WO2024077779A1 - 一种大范围可调占空比的激光熔覆装置 - Google Patents

一种大范围可调占空比的激光熔覆装置 Download PDF

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Publication number
WO2024077779A1
WO2024077779A1 PCT/CN2022/141646 CN2022141646W WO2024077779A1 WO 2024077779 A1 WO2024077779 A1 WO 2024077779A1 CN 2022141646 W CN2022141646 W CN 2022141646W WO 2024077779 A1 WO2024077779 A1 WO 2024077779A1
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Prior art keywords
mirror
parabolic focusing
focusing mirror
duty cycle
conical
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English (en)
French (fr)
Inventor
李加强
金磊
邹翼波
朱刚贤
石世宏
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Suzhou University
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Suzhou University
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    • 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
    • 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
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • 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 the field of additive manufacturing, and in particular to a laser cladding device with a wide range of adjustable duty cycles.
  • the traditional annular laser cladding device adjusts the mirror group to shape the solid spot into an annular spot.
  • each laser beam has the same optical focus and converges into a solid point spot at this position.
  • the duty cycle is a geometric parameter of the annular laser beam, which has a significant impact on the microstructure of metal materials after cladding.
  • the material structure is different at different duty cycle values.
  • the conventional method of changing the duty cycle of the laser beam is to obtain different duty cycle values by changing the defocus amount.
  • this method will change other parameters while obtaining different duty cycles. For example, after changing the defocus amount, while obtaining a new duty cycle, the inner and outer diameters of the spot will change significantly. The change in outer diameter will affect the change in the width of the single cladding track (melt width). Therefore, it is impossible to explore the impact of different duty cycles while ensuring a certain melt width. At the same time, because the defocus amount is changed, it is impossible to determine the extent of the influence of the duty cycle itself on the laser cladding process.
  • the purpose of the present invention is to provide a laser cladding device with a wide range of adjustable duty cycle, which can change the duty cycle without changing the outer diameter of the annular spot, and the adjustment range of the duty cycle is relatively large.
  • the present invention provides the following technical solutions:
  • a laser cladding device with a wide range of adjustable duty cycle comprising a parabolic focusing mirror, a first axicon, a second axicon and a powder spraying device, wherein the parabolic focusing mirror and the second axicon are both annular, and the reflection surfaces of the first axicon and the second axicon are opposite to the reflection surface of the parabolic focusing mirror, so that a light beam incident on the first axicon and the second axicon from the central axis of the parabolic focusing mirror is reflected toward the circumference by the reflection surfaces of the two axicon and incident on the reflection surface of the parabolic focusing mirror, and is further reflected and focused by the reflection surface of the parabolic focusing mirror;
  • the position of the second conical mirror is fixed, the first conical mirror can be moved along the central axis of the parabolic focusing mirror, the powder spraying device is arranged below the second conical mirror, and the reflecting surface of the parabolic focusing mirror makes the focus of the light form a ring line around the central axis of the parabolic focusing mirror.
  • the focus of the light reflected by the parabolic focusing mirror is located on an optical focal plane, and there is a preset plane on the optical focal plane close to the parabolic focusing mirror, and the light reflected from the parabolic focusing mirror forms a solid light spot on the preset plane.
  • the focus of the light reflected by the parabolic focusing mirror is located on an optical focal plane, and a working plane is selected on a side of the optical focal plane close to the parabolic focusing mirror, and the defocus amount of the working plane satisfies:
  • F represents the defocus amount of the working plane
  • D represents the diameter of the ring formed by the focus of the light reflected by the parabolic focusing mirror
  • ⁇ 3 represents the angle between the outgoing light path at the lower limit position of the first conical mirror and the central axis.
  • the duty cycle adjustment range of the light reflected by the parabolic focusing mirror in the selected working plane is:
  • K represents the duty cycle of the light reflected by the parabolic focusing mirror in the selected working plane
  • ⁇ 2 represents the angle between the output light path at the upper limit position of the first conical mirror and the central axis
  • ⁇ represents the angle between the output light path of the second conical mirror and the central axis.
  • an inner diameter of the second axle is less than or equal to a diameter of the first axle.
  • the mirror seat includes a first annular fixing portion
  • the second conical mirror is fixed to the first annular fixing portion
  • the motion adjustment member is passed through the first annular fixing portion and drives the first conical mirror to move along the central axis of the parabolic focusing mirror
  • the first conical mirror is fixed to the top end of the motion adjustment member
  • the powder spraying device is fixed to the bottom end of the motion adjustment member.
  • the mirror mount also includes a connecting portion for fixing the first annular fixing portion
  • the motion adjustment member is a lifting bolt
  • the connecting portion is provided with a channel extending through the first annular fixing portion
  • an adjusting bolt is provided in the channel
  • the first annular fixing portion is provided with a multi-stage bevel gear for transmission connecting the adjusting bolt and the lifting bolt.
  • the mirror seat further includes a second annular fixing portion, the parabolic focusing mirror is fixed to the second annular fixing portion, the second annular fixing portion is located on the outer periphery of the first annular fixing portion, and the two are connected by the connecting portion.
  • a water cooling space for absorbing heat accumulated in the first conical mirror is provided inside the lifting bolt and the first conical mirror, and a cooling space is provided inside the parabolic focusing mirror.
  • it also includes a device housing, which cooperates with the mirror base to encapsulate the parabolic focusing mirror.
  • the laser cladding device with a wide range of adjustable duty cycle includes a parabolic focusing mirror, a first conical mirror, a second conical mirror and a powder spraying device, the parabolic focusing mirror and the second conical mirror are both annular, and the reflection surfaces of the first conical mirror and the second conical mirror are opposite to the reflection surface of the parabolic focusing mirror, so that the light beam incident on the first conical mirror and the second conical mirror from the central axis of the parabolic focusing mirror is reflected by the reflection surfaces of the two toward the circumference and incident on the reflection surface of the parabolic focusing mirror, and is further reflected and focused by the reflection surface of the parabolic focusing mirror.
  • the position of the second conical mirror is fixed, the first conical mirror can move along the central axis of the parabolic focusing mirror, and the powder spraying device is arranged below the second conical mirror.
  • the position of the second axle mirror is fixed, and when the first axle mirror is moved along the central axis of the parabolic focusing mirror, the outer diameter of the section of annular light beam remains unchanged, and the inner diameter of the section of annular light beam changes as the first axle mirror moves along the central axis of the parabolic focusing mirror, so as to adjust the duty cycle of the section of the outgoing light beam, and change the duty cycle without changing the outer diameter of the annular light beam.
  • the reflective surface of the parabolic focusing mirror makes the focus of the light beam form a ring line around the central axis of the parabolic focusing mirror, so that the focus of the light reflected by the parabolic focusing mirror deviates from the central axis of the parabolic focusing mirror, which can greatly reduce the inner diameter of the section of the annular light beam of the outgoing light beam, and reduce the outer diameter of the section of the annular light beam by a small amount, so that the adjustment range of the duty cycle of the section of the annular light beam can be increased. Therefore, the laser cladding device with a wide range of adjustable duty cycle of the present invention can change the duty cycle without changing the outer diameter of the annular light beam, and the adjustment range of the duty cycle is relatively large.
  • FIG1 is a schematic diagram of the optical path of an outgoing light beam of a laser cladding device with a wide range of adjustable duty cycle according to an embodiment of the present invention
  • FIG2 is a schematic diagram showing a change in the duty cycle of the outgoing light beam shown in FIG1 at each defocus plane;
  • FIG3 is a schematic diagram of the optical path of an outgoing light beam whose focus is located on the central axis of a parabolic focusing mirror and a schematic diagram of the change of the duty cycle at each defocus plane;
  • FIG4 is a longitudinal cross-sectional view of a laser cladding device with a wide range of adjustable duty cycles provided by an embodiment of the present invention
  • FIG5 is a schematic diagram of the duty cycle variation of the laser cladding device in the selected working plane according to an embodiment of the present invention.
  • This embodiment provides a laser cladding device with a wide range of adjustable duty cycle, including a parabolic focusing mirror, a first cone mirror, a second cone mirror and a powder spraying device.
  • the parabolic focusing mirror and the second axicon are both annular, and the reflection surfaces of the first axicon and the second axicon are opposite to the reflection surface of the parabolic focusing mirror, so that the light beam incident on the first axicon and the second axicon from the central axis of the parabolic focusing mirror is reflected toward the circumference by the reflection surfaces of the two axicon and incident on the reflection surface of the parabolic focusing mirror, and is further reflected and focused by the reflection surface of the parabolic focusing mirror;
  • the position of the second conical mirror is fixed, the first conical mirror can be moved along the central axis of the parabolic focusing mirror, the powder spraying device is arranged below the second conical mirror, and the reflecting surface of the parabolic focusing mirror makes the focus of the light form a ring line around the central axis of the parabolic focusing mirror.
  • the light beam is incident on the first axicon and the second axicon from the central axis of the parabolic focusing mirror, and is reflected by the reflection surfaces of the two mirrors and emitted toward the circumference.
  • the reflected light beam is incident on the reflection surface of the parabolic focusing mirror, and is reflected and focused by the reflection surface of the parabolic focusing mirror.
  • the light beam reflected by the reflection surface of the parabolic focusing mirror is focused to form a loop around the central axis of the parabolic focusing mirror.
  • a loop refers to a closed curve.
  • the outgoing light beam is focused by the parabolic focusing mirror, there is a section of annular light beam, and the light reflected by the second axle mirror forms the outer light beam of the section of annular light beam, and the light reflected by the first axle mirror forms the inner light beam of the section of annular light beam. Since the position of the second axle mirror is fixed, when the first axle mirror is moved along the central axis of the parabolic focusing mirror, the outer diameter of the section of annular light beam remains unchanged, and the inner diameter of the section of annular light beam changes as the first axle mirror moves along the central axis of the parabolic focusing mirror. In this way, the duty cycle of the section of the outgoing light beam is adjusted, and the duty cycle is changed without changing the outer diameter of the annular light beam.
  • the reflective surface of the parabolic focusing mirror makes the focus of the light form a ring line around the central axis of the parabolic focusing mirror, so that the focus of the light reflected by the parabolic focusing mirror deviates from the central axis of the parabolic focusing mirror, which can greatly reduce the inner diameter of the segment of the annular beam of the outgoing light beam, and reduce the outer diameter of the segment of the annular beam to a smaller extent, so that the duty cycle of the segment of the annular beam can be increased. Therefore, the laser cladding device with a wide range of adjustable duty cycle of the present embodiment can change the duty cycle without changing the outer diameter of the annular beam, and the duty cycle has a large adjustment range.
  • Figure 1 is a schematic diagram of the optical path of the outgoing light beam of the laser cladding device with a large range of adjustable duty cycle in this embodiment
  • Figure 2 is a schematic diagram of the change in the duty cycle of the outgoing light beam shown in Figure 1 at each defocusing plane
  • Figures 1 and 2 show the change process of the duty cycle of the light beam in area A of Figure 4.
  • the e-plane is the optical focal plane
  • the optical focus of the parabolic focusing mirror is located on the e-plane
  • the outgoing light beam is focused on the e-plane
  • the outgoing light beam is in the shape of a ring line on the e-plane.
  • the light reflected by the parabolic focusing mirror forms a solid light spot on the preset plane.
  • a c-plane above the e-plane there is a c-plane above the e-plane, and the outgoing light beam forms a solid light spot on the c-plane, which is formed by the cross-overlapping part of the outgoing light beam.
  • the light spot can be considered as the geometric focus of the outgoing light beam, and its duty cycle can be regarded as 1, and the value of its duty cycle cannot be changed by changing the position of the first conical mirror.
  • the d plane below the e plane is a positive defocusing plane.
  • the a plane and the b plane above the e plane are negative defocus planes, and the present laser cladding device selects the negative defocus plane as the working plane for laser cladding.
  • the two columns of light spots on the right side of Figure 2 are the light spots when the first cone mirror is in the upper limit position and the first cone mirror is in the lower limit position, respectively. As shown in the figure, when the first cone mirror is in the upper limit position, the inner diameter of the light spot on the a plane is very small, and the inner diameter of the light spot on the b plane is very small.
  • the inner diameter of the light spot on the a plane changes greatly when the first cone mirror is in the upper limit position compared to the lower limit position; similarly, for the b plane, the inner diameter of the light spot on the b plane changes greatly when the first cone mirror is in the upper limit position compared to the lower limit position.
  • FIG3 is a schematic diagram of the optical path of the outgoing light beam with the focus on the central axis of the parabolic focusing mirror and a schematic diagram of the change of the duty cycle at each defocus plane, in which a and b are negative defocus working planes, c is the focal plane, and d is the positive defocus working plane.
  • the laser cladding device of this embodiment shown in FIG1 and FIG2 has a larger adjustment range of the spot size and duty cycle at different defocus amounts when the incident angle of the optical path and other optical structures are not changed.
  • FIG4 is a longitudinal cross-sectional view of a laser cladding device with a wide range of adjustable duty ratio provided by the present embodiment.
  • the parabolic focusing mirror 103 and the second axle 102 are annular, and the reflection surfaces of the first axle 101 and the second axle 102 are opposite to the reflection surface of the parabolic focusing mirror 103.
  • the position of the second axle 102 is fixed, and the first axle 101 can move along the central axis of the parabolic focusing mirror 103.
  • the first axicon 101 indicated by the dotted line indicates the upper limit position of the first axicon 101, and the dotted line light represents the light propagation path of the first axicon 101 when it is in the upper limit position.
  • the first axicon 101 indicated by the solid line indicates the lower limit position of the first axicon 101, and the corresponding solid line light represents the light propagation path of the first axicon 101 when it is in the lower limit position.
  • the solid line light corresponding to the second axicon 102 represents the light propagation path of the second axicon 102.
  • the inner diameter of the second axle 102 is less than or equal to the diameter of the first axle 101.
  • the incident solid circular light beam will not be able to completely fall on the two axle oblique mirror surfaces (i.e., the reflection surfaces of the two axles), and the light beam will irradiate other parts, causing the parts to be damaged due to direct exposure to the laser beam, and it can also avoid affecting the size of the final emitted light beam.
  • the first axle 101 can move up and down along the central axis of the parabolic focusing mirror 102.
  • the top of the first axle 101 is not higher than the top of the reflection surface of the parabolic focusing mirror 103, so as to avoid that when the top of the first axle 101 is higher than the top of the reflection surface of the parabolic focusing mirror 103, the light beam will be split by the first axle 101 and will be directed to the parts above the parabolic focusing mirror 103, and the parts above do not have the ability to reflect light.
  • the first conical mirror 101 is at the lower limit position, the bottom end of the first conical mirror 101 is not lower than the top end of the second conical mirror 102.
  • the light separated by the first conical mirror 101 will be projected into the inner wall of the second conical mirror 102 and blocked, which will not only affect the final light beam size but also damage the second conical mirror 102.
  • the reflecting surface of the parabolic focusing mirror 103 satisfies the optical path corresponding to the first cone mirror 101 being in the upper limit position and the optical path corresponding to the lower limit position. Both optical paths maintain a certain safety distance from the powder spraying device 104, and the light reflected by the first cone mirror 101 when it is in the upper limit position cannot be incident on the second cone mirror 102 again.
  • the device of this embodiment may also include a mirror seat and a motion adjustment member, the mirror seat includes a first annular fixing portion, the second cone mirror is fixed to the first annular fixing portion, the motion adjustment member is inserted into the first annular fixing portion and drives the first cone mirror to move along the central axis of the parabolic focusing mirror, the first cone mirror is fixed to the top of the motion adjustment member, and the powder spraying device is fixed to the bottom of the motion adjustment member.
  • the method of driving the motion adjustment member to move to drive the first cone mirror 101 to move is not limited.
  • the mirror seat 105 may also include a connecting portion for fixing the first annular fixing portion
  • the motion adjustment member is a lifting bolt
  • the connecting portion is provided with a channel passing through the first annular fixing portion
  • the channel is provided with an adjustment bolt
  • the first annular fixing portion is provided with a multi-stage bevel gear that drives the adjustment bolt and the lifting bolt.
  • the second conical mirror 102 is fixed to the first annular fixing portion 105
  • the motion adjustment member 106 is provided through the first annular fixing portion 105
  • the first conical mirror 101 is fixed to the top of the motion adjustment member 106
  • the powder spraying device 104 is fixed to the bottom of the motion adjustment member 106.
  • the adjusting bolt 107 is provided through the channel of the connecting portion (not shown in the figure), and the adjusting bolt 107 and the lifting bolt 108 are connected by transmission through the multi-stage gear 108.
  • the multi-stage bevel gear is driven to rotate, and then the lifting bolt is driven to drive the first conical mirror at the top thereof to move, so as to drive the first conical mirror 101 to move up and down along the central axis of the parabolic focusing mirror 103.
  • the mirror base may also include a second annular fixing portion, the parabolic focusing mirror is fixed to the second annular fixing portion, the second annular fixing portion is located at the outer periphery of the first annular fixing portion, and the two are connected by the connecting portion.
  • the parabolic focusing mirror 103 is fixed to the second annular fixing portion 109.
  • a channel is provided in the second annular fixing portion 109, the channel is connected to the channel of the connecting portion, and the adjusting bolt 107 is passed through the channel of the second annular fixing portion 109 and the channel of the connecting portion.
  • a water cooling space for absorbing the heat accumulated in the first conical mirror 101 is provided inside the lifting bolt 107 and the first conical mirror 101, and a cooling space 110 can be provided inside the parabolic focusing mirror 103 to cool the parabolic focusing mirror 103 and the first conical mirror 101.
  • a knob can be provided on the outer end surface of the adjusting bolt 107 and the duty cycle data can be marked to achieve quantitative adjustment.
  • the laser cladding device also includes a device housing 111, and the device housing 111 is provided with a light inlet channel 112.
  • the device housing 111 and the second annular fixing portion 109 of the mirror seat cooperate to encapsulate the parabolic focusing mirror 103, so that the light inlet channel 112, the device housing 111, the parabolic focusing mirror 103, the first conical mirror 101 and the second conical mirror 102 are all coaxially arranged, and the light inlet channel 112 can be used for the laser beam to enter and reach the reflection surface of the first conical mirror 101 and the second conical mirror 102.
  • the laser cladding device also includes a laser source, which is connected to the light inlet channel and incidents the laser beam into the light inlet channel.
  • FIG5 is a schematic diagram of the duty cycle change of the laser cladding device of this embodiment in the selected working plane, and the working plane with a defocus amount of F is taken as an example for explanation.
  • F represents the defocus amount of the working plane
  • D represents the diameter of the ring formed by the focus of the light reflected by the parabolic focusing mirror.
  • L represents the output light path of the second axle
  • L1 represents the actual output light path of the first axle
  • L2 represents the output light path at the lower limit position of the first axle
  • L3 represents the output light path at the upper limit position of the first axle.
  • C1 represents the light spot at the actual working plane of the first axle
  • C2 represents the light spot of the output light path at the lower limit position of the first axle
  • C3 represents the light spot of the output light path at the upper limit position of the first axle.
  • ⁇ 1 represents the angle between the output light path at the actual working position of the first axle and the central axis
  • ⁇ 2 represents the angle between the output light path at the upper limit position of the first axle and the central axis
  • ⁇ 3 represents the angle between the output light path at the lower limit position of the first axle and the central axis
  • ⁇ represents the angle between the output light path of the second axle and the central axis.
  • the focus of the light reflected by the parabolic focusing mirror is located on the optical focal plane.
  • a working plane is selected on the side of the optical focal plane close to the parabolic focusing mirror, and the defocus amount of the working plane satisfies:
  • the second conical mirror 102 When the adjusting bolt 107 is rotated to drive the lifting bolt 106 to move to a certain position, the second conical mirror 102 is located at the position shown in Figure 5.
  • the actual output light path L1 of the first conical mirror is between the output light path L2 of the lower limit position of the first conical mirror and the output light path L3 of the upper limit position of the first conical mirror, which can be regarded as a general situation during laser cladding.
  • the working spot that can be taken on the plane with a defocus amount of F is C1
  • its inner radius and outer radius r1 and r2 are respectively:
  • the maximum light spot on the working plane is the light spot C3 formed by the light path L3 at the upper limit position of the first axon and the light path L1 at the second axon, and its inner radius and outer radius r 3 and r 4 are respectively:
  • the minimum light spot on the working plane is the light spot C2 formed by the light path L2 at the lower limit position of the first axon and the light path L1 of the second axon, and its inner radius and outer radius r 5 and r 6 are respectively:
  • the duty cycle is the area ratio of the hollow area and the spot area of the annular spot formed by the outgoing light beam on the working plane. Its range of variation is:
  • the expected achievable duty cycle range is 0.185 to 0.668.

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Abstract

一种大范围可调占空比的激光熔覆装置，包括抛物聚焦镜、第一锥镜、第二锥镜和喷粉装置，抛物聚焦镜和第二锥镜均为环状，第一锥镜和第二锥镜二者的反射面均与抛物聚焦镜的反射面相对，使得从抛物聚焦镜的中轴入射至第一锥镜和第二锥镜的光束，被二者的反射面向圆周反射出而入射至抛物聚焦镜的反射面，并进一步被抛物聚焦镜的反射面反射并聚焦。第二锥镜的位置固定，第一锥镜可沿着抛物聚焦镜的中轴移动，喷粉装置设置于第二锥镜的下方。本发明的大范围可调占空比的激光熔覆装置，可以在不改变环形光束的外直径的前提下改变占空比，并且占空比的调节范围较大。

Description

一种大范围可调占空比的激光熔覆装置
本申请要求于2022年10月11日提交中国专利局、申请号为202211239793.3、发明名称为“一种大范围可调占空比的激光熔覆装置”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
本发明涉及增材制造领域，特别是涉及一种大范围可调占空比的激光熔覆装置。
背景技术
激光熔覆作为一种先进的表面涂层制备技术，近些年来取得了飞速发展。传统的环形激光熔覆装置，通过调节镜组将实心光斑整形成为环形光斑，同时各激光束具有同一个光学焦点并在该位置汇聚成实心点状光斑。
占空比为环形激光束的一个几何参数，对金属材料的熔覆后微观组织具有重大的影响，在不同的占空比值下的材料组织各异，通过研究发现，可以通过改变环形激光束的占空比来调控得到预期的微观组织，并且大量实验表明，占空比在0～0.5的组织调控效果较为理想和明显。
目前，改变激光束占空比的常规方法有通过改变离焦量来取得不同的占空比数值，但是该种方法在得到不同占空比的同时会改变其它参数，比如改变离焦量后，在得到新的占空比的同时，光斑的内外径均发生较大变化，外径变化即会影响熔覆单道宽度(熔宽)发生变化，那么，在保证熔宽一定情况下就无法探究不同占空比带来的影响；同时，因为改变了离焦量的缘故，无法得出就占空比本身对激光熔覆过程的影响程度。
发明内容
本发明的目的是提供一种大范围可调占空比的激光熔覆装置，可以在不改变环形光斑外径的前提下改变占空比，并且占空比的调节范围较大。
为实现上述目的，本发明提供如下技术方案：
一种大范围可调占空比的激光熔覆装置，包括抛物聚焦镜、第一锥镜、第二锥镜和喷粉装置，所述抛物聚焦镜和所述第二锥镜均为环状，所述第一锥镜和所述第二锥镜二者的反射面均与所述抛物聚焦镜的反射面相对，使得从所述抛物聚焦镜的中轴入射至所述第一锥镜和所述第二锥镜的光束，被二者的反射面向圆周反射出而入射至所述抛物聚焦镜的反射面，并进一步被所述抛物聚焦镜的反射面反射并聚焦；
所述第二锥镜的位置固定，所述第一锥镜可沿着所述抛物聚焦镜的中轴移动，所述喷粉装置设置于所述第二锥镜的下方，所述抛物聚焦镜的反射面使得光线聚焦的焦点形成围绕所述抛物聚焦镜中轴的环线。
可选地，由所述抛物聚焦镜反射出的光线聚焦的焦点位于光学焦平面上，在所述光学焦平面靠近所述抛物聚焦镜一侧存在预设平面，从所述抛物聚焦镜反射出的光线在所述预设平面上形成实心光斑。
可选地，由所述抛物聚焦镜反射出的光线聚焦的焦点位于光学焦平面上，在所述光学焦平面靠近所述抛物聚焦镜一侧选取工作平面，所述工作平面的离焦量满足：
Figure PCTCN2022141646-appb-000001
其中，F表示工作平面的离焦量，D表示由所述抛物聚焦镜反射出的光线聚焦的焦点形成环线的直径，θ 3表示所述第一锥镜下极限位置出射光路与中轴夹角。
可选地，由所述抛物聚焦镜反射出的光线在所选取工作平面的占空比调节范围为：
Figure PCTCN2022141646-appb-000002
其中，K表示由所述抛物聚焦镜反射出的光线在所选取工作平面的占空比，θ 2表示所述第一锥镜上极限位置出射光路与中轴夹角，θ表示所述第二锥镜出射光路与中轴夹角。
可选地，所述第二锥镜的内直径小于等于所述第一锥镜的直径。
可选地，还包括镜座和运动调节件，所述镜座包括第一环状固定部， 所述第二锥镜固定于所述第一环状固定部，所述运动调节件穿设于所述第一环状固定部并带动所述第一锥镜沿着所述抛物聚焦镜的中轴移动，所述第一锥镜固定于所述运动调节件的顶端，所述喷粉装置固定于所述运动调节件的底端。
可选地，所述镜座还包括固定所述第一环状固定部的连接部，所述运动调节件为升降螺栓，所述连接部设置有贯通至所述第一环状固定部的通道，所述通道内设置有调节螺栓，所述第一环状固定部设置有传动连接所述调节螺栓和所述升降螺栓的多级锥齿轮。
可选地，所述镜座还包括第二环状固定部，所述抛物聚焦镜固定于所述第二环状固定部，所述第二环状固定部位于所述第一环状固定部的外周，两者由所述连接部连接。
可选地，所述升降螺栓和所述第一锥镜的内部设置有用于吸收所述第一锥镜积热的水冷却空间，在所述抛物聚焦镜内部设置有冷却空间。
可选地，还包括装置外壳，所述装置外壳与所述镜座配合封装所述抛物聚焦镜。
由上述技术方案可知，本发明所提供的一种大范围可调占空比的激光熔覆装置，包括抛物聚焦镜、第一锥镜、第二锥镜和喷粉装置，抛物聚焦镜和第二锥镜均为环状，第一锥镜和第二锥镜二者的反射面均与抛物聚焦镜的反射面相对，使得从抛物聚焦镜的中轴入射至第一锥镜和第二锥镜的光束，被二者的反射面向圆周反射出而入射至抛物聚焦镜的反射面，并进一步被抛物聚焦镜的反射面反射并聚焦。其中，第二锥镜的位置固定，第一锥镜可沿着抛物聚焦镜的中轴移动，喷粉装置设置于第二锥镜的下方。
经抛物聚焦镜聚焦后的出射光束，存在一段是环形光束，并且是被第二锥镜反射的光线形成了该段环形光束的外侧光线，被第一锥镜反射的光线形成了该段环形光束的内侧光线。因此第二锥镜的位置固定，将第一锥镜沿着抛物聚焦镜的中轴移动时，该段环形光束的外直径不变，该段环形光束的内直径会随着第一锥镜沿着抛物聚焦镜的中轴移动而改变，如此实现调节该段出射光束的占空比，并且是在不改变环形光束的外直径的前提下改变占空比。另外，抛物聚焦镜的反射面使得光线聚焦的焦点形成围绕 抛物聚焦镜中轴的环线，使得由抛物聚焦镜反射出的光线聚焦的焦点偏离了抛物聚焦镜的中轴，能够使出射光束的该段环形光束的内直径较大幅度地减小，使该段环形光束的外直径减小幅度较小，因此可以使得该段环形光束的占空比的调节范围增大。因此，本发明的大范围可调占空比的激光熔覆装置，可以在不改变环形光束的外直径的前提下改变占空比，并且占空比的调节范围较大。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明实施例的大范围可调占空比的激光熔覆装置出射光束的光路示意图；
图2为图1所示的出射光束在各离焦平面处占空比的变化示意图；
图3为出射光束聚焦的焦点位于抛物聚焦镜中轴上的光路示意图以及在各离焦平面处占空比的变化示意图；
图4为本发明实施例提供的一种大范围可调占空比的激光熔覆装置的纵向剖视图；
图5为本发明实施例的激光熔覆装置在所选取工作平面的占空比变化示意图。
具体实施方式
为了使本技术领域的人员更好地理解本发明中的技术方案，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造 性劳动前提下所获得的所有其他实施例，都应当属于本发明保护的范围。
本实施例提供一种大范围可调占空比的激光熔覆装置，包括抛物聚焦镜、第一锥镜、第二锥镜和喷粉装置，
所述抛物聚焦镜和所述第二锥镜均为环状，所述第一锥镜和所述第二锥镜二者的反射面均与所述抛物聚焦镜的反射面相对，使得从所述抛物聚焦镜的中轴入射至所述第一锥镜和所述第二锥镜的光束，被二者的反射面向圆周反射出而入射至所述抛物聚焦镜的反射面，并进一步被所述抛物聚焦镜的反射面反射并聚焦；
所述第二锥镜的位置固定，所述第一锥镜可沿着所述抛物聚焦镜的中轴移动，所述喷粉装置设置于所述第二锥镜的下方，所述抛物聚焦镜的反射面使得光线聚焦的焦点形成围绕所述抛物聚焦镜中轴的环线。
光束从抛物聚焦镜的中轴入射至第一锥镜和第二锥镜，被二者的反射面反射而向圆周发射出，反射出的光线入射至抛物聚焦镜的反射面，被抛物聚焦镜的反射面反射出并聚焦。被抛物聚焦镜的反射面反射出的光线，聚焦的焦点形成围绕抛物聚焦镜中轴的环线。环线是指封闭的曲线。
经抛物聚焦镜聚焦后的出射光束，存在一段是环形光束，并且是被第二锥镜反射的光线形成了该段环形光束的外侧光线，被第一锥镜反射的光线形成了该段环形光束的内侧光线。由于第二锥镜的位置固定，将第一锥镜沿着抛物聚焦镜的中轴移动时，该段环形光束的外直径不变，该段环形光束的内直径会随着第一锥镜沿着抛物聚焦镜的中轴移动而改变，如此，实现了调节该段出射光束的占空比，并且，是在不改变环形光束的外直径的前提下改变占空比。
另外本装置中，抛物聚焦镜的反射面使得光线聚焦的焦点形成围绕抛物聚焦镜中轴的环线，使得由抛物聚焦镜反射出的光线聚焦的焦点偏离了抛物聚焦镜的中轴，能够使出射光束的该段环形光束的内直径较大幅度地减小，使该段环形光束的外直径减小幅度较小，因此可以使得该段环形光束的占空比的调节范围增大。因此，本实施例的大范围可调占空比的激光熔覆装置，可以在不改变环形光束的外直径的前提下改变占空比，并且占空比的调节范围较大。
由抛物聚焦镜反射出的光线聚焦的焦点位于光学焦平面上，由抛物聚焦镜反射出的光线聚焦在光学焦平面上并且各部分光线的焦点形成一环线。示例地可参考图1和图2，图1为本实施例的大范围可调占空比的激光熔覆装置出射光束的光路示意图，图2为图1所示的出射光束在各离焦平面处占空比的变化示意图，图1和图2所示为取图4中A区域光束占空比的变化过程。结合参考图1和图2所示，e平面为光学焦平面，抛物聚焦镜的光学焦点位于e平面上，出射光束聚焦在该e平面上，并且出射光束在e平面上为环线状。
进一步具体地，在光学焦平面靠近抛物聚焦镜一侧存在预设平面，由抛物聚焦镜反射出的光线在预设平面上形成实心光斑。可参考图1和图2，在e平面上方存在c平面，出射光束在c平面上形成实心光斑，由出射光束交叉重叠部分形成。该光斑可认为是出射光束的几何焦点，其占空比可以视为1，并且无法通过改变第一锥镜的位置来改变其占空比的值。
e平面下方的d平面为正离焦平面，出射光束在正离焦平面d平面上的光斑，在将第一锥镜沿着抛物聚焦镜的中轴移动时，光斑的内直径不变，外直径变化。
e平面上方的a平面、b平面为负离焦平面，本激光熔覆装置选择负离焦平面为进行激光熔覆的工作平面。对应参考图2，图2中右侧的两列光斑依次为第一锥镜处于上极限位置、第一锥镜处于下极限位置时的光斑。如图所示，第一锥镜处于上极限位置时，a平面上的光斑内直径很小，b平面上的光斑内直径很小。对于a平面，第一锥镜处于上极限位置与处于下极限位置相比，a平面上的光斑内直径变化较大；同样地，对于b平面，第一锥镜处于上极限位置与处于下极限位置相比，b平面上的光斑内直径变化较大。通过将第一锥镜在上极限位置与下极限位置之间移动，可实现光斑在两个极限大小之间变化，实现占空比在某个范围内的改变。
示例地可结合参考图3，图3为出射光束聚焦的焦点位于抛物聚焦镜中轴上的光路示意图以及在各离焦平面处占空比的变化示意图，图中a、b为负离焦工作平面，c为焦点平面，d为正离焦工作平面。可以明显看出，图3所示与图1和图2所示相比，在不改变光路入射角度和其他光学结构 的情况下，图1和图2所示的本实施例的激光熔覆装置出射光束在不同离焦量处的光斑尺寸和占空比调节范围更大。
示例地可参考图4，图4为本实施例提供的一种大范围可调占空比的激光熔覆装置的纵向剖视图，如图所示，抛物聚焦镜103和第二锥镜102为环状，第一锥镜101和第二锥镜102二者的反射面均与抛物聚焦镜103的反射面相对。第二锥镜102的位置固定，第一锥镜101可沿着抛物聚焦镜103的中轴移动。
图中，虚线表示的第一锥镜101表示第一锥镜101的上极限位置，虚线光线表示第一锥镜101处于上极限位置时的光线传播光路。实线表示的第一锥镜101表示第一锥镜101的下极限位置，对应的实线光线表示第一锥镜101处于下极限位置时的光线传播光路。第二锥镜102对应的实线光线表示第二锥镜102的光线传播光路。
具体地，第二锥镜102的内直径小于等于第一锥镜101的直径，比如光束是垂直射入的，若是第二锥镜102的内直径大于第一锥镜101的直径，就会导致入射的实心圆形光束不能完全落在两个锥镜斜镜面(即两个锥镜的反射面)上，光束会照射到其它零件上，会造成零件因直接受激光束照射而损坏，也可避免影响最终出射的光束尺寸。第一锥镜101可沿着抛物聚焦镜102中轴上下移动。优选地，第一锥镜101处于上极限位置时，第一锥镜101顶端不高于抛物聚焦镜103的反射面顶端，以避免第一锥镜101顶端高于抛物聚焦镜103的反射面顶端时，光束被第一锥镜101分割之后会射向抛物聚焦镜103上方的零件，上方的零件不具备反射光的能力。第一锥镜101处于下极限位置时，所述第一锥镜101底端不低于所述第二锥镜102顶端，若此时第一锥镜101底端低于第二锥镜102的顶端，被第一锥镜101分开的光就会射进第二锥镜102的内壁并且被遮挡，不仅会影响最终的光束尺寸，还会损坏第二锥镜102。
其中，抛物聚焦镜103的反射面满足第一锥镜101处于上极限位置对应的光路和处于下极限位置对应的光路，该两光路均与喷粉装置104保持一定安全距离，以及第一锥镜101上极限位置时反射出的光线不能再次入射到第二锥镜102上。
进一步地，本实施例装置还可包括镜座和运动调节件，所述镜座包括第一环状固定部，所述第二锥镜固定于所述第一环状固定部，所述运动调节件穿设于所述第一环状固定部并带动所述第一锥镜沿着所述抛物聚焦镜的中轴移动，所述第一锥镜固定于所述运动调节件的顶端，所述喷粉装置固定于所述运动调节件的底端。本实施例中，对驱动运动调节件移动以带动第一锥镜101移动的方式不做限定。可选地在一些实施方式中，镜座105还可包括固定所述第一环状固定部的连接部，所述运动调节件为升降螺栓，所述连接部设置有贯通至所述第一环状固定部的通道，所述通道内设置有调节螺栓，所述第一环状固定部设置有传动连接所述调节螺栓和所述升降螺栓的多级锥齿轮。通过转动调节螺栓，驱动多级锥齿轮旋转，进而驱动升降螺栓带动其顶端的第一锥镜运动。
示例地可参考图4所示，第二锥镜102固定于第一环状固定部105，运动调节件106穿设于第一环状固定部105，第一锥镜101固定于运动调节件106的顶端，喷粉装置104固定于运动调节件106的底端。调节螺栓107穿设于连接部(图中未标出)的通道内，通过多级齿轮108将调节螺栓107和升降螺栓108传动连接。通过转动调节螺栓，驱动多级锥齿轮旋转，进而驱动升降螺栓带动其顶端的第一锥镜运动，实现驱动第一锥镜101沿着抛物聚焦镜103的中轴上下移动。
进一步地，镜座还可包括第二环状固定部，所述抛物聚焦镜固定于所述第二环状固定部，所述第二环状固定部位于所述第一环状固定部的外周，两者由所述连接部连接。可参考图4所示，抛物聚焦镜103固定于第二环状固定部109。具体的，在第二环状固定部109内设置有通道，该通道与连接部的通道连通，调节螺栓107穿设于第二环状固定部109的通道以及连接部的通道。
优选地，升降螺栓107和第一锥镜101的内部设置有用于吸收所述第一锥镜101积热的水冷却空间，抛物聚焦镜103内部可设置冷却空间110，以便对抛物聚焦镜103和第一锥镜101进行冷却。调节螺栓107的外端面可设置旋钮并标注占空比数据，实现量化调节。进一步地，本激光熔覆装置还包括装置外壳111，装置外壳111设置有进光通道112，装置外壳111 和镜座的第二环状固定部109配合将抛物聚焦镜103封装，使得进光通道112、装置外壳111、抛物聚焦镜103、第一锥镜101和第二锥镜102均同轴设置，进光通道112可供激光束进入并到达第一锥镜101和第二锥镜102的反射面。进一步地，本激光熔覆装置还包括激光源，激光源与进光通道连接，向进光通道入射激光束。
下面对本激光熔覆装置实现大范围调节占空比的情况进行说明，其中，以非上、下极限位置时的一个位置做具体说明，同时将整个装置进行简化。并且为了阐述的方便，用虚线表示两个极限位置的光路，如图5所示，图5为本实施例的激光熔覆装置在所选取工作平面的占空比变化示意图，取离焦量为F的工作平面为案例进行说明。
其中，F表示工作平面的离焦量，D表示由抛物聚焦镜反射出的光线聚焦的焦点形成环线的直径。L表示第二锥镜出射光路，L1表示第一锥镜实际出射光路，L2表示第一锥镜下极限位置出射光路，L3表示第一锥镜上极限位置出射光路。C1表示在第一锥镜实际工作平面下光斑，C2表示在第一锥镜下极限位置出射光路光斑，C3表示在第一锥镜上极限位置出射光路光斑。θ 1表示第一锥镜实际工作位置出射光路与中轴夹角，θ 2表示第一锥镜上极限位置出射光路与中轴夹角。θ 3表示第一锥镜下极限位置出射光路与中轴夹角，θ表示第二锥镜出射光路与中轴夹角。
由抛物聚焦镜反射出的光线聚焦的焦点位于光学焦平面上，在光学焦平面靠近抛物聚焦镜一侧选取工作平面，工作平面的离焦量满足：
Figure PCTCN2022141646-appb-000003
当旋动调节螺栓107带动升降螺栓106移动到某一位置时，第二锥镜102位于图5所示位置。第一锥镜实际出射光路L1处于第一锥镜下极限位置出射光路L2和第一锥镜上极限位置出射光路L3之间，此时可视为在进行激光熔覆时的一般情形。
此时在离焦量为F的平面上可取的工作光斑即为C1，其内半径、外半径r 1、r 2分别为：
Figure PCTCN2022141646-appb-000004
Figure PCTCN2022141646-appb-000005
在该工作平面的最大光斑为第一锥镜上极限位置出射光路L3与第二锥镜出射光路L1构成的光斑C3，其内半径、外半径r 3、r 4分别为：
Figure PCTCN2022141646-appb-000006
Figure PCTCN2022141646-appb-000007
在该工作平面的最小光斑为第一锥镜下极限位置出射光路L2与第二锥镜出射光路L1构成的光斑C2，其内半径、外半径r 5、r 6分别为：
Figure PCTCN2022141646-appb-000008
Figure PCTCN2022141646-appb-000009
那么在该工作平面下的激光占空比K的值为：
Figure PCTCN2022141646-appb-000010
本实施例中以出射光束在工作平面上形成的环形光斑的中空区域和光斑区域的面积比为占空比。其变化范围为：
Figure PCTCN2022141646-appb-000011
将其带入实验常用的数据：F＝30mm，θ＝19.2°。
预计达到的数据为：θ 2＝18.5°，θ 3＝16.2°。
则预计可达到的占空比变化范围为0.185至0.668。
以上对本发明所提供的一种大范围可调占空比的激光熔覆装置进行了 详细介绍。本文中应用了具体个例对本发明的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本发明的方法及其核心思想。应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以对本发明进行若干改进和修饰，这些改进和修饰也落入本发明权利要求的保护范围内。

Claims (10)

  1. 一种大范围可调占空比的激光熔覆装置，其特征在于，包括抛物聚焦镜、第一锥镜、第二锥镜和喷粉装置，所述抛物聚焦镜和所述第二锥镜均为环状，所述第一锥镜和所述第二锥镜二者的反射面均与所述抛物聚焦镜的反射面相对，使得从所述抛物聚焦镜的中轴入射至所述第一锥镜和所述第二锥镜的光束，被二者的反射面向圆周反射出而入射至所述抛物聚焦镜的反射面，并进一步被所述抛物聚焦镜的反射面反射并聚焦；
    所述第二锥镜的位置固定，所述第一锥镜可沿着所述抛物聚焦镜的中轴移动，所述喷粉装置设置于所述第二锥镜的下方，所述抛物聚焦镜的反射面使得光线聚焦的焦点形成围绕所述抛物聚焦镜中轴的环线。
  2. 根据权利要求1所述的大范围可调占空比的激光熔覆装置，其特征在于，由所述抛物聚焦镜反射出的光线聚焦的焦点位于光学焦平面上，在所述光学焦平面靠近所述抛物聚焦镜一侧存在预设平面，从所述抛物聚焦镜反射出的光线在所述预设平面上形成实心光斑。
  3. 根据权利要求1所述的大范围可调占空比的激光熔覆装置，其特征在于，由所述抛物聚焦镜反射出的光线聚焦的焦点位于光学焦平面上，在所述光学焦平面靠近所述抛物聚焦镜一侧选取工作平面，所述工作平面的离焦量满足：
    Figure PCTCN2022141646-appb-100001
    其中，F表示工作平面的离焦量，D表示由所述抛物聚焦镜反射出的光线聚焦的焦点形成环线的直径，θ 3表示所述第一锥镜下极限位置出射光路与中轴夹角。
  4. 根据权利要求3所述的大范围可调占空比的激光熔覆装置，其特征在于，由所述抛物聚焦镜反射出的光线在所选取工作平面的占空比调节范围为：
    Figure PCTCN2022141646-appb-100002
    其中，K表示由所述抛物聚焦镜反射出的光线在所选取工作平面的占 空比，θ 2表示所述第一锥镜上极限位置出射光路与中轴夹角，θ表示所述第二锥镜出射光路与中轴夹角。
  5. 根据权利要求1所述的大范围可调占空比的激光熔覆装置，其特征在于，所述第二锥镜的内直径小于等于所述第一锥镜的直径。
  6. 根据权利要求1所述的大范围可调占空比的激光熔覆装置，其特征在于，还包括镜座和运动调节件，所述镜座包括第一环状固定部，所述第二锥镜固定于所述第一环状固定部，所述运动调节件穿设于所述第一环状固定部并带动所述第一锥镜沿着所述抛物聚焦镜的中轴移动，所述第一锥镜固定于所述运动调节件的顶端，所述喷粉装置固定于所述运动调节件的底端。
  7. 根据权利要求6所述的大范围可调占空比的激光熔覆装置，其特征在于，所述镜座还包括固定所述第一环状固定部的连接部，所述运动调节件为升降螺栓，所述连接部设置有贯通至所述第一环状固定部的通道，所述通道内设置有调节螺栓，所述第一环状固定部设置有传动连接所述调节螺栓和所述升降螺栓的多级锥齿轮。
  8. 根据权利要求7所述的大范围可调占空比的激光熔覆装置，其特征在于，所述镜座还包括第二环状固定部，所述抛物聚焦镜固定于所述第二环状固定部，所述第二环状固定部位于所述第一环状固定部的外周，两者由所述连接部连接。
  9. 根据权利要求7所述的大范围可调占空比的激光熔覆装置，其特征在于，所述升降螺栓和所述第一锥镜的内部设置有用于吸收所述第一锥镜积热的水冷却空间，在所述抛物聚焦镜内部设置有冷却空间。
  10. 根据权利要求6所述的大范围可调占空比的激光熔覆装置，其特征在于，还包括装置外壳，所述装置外壳与所述镜座配合封装所述抛物聚焦镜。
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