CN114740048A - Active laser infrared thermal imaging-based additive manufacturing quality online monitoring system and method - Google Patents
Active laser infrared thermal imaging-based additive manufacturing quality online monitoring system and method Download PDFInfo
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- CN114740048A CN114740048A CN202210468190.4A CN202210468190A CN114740048A CN 114740048 A CN114740048 A CN 114740048A CN 202210468190 A CN202210468190 A CN 202210468190A CN 114740048 A CN114740048 A CN 114740048A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 88
- 239000000654 additive Substances 0.000 title claims abstract description 85
- 230000000996 additive effect Effects 0.000 title claims abstract description 85
- 238000012544 monitoring process Methods 0.000 title claims abstract description 56
- 238000001931 thermography Methods 0.000 title claims abstract description 42
- 238000000034 method Methods 0.000 title claims abstract description 16
- 230000007547 defect Effects 0.000 claims abstract description 27
- 238000007639 printing Methods 0.000 claims abstract description 26
- 239000013307 optical fiber Substances 0.000 claims abstract description 23
- 238000001514 detection method Methods 0.000 claims abstract description 22
- 230000007246 mechanism Effects 0.000 claims abstract description 15
- 230000008878 coupling Effects 0.000 claims abstract description 13
- 238000010168 coupling process Methods 0.000 claims abstract description 13
- 238000005859 coupling reaction Methods 0.000 claims abstract description 13
- 239000000463 material Substances 0.000 claims abstract description 7
- 238000009792 diffusion process Methods 0.000 claims abstract description 4
- 239000010410 layer Substances 0.000 claims description 32
- 238000009826 distribution Methods 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 5
- 238000000265 homogenisation Methods 0.000 claims description 4
- 238000012545 processing Methods 0.000 claims description 3
- 239000011229 interlayer Substances 0.000 claims description 2
- 230000001360 synchronised effect Effects 0.000 claims description 2
- 238000012797 qualification Methods 0.000 abstract description 3
- 230000008569 process Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 238000005266 casting Methods 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000011897 real-time detection Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 239000002918 waste heat Substances 0.000 description 1
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N25/00—Investigating or analyzing materials by the use of thermal means
- G01N25/72—Investigating presence of flaws
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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
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Abstract
The invention discloses an active laser infrared thermal imaging-based additive manufacturing quality on-line monitoring system and method. The monitoring method comprises the following steps: in the additive manufacturing process of the materials stacked layer by layer on the forming platform, a laser beam emitted by a laser irradiates a certain area of the surface of a solidified current printing layer through an optical fiber coupling laser homogenizing lens to be uniformly heated, the existence of internal defects of the printing layer can block the downward diffusion of heat flow, so that the local temperature rise is formed on the surface, and the surface temperature image of the area is collected through a thermal infrared imager to realize the detection of the internal defects; the laser infrared thermal imaging additive manufacturing quality on-line monitoring system keeps linkage with the printing nozzle through the motion scanning mechanism, and thus on-line monitoring of the quality of the additive manufacturing structure can be realized. The one-time qualification rate of the product is improved, and the product is prevented from being scrapped or repaired.
Description
Technical Field
The invention belongs to the field of additive manufacturing and laser infrared thermal imaging, and particularly relates to an active laser infrared thermal imaging-based additive manufacturing quality online monitoring system and method.
Background
Aerospace equipment is gradually developed towards light weight, diversified functions, complicated structure, long service life, high reliability and low cost, and the traditional manufacturing method combining casting and forging with machining is difficult to meet the manufacturing requirements. In the aspect of integrated forming of a complex structure, the additive manufacturing technology has the advantages that other traditional manufacturing technologies cannot achieve. However, the additive manufacturing is a layered printing forming mode, and the product is easy to have the problems of poor density, anisotropic structure performance, local deformation and stress concentration, and various defects such as air holes, cracks, inclusions and the like. Compared with destructive detection, nondestructive detection can realize nondestructive detection of the whole product, and can be carried out in real time in the manufacturing process. At present, the quality detection of the additive manufacturing products is mostly carried out after the products are manufactured, and the quality detection is also called as off-line monitoring. Defects such as air holes and layering in the additive manufacturing process can cause product quality problems if the defects are not timely processed, and more seriously cause products to be unqualified, thereby causing huge loss. Therefore, a method for monitoring the additive manufacturing process in real time, detecting defects on line and even possibly repairing the additive manufacturing process is needed, the quality of the additive manufacturing product can be greatly improved, the rejection rate of the product is greatly reduced, and the one-time qualified rate of the product is improved.
At present, the research results of on-line monitoring of internal defects are few, an infrared camera is directly adopted to carry out on-line monitoring on the surface temperature of a molten pool, and then the appearance of the molten pool is fed back, but passive infrared thermal imaging on-line monitoring only by means of waste heat in the printing and manufacturing process of an additive manufactured part is prone to being interfered by the background, the internal defects have small influence on the surface temperature distribution, the internal defects are low in detection sensitivity and the like.
Disclosure of Invention
Aiming at the defects or improvement requirements of the prior art, the invention provides an additive manufacturing quality online monitoring system and method based on active laser infrared thermal imaging, and aims to realize real-time quality monitoring of the whole additive manufacturing process, detect whether a defect is generated in a rigid additive manufacturing area through a laser infrared additive manufacturing quality online monitoring system, and take measures in time after the defect is generated, so that the rejection rate of a product is reduced, the one-time qualification rate of the product is improved, and the product is prevented from being scrapped or repaired.
In order to achieve the purpose, the invention adopts the following technical scheme:
an active laser infrared thermal imaging-based additive manufacturing quality online monitoring system comprises a motion scanning mechanism 1, a laser 2, an optical fiber 4, an optical fiber coupling laser homogenizing lens 6, a thermal infrared imager 5 and a control computer 3 provided with image acquisition and processing software; the optical fiber coupling laser homogenization lens 6 is connected with the laser 2 through the optical fiber 4, the thermal infrared imager 5 is connected with the control computer 3 with image acquisition and processing software, the motion scanning mechanism 1 is provided with the high-resolution thermal infrared imager 5 and the laser homogenization lens 6 for mobile scanning, and the control computer 3 with the image acquisition and processing software is simultaneously responsible for synchronous control of the thermal infrared imager 5, the laser 2 and the motion scanning mechanism 1.
In the additive manufacturing process of materials stacked layer by layer on a forming platform, a Gaussian or quasi-Gaussian distribution collimated laser beam emitted by a laser 2 reaches an optical fiber coupling laser homogenizing lens 6 through an optical fiber 4, is homogenized into uniformly distributed laser to irradiate a certain area on the surface of an additive piece 10 for uniform heating, and forms a downward diffused heat flow, the existence of a printing layer internal defect and an interlayer defect 11 can block the downward diffusion of the heat flow, so that a local temperature rise is formed on the surface, and a surface temperature image of the area is collected through an infrared thermal imager 5 so as to realize the detection of the area defect; the thermal infrared imager 5 and the laser homogenizing lens 6 are linked with the printing nozzle 8 through the motion scanning mechanism 1, and therefore on-line monitoring of the overall quality of the additive manufacturing structure is achieved.
The thermal infrared imager 5 is a high-resolution thermal infrared imager, and the resolution reaches 640 x 512.
The monitoring method of the additive manufacturing quality on-line monitoring system based on active laser infrared thermal imaging comprises the following steps:
step 1: installing an additive manufacturing quality online monitoring system of laser infrared thermal imaging, setting a preset delay time between the additive manufacturing system and the additive manufacturing quality online monitoring system of laser infrared thermal imaging, setting additive manufacturing parameters, and performing additive manufacturing on a structural part by controlling a motion system 7;
and 2, step: the setting is finished on a control computer 3 provided with image acquisition and processing software, the laser infrared thermal imaging additive manufacturing quality on-line monitoring system is kept linked with a printing nozzle 8 through a motion scanning mechanism 1, and a high-power laser 2 is controlled to emit light;
and step 3: the collimated laser beam which is generated by the laser 2 and is in Gaussian or quasi-Gaussian distribution is incident on the fiber coupling laser homogenizing lens 6 through the optical fiber 4, is shaped into a uniform laser heat source and irradiates the surface of the solidified printing layer;
and 4, step 4: the method comprises the following steps that (1) along with the beginning of an additive manufacturing process, an additive manufacturing system continuously works, a laser infrared thermal imaging additive manufacturing quality online monitoring system detects a certain area of the surface of a solidified printing layer in a stepping mode, printing of each area of each layer is completed, and the laser infrared thermal imaging additive manufacturing quality online monitoring system detects the corresponding area in time; firstly, the laser 2 does not emit light, and the thermal infrared imager 5 records the initial temperature F in real timeij 1Then the laser 2 emits light, and the thermal infrared imager 5 records the temperature F at the moment of heating in real timeij 2(ii) a Image temperature data is collected according to formula Fij＝|Fij 2- F ij 11,2,3 …, calculating the background differential temperature of the jth area of the ith layer, and processing the background differential temperature in real time through a control computer 3 provided with image acquisition and processing software; when all the areas of all the layers are printed, namely additive manufacturing is finished, the corresponding laser infrared thermal imaging additive manufacturing quality online monitoring system completes detection, and the laser infrared thermal imaging additive manufacturing quality online monitoring system automatically generates a defect detection map.
The laser infrared thermal imaging additive manufacturing quality on-line monitoring system is used for real-time detection in the additive manufacturing process, and a defect detection map with high-precision display on parameters such as the position and the size of a defect is formed in the detection process, so that the real-time quality monitoring of the whole additive manufacturing process can be realized, measures can be taken in time after the defect is generated, the rejection rate of a product is reduced, the one-time qualification rate of the product is improved, and the product is prevented from being scrapped or repaired.
Drawings
Fig. 1 is a schematic diagram of an additive manufacturing quality on-line monitoring system based on active laser infrared thermal imaging according to the present invention.
Fig. 2 is a schematic view of a process flow for detecting an additive manufacturing layer area.
Fig. 3 is an additive manufacturing overall process flow and defect detection diagram.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
As shown in fig. 1, an active laser infrared thermal imaging-based additive manufacturing quality online monitoring system comprises a motion scanning mechanism 1, a laser 2, an optical fiber 4, an optical fiber coupling laser homogenizing lens 6, a thermal infrared imager 5 and a control computer 3 equipped with image acquisition and processing software.
The invention provides an active laser infrared thermal imaging-based additive manufacturing quality on-line monitoring system and method, wherein the system is composed of a high-power laser 2, an optical fiber 4, an optical fiber coupling laser shaping lens 6, a high-resolution thermal infrared imager 5, a control computer 3 provided with image acquisition and processing software, and a motion scanning mechanism 1. The detection method comprises the following steps: when materials are stacked layer by layer on a forming platform to form an additive manufacturing component, a laser beam emitted by a high-power laser 2 irradiates a certain area of the surface of a solidified current printing layer through an optical fiber coupling laser shaping lens 6 to be uniformly heated, the downward diffusion of heat flow is hindered by the existence of internal defects of the printing layer, so that the local temperature rise is formed on the surface, and the surface temperature image of the area is collected through an infrared thermal imager 5 to realize the detection of the internal defects; the laser infrared thermal imaging additive manufacturing quality on-line monitoring system keeps linkage with the printing nozzle 8 through the motion scanning mechanism 1, and thus on-line monitoring of additive manufacturing structure quality can be achieved.
The present invention will be described in further detail with reference to fig. 1 to 3 and specific embodiments.
The invention relates to a monitoring method of an active laser infrared thermal imaging-based additive manufacturing quality on-line monitoring system, which specifically comprises the following steps:
step 1: installing an additive manufacturing quality online monitoring system of laser infrared thermal imaging, setting a proper delay time between the additive manufacturing system and the additive manufacturing quality online monitoring system of laser infrared thermal imaging, setting additive manufacturing parameters, and performing additive manufacturing on a structural part by controlling a motion system 7;
step 2: the setting is finished on a control computer 3 provided with image acquisition and processing software, and a laser infrared thermal imaging additive manufacturing quality online monitoring system is kept linked with a printing nozzle 8 through a motion scanning mechanism 1 to control a high-power laser 2 to emit light;
and step 3: the collimated laser beam which is generated by the high-power laser 2 and is in Gaussian or quasi-Gaussian distribution is incident on the optical fiber coupling laser homogenizing lens 6 through the optical fiber 4, is shaped into a uniform laser heat source and irradiates the surface of the solidified printing layer;
and 4, step 4: when the additive manufacturing process is started, powder is deposited on the surface of the additive material 10 through the powder feeding nozzle 9, the additive manufacturing system works continuously, and the laser infrared additive manufacturing quality online detection system detects a certain area of the surface of the solidified printing layer in a stepping mode. And printing each region of each layer is completed, and the laser infrared thermal imaging additive manufacturing quality online monitoring system carries out corresponding detection in time. Firstly, the laser 2 does not emit light, and the thermal infrared imager 5 records the initial temperature F in real timeij 1Then the laser 2 emits light, and the thermal infrared imager 5 records the temperature F at the moment of heating in real timeij 2(ii) a Image temperature data is collected according to formula Fij＝|Fij 2-Fij 1And (3) calculating the background differential temperature of the jth area of the ith layer, and processing the background differential temperature in real time by a control computer 3 provided with image acquisition and processing software, wherein the j is 1,2 and 3 …. As shown in FIG. 2, when the first region 12 of the first layer is printed and solidified, the laser infrared thermal imaging additive manufacturing quality on-line monitoring system detects the first region of the first layer, and the additive manufacturing system continues to operate and continues to print the second region of the first layerA region 13; when the printing of the first layer second area 13 is finished and solidified, the laser infrared thermal imaging additive manufacturing quality on-line monitoring system detects the first layer third area, after the printing and detection of the first layer are finished, the second layer and the third layer are printed until the additive manufacturing of the object is finished, the corresponding laser infrared thermal imaging additive manufacturing quality on-line monitoring system completes the detection, and the laser infrared thermal imaging additive manufacturing quality on-line monitoring system automatically generates a defect detection map as shown in fig. 3.
Claims (4)
1. The utility model provides an increase material manufacturing quality on-line monitoring system based on active laser infrared thermal imaging which characterized in that: the system comprises a motion scanning mechanism (1), a laser (2), an optical fiber (4), an optical fiber coupling laser homogenizing lens (6), a thermal infrared imager (5) and a control computer (3) provided with image acquisition and processing software; the optical fiber coupling laser homogenization lens (6) is connected with the laser (2) through an optical fiber (4), the thermal infrared imager (5) is connected with the control computer (3) provided with image acquisition and processing software, the motion scanning mechanism (1) carries the high-resolution thermal infrared imager (5) and the laser homogenization lens (6) to perform mobile scanning, and the control computer (3) provided with the image acquisition and processing software is simultaneously responsible for synchronous control of the thermal infrared imager (5), the laser (2) and the motion scanning mechanism (1).
2. The active laser infrared thermal imaging-based additive manufacturing quality on-line monitoring system according to claim 1, wherein: in the additive manufacturing process of materials stacked layer by layer on a forming platform, a Gaussian or quasi-Gaussian distribution collimated laser beam emitted by a laser (2) reaches an optical fiber coupling laser homogenizing lens (6) through an optical fiber (4), is homogenized into uniformly distributed laser to irradiate a certain area on the surface of an additive piece (10) for uniform heating, and forms a heat flow which diffuses downwards, the existence of a printing layer internal defect and an interlayer defect (11) can block the downward diffusion of the heat flow, so that a local temperature rise is formed on the surface, and a surface temperature image of the area is collected through an infrared thermal imager (5) so as to realize the detection of the defect of the area; the thermal infrared imager (5) and the laser homogenizing lens (6) are in linkage with the printing nozzle (8) through the motion scanning mechanism (1), and therefore on-line monitoring of the overall quality of the material increase manufacturing structure is achieved.
3. The active laser infrared thermal imaging-based additive manufacturing quality on-line monitoring system according to claim 1, wherein: the infrared thermal imager (5) is a high-resolution infrared thermal imager, and the resolution reaches 640 x 512.
4. The monitoring method of the active laser infrared thermal imaging-based additive manufacturing quality online monitoring system is characterized by comprising the following steps of:
step 1: installing an additive manufacturing quality online monitoring system of laser infrared thermal imaging, setting a preset delay time between the additive manufacturing system and the additive manufacturing quality online monitoring system of laser infrared thermal imaging, setting additive manufacturing parameters, and performing additive manufacturing on a structural part by controlling a motion system (7);
step 2: the device is arranged on a control computer (3) provided with image acquisition and processing software, and a laser infrared thermal imaging additive manufacturing quality on-line monitoring system is kept linked with a printing nozzle (8) through a motion scanning mechanism (1) to control a high-power laser (2) to emit light;
and step 3: collimated laser beams which are generated by a laser (2) and are distributed in a Gaussian or quasi-Gaussian manner are incident on an optical fiber coupling laser homogenizing lens (6) through an optical fiber (4), and are shaped into a uniform laser heat source to irradiate the surface of the solidified printing layer;
and 4, step 4: the method comprises the following steps that (1) along with the beginning of an additive manufacturing process, an additive manufacturing system continuously works, a laser infrared thermal imaging additive manufacturing quality online monitoring system detects a certain area of the surface of a solidified printing layer in a stepping mode, printing of each area of each layer is completed, and the laser infrared thermal imaging additive manufacturing quality online monitoring system detects the corresponding area in time; firstly, the laser (2) does not emit light, and the thermal infrared imager (5) records the initial temperature F in real timeij 1Then the laser (2) emits light, and the thermal infrared imager (5) records the temperature F at the moment of forming heating in real timeij 2(ii) a Image temperature data is acquiredAccording to the formula Fij＝|Fij 2-Fij 11,2,3 …, calculating the background differential temperature of the jth area of the ith layer, and processing the background differential temperature in real time through a control computer (3) provided with image acquisition and processing software; when all the areas of all the layers are printed, namely additive manufacturing is finished, and meanwhile, the corresponding laser infrared thermal imaging additive manufacturing quality online monitoring system is used for detecting and finishing, and the laser infrared thermal imaging additive manufacturing quality online monitoring system automatically generates a defect detection map.
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| CN115447137A (en) * | 2022-09-29 | 2022-12-09 | 哈尔滨工程大学 | Photocuring 3D printing device and printing method |
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