CN115138867A - Device and method for monitoring, feeding back and optimizing molding quality of gradient material manufactured by laser additive in real time - Google Patents
Device and method for monitoring, feeding back and optimizing molding quality of gradient material manufactured by laser additive in real time Download PDFInfo
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B22—CASTING; POWDER METALLURGY
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- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
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Abstract
The invention provides a device and a method for monitoring, feeding back and optimizing molding quality of a gradient material manufactured by laser additive in real time, belongs to the technical field of additive manufacturing, and mainly aims at the field of gradient materials manufactured by laser additive. The device comprises a laser cladding platform, an ultrasonic monitoring feedback device and a computer control platform. The ultrasonic monitoring and feedback device carries out real-time monitoring and feedback on the quality of a deposition layer manufactured by the laser cladding platform, meanwhile, ultrasonic waves can eliminate partial residual thermal stress in the deposition process of a workpiece, the computer control platform receives the fed back quality data of the deposition layer, the defect of the deposition layer is effectively diagnosed through a response statistical model in the platform, and the real-time regulation and optimization of process parameters are carried out. The device and the method can effectively solve the problem of poor workpiece forming quality caused by the fact that the defect generation condition in the material increase process cannot be obtained in real time and the process parameter adjustment is made, and the problem of residual thermal stress generated along with the continuous increase of different component gradient deposition layers.
Description
Technical Field
The invention belongs to the technical field of additive manufacturing, mainly aims at the field of laser additive manufacturing gradient materials, and particularly relates to a device and a method for monitoring, feeding back and optimizing the molding quality of an additive manufacturing gradient material in real time.
Background
The Functional Gradient Material (FGM) is a novel composite material with two or more materials compounded and gradient change of components and structures, no obvious interface is arranged in the composite material, and the components and the tissue properties of the material are gradient changed. The method is generally applied to extreme working conditions of pressure, temperature, corrosivity and the like, wherein the working environment changes along with the position, such as the fields of aerospace, nuclear power, ocean engineering and the like. Laser Melting Deposition (LMD) is a typical additive manufacturing technology, and compared with the traditional forming process, the Laser Melting Deposition (LMD) has the characteristics of short processing period, flexible design, high dimensional precision of a formed part, environmental friendliness and the like. The laser coaxial powder feeding system is more suitable for preparing gradient materials with continuously changed component proportions, the continuous change between layers of the contents of the two materials can be realized by adjusting the powder conveying amount and the powder conveying proportion, the component design is more flexible, and the transition is more uniform.
Compared with the preparation of an alloy material, the difficulty of preparing the gradient material by using a laser melting deposition technology is higher, and the defects of nonuniform melting, air holes, cracks and the like are often generated along with the gradient change of the material and components, which are caused by different physical properties of different materials, such as density, thermal expansion coefficient, melting point, laser absorption rate and the like, so that the component design in actual operation is required to be more reasonable, and the selection of process parameters is required to be more accurate. The actual material increase process is carried out in a closed cavity, so that the defect generation condition in the material increase process cannot be obtained in real time and the process parameters cannot be adjusted in time. In addition, the increasing number of different compositional gradient deposition layers creates extreme residual thermal stresses on the workpiece.
Therefore, the invention builds a device and a method for monitoring, feeding back and optimizing the molding quality of the additive manufacturing gradient material in real time, monitors the quality of a solidified and molded deposition layer in real time through an ultrasonic monitoring and feeding back device, feeds back data (type, position, size and number of defects) of the deposition layer quality to a computer control platform, controls the working process of a laser cladding platform, regulates and optimizes process parameters in real time, and simultaneously can eliminate partial residual thermal stress of a workpiece in the deposition process under the action of ultrasonic waves, thereby finally obtaining a functional gradient material workpiece with better molding quality.
Disclosure of Invention
The invention aims to provide a device and a method for monitoring, feeding back and optimizing the molding quality of an additive manufacturing gradient material in real time, which effectively solve the problem of poor molding quality of a final workpiece caused by the fact that the quality of a deposited layer of a laser additive manufacturing gradient material cannot be monitored and fed back in real time and defects are effectively diagnosed, and meanwhile, ultrasonic waves can eliminate partial residual thermal stress of the workpiece in the deposition process so as to further improve the quality of the workpiece.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
on the one hand, the device for monitoring, feeding back and optimizing the molding quality of the additive manufacturing gradient material in real time is disclosed and provided, and mainly comprises a laser cladding platform, an ultrasonic monitoring and feeding back device and a computer control platform.
Specifically, the laser cladding platform consists of a laser, a laser cladding head, a laser water cooling machine, an airflow type double-hopper powder feeder and an argon bottle, and is used for additive manufacturing of gradient materials;
specifically, the ultrasonic monitoring feedback device comprises an ultrasonic flaw detector and an ultrasonic probe. Under the excitation of the ultrasonic flaw detector, the ultrasonic probe emits an ultrasonic signal to detect the quality of the settled layer in real time. If defects appear in the settled layer, the ultrasonic signals can be reflected, the ultrasonic signals are converted into electric signals through the transducer, the received echo electric signals are amplified by the ultrasonic flaw detector, the echo electric signals with different properties correspond to the defects of the settled layer, and the electric signals are fed back to the computer control platform to be displayed and analyzed. The ultrasonic probe is fixed on the laser cladding head through the bolt and is arranged behind the laser cladding head, so that the real-time monitoring and feedback of the quality of a deposited layer in the laser melting and depositing process of the gradient material can be realized. Meanwhile, the ultrasonic wave can also eliminate partial residual thermal stress of the workpiece in the deposition process.
Specifically, the computer control platform is used for receiving the quality data of the deposition layer monitored by the ultrasonic monitoring feedback device in real time, and the fed back quality data of the deposition layer mainly comprises the types (air holes, cracks, bulges, inclusions, collapse and the like), the positions, the sizes, the quantities and the like of defects generated in the deposition layer in the laser melting deposition process. The specific type, position, size and quantity of defects in the deposition layer are effectively diagnosed through a response statistical model in a computer control platform, and the process parameters are correspondingly adjusted and optimized according to the response statistical model to continue the laser melting deposition process;
specifically, through designing orthogonal experiments of single-channel single-layer and single-channel multilayer gradient materials, reasonable component gradient intervals, gradient ranges, appropriate laser power P (W), scanning speed V (mm/s), powder feeding speed V (g/min) and other process parameters are determined. On the basis, the defects (air holes, cracks, upward bulges, inclusions, downward collapses and the like) are artificially manufactured by adopting preset interference factors, and the corresponding laser melting deposition defect experiment is designed for parameters such as laser power P (W), scanning speed V (mm/s), defocusing amount f (mm) and the like. The ultrasonic monitoring feedback device is used for acquiring echo electric signals in the orthogonal experiment and defect experiment processes to obtain corresponding deposition layer quality data in the laser melting deposition process and feeding the deposition layer quality data back to the computer control platform, and the computer control platform receives the deposition layer quality data and analyzes, stores and displays the deposition layer quality data. And analyzing the correlation between the electric signal received by the computer control platform and the molding quality (defect type, position, size and quantity) of the laser additive manufacturing gradient material under the corresponding process parameters by using a statistical method, and establishing a correlation database of the process parameters and the molding quality of the laser melting deposition gradient material, thereby constructing a response statistical model between the electric signal which is monitored and fed back in real time and the molding quality of the laser melting deposition gradient deposition layer under different process parameters.
On the other hand, the method for monitoring, feeding back and optimizing the molding quality of the additive manufacturing gradient material in real time is disclosed, and the method comprises the following specific operation steps:
(1) Fixing the substrate on a workbench, introducing argon into the closed cavity to ensure that the closed cavity is in a vacuum state, preheating the substrate, and performing a laser additive manufacturing process of a gradient material;
(2) Powder with different components is respectively placed in the two hoppers of the airflow type double hopper, and gradient change of the components of the deposition layer is realized by changing the rotating speed of the two powder discs in the deposition process;
(3) The quality of the additive manufacturing gradient material deposition layer is monitored and fed back in real time: in the laser additive manufacturing process, an ultrasonic probe arranged behind a laser cladding head emits ultrasonic signals under the excitation of an ultrasonic flaw detector, the quality of a solidified and formed deposition layer can be monitored in real time, the reflected ultrasonic signals are converted into electric signals through a transducer, the ultrasonic flaw detector amplifies received echo electric signals and feeds back the quality data of the deposition layer to a computer control platform, and the fed back quality data of the deposition layer mainly comprises the types (air holes, cracks, upward protrusions, inclusions, downward collapse and the like), positions, sizes, quantity and the like of defects generated in the deposition layer in the laser melting deposition process;
(4) Analyzing the quality data information of the deposition layer and optimizing the forming quality: according to the correlation database of the process parameters and the molding quality of the laser melting deposition gradient material, a response statistical model for monitoring the feedback electric signals in real time and the molding quality of the laser melting deposition gradient deposition layer under different process parameters is established, the feedback deposition layer quality information is diagnosed through the response statistical model, when the defects of uneven melting or large-size air holes, cracks and the like do not appear in the deposition layer, the quality of the deposition layer is judged to be qualified, the computer control platform issues an instruction to the laser cladding platform, and the process of manufacturing the gradient material by laser additive manufacturing can be continued. If the deposited layer has defects, judging that the quality of the deposited layer is unqualified, sending an instruction to a laser cladding platform, stopping the process of manufacturing the gradient material by the laser additive, judging the types (air holes, cracks, convex protrusions, inclusions, collapse and the like), the positions, the sizes and the number of the defects by a computer control platform, correspondingly adjusting and optimizing the process parameters according to a response statistical model, and continuing the laser melting deposition process.
The above one or more technical solutions have the following beneficial effects:
1. the invention discloses a device and a method for monitoring, feeding back and optimizing molding quality of an additive manufacturing gradient material in real time.
2. The invention discloses a device and a method for monitoring, feeding back and optimizing the molding quality of an additive manufacturing gradient material in real time, wherein an ultrasonic monitoring device is used for monitoring the molding quality of functional gradient deposition layers with different components in real time, and feeding back data to a computer control platform for storage and calculation analysis.
Drawings
FIG. 1 is a schematic view of an apparatus for real-time monitoring, feedback and optimization of additive manufacturing gradient material molding quality according to the present invention;
FIG. 2 is a flow chart of a method for real-time monitoring and feedback of defects of a functionally graded material for laser additive manufacturing of titanium-based ceramics according to the present invention;
in the figure: 1, a laser; 2 laser cladding head; 3, a laser water cooler; 4 an argon bottle; 5 airflow type double-hopper powder feeder; 6, a computer control platform; 7, an ultrasonic flaw detector; 8, an ultrasonic probe; 9 protecting the ultrasonic probe; 10, workpiece; 11 a substrate; 12, a workbench; 13 different component powders.
Detailed Description
In order to better understand the technical content of the present invention, the objects, technical solutions and advantages of the present invention will be made clearer in the following description of the present invention with reference to the accompanying drawings and specific embodiments, which are given as examples of laser additive manufacturing of gradient materials. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting of the invention. It should be further noted that, for the convenience of description, only some of the structures related to the present invention are shown in the drawings, not all of the structures.
In the description of the present invention, unless expressly stated or limited otherwise, the terms "connected," "connected," and "fixed" are to be construed broadly, e.g., as meaning permanently connected, removably connected, or integral to one another; can be mechanically or electrically connected; either directly or indirectly through intervening media, either internally or in any other relationship. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
In the present invention, unless otherwise expressly stated or limited, "above" or "below" a first feature means that the first and second features are in direct contact, or that the first and second features are not in direct contact but are in contact with each other via another feature therebetween. Also, the first feature being "on," "above" and "over" the second feature includes the first feature being directly on and obliquely above the second feature, or merely indicating that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature includes the first feature being directly under and obliquely below the second feature, or simply meaning that the first feature is at a lesser elevation than the second feature.
In the description of the present embodiment, the terms "upper", "lower", "right", etc. are used based on the orientations or positional relationships shown in the drawings for convenience of description and simplicity of operation, but do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used only for descriptive purposes and are not intended to have a special meaning.
Referring to fig. 1, the device for real-time monitoring and feedback of the defect of the laser additive manufacturing gradient material provided by the invention specifically comprises a laser 1, a laser cladding head 2, a laser water cooler 3, an airflow type double-hopper powder feeder 5, an argon gas bottle 4, a workbench 12, a substrate 11, a workpiece 10, an ultrasonic flaw detector 7, an ultrasonic probe 8, an ultrasonic probe protective cover 9 and a computer control platform 6.
Specifically, different powder components used in laser additive manufacturing are respectively subjected to ball milling, then dried in a vacuum drying oven, the dried powder 13 with different components is respectively placed in two hoppers of an airflow type double-hopper powder feeder 5, the rotating speeds of the two powder trays are adjusted by programming the airflow type double-hopper powder feeder 5, and the gradient change of the components of the deposition layer is realized by changing the rotating speeds of the two powder trays in real time.
Specifically, be fixed in laser cladding head 2 rear with ultrasonic transducer 8, ultrasonic transducer safety cover 9 can shelter from the splash in the laser vibration material disk manufacturing process, prevent to cause the damage to ultrasonic transducer 8, polish the processing to 11 surfaces of base plate, wash and weather with alcohol, preheat the back with base plate 11, the level is placed on workstation 12, let in high-purity argon gas at airtight cavity through argon gas bottle 4, get rid of the air in the cavity, build the environment of vacuum, avoid the gradient material of oxidation vibration material disk manufacturing.
Specifically, a scanning path numerical control program of the laser cladding head is written, and technological parameters of the deposition process are set, wherein the technological parameters comprise laser power P (W), scanning speed V (mm/s), powder feeding speed V (g/min), defocusing amount f (mm), spot diameter phi (mm), interlayer lifting amount delta (mm), interlayer cooling time t(s) and the like.
Specifically, a laser 1 and a laser water cooler 3 are started, the laser 1 emits laser, and after powder to be melted is fed into a laser cladding head 2 by an airflow type double-hopper powder feeder 5, laser melting deposition of a gradient material is performed on a substrate 11 to obtain a workpiece 10.
Specifically, when the gradient material is manufactured by laser additive manufacturing, the ultrasonic probe 8 fixed behind the laser cladding head 2 can timely monitor the quality of a solidified and formed deposition layer in real time, convert a reflected ultrasonic signal into an electric signal through the transducer, transmit the electric signal to the ultrasonic flaw detector 7 for amplification, and feed the electric signal back to the computer control platform in real time for data storage and calculation analysis, and during monitoring, the ultrasonic wave generated by the ultrasonic probe 8 can eliminate the residual thermal stress of the workpiece 10 part in the deposition process.
Specifically, the response statistical model in the computer control platform 6 diagnoses the defects effectively in time according to the fed back quality data of the deposition layer, adjusts and optimizes the process parameters in real time, reduces the generation of defects in the deposition process and improves the quality of the deposition layer.
Specifically, after laser additive manufacturing is completed, the laser 1, the laser water cooler 3, the airflow type double-hopper powder feeder 5 and the ultrasonic flaw detector 7 are sequentially closed, and the argon bottle 4 is closed after the workpiece is cooled for a period of time, so that the surface of the workpiece 10 is prevented from being oxidized, and the forming quality of the workpiece 10 is improved.
It should be understood that the above-described embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. Numerous obvious variations, adaptations and substitutions will occur to those skilled in the art without departing from the scope of the invention. This need not be, nor should it be exhaustive of all embodiments. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the protection scope of the claims of the present invention.
Claims (3)
1. A device for monitoring, feeding back and optimizing the molding quality of an additive manufacturing gradient material in real time is characterized by mainly comprising a laser cladding platform, an ultrasonic monitoring and feeding back device and a computer control platform;
the laser cladding platform comprises a laser (1), a laser cladding head (2), a laser water cooling machine (3), an airflow type double-hopper powder feeder (5) and an argon bottle (4), and is used for laser additive manufacturing of gradient materials;
the ultrasonic monitoring feedback device comprises an ultrasonic flaw detector (9) and an ultrasonic probe (8); under the excitation of the ultrasonic flaw detector (9), the ultrasonic probe (8) transmits an ultrasonic signal to detect the quality of a deposition layer in real time; if the deposited layer has defects, the ultrasonic signals are reflected and converted into electric signals through the transducer, the received echo electric signals are amplified by the ultrasonic flaw detector (9), the echo electric signals with different properties correspond to the defects of the deposited layer, and the electric signals are fed back to the computer control platform (6) to be displayed and analyzed; the ultrasonic probe (8) is fixedly connected to the laser cladding head (2) through a bolt and is arranged behind the laser cladding head, so that the quality of a deposited layer can be monitored and fed back in real time in the laser melting and depositing process of the gradient material; meanwhile, the ultrasonic wave can also eliminate partial residual thermal stress of the workpiece in the deposition process;
the computer control platform (6) is used for receiving the quality data of the deposition layer monitored by the ultrasonic monitoring feedback device in real time, and the fed back quality data of the deposition layer mainly comprises the types (air holes, cracks, bulges, inclusions, collapse and the like), the positions, the sizes, the quantity and the like of defects generated in the deposition layer in the laser melting deposition process; and the specific type, position, size and number of defects in the deposition layer are effectively diagnosed through the response statistical model in the computer control platform (6), and the process parameters are correspondingly adjusted and optimized according to the response statistical model to continue the laser melting deposition process.
2. The device for monitoring, feeding back and optimizing the molding quality of the additive manufacturing gradient material in real time according to claim 1, wherein the response statistical model determines reasonable component gradient intervals, gradient ranges and appropriate process parameters such as laser power P (W), scanning speed V (mm/s) and powder feeding speed V (g/min) by designing orthogonal experiments of single-channel single layer and single-channel multilayer of the gradient material; on the basis, the defects (air holes, cracks, upward bulges, inclusions, downward collapses and the like) are artificially manufactured by adopting preset interference factors, and corresponding laser melting deposition defect experiments are designed for parameters such as laser power P (W), scanning speed V (mm/s), defocusing amount f (mm) and the like; acquiring echo electric signals in the orthogonal experiment and defect experiment processes through an ultrasonic monitoring feedback device to obtain corresponding deposition layer quality data in the laser melting deposition process and feed the deposition layer quality data back to the computer control platform (6), wherein the computer control platform (6) receives the deposition layer quality data and analyzes, stores and displays the deposition layer quality data; and analyzing the correlation between the electric signals received by the computer control platform (6) and the molding quality (defect type, position, size and quantity) of the laser additive manufacturing gradient material under corresponding process parameters by using a statistical method, and establishing a correlation database of the process parameters and the molding quality of the laser melting deposition gradient material, so as to construct a response statistical model between the electric signals monitored and fed back in real time and the molding quality of the laser melting deposition gradient deposition layer under different process parameters.
3. The method for the additive manufacturing gradient material forming quality real-time monitoring feedback and optimization device according to claim 1, wherein a method for the additive manufacturing gradient material forming quality real-time monitoring feedback and optimization is adopted, and the method specifically comprises the following steps:
(1) Fixing a substrate (12) on a workbench, introducing argon into a closed cavity through an argon bottle (4) to ensure that the closed cavity is in a vacuum state, preheating the substrate (12), and performing a laser additive manufacturing process of a gradient material;
(2) Powder with different components is respectively placed in the two hoppers of the airflow type double-hopper powder feeder (5), and gradient change of the components of a deposition layer is realized by changing the rotating speed of the two powder disks in the deposition process;
(3) And (3) monitoring and feeding back the quality of the deposition layer of the additive manufacturing gradient material in real time: in the laser additive manufacturing process, the ultrasonic probe (8) arranged behind the laser cladding head emits ultrasonic signals under the excitation of the ultrasonic flaw detector (7), the quality of a solidified and formed deposition layer can be monitored in real time, the reflected ultrasonic signals are converted into electric signals through the transducer, the ultrasonic flaw detector (7) amplifies the received echo electric signals and feeds back the quality data of the deposition layer to the computer control platform (6), and the fed back quality data of the deposition layer mainly comprises the types (air holes, cracks, upward bulges, inclusions, downward collapse and the like), positions, sizes, quantity and the like of defects generated in the deposition layer in the laser melting deposition process;
(4) Analyzing the quality data information of the deposition layer and optimizing the forming quality: according to a correlation database of the process parameters and the molding quality of the laser melting deposition gradient material, a response statistical model for monitoring the feedback electric signals in real time and the molding quality of the laser melting deposition gradient deposition layer under different process parameters is established, the feedback deposition layer quality information is diagnosed through the response statistical model, when the defects of uneven melting or large-size air holes, cracks and the like do not appear in the deposition layer, the quality of the deposition layer is judged to be qualified, the computer control platform (6) gives an instruction to the laser cladding platform, and the process of manufacturing the gradient material by laser additive manufacturing can be continued; and if the deposited layer has defects, judging that the quality of the deposited layer is unqualified, sending an instruction to a laser cladding platform, stopping the process of manufacturing the gradient material by the laser additive, judging the types (air holes, cracks, bulges, inclusions, collapse and the like), the positions, the sizes and the number of the defects through the computer control platform (6), correspondingly adjusting and optimizing the process parameters according to the response statistical model, and continuing the laser melting deposition process.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210874026.3A CN115138867B (en) | 2022-07-22 | 2022-07-22 | Device and method for real-time monitoring feedback and optimization of molding quality of gradient material in laser additive manufacturing |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210874026.3A CN115138867B (en) | 2022-07-22 | 2022-07-22 | Device and method for real-time monitoring feedback and optimization of molding quality of gradient material in laser additive manufacturing |
Publications (2)
| Publication Number | Publication Date |
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| CN115138867A true CN115138867A (en) | 2022-10-04 |
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| CN117805248A (en) * | 2024-02-29 | 2024-04-02 | 云耀深维(江苏)科技有限公司 | Method and system for realizing additive manufacturing quality monitoring by utilizing acoustic measurement |
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