CN114740048B - Active laser infrared thermal imaging-based online monitoring system and method for manufacturing quality of additive - Google Patents
Active laser infrared thermal imaging-based online monitoring system and method for manufacturing quality of additive Download PDFInfo
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- 239000000654 additive Substances 0.000 title claims abstract description 80
- 230000000996 additive effect Effects 0.000 title claims abstract description 80
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 80
- 238000012544 monitoring process Methods 0.000 title claims abstract description 55
- 238000001931 thermography Methods 0.000 title claims abstract description 41
- 238000000034 method Methods 0.000 title claims abstract description 23
- 230000007547 defect Effects 0.000 claims abstract description 26
- 239000013307 optical fiber Substances 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
- 230000008569 process Effects 0.000 claims abstract description 8
- 238000009792 diffusion process Methods 0.000 claims abstract description 6
- 239000000463 material Substances 0.000 claims abstract description 4
- 239000010410 layer Substances 0.000 claims description 32
- 238000001514 detection method Methods 0.000 claims description 17
- 238000010586 diagram Methods 0.000 claims description 7
- 238000009826 distribution Methods 0.000 claims description 6
- 239000007921 spray Substances 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 3
- 239000011229 interlayer Substances 0.000 claims description 2
- 230000001360 synchronised effect Effects 0.000 claims description 2
- 238000009827 uniform distribution Methods 0.000 claims 1
- 238000012797 qualification Methods 0.000 abstract description 4
- 239000000835 fiber Substances 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 238000009659 non-destructive testing Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 230000008439 repair process Effects 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 238000005266 casting Methods 0.000 description 1
- 238000009658 destructive testing Methods 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000012545 processing 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
- G01—MEASURING; TESTING
- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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Abstract
The invention discloses an active laser infrared thermal imaging-based online monitoring system and method for additive manufacturing quality. The monitoring method comprises the following steps: in the process of stacking material additive manufacturing layer by layer on a forming platform, laser beams emitted by a laser irradiate a certain area on the surface of a cured current printing layer through an optical fiber coupling laser homogenizing lens, the area is uniformly heated, the existence of internal defects of the printing layer can prevent downward diffusion of heat flow, so that local temperature rise is formed on the surface, and the temperature image of the surface of the area is acquired through a thermal infrared imager, so that the internal defects of the area are detected; the online monitoring system for the quality of the additive manufacturing by laser infrared thermal imaging can realize online monitoring of the structural quality of the additive manufacturing by keeping linkage with the printing nozzle through the motion scanning mechanism. The disposable qualification rate of the product is improved, and the product is prevented from being scrapped or reworked.
Description
Technical Field
The invention belongs to the field of additive manufacturing and laser infrared thermal imaging, and particularly relates to an online monitoring system and method for additive manufacturing quality based on active laser infrared thermal imaging.
Background
Aerospace equipment is gradually developed towards the directions of light weight, functional diversity, structural complexity, long service life, high reliability and low cost, and the manufacturing method of combining traditional casting and forging with mechanical processing is difficult to meet the manufacturing requirements. In terms of complex structure integrated forming, additive manufacturing techniques have other advantages that are not realized by conventional manufacturing techniques. But is limited by the additive manufacturing mode of layered printing, the product is easy to have poor compactness, anisotropic tissue performance, local deformation and stress concentration, and various defects such as air holes, cracks, inclusions and the like are caused. Nondestructive testing, as opposed to destructive testing, can achieve non-destructive testing of the entire product and can be performed in real-time during the manufacturing process. Currently, quality inspection of additive manufactured products is often performed after the product is manufactured, and is also referred to as off-line inspection. Defects such as air holes, layering and the like in the additive manufacturing process can cause problems in product quality if not timely processed, and more serious products are disqualified, so that huge losses are caused. Therefore, the real-time monitoring, the online detection of defects and the possible realization of process repair of the additive manufacturing process are needed, the quality of the additive manufactured parts can be greatly improved, the rejection rate of products is greatly reduced, and the disposable qualification rate of the products is improved.
At present, the online monitoring of internal defects has few research results, namely the online monitoring of the surface temperature of a molten pool is directly carried out by adopting an infrared camera, and the appearance of the molten pool is fed back, but the online monitoring of passive infrared thermal imaging is carried out only by means of waste heat in the printing and manufacturing process of an additive manufacturing part, so that the problems of easy background interference, small influence of the internal defects on the surface temperature distribution, low detection sensitivity of the internal defects and the like exist.
Disclosure of Invention
Aiming at the defects or improvement demands of the prior art, the invention provides an active laser infrared thermal imaging-based online monitoring system and an active laser infrared thermal imaging-based online monitoring method for the quality of additive manufacturing, which aim to realize real-time quality monitoring of the whole process of additive manufacturing, detect whether defects are generated in a newly-manufactured area of the additive manufacturing through the laser infrared online monitoring system, and timely take measures after the defects are generated, so that the rejection rate of manufactured parts is reduced, the one-time qualification rate of the products is improved, and the scrapping or repair of the products is prevented.
In order to achieve the above purpose, the invention adopts the following technical scheme:
An active laser infrared thermal imaging-based online monitoring system for manufacturing quality of an additive 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 homogenizing 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 provided with the image acquisition and processing software, the motion scanning mechanism 1 carries the high-resolution thermal infrared imager 5 and the laser homogenizing lens 6 for 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.
In the process of stacking material additive manufacturing layer by layer on a forming platform, gaussian or quasi-Gaussian distribution collimated laser beams emitted by a laser 2 reach an optical fiber coupling laser homogenizing lens 6 through an optical fiber 4, uniformly distributed laser is irradiated to a certain area on the surface of an additive piece 10 to be uniformly heated, downward diffusion heat flow is formed, the existence of internal defects and interlayer defects 11 in a printing layer can prevent the downward diffusion of the heat flow, so that local temperature rise is formed on the surface, and an infrared thermal imager 5 is used for collecting surface temperature images of the area to realize detection of the area defects; the thermal infrared imager 5 and the laser homogenizing lens 6 are kept linked with the printing spray head 8 through the motion scanning mechanism 1, so that the on-line monitoring of the integral quality of the additive manufacturing structure is realized.
The thermal infrared imager 5 is a high-resolution thermal infrared imager, and the resolution reaches 640 x 512.
The monitoring method of the online monitoring system for the manufacturing quality of the additive based on the active laser infrared thermal imaging comprises the following steps:
Step 1: the method comprises the steps that an online monitoring system for the manufacturing quality of the additive with laser infrared thermal imaging is installed, a preset delay time is set between the online monitoring system for the manufacturing quality of the additive with laser infrared thermal imaging, additive manufacturing parameters are set, and additive manufacturing of structural parts is conducted through a control motion system 7;
Step 2: the setting is completed on a control computer 3 provided with image acquisition and processing software, and the on-line monitoring system of the laser infrared thermal imaging additive manufacturing quality is kept linked with a printing spray head 8 through a motion scanning mechanism 1 to control the light emission of a high-power laser 2;
Step 3: the collimated laser beams with Gaussian or quasi-Gaussian distribution generated by the laser 2 are incident on the fiber coupling laser homogenizing lens 6 through the fiber 4, shaped into uniform laser heat sources and irradiated to the surface of the cured printing layer;
Step 4: as the additive manufacturing process starts, the additive manufacturing system continuously works, the laser infrared thermal imaging online monitoring system for the additive manufacturing quality detects certain areas on the surface of the cured printing layer in a stepping mode, each area of each layer is printed, and the laser infrared thermal imaging online monitoring system for the additive manufacturing quality detects corresponding areas in time; firstly, the laser 2 does not emit light, the thermal infrared imager 5 records an initial temperature F ij 1 in real time, then the laser 2 emits light, and the thermal infrared imager 5 records a temperature F ij 2 forming a heating moment in real time; the image temperature data are collected, the background differential temperature of the jth region of the ith layer is calculated according to the formula F ij=|Fij 2-Fij 1 I, i, j=1, 2 and 3 …, and the background differential temperature is processed in real time by a control computer 3 provided with image collecting and processing software; when printing of all areas of all layers is finished, namely additive manufacturing is finished, and meanwhile detection of a corresponding laser infrared thermal imaging additive manufacturing quality on-line monitoring system is finished, the laser infrared thermal imaging additive manufacturing quality on-line monitoring system automatically generates a defect detection diagram.
According to the invention, 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 diagram with high-precision display on parameters such as defect position, size and the like 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 timely taken after defects are generated, the rejection rate of a product is reduced, the disposable qualification rate of the product is improved, and the product is prevented from being scrapped or reworked.
Drawings
Fig. 1 is a schematic diagram of an online monitoring system for manufacturing quality of an additive based on active laser infrared thermal imaging according to the present invention.
Fig. 2 is a schematic diagram of a process detection flow for an additive manufacturing layer region.
FIG. 3 is a diagram of the overall process flow and defect detection for additive manufacturing.
Detailed Description
The invention will be described in further detail with reference to the drawings and the detailed description.
As shown in FIG. 1, the online monitoring system for the manufacturing quality of the additive based on the active laser infrared thermal imaging 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 invention provides an active laser infrared thermal imaging-based online monitoring system and method for additive manufacturing quality, wherein the system comprises 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 the additive manufacturing component is formed by stacking materials layer by layer on a forming platform, laser beams emitted by a high-power laser 2 irradiate a certain area on the surface of a cured current printing layer through an optical fiber coupling laser shaping lens 6 to be uniformly heated, the existence of internal defects of the printing layer can prevent downward diffusion of heat flow, so that local temperature rise is formed on the surface, and the surface temperature image of the area is acquired through a thermal infrared imager 5 to realize detection of the internal defects of the area; the online monitoring system for the quality of the additive manufacturing by laser infrared thermal imaging can realize online monitoring of the structural quality of the additive manufacturing by keeping linkage of the motion scanning mechanism 1 and the printing nozzle 8.
The invention is described in further detail below in connection with fig. 1 to 3 and the specific embodiments.
The invention relates to a monitoring method of an online monitoring system for additive manufacturing quality based on active laser infrared thermal imaging, which comprises the following steps:
Step 1: the online monitoring system of the additive manufacturing quality of the laser infrared thermal imaging is installed, a proper delay time is set between the online monitoring system of the additive manufacturing quality of the laser infrared thermal imaging and the online monitoring system of the additive manufacturing quality of the laser infrared thermal imaging, additive manufacturing parameters are set, and additive manufacturing of structural parts is carried out by controlling the motion system 7;
Step 2: the setting is completed on a control computer 3 provided with image acquisition and processing software, and the on-line monitoring system of the laser infrared thermal imaging additive manufacturing quality is kept linked with a printing spray head 8 through a motion scanning mechanism 1 to control the light emission of a high-power laser 2;
Step 3: the collimated laser beams which are generated by the high-power laser 2 and are in Gaussian or quasi-Gaussian distribution are incident on the optical fiber coupling laser homogenizing lens 6 through the optical fiber 4, are shaped into uniform laser heat sources, and are irradiated to the surface of the cured printing layer;
step 4: as the additive manufacturing process begins, powder is deposited onto the surface of the additive 10 through the powder delivery nozzle 9, the additive manufacturing system continues to operate, and the laser infrared additive manufacturing quality online detection system detects a certain area of the surface of the cured print layer in a step-wise manner. Printing of each region of each layer is completed, and the online monitoring system of the additive manufacturing quality of laser infrared thermal imaging carries out corresponding detection in time. Firstly, the laser 2 does not emit light, the thermal infrared imager 5 records an initial temperature F ij 1 in real time, then the laser 2 emits light, and the thermal infrared imager 5 records a temperature F ij 2 forming a heating moment in real time; the image temperature data is collected, and according to the formula F ij=|Fij 2-Fij 1 |, i, j=1, 2,3 …, the background differential temperature of the j-th area of the i-th layer is calculated, and the background differential temperature is processed in real time by a control computer 3 provided with image collecting and processing software. As shown in fig. 2, when the first layer first area 12 is completely printed and solidified, the laser infrared thermal imaging additive manufacturing quality on-line monitoring system detects the first layer first area, and the additive manufacturing system still continuously works at this time, and continues to print the first layer second area 13; when the first layer second area 13 is printed and solidified, the laser infrared thermal imaging additive manufacturing quality on-line monitoring system detects a first layer third area, and sequentially after the first layer is printed and detected, the second layer and the third layer are printed until the additive manufacturing of an object is completed, the corresponding laser infrared thermal imaging additive manufacturing quality on-line monitoring system detects the completion, and the laser infrared thermal imaging additive manufacturing quality on-line monitoring system automatically generates a defect detection diagram, as shown in fig. 3.
Claims (1)
1. A monitoring method of an online monitoring system for additive manufacturing quality based on active laser infrared thermal imaging 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 homogenizing lens (6) is connected with the laser (2) through the optical fiber (4), the infrared thermal 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 infrared thermal imager (5) to carry out mobile scanning with the laser homogenizing lens (6), and the control computer (3) provided with the image acquisition and processing software is simultaneously responsible for synchronous control of the infrared thermal imager (5), the laser (2) and the motion scanning mechanism (1);
In the process of layer-by-layer stacking material additive manufacturing on a forming platform, gaussian or quasi-Gaussian distribution collimated laser beams emitted by a laser (2) reach an optical fiber coupling laser homogenizing lens (6) through an optical fiber (4), laser which is homogenized into uniform distribution irradiates a certain area on the surface of an additive piece (10) to be uniformly heated, downward diffusion heat flow is formed, the existence of internal defects of a printing layer and interlayer defects (11) can prevent the downward diffusion of the heat flow, so that local temperature rise is formed on the surface, and an infrared thermal imager (5) is used for collecting surface temperature images of the area to realize the detection of the defects of the area; the thermal infrared imager (5) and the laser homogenizing lens (6) are kept linked with the printing nozzle (8) through the motion scanning mechanism (1), so that the online monitoring of the integral quality of the additive manufacturing structure is realized;
the thermal infrared imager (5) is a high-resolution thermal infrared imager, and the resolution reaches 640 x 512;
the monitoring method is characterized by comprising the following steps of:
Step 1: the method comprises the steps that an online monitoring system for the manufacturing quality of the additive with laser infrared thermal imaging is installed, a preset delay time is set between the online monitoring system for the manufacturing quality of the additive with laser infrared thermal imaging, additive manufacturing parameters are set, and additive manufacturing of structural parts is carried out by controlling a motion system (7);
Step 2: the setting is completed on a control computer (3) provided with image acquisition and processing software, and the laser infrared thermal imaging additive manufacturing quality on-line monitoring system is linked with a printing spray head (8) through a motion scanning mechanism (1) to control the light emission of a high-power laser (2);
Step 3: the collimated laser beams which are generated by the laser (2) and are in Gaussian or quasi-Gaussian distribution are incident on the optical fiber coupling laser homogenizing lens (6) through the optical fiber (4), are shaped into uniform laser heat sources, and are irradiated to the surface of the cured printing layer;
step 4: as the additive manufacturing process starts, the additive manufacturing system continuously works, the laser infrared thermal imaging online monitoring system for the additive manufacturing quality detects certain areas on the surface of the cured printing layer in a stepping mode, each area of each layer is printed, and the laser infrared thermal imaging online monitoring system for the additive manufacturing quality detects corresponding areas in time; firstly, the laser (2) does not emit light, the thermal infrared imager (5) records an initial temperature F ij 1 in real time, then the laser (2) emits light, and the thermal infrared imager (5) records a temperature F ij 2 forming a heating moment in real time; the image temperature data are collected, the background differential temperature of the jth region of the ith layer is calculated according to the formula F ij=|Fij 2-Fij 1 I, i, j=1, 2 and 3 …, and the background differential temperature is processed in real time by a control computer (3) provided with image collecting and processing software; when printing of all areas of all layers is finished, namely additive manufacturing is finished, and meanwhile detection of a corresponding laser infrared thermal imaging additive manufacturing quality on-line monitoring system is finished, the laser infrared thermal imaging additive manufacturing quality on-line monitoring system automatically generates a defect detection diagram.
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