparation method for directional blades. In the actual preparation of the directional superalloy by laser cladding, two problems are usually faced. One is that the directionally solidified superalloys such as DZ125, MarM247, and CM247LC are easily cracked due to the large stress in the laser repair process; the other is The orientation problem of the material, especially when the height of the printed part is relatively high, the heat accumulation is relatively large, resulting in poor epitaxial growth, and the orientation cannot be guaranteed.
发明内容Contents of the invention
有鉴于此,本发明提供一种预防定向凝固高温合金裂纹的增材制造方法,以解决增材制造的定向凝固金属零部件在修复或制造过程中的开裂和无法保证定向性问题。In view of this, the present invention provides an additive manufacturing method for preventing cracks in directionally solidified superalloys, so as to solve the problems of cracking and inability to guarantee orientation of additively manufactured directionally solidified metal parts during repair or manufacturing.
本发明的预防定向凝固高温合金裂纹的增材制造方法,包括冷却装置和加热装置,所述冷却装置和加热装置通过以下步骤应用在增材制造过程中:The additive manufacturing method for preventing directionally solidified superalloy cracks of the present invention includes a cooling device and a heating device, and the cooling device and the heating device are applied in the additive manufacturing process through the following steps:
S1:增材制造:采用激光熔覆设备在基板上进行增材制造;S1: Additive manufacturing: use laser cladding equipment to perform additive manufacturing on the substrate;
S2:在线冷却和在线加热:冷却装置设置于热源前方并跟随热源对熔池前段实时冷却,所述加热装置设置于热源后侧并跟随热源对熔池后段实时加热,以使得熔池的固液界面有足够的温度梯度。S2: Online cooling and online heating: the cooling device is set in front of the heat source and follows the heat source to cool the front section of the molten pool in real time, and the heating device is set behind the heat source and follows the heat source to heat the rear section of the molten pool in real time, so that the solid state of the molten pool There is sufficient temperature gradient at the liquid interface.
进一步,所述冷却装置包括可通入液氮的铝箔,所述铝箔贴于热源前段的熔覆层上。Further, the cooling device includes an aluminum foil that can be fed with liquid nitrogen, and the aluminum foil is pasted on the cladding layer at the front end of the heat source.
进一步,所述加热装置包括两个加热线圈,两个加热线圈位于熔池后段熔覆层的两侧。Further, the heating device includes two heating coils, and the two heating coils are located on both sides of the cladding layer in the rear section of the molten pool.
进一步,步骤S1中,基板与增材制造原料材料相同。Further, in step S1, the substrate is the same as the additive manufacturing raw material.
进一步,还包括设置于激光熔覆设备上用于对热源后侧熔覆层进行温度检测的温度检测装置。Further, it also includes a temperature detection device arranged on the laser cladding equipment for detecting the temperature of the cladding layer on the rear side of the heat source.
进一步,所述冷却装置、加热装置以及温度检测装置以可转动的方式安装于激光熔覆设备上。Further, the cooling device, the heating device and the temperature detection device are rotatably installed on the laser cladding equipment.
进一步,步骤S1中,在增材制造前,用丙酮和酒精清洗基板。Further, in step S1, the substrate is cleaned with acetone and alcohol before additive manufacturing.
进一步,所述冷却装置和加热装置还以高度可调的方式安装于送粉装置上。Further, the cooling device and the heating device are installed on the powder feeding device in a height-adjustable manner.
本发明的有益效果:Beneficial effects of the present invention:
本发明加热装置跟在熔池的后方随着熔池同步移动,可以有效减缓熔池后段熔覆层的固态冷却速度,减少残余应力;冷却装置设置在熔池前段,并随着熔池同步移动,用于冷却熔池前段熔覆层的温度,使熔池固液界面的温度梯度足够大,促进定向晶的生成,提高凝固的定向性,可解决随着打印高度变高热累积较大导致的定向晶粗大问题;而且该方式实现了跟随打印的实时冷却和加热,不影响打印效率,且简化工件后期热处理工艺。The heating device of the present invention follows the rear of the molten pool and moves synchronously with the molten pool, which can effectively slow down the solid-state cooling speed of the cladding layer in the rear section of the molten pool and reduce residual stress; the cooling device is arranged at the front section of the molten pool and is synchronized with the molten pool Moving, used to cool the temperature of the cladding layer in the front section of the molten pool, so that the temperature gradient of the solid-liquid interface of the molten pool is large enough to promote the formation of oriented crystals and improve the orientation of solidification, which can solve the problem of large heat accumulation as the printing height becomes higher. The problem of coarse oriented crystals; and this method realizes real-time cooling and heating following printing, does not affect printing efficiency, and simplifies the later heat treatment process of workpieces.
附图说明Description of drawings
下面结合附图和实施例对本发明作进一步描述。The present invention will be further described below in conjunction with the accompanying drawings and embodiments.
图1为本发明结构示意图;Fig. 1 is a structural representation of the present invention;
具体实施方式Detailed ways
如图所示,本实施例中的预防定向凝固高温合金裂纹的增材制造方法,包括冷却装置1和加热装置2,所述冷却装置和加热装置通过以下步骤应用在增材制造过程中:As shown in the figure, the additive manufacturing method for preventing directionally solidified superalloy cracks in this embodiment includes a
S1:增材制造:采用激光熔覆设备3在基板4上进行增材制造;在激光修复过程中,待修复的零部件作为基板;S1: Additive manufacturing: use laser cladding equipment 3 to perform additive manufacturing on the
S2:在线冷却和在线加热:冷却装置设置于热源前方并跟随热源对熔池前段实时冷却,所述加热装置设置于热源后侧并跟随热源对熔池后段实时加热,以使得熔池的固液界面有足够的温度梯度。S2: Online cooling and online heating: the cooling device is set in front of the heat source and follows the heat source to cool the front section of the molten pool in real time, and the heating device is set behind the heat source and follows the heat source to heat the rear section of the molten pool in real time, so that the solid state of the molten pool There is sufficient temperature gradient at the liquid interface.
热源为增材制造设备烧结原料的位置也为熔池的位置;激光熔覆是通过在基材表面添加熔覆材料,并利用高能密度的激光束使之与基材表面薄层一起熔凝的方法,在基层表面形成冶金结合的添料熔覆层,激光熔覆设备用于增材制造时,通过喷涂粉末材料并实时烧结的方式,逐层实现烧结;激光熔覆设备为现有设备,具体不在赘述;冷却装置和加热装置可设置于激光熔覆设备的送粉器上,可以实现打印过程中的同步移动,具体不在赘述;加热装置的加热温度为1100℃,该装置跟在熔池的后方随着熔池同步移动,可以有效减缓熔池后段熔覆层的固态冷却速度,减少残余应力;冷却装置设置在熔池前段,并随着熔池同步移动,用于冷却熔池前段熔覆层的温度,使熔池固液界面的温度梯度足够大,促进定向晶的生成,提高凝固的定向性,可解决随着打印高度变高热累积较大导致的定向晶粗大问题;而且该方式实现了跟随打印的实时冷却和加热,不影响打印效率,且简化工件后期热处理工艺;The heat source is the position of the sintered raw material of the additive manufacturing equipment and the position of the molten pool; laser cladding is achieved by adding cladding materials on the surface of the substrate and using a high-energy-density laser beam to fuse it together with the thin layer on the surface of the substrate The method is to form a metallurgically bonded cladding layer on the surface of the base layer. When the laser cladding equipment is used for additive manufacturing, the sintering is realized layer by layer by spraying powder materials and sintering in real time; the laser cladding equipment is an existing equipment. The details will not be repeated; the cooling device and the heating device can be set on the powder feeder of the laser cladding equipment, which can realize the synchronous movement during the printing process, and the details will not be repeated; the heating temperature of the heating device is 1100 ° C, and the device follows the molten pool The back of the molten pool moves synchronously with the molten pool, which can effectively slow down the solid-state cooling rate of the cladding layer in the rear section of the molten pool and reduce residual stress; the cooling device is set at the front section of the molten pool and moves synchronously with the molten pool to cool the front section of the molten pool The temperature of the cladding layer makes the temperature gradient of the solid-liquid interface of the molten pool large enough to promote the formation of oriented crystals and improve the orientation of solidification, which can solve the problem of coarse oriented crystals caused by large heat accumulation as the printing height becomes higher; and the The method realizes the real-time cooling and heating following the printing, does not affect the printing efficiency, and simplifies the post-heat treatment process of the workpiece;
本实施例中,所述冷却装置包括可通入液氮的铝箔1a,所述铝箔贴于热源前段的熔覆层上。铝箔可折叠形成中空的腔室,或者铝箔可适当增加厚度并开设相应的腔室,结合图1所示,冷却装置还包括装有液氮的容器罐1b,其中容器罐的出口通过管道与铝箔内腔连通,容器罐的出口处设置有阀门调节液氮的流量,铝箔用卡扣安装在熔池前段的送粉器上,这样可以保证打印过程中冷却装置与熔池的同步移动性,保证冷却装置一直位于熔池的前段,该结构的冷却装置其冷却效果甚佳,利用该装置可以使熔池固液界面的温度梯度足够大,促进定向晶的生成。In this embodiment, the cooling device includes an aluminum foil 1a that can be filled with liquid nitrogen, and the aluminum foil is pasted on the cladding layer at the front end of the heat source. The aluminum foil can be folded to form a hollow chamber, or the thickness of the aluminum foil can be appropriately increased and a corresponding chamber can be opened. As shown in Figure 1, the cooling device also includes a
本实施例中,所述加热装置包括两个加热线圈,两个加热线圈位于熔池后段熔覆层的两侧。加热装置安装在熔池后段的送粉器上,实现与熔池的同步移动,加热线圈为感应线圈,线圈呈椭圆形结构,紧跟在熔池后段的试样两侧,可防止加热线圈与未凝结的熔覆层接触,其中加热线圈采用电加热,可根据所需调节加热温度;In this embodiment, the heating device includes two heating coils, and the two heating coils are located on both sides of the cladding layer in the rear section of the molten pool. The heating device is installed on the powder feeder at the rear of the molten pool to realize synchronous movement with the molten pool. The heating coil is an induction coil with an elliptical structure, which closely follows the two sides of the sample at the rear of the molten pool to prevent heating The coil is in contact with the uncondensed cladding layer, and the heating coil adopts electric heating, and the heating temperature can be adjusted according to the requirement;
本实施例中,步骤S1中,基板与增材制造原料材料相同。增材制造过程中熔覆层冷却后与基板粘连为一体,使得成型的零部件固定在基板上,提高零部件成型过程中的稳定性,在烧结完成后,将成型零件从基板上切下。In this embodiment, in step S1, the substrate is the same as the additive manufacturing raw material. During the additive manufacturing process, the cladding layer is cooled and adhered to the substrate as a whole, so that the formed parts are fixed on the substrate, improving the stability of the parts during the forming process. After the sintering is completed, the formed parts are cut from the substrate.
本实施例中,还包括设置于激光熔覆设备上用于对热源后侧熔覆层进行温度检测的温度检测装置5。温度检测装置优选红外测温装置,其中温度检测装置包括红外测温装置5a以及温度显示仪5b,其中红外测温装置5a用于检测热源后侧熔覆层的温度,红外测温装置5a将检测的温度数据传递至温度显示仪5b,并通过温度显示仪5b的计算实时控制加热线圈的加热温度,温度显示仪5b上具有控制面板,用于手动控制加热线圈的温度,灵活设定加热温度,便于控制感应加热装置的加热温度;红外测温装置测试的是紧跟熔池后端的感应加热区域温度。In this embodiment, it also includes a
本实施例中,所述冷却装置、加热装置以及温度检测装置以可转动的方式安装于激光熔覆设备上。结合图1所示,激光熔覆设备具有两个送粉器3a,两个送粉器位于激光器3b的两侧,送粉器喷嘴喷射方向以及激光器的激光方向交于一点,其交点位于最上方熔覆层处;送粉装置可围绕激光器转动,冷却装置安装于其中一个送粉器上,加热装置和温度检测装置安装于另一个送粉器上,此时转动送粉器互换两个送粉器的位置即可调节冷却装置、加热装置和温度检测装置的位置,每烧结完一层后,调节两个送粉器的位置,如此往复直至打印结束;In this embodiment, the cooling device, the heating device and the temperature detection device are rotatably installed on the laser cladding equipment. As shown in Figure 1, the laser cladding equipment has two
本实施例中,步骤S1中,在增材制造前,用丙酮和酒精清洗基板。通过对基板的清洗利于烧结层与基板的粘接,提高整个成型零件的稳定性,防止零件在成型过程中错位,便于送粉器和激光器的空间定位。In this embodiment, in step S1, the substrate is cleaned with acetone and alcohol before additive manufacturing. The cleaning of the substrate facilitates the bonding of the sintered layer and the substrate, improves the stability of the entire molded part, prevents the misalignment of the part during the molding process, and facilitates the spatial positioning of the powder feeder and the laser.
本实施例中,所述冷却装置和加热装置还以高度可调的方式安装于送粉装置上。冷却装置和加热装置可通过电动伸缩杆调节高度,通过该结构可调节冷却装置以及加热装置的位置,便于调节温度阶梯。In this embodiment, the cooling device and the heating device are also installed on the powder feeding device in a height-adjustable manner. The height of the cooling device and the heating device can be adjusted through the electric telescopic rod, and the position of the cooling device and the heating device can be adjusted through this structure, which is convenient for adjusting the temperature step.
在增材制造过程总,首先将成分与增材制造原料相同的定向平整基板用丙酮和酒精进行清洗,并校准加热装置和冷却装置高度和温度;然后采用激光熔覆设备进行增材制造,激光熔覆设备激光束斑尺寸尽可能地小,束斑尺寸1-2mm左右,激光功率在1000w-1800w左右;在打印的过程中加热装置一直随着熔覆头的移动而移动,以使得加热装置随熔池移动,并利用测温装置实时反馈和调节温度,对于高温合金温度设定在800-1050℃左右,并根据材料不同来调节温度;冷却装置随着打印的进行同步冷却熔池前段的温度,保证在打印过程中熔池前段保持一个较低的温度,特别是保证打印高度较高的部件时熔池前段的温度较低,一般在打印部件高度在20mm以下,液氮的流速较小,当打印部件高度超过50mm 后,适当的开大液氮的流速,当然实际的冷却速度根据打印结构件的大小及材料的导热都有关系,需依据实际情况来进行调节;依次重复上述打印步骤完成零部件的增材制造,制造完成后将成型的零部件从基板上切下进行检测、表面处理、热处理等工序。In the additive manufacturing process, firstly, the oriented flat substrate with the same composition as the additive manufacturing raw material is cleaned with acetone and alcohol, and the height and temperature of the heating device and the cooling device are calibrated; then the laser cladding equipment is used for additive manufacturing. The laser beam spot size of the cladding equipment should be as small as possible, the beam spot size is about 1-2mm, and the laser power is about 1000w-1800w; during the printing process, the heating device always moves with the cladding head, so that the heating device Move with the molten pool, and use the temperature measuring device to feed back and adjust the temperature in real time. For high-temperature alloys, the temperature is set at about 800-1050 ° C, and the temperature is adjusted according to different materials; the cooling device cools the front part of the molten pool synchronously with the printing. Temperature, to ensure that the front part of the molten pool maintains a low temperature during the printing process, especially to ensure that the temperature of the front part of the molten pool is low when printing parts with a high height. Generally, when the height of the printed part is below 20mm, the flow rate of liquid nitrogen is small , when the height of the printed part exceeds 50mm, properly increase the flow rate of liquid nitrogen. Of course, the actual cooling rate depends on the size of the printed structural part and the heat conduction of the material, and it needs to be adjusted according to the actual situation; repeat the above printing steps in turn The additive manufacturing of parts is completed, and after the manufacturing is completed, the formed parts are cut from the substrate for inspection, surface treatment, heat treatment and other processes.
最后说明的是,以上实施例仅用以说明本发明的技术方案而非限制,尽管参照较佳实施例对本发明进行了详细说明,本领域的普通技术人员应当理解,可以对本发明的技术方案进行修改或者等同替换,而不脱离本发明技术方案的宗旨和范围,其均应涵盖在本发明的权利要求范围当中。Finally, it is noted that the above embodiments are only used to illustrate the technical solutions of the present invention without limitation. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be carried out Modifications or equivalent replacements without departing from the spirit and scope of the technical solution of the present invention shall be covered by the claims of the present invention.
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