WO2018064864A1 - 激光宽带熔覆装置 - Google Patents

激光宽带熔覆装置 Download PDF

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Publication number
WO2018064864A1
WO2018064864A1 PCT/CN2016/112644 CN2016112644W WO2018064864A1 WO 2018064864 A1 WO2018064864 A1 WO 2018064864A1 CN 2016112644 W CN2016112644 W CN 2016112644W WO 2018064864 A1 WO2018064864 A1 WO 2018064864A1
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Prior art keywords
laser
double
mirror
reflecting surface
reflecting
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PCT/CN2016/112644
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English (en)
French (fr)
Inventor
石拓
石世宏
史建军
傅戈雁
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苏州大学张家港工业技术研究院
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Priority to US16/319,379 priority Critical patent/US20190331929A1/en
Publication of WO2018064864A1 publication Critical patent/WO2018064864A1/zh

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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/09—Beam shaping, e.g. changing the cross-sectional area, not otherwise provided for
    • G02B27/0911—Anamorphotic systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B22F7/04—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • 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
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • 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
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/0604—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams
    • B23K26/0608—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams in the same heat affected zone [HAZ]
    • 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
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
    • B23K26/0643—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms comprising mirrors
    • 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
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/067—Dividing the beam into multiple beams, e.g. multifocusing
    • 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
    • B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
    • B23K26/144—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor the fluid stream containing particles, e.g. powder
    • 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
    • B23K26/34—Laser welding for purposes other than joining
    • 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
    • B23K26/60—Preliminary treatment
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/09—Beam shaping, e.g. changing the cross-sectional area, not otherwise provided for
    • G02B27/0938—Using specific optical elements
    • G02B27/0977—Reflective elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/09—Beam shaping, e.g. changing the cross-sectional area, not otherwise provided for
    • G02B27/0938—Using specific optical elements
    • G02B27/0977—Reflective elements
    • G02B27/0983—Reflective elements being curved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • 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
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/55—Two or more means for feeding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • 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
    • B22F12/70—Gas flow means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/10—Beam splitting or combining systems
    • G02B27/14—Beam splitting or combining systems operating by reflection only
    • 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

Definitions

  • the invention relates to a laser broadband cladding device, belonging to the field of 3D forming.
  • Laser direct 3D cladding deposition forming of metal and alloy components, important functions, surface cladding strengthening modification, repair and remanufacturing, etc. have great application value in aerospace, defense, shipbuilding, mining, metallurgy, machinery manufacturing and other fields.
  • the prospect is the key development direction of the current developed countries. China has also clearly listed the basic processes of metal additive manufacturing and the research and development of core components as key development areas.
  • laser broadband cladding is an efficient laser cladding additive manufacturing technology.
  • the laser wide-band cladding has a large width of single-pass forming, and can reach 10-40mm in one scan (only ⁇ 1-5mm for narrow-band cladding), so the cladding efficiency is high; large-area laser broadband cladding can greatly reduce the number of overlaps and repeated heating. , reducing the probability of defects caused by this, uneven thickness, decreased tissue properties, and the like.
  • Traditional large-scale parts manufacturing often requires large die forging or die-casting machines. The manufacturing cost is high, the cycle is long, the constraints are many, and the defects are difficult to control.
  • the wide-band laser cladding additive manufacturing is discrete layer-by-layer free-stacking, which can save large forging. Machines and other equipment, the discretization of metallurgical processes and the process of forming gradient materials are more conducive to ensuring microstructure and control defects, and are highly advantageous in the field of reinforcement, repair and direct 3D forming of large metal parts. .
  • Laser broadband cladding mainly includes several key technologies such as laser beam quality and transformation, broadband powder beam transportation, and light powder coupling.
  • the existing method for broadband powder beam transportation is to synchronously feed a broadband spot on a processing surface from one side or both sides of a rectangular solid laser beam, and the powder bundle is fused under the action of light energy to form a broadband melting channel.
  • Double-sided powder feeding can perform round-trip two-way scanning, which can improve the forming efficiency.
  • the powder bundle is located outside the laser beam, which can be called "out-of-light broadband powder feeding". It is not difficult to analyze the existing out-of-band broadband powder feeding method in combination with Fig. 1a, such as poor coupling of light powder, low powder utilization rate, unstable cladding quality, and unsuitable for complex structure formation with large spatial inclination change.
  • the prior art provides a double-beam hollow light intra-band broadband powder feeding method (Fig. 2), and the optical path and powder feeding principle are as follows: applying a semiconductor or fiber laser flat-top light source currently used in the market, and splitting the light The mirror splits the incident laser beam into two, and then reflects it into a hollow double-focus beam through the focusing mirror. The powder beam is vertically fed into the center of the double-focus spot (melting pool) by the powder feeding tube to complete the coupling of the light powder. As can be seen in conjunction with Fig. 2 and Fig. 1b, since the solid beam is changed to a hollow double beam, the two powders are fed laterally into a single bundle of powder for vertical feeding, and the position of the light and powder is just reversed.
  • Fig. 2 shows that the solid beam is changed to a hollow double beam, the two powders are fed laterally into a single bundle of powder for vertical feeding, and the position of the light and powder is just reversed.
  • the split two beams are located on both sides of the bundle, as shown in Figure 1b, Figure 2.
  • the distance between the two spots is slightly increased.
  • the molten pool is still formed in the irradiation area and the gap of the double beam, and the center line of the powder beam can always be vertically aligned with the center line of the molten pool; the collimation protection surrounding the single powder beam
  • the air curtain is used for three purposes: collimating the powder bundle, protecting the molten pool, protecting the inner cavity of the nozzle, and the parallel single powder bundle single air curtain has no interference. If there is fluctuation between the nozzle and the processing surface, the light powder will not be misaligned, and the amount of powder entering the molten pool will not change much. The relative position of the light powder does not change during the two-way round-trip scanning.
  • the single broadband powder bundle is always in the middle of the double spot. There is always one light band in the two directions.
  • the powder is trapped in the molten pool at the trailing edge of the powder.
  • the powder dispersion and surface adhesion are greatly reduced, not only the powder utilization. The rate is greatly improved, and the amount of powder entering the molten pool is stable, the melting pool is more stable, the surface of the melt is smoother, and the source of defects is reduced.
  • the collimating shielding gas tightly surrounds the powder bundle for coaxial conveying, which can form a pressure air curtain (Fig. 1b) on the powder bundle to further regularize and collimate the powder bundle.
  • the powder space is more accurate, straight, thin and quite, and the space is completed.
  • the powder air flow is always pressed vertically toward the molten pool, which is beneficial to the stability and non-flow of the molten pool.
  • the double-reflection focusing mirror brings great flexibility to the wide-spot light-powder coupling.
  • different spot sizes and energy distributions can be obtained, such as energy-enhanced saddle-type light intensity distribution at both ends, or low-energy density beam with increased preheating and slow cooling function.
  • the existing double-beam intra-wideband powder feeding still has the following problems: due to the quenching and quenching action of the laser cladding, the processing material is subject to large overheating and undercooling, which easily causes cracking of the molten layer.
  • the preheating and cooling technology is introduced, and the preheating of the substrate and the slow cooling after the cladding can effectively reduce the temperature gradient and release the residual thermal stress.
  • the preheating and slow cooling technology uses electromagnetic induction, resistance heating and other external heat sources to heat the workpiece base.
  • the heating temperature is generally 200-600 °C.
  • the overall heating has certain effect, but the repair of large parts.
  • one of the methods is to directly use the low-density laser beam to perform local follow-up preheating and slow cooling in front of and behind the molten pool.
  • This method does not require other heat sources and devices.
  • Carl Edward Ericson proposed the concept of using a laser to input a high-density small circular beam for cladding, and another laser to input a coaxial low-density large circular beam for preheating and slow cooling (see US patent for details).
  • the preheating slow cooling method of the elliptical uniform beam is to divide the laser beam into a superimposed small rectangular cladding beam and a large elliptical preheating slow cooling beam (for details, see Chinese Patent Application No. CN201410480190.1); Zhou Shengfeng, Dai Xiaoqin
  • the following two methods are as follows: one is that the beam passes through two points of transmission, one on the processing surface is a cladding spot, and the other is a preheating spot; the second is to use the aforementioned two beams as preheating and Slow cooling spot is set, then an additional laser beam onto the outgoing light spot formed cladding placed in a preheated slow cooling intermediate spot (specifically see China Patent Application No. CN201110352225. No. Nos CN20110352257.X).
  • the object of the present invention is to provide a laser broadband cladding device which can meet the requirements of process heat treatment of different materials and structures, and reduce defects such as residual thermal stress and crack of the molten layer.
  • the present invention provides a laser broadband cladding device capable of emitting laser light from a laser The beam is converted and projected onto the processing surface for broadband laser cladding processing, the laser broadband cladding device comprising a mirror and a double profile reflecting component, the mirror reflecting the laser beam to the double profile reflecting component,
  • the double-profile reflecting member includes an upper reflecting surface and a lower reflecting surface below the upper reflecting surface, the upper reflecting surface is a parabolic focusing surface, and the lower reflecting surface is a plane, and the upper reflecting surface receives the laser beam Reflecting to form a cladding spot on the processing surface, the lower reflecting surface receiving the laser beam and reflecting it to form a preheating slow cooling spot on the processing surface, the preheating slow cooling spot being located outside the cladding spot .
  • the double-profile reflecting member is a mirror, and the double-profile reflecting member has a working profile, and the upper reflecting surface and the lower reflecting surface are formed on the working profile.
  • the double-profile reflecting member is composed of two mirrors, the upper reflecting surface is formed on one of the mirrors, and the lower reflecting surface is formed on the other of the mirrors .
  • the double-profile reflecting members are two groups, and the upper reflecting surfaces of the two sets of the double-profile reflecting members are oppositely disposed, and the lower reflecting surfaces of the two sets of the double-profile reflecting members are oppositely disposed.
  • the mirror is a beam splitting plane mirror
  • the beam splitting plane mirror includes a first reflecting surface and a second reflecting surface disposed facing away from the laser beam, the first reflecting surface Facing a set of the double-profile reflecting members, the second reflecting surface faces the other set of the double-profile reflecting members.
  • the first reflecting surface and the second reflecting surface of the beam splitting plane mirror are arranged symmetrically away from each other.
  • the angle between the first reflecting surface and the second reflecting surface is between 60° and 120°.
  • the laser broadband cladding device further includes a powder feeding tube or a powder feeding flat tube, and one end of the powder feeding tube or the powder feeding flat tube is located below the mirror and vertically The working surface extends.
  • the laser broadband cladding device further includes a collimating mirror disposed between the laser and the mirror, the collimating mirror collimating the diverging laser beam emitted by the laser into parallel light Project to the mirror.
  • the double-profile reflecting members are respectively movable relative to the light-emitting direction of the beam splitting mirror.
  • the cladding spot is a broadband focused line spot
  • the preheating slow cooling spot is a rectangular spot.
  • the laser broadband cladding device of the present invention has an upper reflecting surface and a lower reflecting surface on the double-profile reflecting member, and the upper reflecting surface is a parabolic focusing surface, and the lower reflecting surface is a flat surface.
  • a high-density cladding spot is formed on the processing surface by the upper focusing reflection surface, and a low-density preheating slow cooling spot can be formed on the processing surface through the lower reflection plane, thereby meeting the process heat treatment requirements of different materials and structures, and reducing The thermal stress of the molten layer and the reduction of defects such as hot cracks are generated.
  • Figure 1a is a schematic diagram of a conventional single-beam double-side feed powder
  • Figure 1b is a schematic diagram of a conventional double beam internal powder feeding
  • FIG. 2 is a schematic diagram of a conventional double beam optical broadband feeding
  • FIG. 3 is a schematic structural view of a laser broadband cladding device according to a preferred embodiment of the present invention.
  • a broken line is a projection direction of a laser beam.
  • a laser broadband cladding device 10 converts and projects a laser beam emitted from a laser (not shown) onto a processing surface 20 for broadband laser cladding processing.
  • the laser uses a power of 1000 W to 20000 W, and the laser beam of the laser emitter is transmitted by the optical fiber 50.
  • the laser broadband cladding device 10 is located above the processing surface 20.
  • the laser broadband cladding device 10 includes a collimating mirror 1, a mirror 2, and a double-profile reflecting member 3.
  • the specification of the collimating mirror 1 is selected according to the power level of the laser, and the collimating mirror 1 is located between the laser and the mirror 2. In the present embodiment, the collimating mirror 1 is located directly above the mirror 2.
  • the mirror 2 has a reflecting surface.
  • the double-profile reflecting members 3 are two sets, and the two sets of the double-profile reflecting members 3 are located on both sides of the mirror 2, and the reflecting surface is inclined upward and faces the double-profile reflecting member 3.
  • the double-profile reflecting member 3 includes an upper reflecting surface 31 and a lower reflecting surface 32 located below the upper reflecting surface 31.
  • the upper reflecting surface 31 is a parabolic focusing surface, and the lower reflecting surface 32 is a flat surface.
  • the plane 31 is inclined toward the processing surface 20, and the extension line of the plane 32 is at an angle with the extension line of the lower processing surface 20, and the angle is an acute angle.
  • the collimating mirror 1 collimates the diverging laser beam outputted by the optical fiber 50 into a parallel laser beam and projects it to the mirror 2, which reflects the laser beam to the double-profile reflecting member 3, the double
  • the upper reflecting surface 31 of the surface reflecting member 3 receives the laser beam and reflects it in focus to form a wide-band focusing line spot 30 (i.e., a high-density cladding spot) on the processing surface 20, and the lower reflecting surface 32 receives the laser beam
  • the reflection is such that a rectangular spot 40 (i.e., a low density preheated slow cooling spot) is formed on the machined surface 20, the rectangular spot 40 being located outside of the broadband focus line spot 30.
  • the beam when the laser or other optical device outputs a desired parallel beam, the beam does not need to be collimated, and the collimating mirror 1 may not be used, i.e., the laser broadband cladding device 10 does not include a collimating mirror.
  • the double-profile reflecting member 3 is a mirror 2, and the double-profile reflecting member 3 has a working surface 33, and the upper reflecting surface 31 and the lower reflecting surface 32 are formed in the work. On the profile 33.
  • the upper reflecting surface 31 and the lower reflecting surface 32 may be integrally formed to form the working profile 33.
  • This design makes the overall structure simpler.
  • the double-profile reflecting member 3 may be composed of two mirrors, the upper reflecting surface 31 being formed on one of the mirrors, and the lower reflecting surface 32 being formed on the other mirror. The two mirrors can be joined by a connector or by an adhesive.
  • the focusing focal length of the upper reflecting surface is 150 mm to 500 mm, and the widths of the upper reflecting surface and the lower reflecting surface are respectively Equal, and the size ratio in the height direction is 8:2 to 7:3.
  • the two upper reflecting surfaces 31 are disposed on the center line of the symmetric mirror 2, and the two broadband focusing line spots 30 formed on the focusing focal plane or the working surface are line-shaped spots distributed with respect to the center line. Its wire thickness is about 1 to 3 mm. Symmetrical two lower reflecting surfaces The center line of the mirror is set, and the distance between the two rectangular spots reflected on the processing surface and the focused line type spot is 0 to 3 mm.
  • the mirror 2 adopts a beam splitting plane mirror, and the beam splitting plane mirror 2 has a first reflecting surface 21 and a second reflecting surface 22 which are arranged opposite to each other and introduce a laser beam, the first reflection
  • the face 21 faces a set of said double-profile reflecting members 3, said second reflecting faces 22 facing the other set of said double-profile reflecting members 3.
  • This design makes the overall structure simpler.
  • the first reflective surface 21 and the second reflective surface 22 are specifically arranged in a back symmetric manner. It is true that the number of mirrors 2 can also be two.
  • the two mirrors 2 include a first mirror and a second mirror, the first mirror has a first reflecting surface, and the second mirror has a second reflecting surface, the first reflecting surface and the second reflecting surface
  • the reflecting surface is disposed away from the back, and the first mirror and the second mirror may also be arranged symmetrically in a back direction, the first reflecting surface facing one of the two sets of the double-profile reflecting members 3, the second The reflecting surface faces the other of the two sets of the double-profile reflecting members 3.
  • the angle between the first reflecting surface and the second reflecting surface is between 60° and 120°, preferably 90°, when a value of 90° is used. Compared with other values, its structure is the simplest and easy to manufacture.
  • the double-profile reflecting member 3 is arranged to be movable relative to the beam splitting mirror 2, that is, two The relative spacing of the double-profile reflecting members 3 is adjustable, so that the two wide-band focusing line spots 30 on the processing surface 20 can be separated (with a certain pitch) or overlap and the distance between the two broadband focusing line spots 30 can be realized. Or the degree of overlap change (the amount of focus beam defocus and line spot thickness can be unchanged).
  • the two beams of the reflected laser beam are collinearly inverted, and the two double profiles are
  • the reflecting member 3 is movable in the horizontal direction with respect to the spectroscopic plane mirror 2 (the direction indicated by the arrow a in FIG. 3 is the moving direction of the double-profile reflecting member 3 in the present embodiment, that is, the horizontal direction, which is also a beam splitting plane.
  • the angle between the two reflecting surfaces on the beam splitting mirror is not 90°, the two double-profile reflecting members 3 will oppose the splitting plane mirror.
  • the light directions of the two laser beams of 2 are respectively moved.
  • the laser broadband cladding device 10 further includes a powder feeding tube (not shown), one end of the powder feeding tube is located below the mirror 2, specifically: the powder feeding tube is located directly below the mirror 2 .
  • One end of the powder feeding tube extends below the mirror 2 and extends below the mirror 2 and perpendicular to the working surface 20, and the powder feeding tube is located after the two upper reflecting surfaces 31 receive the laser beam.
  • the nozzle (nozzle) of the powder feeding tube is aligned with the center of the two broadband focusing line spots 30 on the processing surface 20, and the distance from the working surface is between 10 and 40 mm.
  • the width of the broadband cladding is formed according to the line length of the broadband focus line spot.
  • the powder feeding tube can be designed to be 3 to 7 according to different cladding widths, and the rows of tubes arranged side by side are formed, and the tube is parallel to the broadband focus line.
  • a collimated air passage parallel to the powder feeding tube and coaxial with the powder feeding tube is disposed around the powder feeding tube.
  • the principle of the internal powder feeding is as follows: the powder feeding tube is located below the mirror 2, and enters in the middle cavity of the two double-profile reflecting members 3, and then turns downwards and vertically processes the two broadband focusing lines on the surface 20.
  • the center of the spot 30 is sprayed with a linear powder bundle, and a collimated air passage parallel to the powder feeding tube is arranged around the powder feeding tube, and the quasi-straight air surrounding the powder feeding tube is collimated and coaxially vertical.
  • the center of the two wide-band focus line spots 30 on the processing surface 20 is subjected to double-bundle beam internal powder feeding cladding forming on a horizontal base surface or a large-angle spatial inclined base surface.
  • the working principle of the above laser broadband cladding device 10 is as follows: the laser beam output by the laser is transmitted by the fiber 50 of the square-section core, collimated into a parallel square laser beam by the collimator lens 1, and then enters the beam splitting mirror 2 and The dichroic plane mirror 2 is divided into two bundles of rectangular laser beams, and then enters two sets of double-profile mirrors 3 on both sides of the beam splitting plane mirror 2, since each set of the double-profile reflecting members 3 includes an upper reflecting surface 31. And the lower reflecting surface 32, wherein the upper reflecting surface 31 is a parabolic focusing surface, and the lower reflecting surface 32 is a flat surface. Therefore, after the upper reflecting surface 31 receives light, the linear focusing beam is reflected to form on the lower processing surface 20.
  • the two double-profile reflecting members 3 can also adjust the distance between them and the mirror 2 to achieve separation (with a certain spacing) between the two broadband focusing line spots 30 on the processing surface 20 or Overlap and achieve the variation of the pitch distance or overlap degree of the two broadband focus line spots 30 (the amount of defocus and the line spot thickness can be unchanged).
  • the laser broadband cladding device 10 is provided with an upper reflecting surface 31 and a lower reflecting surface 32 on the double-profile reflecting member 3, and the upper reflecting surface 31 is a parabolic focusing surface, and the lower reflecting surface 32 is a flat surface.
  • a high-density broadband focusing line spot 30 ie, a cladding spot
  • a low-density rectangular spot is formed on the processing surface 20 through the lower reflecting surface 32 (ie, a preheating slow cooling spot) ), which helps to improve the powder utilization rate, reduce the thermal stress and crack probability of the molten layer, and improve the quality of the broadband cladding.
  • the double-profile reflecting member 3 By disposing the double-profile reflecting member 3 to be movable relative to the beam splitting plane mirror 2, specifically, the double-profile reflecting member can be respectively moved relative to the light-emitting direction of the beam splitting mirror, thereby double-high-density broadband focusing line
  • the spot can adjust the degree of coincidence or resolution to adjust the change of the width of the molten pool, that is, to realize the controllable change of the power density in the molten pool, and at the same time, form a follow-up preheating slow cooling zone before and after the working surface moves the molten pool, which is helpful to further Reduce the thermal stress and crack probability of the melt.
  • the laser broadband cladding device 10 of the present invention can realize the formation of two cladding spots and two preheating slow cooling spots by using only one laser, and has a simple and compact structure. Since the powder feeding tube is located below the mirror 2, and the powder feeding tube is located between the laser beams formed by the two upper reflecting surfaces 31 receiving the laser beam and reflected, the nozzle of the powder feeding tube is directed to the processing.
  • the two widebands on the face 20 focus on the center of the line spot 30, so that the laser beam formed by the reflection of the upper reflecting surface 31 always wraps the powder bundle from both sides, regardless of the focus position of the single-row pink spot in the powder discharge tube.
  • the light powder can be accurately coupled, and is not sensitive to the defocusing fluctuation of the device; the powder bundle outputted from the powder feeding tube is always located between the double-focusing beams to realize vertical feeding, the light incident rate is high, and the powder utilization rate is
  • the powder is used to feed the powder, so that the powder beam divergence angle is small, and the cross-sectional area of the powder bundle does not change much. Conducive to the stability of the melt channel size and improve the forming quality.
  • the collimating air passage is coaxially arranged coaxially with the powder feeding tube around the powder feeding tube, the collimating air curtain helps to further regulate and bundle the powder to make it fine, quite, accurate, straight and controllable.
  • the nature is further increased, and at the same time, it is specially adapted to the space-changing attitude and tilting angle dynamic motion operation of the nozzle, and the multi-directional reinforcement repair of the large-scale complex parts in the space or the 3D additive manufacturing is completed.

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Abstract

一种激光宽带熔覆装置，用于将激光器发出的激光束转换并投射在加工面（20）上用于宽带激光熔覆加工，激光宽带熔覆装置包括反射镜（2）和双型面反射部件（3），反射镜（2）将激光束反射给双型面反射部件（3），双型面反射部件（3）包括上部反射面（31）和位于上部反射面（31）下方的下部反射面（32），上部反射面（31）为抛物面聚焦型面，下部反射面（32）为平面，上部反射面（31）接收激光束后将其反射以在加工面（20）上形成熔覆光斑（30），下部反射面（32）接收激光束后将其反射以在加工面上形成预热缓冷光斑（40），预热缓冷光斑（40）位于熔覆光斑（30）的外侧，可满足不同材料和结构的工艺热处理需求，降低熔层残余热应力和裂纹等缺陷的几率。

Description

激光宽带熔覆装置
本申请要求了申请日为2016年10月09日，申请号为201610879013.X，发明名称为“激光宽带熔覆装置”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本发明涉及一种激光宽带熔覆装置，属于3D成形领域。
背景技术
金属及合金零构件的激光直接3D熔覆沉积成形、重要功能表面熔覆强化改性、修复再制造等在航空航天、国防、造船、矿山、冶金、机械制造等领域具有极大的应用价值和前景，是当前各发达国家的重点发展方向。我国也已明确将金属增材制造的基础性工艺和核心基础部件的研发列为重点发展领域。其中，激光宽带熔覆是一种高效的激光熔覆增材制造技术。激光宽带熔覆单道成形宽度大，一次扫描可达到10-40mm(窄带熔覆仅为φ1-5mm)，因此熔覆效率高；大面积激光宽带熔覆还可大大减少搭接次数和重复受热，减少由此带来的缺陷几率，厚度不均、组织性能下降等。传统大型零件制造往往需要借助大型模锻或压铸机，制造成本高、周期长、限制条件多、缺陷难以控制，而宽带激光熔覆增材制造是离散的逐层自由堆积成形，可以节省大型锻压机等设备，其离散化的冶金过程与可成形梯度材料的工艺更有利于保证微观组织性能和控制缺陷，在大型金属零构件的强化、修复和直接3D成形等增材制造领域都极具优势。
激光宽带熔覆主要包括激光光束质量及变换、宽带粉束输送、光粉耦合等几项关键技术。宽带粉束输送的现有方法是：从矩形实心激光束的一侧或双侧同步送入加工面上的宽带光斑上，粉束在光能辐照作用下熔凝形成宽带熔道。双侧送粉可进行往返双向扫描，可提高成形效率。但无论是单侧还是双侧送粉，粉束都位于激光束的外侧，可称之为“光外宽带送粉”。结合图1a不难分析现有光外宽带送粉方式尚存在一些不足，如光粉耦合性差、粉末利用率低、熔覆质量不稳定、不适合空间大倾角变化复杂结构成形等问题。
为了解决上述问题，现有技术提供了一种双光束中空光内宽带送粉方法(图2)，其光路与送粉原理为：应用目前市场上多用的半导体或光纤激光器平顶光源，经分光镜将入射激光束一分为二，再经聚焦镜反射成中空双聚焦光束，粉束由送粉排管垂直送入双聚焦光斑(熔池)中间，完成光粉的耦合。结合图2和图1b可以看出，由于将实心光束改为中空的双光束，将两束粉末侧向送进改为单束粉垂直送进，光、粉位置正好对换。由此带来的优点：
(1)分光后的双光束位于两侧包夹粉束，如图1b，图2。在离焦位置，双光斑间距稍加大，在阈值范围内，双光束辐照区与间隙处仍然形成熔池，粉束中线始终能垂直对准熔池中线；包围单粉束的准直保护气帘一气三用：准直粉束、保护熔池、保护喷头内腔，平行的单粉束单气帘无干涉。喷头与加工面之间如有上下波动离焦，光粉对中也不会错位，进入熔池的粉末量基本无太大变化。双向往返扫描时光粉相对位置也不会变。
(2)单条宽带粉束始终位于的双光斑中间，往返两个方向扫描总有一条光带处在粉末的后沿将粉末捕获在熔池中，粉末发散和表面粘附大大减少，不仅粉末利用率大大提高，而且进入熔池的粉量稳定，熔池熔凝过程更稳定，熔道表面更光洁，减少了缺陷源。
(3)准直保护气紧紧包围粉束同轴输送，可对粉束形成压力气帘(图1b)而进一步规整和准直粉束，粉末空间更准、直、细、挺，在完成空间大倾角熔覆和动态摆动成形时，粉气流始终垂直压向熔池，有利于熔池稳定和不流淌。
(4)双反射聚焦镜给宽斑光粉耦合方式带来极大灵活性。将两个聚焦反射镜设计成不同工作面型，可得到不同的光斑尺寸和能量分布，如两端部能量增强的鞍型光强分布、或增加预热缓冷功能的低能密度光束等，可灵活以满足不同功能的光能分布或光粉耦合要求。
但是，现有的双光束光内宽带送粉仍存在如下问题：由于激光熔覆的骤冷骤热作用会使加工材料产生大的过热和过冷度，容易引起熔层的开裂。为了解决上述问题，引入预热冷缓技术，基体的预热和熔覆后缓冷可有效降低温度梯度，释放残余热应力。现预热缓冷技术较多采用电磁感应、电阻加热等外部热源的方法，对加工件基体进行整体加热，加热温度一般为200—600℃,整体加热有一定的效果，但在大件的修复或3D成形时，加工点的位置变化会造成离加热区的距离变化，从而带来预热缓冷温度的变化，另附加装置也显累赘。为了避免上述影响，方法之一是直接采用低密度激光束在熔池前方和后方进行局部随动预热和缓冷，此方法不需采用其他热源及装置。如，Carl Edward Ericson提出了使用一台激光器输入高密度小圆形光束进行熔覆，另一台激光器输入同轴的低密度大圆形光束进行预热与缓冷的概念(具体详见美国专利申请第US2009/0283501A1号)；王东生提出了一种2个矩形光斑叠加，形成一熔覆+预热缓冷作用的凸型光斑，功率密度中间大两边小，模拟仿真证明：凸型光斑降低了熔覆区和非熔覆区的温度梯度，热应力减小10％，减小了开裂趋势(具体详见中国专利申请第CN201310286772.1号)；马广义等提出了一种激光熔覆过程利用椭圆形均匀光束的预热缓冷方法，即把激光束分成叠加的小矩形熔覆光束和大椭圆形预热缓冷光束(具体详见中国专利申请第CN201410480190.1号)；周圣丰、戴晓琴提出了下述两种方法，一是光束通过透射一分二束，至加工面上一个为熔覆斑、一个为前置预热斑；二是将前述2束光作为前置预热和后置缓冷光斑，再另加一台激光器出射光束投射形成熔覆光斑置于预热缓冷光斑中间(具体详见中国专利申请第CN201110352225.号和第CN20110352257.X号)。
上述采用主、辅多光束进行随动预热和缓冷的内容大都报道了光路及原理，有的采用仿真方法进行了效果验证，有的用预涂覆方法进行了熔覆。但熔覆主光束和预热缓冷辅光束的光学镜组集成方法或一体化喷头装置少有报道。
发明内容
本发明的目的在于提供一种激光宽带熔覆装置，其可满足不同材料和结构的工艺热处理需求，降低熔层残余热应力和裂纹等缺陷几率。
为实现上述发明目的，本发明提供了一种激光宽带熔覆装置，可将激光器所发出的激光 束转换并投射在加工面上用于宽带激光熔覆加工，所述激光宽带熔覆装置包括反射镜和双型面反射部件，所述反射镜将激光束反射给双型面反射部件，所述双型面反射部件包括上部反射面和位于所述上部反射面下方的下部反射面，所述上部反射面为抛物聚焦型面，所述下部反射面为平面，所述上部反射面接收激光束后将其反射以在加工面上形成熔覆光斑，所述下部反射面接收激光束后将其反射以在加工面上形成预热缓冷光斑，所述预热缓冷光斑位于熔覆光斑的外侧。
作为本发明的进一步改进，所述双型面反射部件为一块反射镜，所述双型面反射部件具有工作型面，所述上部反射面和下部反射面形成在所述工作型面上。
作为本发明的进一步改进，所述双型面反射部件由两块反射镜组成，所述上部反射面形成在其中一块所述反射镜上，所述下部反射面形成在另一块所述反射镜上。
作为本发明的进一步改进，所述双型面反射部件为两组，两组所述双型面反射部件的上部反射面相对设置，两组所述双型面反射部件的下部反射面相对设置。
作为本发明的进一步改进，所述反射镜为分光平面反射镜，所述分光平面反射镜包括背向布置并迎向入激光束的第一反射面和第二反射面，所述第一反射面朝向一组所述双型面反射部件，所述第二反射面朝向另一组所述双型面反射部件。
作为本发明的进一步改进，所述分光平面反射镜的第一反射面和第二反射面背向对称布置。
作为本发明的进一步改进，所述第一反射面和第二反射面的夹角在60°～120°之间。
作为本发明的进一步改进，所述激光宽带熔覆装置还包括送粉排管或送粉扁管，所述送粉排管或送粉扁管的一端位于所述反射镜的下方并垂直所述工作面延伸。
作为本发明的进一步改进，所述激光宽带熔覆装置还包括设置在所述激光器与反射镜之间的准直镜，所述准直镜将激光器所发出的发散激光束准直为平行光后投射至反射镜。
作为本发明的进一步改进，所述双型面反射部件可分别相对所述分光平面反射镜出光方向移动。
作为本发明的进一步改进，所述熔覆光斑为宽带聚焦线斑，所述预热缓冷光斑为矩形光斑。
本发明的有益效果是：本发明的激光宽带熔覆装置通过在双型面反射部件上设置上部反射面和下部反射面，且该上部反射面为抛物聚焦型面，下部反射面为平面，以通过该上部聚焦反射面在加工面上形成高密度的熔覆光斑，通过该下部反射平面在加工面上可形成低密度的预热缓冷光斑，从而满足不同材料和结构的工艺热处理需求，降低熔层热应力和减少热裂纹等缺陷生成几率。
附图说明
图1a为现有单光束双侧外送粉的原理图；
图1b为现有双光束内送粉的原理图；
图2为现有双光束光内宽带送粉示意图；
图3为本发明一较佳实施例所示的一种激光宽带熔覆装置的结构示意图，图中，虚线为激光光束的投射方向。
具体实施方式
以下将结合附图所示的各实施方式对本发明进行详细描述。但这些实施方式并不限制本发明，本领域的普通技术人员根据这些实施方式所做出的结构、方法、或功能上的变换均包含在本发明的保护范围内。
请参见图1，本发明一较佳实施例所示的一种激光宽带熔覆装置10将激光器(未图示)所发出的激光束转换并投射在加工面20上用于宽带激光熔覆加工，该激光器采用的功率为1000W～20000W，所述激光发射器的激光束由光纤50传递。该激光宽带熔覆装置10位于加工面20的上方。该激光宽带熔覆装置10包括准直镜1、反射镜2及双型面反射部件3。所述准直镜1的规格根据激光器的功率大小选择，所述准直镜1位于激光器与反射镜2之间，在本实施例中，该准直镜1位于反射镜2的正上方。该反射镜2具有反射面。所述双型面反射部件3为两组，两组所述双型面反射部件3位于所述反射镜2的两侧面，该反射面朝上倾斜设置，并朝向双型面反射部件3。所述双型面反射部件3包括上部反射面31和位于所述上部反射面31下方的下部反射面32，所述上部反射面31为抛物聚焦型面，所述下部反射面32为平面。所述平面31为朝加工面20倾斜设置，该平面32的延伸线与下部的加工面20的延伸线成一定夹角，该夹角为一锐角。所述准直镜1将光纤50传递输出的发散激光束准直为平行的激光束后投射至反射镜2，所述反射镜2将该激光束反射给双型面反射部件3，所述双型面反射部件3的上部反射面31接收激光束后将其聚焦反射以在加工面20上形成宽带聚焦线斑30(即高密度熔覆光斑)，所述下部反射面32接收激光束后将其反射以在加工面20形成矩形光斑40(即低密度预热缓冷光斑)，该矩形光斑40位于宽带聚焦线斑30的外侧。在其他实施方式中，当激光器或其他光学装置输出为理想的平行光束时，则光束不需准直，可不采用准直镜1，即激光宽带熔覆装置10不包括准直镜。
在本实施例中，所述双型面反射部件3为一块反射镜2，所述双型面反射部件3具有工作型面33，所述上部反射面31和下部反射面32形成在所述工作型面33上。所述上部反射面31和下部反射面32可以一体成型以形成该工作型面33。通过此种设计，使得整体结构更为简单。在其他实施方式中，该双型面反射部件3可以由两块反射镜组成，所述上部反射面31形成在其中一块反射镜上，所述下部反射面32形成在另一块反射镜上。两块反射镜可通过连接件连接或通过粘胶剂粘结。不管该上部反射面31和下部反射面32形成一块反射镜上，还是分别形成在两块反射镜上，该上部反射面的聚焦焦距在150mm～500mm，所述上部反射面和下部反射面的宽度相等，且在高度方向上的尺寸比例为8:2～7:3。另外，在本实施例中，两个上部反射面31对称反射镜2的中心线设置，在聚焦焦面或工作面上形成的两条宽带聚焦线斑30为相对中心线分布的线型斑，其线厚尺寸约1～3mm。两个下部反射面对称 反射镜中心线设置，反射至加工表面上的两块矩形光斑与聚焦线型光斑的距离0～3mm。
在本实施了中，所述反射镜2采用分光平面反射镜，所述分光平面反射镜2具有背向布置并引入激光束的第一反射面21和第二反射面22，所述第一反射面21朝向一组所述双型面反射部件3，所述第二反射面22朝向另一组所述双型面反射部件3。通过此种设计，可以使整体结构更为简单。在本实施例中，该第一反射面21和第二反射面22具体为背向对称布置。诚然，所述反射镜2的数量还可以为两个。两个所述反射镜2包括第一反射镜和第二反射镜，所述第一反射镜具有第一反射面，所述第二反射镜具有第二反射面，该第一反射面和第二反射面背向设置，该第一反射镜和第二反射镜同样可以为背向对称布置，所述第一反射面朝向两组所述双型面反射部件3中的一组，所述第二反射面朝向两组所述双型面反射部件3中的另一组。不管上述反射镜2采用分光平面反射镜还是其他，所述第一反射面和第二反射面的夹角在60°～120°之间，优选为90°，当采用90°这一数值时，相对其他值来说，其结构最为简单，便于制造。
为了使工作面上的宽带聚焦线斑30、矩形光斑40的位置可调，以满足不同工艺需求，将所述双型面反射部件3设置成可相对所述分光平面反射镜2移动，即两双型面反射部件3的相对间距可调，从而可实现在加工面20上的中间2条宽带聚焦线斑30相离(有一定间距)或重叠及实现2条宽带聚焦线斑30的间距距离或重叠度变化(聚焦光束离焦量与线斑粗细可不变)。在本实施例中，分光平面反射镜2上第一反射面和第二反射面之间的夹角为90°时，2束被反射的激光束共线反向，所述2个双型面反射部件3可相对所述分光平面反射镜2沿水平方向移动(图3中箭头a所示方向为在本实施例中双型面反射部件3的移动方向，即水平方向，其还为分光平面反射镜2的出光方向)，在其他实施方式中，当分光平面反射镜上2个反射面之间夹角不为90°时，2个双型面反射部件3将相对所述分光平面反射镜2的2束激光束的出光方向分别移动。
所述激光宽带熔覆装置10还包括送粉排管(未图示)，该送粉排管的一端位于所述反射镜2的下方，具体为：送粉排管位于反射镜2的正下方。所述送粉排管的一端伸入至反射镜2的下方，并朝反射镜2的下方并垂直工作面20延伸，所述送粉排管位于两个所述上部反射面31接收激光束后并反射形成的2束激光束之间，且送粉排管的管口(喷嘴)对准加工面20上的2条宽带聚焦线斑30的中心，距工作面距离在10～40mm之间。通过此种设计，可形成光束宽带内送粉。根据宽带聚焦线斑的线长形成宽带熔覆的宽度，根据不同熔覆宽带可将所述送粉管设计为3～7根，形成并排设置的排管，排管与宽带聚焦线斑平行。送粉排管周围布置有与送粉排管平行且同轴的准直气道。该宽带内送粉原理为：送粉排管位于反射镜2的下方，并在2块双型面反射部件3中间空腔进入，然后转向朝下并垂直加工面20上的2个宽带聚焦线斑30的中心以喷出线形粉束，送粉排管周围布置与送粉管平行且同轴的准直气道，工作中准直气包围送粉排管所送出的粉束并同轴垂直射向加工面20上的2个宽带聚焦线斑30的中心，在水平基面或大角度空间倾斜基面上进行双宽带光束内送粉熔覆成形。
上述激光宽带熔覆装置10的工作原理如下：激光器输出的激光束由方形截面纤芯的光纤50传递，通过准直镜1后准直为平行的方形激光束，然后进入分光平面反射镜2并被该分光平面反射镜2分割成2束矩形激光束，然后分别进入分光平面反射镜2两侧的两组双型面反射镜3，由于每组双型面反射部件3均包括上部反射面31和下部反射面32，且该上部反射面31为抛物聚焦型面，下部反射面32为平面，所以，上部反射面31受光后将反射出线型聚焦光束，以在下方的加工面20上形成2条光能密度较高的宽带聚焦线斑30(即熔覆光斑)，下部反射面32受光反射至下方的加工面20上以形成2块光能密度较低的矩形光斑40(即预热缓冷光斑)。在使用的时候，两个双型面反射部件3还可以调节其与反射镜2之间的距离，以实现在加工面20上的中间2条宽带聚焦线斑30相离(有一定间距)或重叠及实现2条宽带聚焦线斑30的间距距离或重叠度变化(离焦量与线斑粗细可不变)。
综上所述：激光宽带熔覆装置10通过在双型面反射部件3上设置上部反射面31和下部反射面32，且该上部反射面31为抛物聚焦型面，下部反射面32为平面，以通过该上部反射面31在加工面20上形成高密度宽带聚焦线斑30(即熔覆光斑)，通过该下部反射面32在加工面20上形成低密度矩形斑(即预热缓冷光斑)，从而有助于提高粉末利用率，降低熔层热应力和裂纹几率，提高宽带熔覆质量。
通过将所述双型面反射部件3设置成可相对所述分光平面反射镜2移动，具体为该双型面反射部件可分别相对所述分光反射镜出光方向移动，从而双高密度宽带聚焦线斑可调节重合度或分离度，以调节熔池宽度变化，即实现熔池内功率密度的可控变化，同时，形成了工作表面移动熔池前后的随动预热缓冷区，有助于进一步降低熔层热应力和裂纹几率。
另外，与现有技术相比，本发明的激光宽带熔覆装置10可以仅采用一台激光器即可实现形成2条熔覆光斑和2条预热缓冷光斑，结构简单紧凑。由于送粉排管位于反射镜2的下方，且该送粉排管位于两个所述上部反射面31接收激光束后并反射形成的激光束之间，又送粉管的管口射向加工面20上的两宽带聚焦线斑30的中心，从而使上部反射面31反射形成的激光束始终从两侧包夹粉束，无论送粉排管出射的单排粉束在线型光斑的聚焦位置或离焦位置，光粉皆能精确耦合，对装置离焦波动不敏感；从送粉管内输出的粉束始终位于双聚焦光束之间以实现垂直送进，入光率高，粉末利用率成倍增加，在节材环保的同时，可减少粉末粘附，提高表面质量；本实施例通过采用多根送粉管送粉，使得粉束发散角很小，粉束截面积变化不大，从而有利于熔道尺寸稳定，提高成形质量。
除此之外，由于送粉管周围布置有与送粉管平行同轴的准直气道，准直气帘有助于进一步规整和集束粉末，使之达到细、挺、准、直，可控性进一步增加，同时特别适应喷头做空间变姿态变倾角动态运动作业，完成空间大型复杂零件的多方位强化修复或3D增材制造。
应当理解，虽然本说明书按照实施方式加以描述，但并非每个实施方式仅包含一个独立的技术方案，说明书的这种叙述方式仅仅是为清楚起见，本领域技术人员应当将说明书作为一个整体，各实施方式中的技术方案也可以经适当组合，形成本领域技术人员可以理解的其 他实施方式。
上文所列出的一系列的详细说明仅仅是针对本发明的可行性实施方式的具体说明，它们并非用以限制本发明的保护范围，凡未脱离本发明技艺精神所作的等效实施方式或变更均应包含在本发明的保护范围之内。

Claims (11)

  1. 一种激光宽带熔覆装置，可将激光器所发出的激光束转换并投射在加工面上用于宽带激光熔覆加工，其特征在于，所述激光宽带熔覆装置包括反射镜和双型面反射部件，所述反射镜将激光束反射给双型面反射部件，所述双型面反射部件包括上部反射面和位于所述上部反射面下方的下部反射面，所述上部反射面为抛物聚焦型面，所述下部反射面为平面，所述上部反射面接收激光束后将其反射以在加工面上形成熔覆光斑，所述下部反射面接收激光束后将其反射以在加工面上形成预热缓冷光斑，所述预热缓冷光斑位于熔覆光斑的外侧。
  2. 如权利要求1所述的激光宽带熔覆装置，其特征在于：所述双型面反射部件为一块反射镜，所述双型面反射部件具有工作型面，所述上部反射面和下部反射面形成在所述工作型面上。
  3. 如权利要求1所述的激光宽带熔覆装置，其特征在于：所述双型面反射部件由两块反射镜组成，所述上部反射面形成在其中一块所述反射镜上，所述下部反射面形成在另一块所述反射镜上。
  4. 如权利要求1所述的激光宽带熔覆装置，其特征在于：所述双型面反射部件为两组，两组所述双型面反射部件的上部反射面相对设置，两组所述双型面反射部件的下部反射面相对设置。
  5. 如权利要求4所述的激光宽带熔覆装置，其特征在于：所述反射镜为分光平面反射镜，所述分光平面反射镜包括背向布置并迎向入激光束的第一反射面和第二反射面，所述第一反射面朝向一组所述双型面反射部件，所述第二反射面朝向另一组所述双型面反射部件。
  6. 如权利要求5所述的激光宽带熔覆装置，其特征在于：所述分光平面反射镜的第一反射面和第二反射面背向对称布置。
  7. 如权利要求5所述的激光宽带熔覆装置，其特征在于：所述第一反射面和第二反射面的夹角在60°～120°之间。
  8. 如权利要求1所述的激光宽带熔覆装置，其特征在于：所述激光宽带熔覆装置还包括送粉排管或送粉扁管，所述送粉排管或送粉扁管的一端位于所述反射镜的下方并垂直所述工作面延伸。
  9. 如权利要求1所述的激光宽带熔覆装置，其特征在于：所述激光宽带熔覆装置还包括设置在所述激光器与反射镜之间的准直镜，所述准直镜将激光器所发出的发散激光束准直为平行光后投射至反射镜。
  10. 如权利要求1至9项中任意一项所述的激光宽带熔覆装置，其特征在于：所述双型面反射部件可分别相对所述分光平面反射镜出光方向移动。
  11. 如权利要求1所述的激光宽带熔覆装置，其特征在于：所述熔覆光斑为宽带聚焦线斑，所述预热缓冷光斑为矩形光斑。
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