CN116329740A - Method and device for in-situ monitoring and process control of laser fusion welding - Google Patents
Method and device for in-situ monitoring and process control of laser fusion welding Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/03—Observing, e.g. monitoring, the workpiece
- B23K26/032—Observing, e.g. monitoring, the workpiece using optical means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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Abstract
The invention provides a method and a device for in-situ monitoring and process control of laser fusion welding, which comprise a high-power laser light source, an optical sensing part, an interference imaging part and a server unit, wherein the optical sensing part generates spectrum information according to received intrinsic light emitted from a fusion welding area; the server unit analyzes the optical information and the interference imaging information and dynamically controls the welding process parameters according to the analysis result. Through the monitoring and the control of the device, the whole welding process of a fusion welding area is accurately monitored in real time, the depth of a key hole is directly measured through interference imaging information, the accurate information about the measuring result of the fusion welding in-situ area can be provided in real time, the dynamic control of the welding process treatment parameters is carried out in real time, and the product yield is greatly improved.
Description
Technical Field
The invention relates to the technical field of laser fusion welding, in particular to a method and a device for in-situ monitoring and process control of laser fusion welding.
Background
Laser welding is widely used in various industries, such as the fields of automobiles, shipbuilding, aerospace, bridge building and the like, due to high material processing capacity, high automation degree and small formed thermal influence. In the field of electric automobiles, for automobile processing, the laser welding precision needs to reach the millimeter level, and for lithium battery processing, because the thickness of a processed material is very thin, the welding precision needs to reach the micrometer/submicron level, and the laser welding precision is certainly higher in the requirement of similar industrial welding fusion scenes with high precision requirements.
During laser welding, the material is heated to a certain temperature quickly, and then the molten metal begins to gasify, so that a keyhole is formed in the center of a molten pool, and laser energy is locked inside the keyhole. The keyhole with different shapes and depths can cause the laser energy to generate different distribution, thereby having great influence on welding precision, and therefore, accurate monitoring of the keyhole in the welding process has great significance for controlling the welding precision.
The key hole structure is fine, and the welding process can be optimized only by high-precision monitoring, so that the welding quality is improved. In the prior art, the following laser welding keyhole monitoring technologies exist:
1. coaxial vision detection system
The coaxial detection system is realized by a beam splitter arranged on the laser head. In general, there are three techniques for detection systems: visual detection of visible light, visual detection of infrared and visible light and visual detection of auxiliary light source. However, no one of the three techniques is adopted, and the imaging cannot be detected coaxially with high precision.
2. Acoustic detection
The acoustic detection includes both contact type acoustic detection and noncontact type acoustic detection. The contact type acoustic detection mainly detects the sounding, so that the detection is used for detecting stress waves at high temperature and high pressure (refer to pressure) in equipment or workpieces, and the detectable frequency is not more than 200KHz. Non-contact sound detection mainly refers to detection of sound audible to human ears propagating in the air, and the frequency range of detection is about 20Hz-20KHz, and pressure wave changes when plasma and metal vapor occur are mainly monitored. From the current application situation, the disadvantage of acoustic detection is large precision error, and the requirement of high-precision welding cannot be met.
3. Plasma charge detection system
The detection principle of the plasma charge detection system is as follows: during welding, electric charges are generated in plasma generated by laser induction, and a contact probe of a plasma charge detection system detects the electric charge intensity of a plasma region, so that the welding state is identified. At present, the plasma charge detection system has the following defects: the plasma produces electromagnetic interference that can damage the metrology instrument.
From the above description, the existing monitoring system can not achieve measurement accuracy or generate electromagnetic interference, so that there is no detection system capable of accurately monitoring a keyhole in situ in real time during welding in the prior art. Therefore, the inventor considers that it is necessary to provide a novel device and method for in-situ monitoring and process control of laser fusion welding, so as to accurately monitor the keyhole in real time and further improve the welding precision.
Disclosure of Invention
The embodiment of the application provides a device and a method for in-situ monitoring and process control of laser fusion welding, which are used for solving the technical problems of low accuracy and electromagnetic interference generation of key hole monitoring in the prior detection technology.
The embodiment of the application provides a device for in-situ monitoring and process control of laser fusion welding, which comprises:
the system comprises a high-power laser light source, an optical sensing part, an interference imaging part and a server unit; the high-power laser light source, the optical sensing part and the interference imaging part are respectively connected with the server unit;
the laser beam emitted by the high-power laser source irradiates the target material to form a fusion welding area by fusion welding, and the fusion welding area is provided with a keyhole;
the optical sensing part generates spectral information according to the received intrinsic light emitted from the fusion welding area and transmits the spectral information to the server unit;
a part of light emitted by the interference imaging part forms reference light; the other part of the light irradiates a fusion welding area on the target material and is reflected to form reflected light, the reflected light is imaged in an interference way with the reference light, the interference imaging is carried out synchronously with the optical sensing part receiving the intrinsic light emitted from the fusion welding area, and the interference imaging part sends interference imaging information to the server unit; the interference imaging information comprises keyhole measurement information;
the server unit analyzes the optical information and the interference imaging information, and dynamically controls the fusion welding process processing parameters through the server unit according to the analysis result.
Further, the device also comprises a color separation part, wherein the color separation part comprises a color separation lens;
the high-power laser light source comprises a laser, a modulator, a first isolator and a programmable pulse generator; the laser is connected with the modulator, and the modulator is respectively connected with the first isolator and the programmable pulse generator;
the optical sensing part comprises an industrial camera;
the interference imaging part comprises a sensing spectrum light source, a polarizer PC1, a second isolator, a half wave plate, a 1/4 wave plate, a dispersion mismatch compensation unit, a 50:50 coupling arm, a polarizer PC2, a grating and a linear array detector which are sequentially arranged; the system also comprises a reference mirror, a polarizer PC4 arranged between the reference mirror and a 50:50 coupling arm, and a polarizer PC3 arranged between the 50:50 coupling arm and a color separation lens; wherein,,
the server unit is connected with the spectrum light source for sensing, and the linear array detector is connected with the server unit.
Further, the laser beam emitted by the high-power laser source irradiates the target material through the color separation lens to form a fusion welding area;
the intrinsic light emitted by the fusion welding area is received by an industrial camera through a color separation lens; generating real-time imaging information from the received intrinsic light by the industrial camera, the real-time imaging information being transmitted to a server unit;
the light emitted by the sensing spectrum light source sequentially passes through a polarizer PC1, a second isolator, a half wave plate, a 1/4 wave plate, a dispersion mismatch compensation unit and a 50:50 coupling arm, and is divided into two beams by the 50:50 coupling arm, wherein one beam of light irradiates a fusion welding area on a target material through a polarizer PC3 and a color separation lens and is reflected to form reflected light, and the reflected light reaches a grating along the color separation lens, the polarizer PC3 and the 50:50 coupling arm; the other beam of light irradiates a reference mirror through a polarizer PC4, the reference mirror reflects the reference light to form reference light, the reference light reaches a grating through the polarizer PC4 and a 50:50 coupling arm, the reflected light and the reference light are subjected to interference imaging behind the grating, an image formed by interference is detected by a linear array detector, and interference imaging information detected by the linear array detector is sent to a server unit.
Further, the intrinsic light is obtained by performing a scan over the fusion welding area, and the intrinsic light is intrinsic light of a real-time fusion welding site in-situ monitoring process.
Further, the light beam irradiated to the fusion welding area by the interference imaging part is an imaging light beam,
the optical sensor is arranged to measure the entire fusion welding area, which contains the locations of the keyhole and the turbulent pores.
Further, a laser beam emitted from a high-power laser light source to irradiate a target material for fusion welding is a material processing beam, the optical sensor portion is arranged and the imaging beam is applied such that the imaging beam and a beam spot associated with the optical sensor portion are positioned at a predetermined offset distance from the material processing beam.
The embodiment of the application also provides a method for in-situ monitoring and process control of laser fusion welding, which comprises the following steps:
applying a laser beam emitted by a high-power laser source to a target material of a fusion welding area to form a fusion welding area, wherein the fusion welding area is provided with a keyhole, and the laser beam is applied to perform scanning;
the optical sensing part generates spectrum information according to the received intrinsic light emitted from the fusion welding area and sends the spectrum information to the server unit;
a part of light emitted by the interference imaging part forms reference light; the other part of the light irradiates a fusion welding area on the target material and is reflected to form reflected light, the reflected light is imaged in an interference way with the reference light, the interference imaging is carried out synchronously with the optical sensing part receiving the intrinsic light emitted from the fusion welding area, and the interference imaging part sends interference imaging information to a server unit; the interference imaging information comprises key hole information;
the server unit analyzes the real-time imaging information and the interference imaging information, and dynamically controls the processing parameters of the fusion welding process through the computer system according to the analysis result.
Further, the intrinsic light is obtained by performing a scan over the fusion welding area, and the intrinsic light is intrinsic light of a real-time fusion welding site in-situ monitoring process.
Further, the light beam irradiated to the fusion welding area by the interference imaging part is an imaging light beam, and the optical sensing part is arranged to measure the whole fusion welding area including the positions of the key holes and the turbulent pores.
Further, a laser beam emitted from a high-power laser light source to irradiate a target material of a welding region for welding is a material processing beam, the optical sensing portion is arranged and the imaging beam is applied such that the imaging beam and a beam spot associated with the optical sensing portion are positioned at a predetermined offset distance from the material processing beam.
The embodiment provided by the application has at least the following beneficial effects:
the embodiment of the application provides a technical scheme for in-situ monitoring and process control of laser fusion welding, which comprises the following steps: a high-power laser light source, an optical sensing part, an interference imaging part and a server unit; the high-power laser source, the optical sensing part and the interference imaging part are respectively connected with the server unit; the optical sensing part generates spectral information according to the received intrinsic light emitted from the fusion welding area and transmits the spectral information to the server unit; the interference imaging part transmits interference imaging information to the server unit; the interference imaging information can provide accurate keyhole information; the server unit analyzes the optical information and the interference imaging information, and dynamically controls the welding process processing parameters through the computer system according to the analysis result. The device and the method can implement full inspection on the whole welding process of all parts, can check the bottom of the keyhole by interference imaging information, directly measure the depth of the keyhole, and can provide a large amount of information about the measurement result of a fusion welding in-situ area in real time, thereby dynamically controlling the processing parameters of the welding process in real time and improving the welding process to achieve the optimal effect.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this application, illustrate embodiments of the application and together with the description serve to explain the application and do not constitute an undue limitation to the application. In the drawings:
FIG. 1 is a schematic diagram of an apparatus for in-situ monitoring and process control of laser fusion welding according to an embodiment of the present application;
FIG. 2 is a schematic view of a fusion welding in situ area provided in an embodiment of the present application;
FIG. 3 is a schematic diagram of a method for processing in-situ monitoring and process control data of laser fusion welding according to an embodiment of the present application;
FIG. 4 is a schematic diagram of adjustable parameters of a high-power laser source according to an embodiment of the present disclosure;
FIG. 5 is a schematic view of adjustable parameters of the fusion welding material feed provided in an embodiment of the present application;
fig. 6 is a schematic diagram of adjustable parameters of an arc welding process according to an embodiment of the present application.
Detailed Description
For the purposes, technical solutions and advantages of the present application, the technical solutions of the present application will be clearly and completely described below with reference to specific embodiments of the present application and corresponding drawings. It will be apparent that the described embodiments are only some, but not all, of the embodiments of the present application. All other embodiments, which can be made by one of ordinary skill in the art without undue burden from the present disclosure, are within the scope of the present disclosure.
The on-line monitoring in the laser welding process is mainly concentrated on the key hole, and the depth, edge side position and other information of the key hole need to be monitored.
Example 1
Aiming at the high-precision requirement of welding process in the current market, as shown in fig. 1 and 2, the embodiment of the application provides a device for in-situ monitoring and process control of laser fusion welding, which comprises:
a server unit, a high-power laser light source, an optical sensor unit, and an interference imaging unit; the high-power laser source, the optical sensing part and the interference imaging part are respectively connected with the server unit;
the laser adopts the modulated laser, and the high-power laser light source comprises a laser, a modulator, a first isolator and a programmable pulse generator; the laser is connected with the modulator, and the modulator is respectively connected with the first isolator and the programmable pulse generator; the modulator can be controlled by the server unit, and the programmable pulse can be used for programming and designing various pulses in advance for the server unit to select and call.
Further, the high power laser is a pulsed laser that can employ a variety of wavelengths, such as 1064 to 1070 nm wavelengths produced by Nd: YAG and ytterbium doped fiber lasers and 10600nm wavelengths produced by CO2 lasers.
The laser beam emitted by the high-power laser source irradiates the target material to form a fusion welding area;
in the turbulent pore generation mode, the extracted keyhole depth (within ±15 μm of the keyhole diameter deviation) is shown in fig. 2, and the keyhole depth features formed by bubbles and pores are also identified; the system can capture keyhole extrusion, "pull-up" and spike phenomena in real time.
The optical sensing part generates spectral information according to the received intrinsic light emitted from the fusion welding area and transmits the spectral information to the server unit;
it should be noted that the intrinsic light is obtained by performing a scan over the fusion welding area and is the intrinsic light of a real-time fusion welding site in-situ monitoring process.
A part of light emitted by the interference imaging part forms reference light; the other part of the light irradiates a fusion welding area on the target material and is reflected to form reflected light, the reflected light is imaged in an interference way with the reference light, and the interference imaging part sends interference imaging information to the server unit; the interference imaging information comprises key hole information;
it should be noted that, the device can be set according to the requirements of application scenes, and the mode of measuring all physical quantities is not needed, so that one or more kinds of measurement associated with the imaging light beam by the optical sensing part can be gated; wherein, the related data are measured simultaneously, and can be fused on system processing to be used as a fusion welding real-time measured data set; one or more measurements associated with the imaging beam are used to temporally or spatially gate one or more measurements associated with the at least one light emission received by the one or more external optical sensors, wherein the external optical sensors perform measurements during welding, and the measuring beam can view the keyhole bottom, directly measuring penetration.
The server unit analyzes the optical information and the interference imaging information, and dynamically controls the laser beam emitted by the high-power laser source through the computer system according to the analysis result.
It should be noted that, various graphic processing methods may be used to analyze the optical information and the interference imaging information, and the method used in the embodiment of the present application is shown in fig. 3, where the interference pattern processor performs the dynamic control on the welding processing parameters according to the interference result by overlapping and interfering the measured interference pattern with the calculated expected interference pattern on a per-detection element basis. By adopting the method, the difference between the two can be quickly compared, and further, the welding process parameters can be dynamically adjusted.
As shown in fig. 4-6, the welding process parameters controlled by the feedback controller include at least one of:
1. composite laser beam: on/off state, average power, pulse duration, density, energy, wavelength, pulse repetition rate, pulse energy, pulse shape, scan speed, focal diameter, focal position, etc.;
2. fusion welding material feed rate: cooling medium flow rate, assist gas pressure, assist gas blend, etc.;
3. arc welding process parameters: such as voltage, current, wire feed rate, etc.;
4. additive material feed rate.
It should be further noted that, as shown in fig. 1 and 2, the apparatus for in-situ monitoring and process control of laser fusion welding in the embodiments of the present application further includes a color separation portion, where the color separation portion includes a color separation lens; the dichroic lens may employ various dichroic prisms, which are not illustrated herein.
The optical sensor has various forms, such as a multispectral camera, which is developed based on a general aviation camera. Multispectral photography is to expand towards infrared light and ultraviolet light on the basis of visible light, and to make the multispectral photography receive the information radiated or reflected by the same target on different narrow spectral bands respectively through the combination of various optical filters or optical splitters and various photosensitive films, so that several photos of different spectral bands of the target can be obtained.
Preferably, the optical sensing section of the present application includes an industrial camera for aiming the main process beam, aiming the material, inspecting the material focus, and aiming and machining the beam spot.
The interference imaging part comprises a sensing spectrum light source, a polarizer PC1, a second isolator, a half wave plate, a 1/4 wave plate, a dispersion mismatch compensation unit, a 50:50 coupling arm, a polarizer PC2, a grating and a linear array detector which are sequentially arranged; the system also comprises a reference mirror, a polarizer PC4 arranged between the reference mirror and a 50:50 coupling arm, and a polarizer PC3 arranged between the 50:50 coupling arm and a color separation lens; wherein,,
the server unit is connected with the spectrum light source for sensing, and the linear array detector is connected with the server unit.
In the melted metal area, only interference laser with a specific wave band can detect the welding quality through an interference principle; thus, the present application uses a tunable broad spectrum laser for the sensing spectral light source.
It should be noted that, the polarizer according to the embodiment of the present application may be a variety of polarizers available in the market.
It should be noted that at least one optical path difference exists between the reference light and the reflected light. Where optical path refers to all the space and matter traversed by the imaging light that contributes to the optical path delay, including physical path length and optical media with optical dispersion and other optical frequency-dependent phase changes, phase and/or group velocity changes.
It should be further noted that the optical path traveled by the reference light is referred to as a reference arm, and the reference arm is configured such that the path length of the reference arm is adjustable for compensating for positional displacement in the sample; such adjustment may be achieved by an electro-translational stage, piezoelectric element, tensile sample or reference fiber, electromagnetic solenoid or voice coil, and/or by including several reference mirrors that may be introduced or removed from the reference arm beam path.
It should be noted that, the reference mirror may be driven by a stepper motor, and the reference mirror is driven by a stepper motor to move and adjust to a proper position for different welding processes such as different laser sources, so as to obtain a required optical path difference.
The laser beam emitted by the high-power laser source irradiates the target material through the color separation lens to form a fusion welding area;
the intrinsic light emitted by the fusion welding area is received by an industrial camera through a color separation lens; generating spectral information from the received intrinsic light by the industrial camera, the spectral information being sent to a server unit;
the light emitted by the sensing spectrum light source sequentially passes through the polarizer PC1, the second isolator, the half-wave plate, the 1/4 wave plate, the dispersion mismatch compensation unit and the 50:50 coupling arm, and is divided into two beams by the 50:50 coupling arm, wherein one beam of light irradiates a fusion welding area on a target material through the polarizer PC3 and the color separation lens and is reflected to form reflected light, and the reflected light reaches the grating along the color separation lens, the polarizer PC3 and the 50:50 coupling arm; the other beam of light irradiates a reference mirror through a polarizer PC4, the reference mirror reflects the reference light to form reference light, the reference light reaches a grating through the polarizer PC4 and a 50:50 coupling arm, the reflected light and the reference light are subjected to interference imaging behind the grating, an image formed by interference is detected by a linear array detector, and interference imaging information detected by the linear array detector is sent to a server unit.
It should be noted that the intrinsic light is obtained by performing a scan over the fusion welding area and is the intrinsic light of a real-time fusion welding site in-situ monitoring process.
The light beam irradiated to the fusion welding area by the interference imaging part is imaging light, and the optical sensing part is arranged to measure the whole fusion welding area, and the fusion welding area comprises the positions of the key holes and the turbulent flow holes.
The laser beam emitted from the high-power laser light source to irradiate the target material for fusion welding is a material processing beam, the optical sensor portion is arranged and the imaging beam is applied such that the imaging beam and a beam spot associated with the optical sensor portion are positioned at a predetermined offset distance from the material processing beam.
Wherein the predetermined offset distance may be fixed or variable.
Wherein the imaging beam is coaxial with the material handling beam.
The welding process supports sintering, welding, brazing, and combinations thereof.
Example 2
The application also provides a method for in-situ monitoring and process control of laser fusion welding, which comprises the following steps:
applying a laser beam emitted from a high-power laser source to a target material to form a fusion welding area, wherein the laser beam is applied to perform scanning;
the optical sensing part generates spectrum information according to the received intrinsic light emitted from the fusion welding area and sends the spectrum information to the server unit;
a part of light emitted by the interference imaging part forms reference light; the other part of the light irradiates a fusion welding area on the target material and is reflected to form reflected light, the reflected light is imaged by interference with the reference light, and the interference imaging part sends interference imaging information to the server unit;
the server unit analyzes the spectrum information and the interference imaging information, and dynamically controls laser emitted by the high-power laser source through the computer system according to the analysis result.
In this method, the intrinsic light is obtained by performing a scan on the fusion welding area, and the intrinsic light is an intrinsic light of a real-time fusion welding site in-situ monitoring process.
In the method, the light beam irradiated to the fusion welding area by the interference imaging part is an imaging light beam,
the optical sensor is arranged to measure the entire fusion welding area, which contains the locations of the keyhole and the turbulent pores.
In the method, the laser beam emitted from the high-power laser light source to irradiate the target material for fusion welding is a material processing beam, the optical sensor is arranged and the imaging beam is applied such that the imaging beam and a beam spot associated with the optical sensor are positioned at a predetermined offset distance from the material processing beam.
It should be noted that the system also comprises a record generator, wherein the record generator generates at least one record based on the output of the device for in-situ monitoring and process control of the laser fusion welding, and the device supports at least one of a signal processor, a signal generator, a feedback processor and a record generator for calling;
as the beam continues to penetrate the welding target, the depth may be imaged, so that the final depth of the weld within the target may also be measured, displayed, recorded on a storage medium, and/or transmitted to a controller;
the main control unit of the controller is one of FPGA, ASIC, MCU, CPU, and an FPGA or an ASIC is used in the image processor to reduce processing delay, so that the processing speed is improved; interfaces and/or signal trend tracking algorithms that may run in real-time.
Example 3
The device for in-situ monitoring and process control of laser fusion welding comprises an interferometer, a broad spectrum source, a spectrometer and a welding platform. There are welding lasers that generate a welding beam that is controlled by a welding controller, and a focusing objective combines the imaging and welding beams to transmit to the welding workpiece and collect imaging light backscattered from the welding area (possibly with additional welding inputs such as assist gases, arcs, additive materials, etc.) in view of feedback control. The spectral interferogram data from the interferometer is passed to an electronic process that generates electronic feedback control for the welding controller. The processing results generate an output for the image display. In this case, the interferometer is connected by a spatial coupler to the weld platform camera port through an optical fiber. The interferometer is used to monitor the depth of keyhole formation, ensuring that it is the proper depth for welding all workpieces.
In pulsed laser welding, the interferometer may be operated at a multiple of the welding laser repetition rate, providing images from before, during and after laser exposure. The interferometer can directly monitor the keyhole stability using a continuous wave welding source. Feedback of this information can be used to optimize welding parameters (e.g., laser intensity, feed rate, and assist gas) to improve keyhole stability. The image display displays real-time information to the operator regarding keyhole penetration and stability during the welding process and provides an operational record of the weld creation in the exact area on the work piece.
The interferometer includes: a combiner; a reference arm applying a first component of the imaging light to an input of the reference arm, thereby generating an output signal of the reference arm, the reference arm having the other optical path length; and a sample arm applying a second component of imaging light to the sample arm, thereby producing an output signal of the sample arm, at least one component of the output signal of the sample arm comprising a reflection of the imaging light component from the sample location, the sample arm having the at least one optical path length; wherein a combiner combines the output signals of the reference arm and the output signals of the sample arm to produce a combined signal as the interferometry output; the apparatus further includes a signal detector configured to generate an interference pattern from the interferometric output.
Further, an analysis is performed based on the interferometry output to produce a signal reflecting the accurate depth measurement of the material processing beam at the sample location.
Further, analysis is performed based on the interferometric output and a feedback control is generated that controls the depth cut relative to the interface closest to the cutting laser.
Further, analysis is performed based on the interferometry output and a feedback control is generated that controls the depth cut relative to the interface beyond the current depth of cut.
Further, at least one process parameter of the material modification process is controlled based on the depth measurement.
Further, an optical parameter of the material is generated based on the interferometric output.
Further, the feedback processor generates an indication of the optical index of the material via the interferometric output; the apparatus further comprises: a computer readable medium; and a record generator that generates a record of the material modification process based on the multiple interferometry outputs and stores the record on a computer-readable medium; the feedback controller is a real-time controller that controls at least one process parameter of the material modification process during the process.
It should be noted that during additive manufacturing processes, for measuring/quantifying material injection during processing, such information may be used to evaluate process parameter spatial quality and/or stability, which information is used for feedback/control purposes, determining material injection quantity, frequency, periodicity, regularity, velocity, momentum, and/or force based on interferometric output. The plurality of scattering information is used as a quality assurance amount/suppression parameter for the additive manufacturing process. The plurality of scattering information may be used as feedback control parameters for the additive manufacturing process. Imaging measurement feedback can be used to improve the accuracy and precision of the feed stream.
The beam from the sample arm of the interferometer is arranged coaxially with the laser. This can be done in free space with a suitable beam splitter. This ensures that the imaging is along coaxial with the beam direction. The length of the reference arm is set so that the sample arm and the reference arm closely match. The user can fine tune the position of the laser through registration of the imaging system with the imaging of the other imaging modality industrial probe. This would allow a user to view a small weld area in real time using an interferometer in a larger welding context.
It should be noted that, due to the limited spectral resolution in the detector, this sensitivity tends to decrease with increasing path length difference, counteracting the natural sample reflectivity (which tends to decrease with increasing depth). Thus, deeper structures (often less reflective) in the sample are compared to the surface structures (often more reflective).
FIG. 4 is a schematic diagram of adjustable parameters of a high-power laser source according to an embodiment of the present disclosure; an in-situ monitoring and process control device for laser fusion welding is characterized in that the adjustable parameters of a high-power laser light source comprise one or more of switch state, average power, energy, wavelength, scanning speed, density, focus, pulse repetition rate, pulse energy, pulse shape and pulse duration.
FIG. 5 is a schematic view of adjustable parameters of the fusion welding material feed provided in an embodiment of the present application; an in-situ monitoring and process control device for laser fusion welding is characterized in that the feeding adjustable parameters of fusion welding materials comprise feeding rate, cooling medium flow rate, auxiliary gas pressure and auxiliary gas blend.
Fig. 6 is a schematic diagram of adjustable parameters of an arc welding process according to an embodiment of the present application. An in-situ monitoring and process control device for laser fusion welding is characterized in that the feed rate adjustable parameters of additive materials comprise current, voltage and wire feeding speed as arc welding process parameters.
It should be understood by those skilled in the art that the technical means or components or methods of all the above embodiments may be mutually referred to and combined, and the cases of the above combined embodiments are all included in the protection scope of the present application.
It should be noted that the fusion welding process is detected with higher sensitivity. Another advantage of this approach is that smoke, plasma, debris and other light scattering sources near the imaging system appear deeper in the image, are attenuated, and do not wrap around the region of interest due to complex conjugate blur. Metal, polymer, tissue and ceramic, and other materials are perforated during percussive drilling and suction cup drilling. Tracking the bottom of the well during drilling; controlling perforation speed; observing the point when the material is perforated; a point in time at which the laser perforated material is expected; adjusting the laser process to avoid damaging the surface below the new hole; confirming that the hole is not refilled after the laser is turned off; controlling drilling, cutting or welding to a selected depth; controlling drilling, cutting or welding to a selected depth relative to a selected material interface; and producing an indication of impending breakthrough during laser drilling, laser cutting or laser welding.
The open loop mode may be realized, for example, by selecting a control law defining zero feedback data. An operator may wish to not implement closed loop control for various reasons; merely as a means of characterizing and measuring the performance of a standard laser welding system;
the at least one optical sensor is coupled to the device by an optical fiber; the optical fiber is one of a multi-clad optical fiber or a multi-core optical fiber, or both, and wherein the imaging light is connected to at least one optical fiber with the at least one optical sensing portion; the at least one light emission received by the one or more optical sensors is an intrinsic light emission inherent to the fusion welding process.
It should be noted that, compared with the prior art, the method adopts the optical sensing part and the interference imaging part to synchronously measure, and the mutual measurement information is processed as shown in fig. 3, so that the information such as the processing depth and the like can be synchronously and accurately measured in situ in the laser processing process, thereby achieving the function of dynamically optimizing the processing parameters; and meanwhile, by adopting measures such as a tunable wide-spectrum laser light source, the detection precision is further optimized, so that the high-precision processing requirement is met.
The invention can allow real-time in-situ measurement to be completed in the welding process, and a measuring beam can check the bottom of a keyhole to directly measure the penetration, which is also an important characteristic of the welding measurement technology of the new generation. The measurement results can provide a large amount of information of the whole weld joint almost the same as the metallographic test results in real time, and the sample itself is not required to be damaged. The measuring beam can be measured before the laser beam to acquire the information before welding. And the surface quality of the finished product welding seam can be confirmed by measuring after the welding is finished. The method has the advantages that the manufacturer can carry out full inspection on the whole welding process of all parts, provide more complete and accurate key data record, keep effective traceability, discover defective products as soon as possible, and avoid quality risks caused by the fact that defective products flow into market sales.
It should also be noted that the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one … …" does not exclude the presence of other like elements in a process, method, article or apparatus that comprises the element.
It will be appreciated by those skilled in the art that embodiments of the present application may be provided as a method, system, or computer program product. Accordingly, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The foregoing is merely exemplary of the present application and is not intended to limit the present application. Various modifications and changes may be made to the present application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc. which are within the spirit and principles of the present application are intended to be included within the scope of the claims of the present application.
Claims (10)
1. An apparatus for in-situ monitoring and process control of laser fusion welding, comprising:
the system comprises a high-power laser light source, an optical sensing part, an interference imaging part and a server unit; the high-power laser light source, the optical sensing part and the interference imaging part are respectively connected with the server unit;
the laser beam emitted by the high-power laser source irradiates the target material to form a fusion welding area by fusion welding, and the fusion welding area is provided with a keyhole;
the optical sensing part generates spectral information according to the received intrinsic light emitted from the fusion welding area and transmits the spectral information to the server unit;
a part of light emitted by the interference imaging part forms reference light; the other part of the light irradiates a fusion welding area on the target material and is reflected to form reflected light, the reflected light is imaged in an interference way with the reference light, the interference imaging is carried out synchronously with the optical sensing part receiving the intrinsic light emitted from the fusion welding area, and the interference imaging part sends interference imaging information to the server unit; the interference imaging information comprises keyhole measurement information;
the server unit analyzes the optical information and the interference imaging information and dynamically controls the processing parameters of the fusion welding process according to the analysis result.
2. The apparatus for in-situ monitoring and process control of laser fusion welding as defined in claim 1, further comprising a color separation section including a color separation lens;
the high-power laser light source comprises a laser, a modulator, a first isolator and a programmable pulse generator; the laser is connected with the modulator, and the modulator is respectively connected with the first isolator and the programmable pulse generator;
the optical sensing part comprises an industrial camera;
the interference imaging part comprises a sensing spectrum light source, a polarizer PC1, a second isolator, a half wave plate, a 1/4 wave plate, a dispersion mismatch compensation unit, a 50:50 coupling arm, a polarizer PC2, a grating and a linear array detector which are sequentially arranged; the system also comprises a reference mirror, a polarizer PC4 arranged between the reference mirror and a 50:50 coupling arm, and a polarizer PC3 arranged between the 50:50 coupling arm and a color separation lens; wherein,,
the server unit is connected with the spectrum light source for sensing, and the linear array detector is connected with the server unit.
3. The device for in-situ monitoring and process control of laser fusion welding according to claim 2, wherein the laser beam emitted by the high-power laser source irradiates the target material through the dichroic lens to form a fusion welding area;
the intrinsic light emitted by the fusion welding area is received by an industrial camera through a color separation lens; generating real-time imaging information from the received intrinsic light by the industrial camera, the real-time imaging information being transmitted to a server unit;
the light emitted by the sensing spectrum light source sequentially passes through a polarizer PC1, a second isolator, a half wave plate, a 1/4 wave plate, a dispersion mismatch compensation unit and a 50:50 coupling arm, and is divided into two beams by the 50:50 coupling arm, wherein one beam of light irradiates a fusion welding area on a target material through a polarizer PC3 and a color separation lens and is reflected to form reflected light, and the reflected light reaches a grating along the color separation lens, the polarizer PC3 and the 50:50 coupling arm; the other beam of light irradiates a reference mirror through a polarizer PC4, the reference mirror reflects the reference light to form reference light, the reference light reaches a grating through the polarizer PC4 and a 50:50 coupling arm, the reflected light and the reference light are subjected to interference imaging behind the grating, an image formed by interference is detected by a linear array detector, and interference imaging information detected by the linear array detector is sent to a server unit.
4. The apparatus for laser welding in-situ monitoring and process control according to claim 1, wherein the intrinsic light is obtained by performing a scan over the welding area and is intrinsic light of a real-time welding site in-situ monitoring process.
5. The laser welding in-situ monitoring and process control apparatus according to claim 1, wherein the beam of light impinging on the welding area by the interference imaging section is an imaging beam, and the optical sensing section is arranged to measure the entire welding area, including the location of the keyhole and the turbulent aperture.
6. The laser welding in-situ monitoring and process control apparatus of claim 5, wherein the laser beam emitted by the high power laser source that irradiates the target material for welding is a material handling beam, the optical sensing portion is arranged and the imaging beam is applied such that the imaging beam and a beam spot associated with the optical sensing portion are positioned at a predetermined offset distance from the material handling beam.
7. A method for in-situ monitoring and process control of laser fusion welding, comprising:
applying a laser beam emitted by a high-power laser source to a target material of a fusion welding area to form a fusion welding area, wherein the fusion welding area is provided with a keyhole, and the laser beam is applied to perform scanning;
the optical sensing part generates spectrum information according to the received intrinsic light emitted from the fusion welding area and sends the spectrum information to the server unit;
a part of light emitted by the interference imaging part forms reference light; the other part of the light irradiates a fusion welding area on the target material and is reflected to form reflected light, the reflected light is imaged in an interference way with the reference light, the interference imaging is carried out synchronously with the optical sensing part receiving the intrinsic light emitted from the fusion welding area, and the interference imaging part sends interference imaging information to a server unit; the interference imaging information comprises key hole information;
the server unit analyzes the real-time imaging information and the interference imaging information, and dynamically controls the processing parameters of the fusion welding process through the computer system according to the analysis result.
8. The method of laser fusion welding in-situ monitoring and process control according to claim 7, wherein the intrinsic light is obtained by performing a scan over the fusion welding area and is intrinsic light of a real-time fusion welding site in-situ monitoring process.
9. The method of in situ monitoring and process control of laser fusion welding according to claim 7, wherein the beam of light impinging on the fusion welding area by the interferometric imaging is an imaging beam, and the optical sensing section is arranged to measure the entire fusion welding area including the location of the keyhole and the turbulent aperture.
10. The method of in situ monitoring and process control of laser fusion welding according to claim 9, wherein the laser beam emitted by the high power laser source illuminating the target material of the fusion welding area for fusion welding is a material handling beam, the optical sensor is arranged and the imaging beam is applied such that the imaging beam and the beam spot associated with the optical sensor are positioned at a predetermined offset distance from the material handling beam.
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