CN111036911B - A method for removing pore defects in metal additive manufacturing components based on online monitoring - Google Patents
A method for removing pore defects in metal additive manufacturing components based on online monitoring Download PDFInfo
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Abstract
一种基于在线监测的金属增材制造构件孔隙缺陷清除方法，包括一套DED金属增材制造系统，一套用于在增材制造过程中实时监控孔隙缺陷位置的在线监测系统，一套用于进行缺陷修复的激光冲击强化系统以及将增材制造过程、在线监测过程、激光冲击强化过程三者相协调配合的中控系统，中控系统依据在线监测系统获得的孔隙分布模型，控制激光冲击强化系统利用高能量脉冲激光对增材制造试样进行层间3D冲击强化，对于气孔缺陷通过先将缺陷上方薄层金属击溃，然后通过DED金属增材制造系统控制后续成形过程中的给料对其进行消除；对于长度方向平行于制造方向的裂纹，中控系统通过施加残余压应力的方式使裂纹闭合，本发明能够在检测出缺陷后将其清除。
A method for removing pore defects of metal additive manufacturing components based on online monitoring, including a DED metal additive manufacturing system, an online monitoring system for real-time monitoring of the positions of pore defects during the additive manufacturing process, and a set for defect detection The repaired laser shock peening system and the central control system that coordinates the additive manufacturing process, the online monitoring process and the laser shock peening process. The central control system controls the laser shock peening system to use the pore distribution model obtained by the online monitoring system. The high-energy pulsed laser performs interlayer 3D impact strengthening on the additive manufacturing sample. For the porosity defect, the thin layer of metal above the defect is first broken, and then the DED metal additive manufacturing system is used to control the feed in the subsequent forming process to eliminate it. ; For a crack whose length direction is parallel to the manufacturing direction, the central control system closes the crack by applying residual compressive stress, and the present invention can remove the defect after detecting it.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a method for eliminating pore defects of a metal additive manufacturing component based on online monitoring.
Background
Directional Energy Deposition (DED) is an important branch of the metal additive manufacturing field, and pores and cracks are the most common defects inside the DED, and firstly, the pores can generate microcracks to cause lower mechanical strength; secondly, the fatigue life of the entire component is also reduced due to the different sizes and shapes of the pores distributed throughout the space. At present, in experiments and production practices, internal pores are required to be controlled, process parameters are generally optimized, and high-quality raw materials or shielding gases and the like are selected, but even the internal pores of the component cannot be completely eliminated. In order to find the internal pores in real time in the manufacturing process, most of the current researchers adopt an online monitoring technology to realize the real-time monitoring of the internal pores.
In chinese patent (publication No. CN 109676135 a), an online monitoring and defect repairing apparatus for visual grayscale difference in laser additive manufacturing is provided, which is integrated into an additive manufacturing system, and utilizes an image grayscale analysis technique to perform nondestructive detection on a molded component, and invokes a manufacturing execution mechanism to realize limited defect repair by optimizing a manufacturing process. The repair method is not departed from the traditional method for repairing the defects of the formed component by modifying the process parameters of the manufacturing process, has limited repair capability and cannot repair some internal defects which are formed.
In chinese patent (publication No. CN 108931535 a), an on-line monitoring method for laser additive manufacturing air hole defects is provided, in which a gray processing module, an image filtering and noise reduction module, and an air bubble feature extraction module are used to realize on-line monitoring for laser additive manufacturing air hole defects, but the method is only limited to on-line monitoring, and the monitored defects cannot be compensated after the monitoring is completed.
In chinese patent (No. CN 105248011B), a method of a laser shock forging and laser cutting composite additive manufacturing apparatus is provided, in which an energy source laser originally used for laser additive manufacturing is divided into three parts, which are respectively used for laser additive manufacturing, laser shock forging and laser cutting, but the laser used for laser additive manufacturing is continuous laser and has low power, and cannot form an effective shock strengthening effect on a workpiece after light splitting.
In chinese patent (No. CN 107378250B), a laser cladding impact forging composite molding method for large-size parts based on CCD monitoring is provided, which has the problems that defects inside the parts cannot be effectively detected based on CCD alone, and a lot of time and energy are wasted if the whole large-size parts are subjected to laser impact forging; in addition, the beneficial effect of laser shock forging is weaker than that of laser shock strengthening, and the internal pore defects can not be effectively influenced; and the method only aims at laser cladding forming and has larger limitation.
Based on the prior art, when the pore defects are required to be repaired, only the serious parts of the defects can be cut off, and then the defective parts are reprinted, so that the macro-morphology of the formed workpiece is changed, and on the other hand, a path needs to be further modeled, sliced and planned when the formed workpiece is repaired. Thus, not only much time and effort is consumed for the repair process, but also vibration, debris, and the like generated during the cutting process adversely affect the manufacturing process. As can be seen from the above prior art, some progress has been made in monitoring the internal pores of the additive manufactured component, but the repair of internal pore defects still remains to adjust the manufacturing parameters and materials, and there is no method for removing the defects after the defects are detected.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide a method for removing the pore defects of the metal additive manufacturing component based on online monitoring, which can remove the defects after the defects are detected.
In order to achieve the purpose of the invention, the invention adopts the technical scheme that:
a metal additive manufacturing component pore defect clearing method based on-line monitoring comprises a set of DED metal additive manufacturing system, a set of on-line monitoring system for monitoring the position of a pore defect in an additive manufacturing process in real time, a set of laser shock strengthening system for repairing the defect and a central control system for coordinating and matching the additive manufacturing process, the on-line monitoring process and the laser shock strengthening process, wherein the central control system controls the laser shock strengthening system to carry out interlayer 3D shock strengthening on an additive manufacturing sample by using high-energy pulse laser according to a pore distribution model obtained by the on-line monitoring system, and eliminates the pore defect by firstly crushing a thin layer of metal above the defect and then controlling feeding in a subsequent forming process by the DED metal additive manufacturing system; for cracks with the length direction parallel to the manufacturing direction, the central control system closes the cracks by applying residual compressive stress.
A metal additive manufacturing component pore defect removing method based on online monitoring comprises the following steps:
1) carrying out three-dimensional modeling through computer CAD software, and layering and path planning on the model by using DED metal additive manufacturing system slice layering software;
2) the DED metal additive manufacturing system carries out an additive manufacturing process, stacking and solidifying of the front n-layer material on the substrate are carried out, meanwhile, the online monitoring system continuously works, control parameters are fed back in real time, and the central control system corrects the additive manufacturing parameters according to the fed back parameters;
3) after the first n layers of materials are stacked, the online monitoring system feeds back the position, the shape and the size of an internal pore, and the central control system presets laser shock strengthening parameters according to a pore distribution model obtained by the online monitoring system;
4) the laser shock peening system starts to work, aiming at the distribution of internal pores, the laser shock peening system performs key shock peening on the part with the defects, crushes the surface of the part with the defects to expose the pores, and can perform shock peening on the side surface of the defect close to the side surface of the sample and directly repair the defect on the side surface;
5) the DED metal additive manufacturing system starts additive manufacturing of the (n + 1) th layer, repairs the defects according to the sizes and shapes of the defects, and gradually completes filling in the subsequent m-layer manufacturing process;
6) and (5) repeating the steps 2) and 5) until the sample is produced.
The DED metal additive manufacturing system comprises a LENS system and a WAAM system, and is respectively used for additive manufacturing of powder materials and wire materials; the LENS system comprises a fiber laser, a five-axis motion control system, a powder feeder, a coaxial distribution nozzle, an argon protection box and a water cooling machine; the WAAM system comprises a six-axis industrial robot integrated with an arc welding gun, a wire feeding system, a power supply system and a control system.
The laser shock peening system comprises Nd, YAG high-energy pulse laser, optional restraint layer and absorption layer, wherein Q-switch technology is applied to the Nd, YAG high-energy pulse laser and optional restraint layer and absorption layer; the absorption layer is made of aluminum foil adhesive tape; the constraint layer is made of K9 glass or transparent polymer.
The online monitoring system comprises an X-ray emitter, a high-speed camera, a light filter, a wave motor, a slit and a reflector, wherein X-rays enter an additive manufacturing working area through the control of the slit and the shutter, and after the X-rays pass through a sample, the high-speed camera is used for capturing the X-rays converted into visible light; the internal defects of the formed sample can be reconstructed in a computer through pictures shot by a high-speed camera, and the internal defects are used for determining the defect positions and the defect appearance of the sample.
Compared with the prior art, the invention has the beneficial effects that:
1. the X-ray is used as an online monitoring means, so that the distribution conditions of pores and cracks in a formed sample can be better acquired, and impact position information is provided for the next laser impact process.
2. By adopting the composite process of laser shock peening and additive manufacturing, the defects generated in the production process can be eliminated in real time, secondary additive repair can be carried out according to the positions of the defects, and the completeness of the internal structure and the surface of the finally-formed sample is ensured.
3. When the internal defects are repaired, the conditions of warping, deformation, substrate separation and the like in the additive manufacturing process can be avoided by combining laser shock peening with additive manufacturing.
4. By adjusting reasonable parameters, the recrystallization of a laser impact area can be further promoted while the defects are repaired, and a metal sample with more uniform internal microstructure is obtained.
5. The laser shock strengthening treatment is carried out in the additive manufacturing process, and the surface of the material is remelted in the material deposition of the next layer, so that a practical protective layer is not needed to avoid the surface from being ablated, and the laser shock strengthening process is simplified.
Drawings
FIG. 1 is a flow chart of the method of the present invention.
FIG. 2 shows the surface condition of the additive manufactured part after the laser shock peening treatment according to the method of the present invention.
Detailed Description
The method of the present invention is described in detail below with reference to the accompanying drawings and examples.
As shown in fig. 1, a method for removing pore defects of a metal additive manufacturing component based on online monitoring includes the following steps:
1) carrying out three-dimensional modeling by using computer CAD software to obtain a sample model with the size of 100mm x 60mm, and carrying out layering and path planning on the model by using DED metal additive manufacturing system slice layering software;
2) the DED metal additive manufacturing system carries out the additive manufacturing process, wire AA5183 aluminum alloy is selected as a raw material, the deposition of the 1 st layer of material is carried out, and the previous 1 layer is selected in the embodiment because the thickness of a single layer of the deposited material of the WAAM process is large;
in the deposition process of the WAAM process, the wire feeding speed is 15.0m/min, the running speed of a printing head is 12mm/s, the current range is 230-;
meanwhile, the on-line monitoring system continuously works, feeds back control parameters in real time, and reconstructs the internal structure of the sample through software after returning the detection result to the computer to calibrate the impact strengthening area and the impact parameters;
the X-ray scanning follows the arc welding head, the scanning range is about 30X 30mm, after the X-ray passes through a sample, the X-ray is converted into visible light by a scintillator and is shot by a high-speed camera, the shooting speed is 2kHz, and the picture resolution is 1024X 1024;
3) performing 1 st impact reinforcement, automatically calibrating impact reinforcement parameters of a laser impact reinforcement system by a central control system of a computer, wherein the parameters which can be adjusted by the computer comprise a light spot diameter of 0.1-20 mm, a longitudinal overlapping rate of 0-90%, a transverse overlapping rate of 0-90%, pulse energy of 0.1-50J and a repetition frequency of 0.5-10 Hz;
the protective layer selected by the laser shock strengthening system is an aluminum foil adhesive tape, and the restraint layer is K9 glass; aiming at internal pore distribution, performing key impact reinforcement on a part with defects, crushing the surface of the part with defects to expose pores, performing impact reinforcement on the side surface of the part close to the side surface of a sample, and directly repairing the defects on the side surface, and referring to fig. 2, fig. 2 shows that plastic deformation obviously occurs in a thicker wire frame when the surface of the additive manufacturing component is subjected to the laser impact reinforcement treatment, and the inner part of the thin wire frame is an internal pore exposed after the impact reinforcement;
5) the DED metal additive manufacturing system starts to deposit the next layer of material, the defect exposed by the last impact reinforcement is filled and repaired in the manufacturing process, and the operation parameters of the DED metal additive manufacturing system are determined in real time by reading the size and the position shape of the defect fed back by the online monitoring system through the computer;
6) and (5) repeating the steps 2) and 5) until the production of the sample is finished, repairing the defects in the whole sample, and obtaining the ideal sample with the bulk density close to 100%.
The DED metal additive manufacturing system comprises a LENS system and a WAAM system, and is respectively used for additive manufacturing of powder materials and wire materials; the LENS system comprises a fiber laser, a five-axis motion control system, a powder feeder, a coaxial distribution nozzle, an argon protection box and a water cooling machine; the WAAM system comprises a six-axis industrial robot integrated with an arc welding gun, a wire feeding system, a power supply system and a control system.
The laser shock peening system comprises Nd, YAG high-energy pulse laser, optional restraint layer and absorption layer, wherein Q-switch technology is applied to the Nd, YAG high-energy pulse laser and optional restraint layer and absorption layer; the absorption layer is made of an aluminum foil adhesive tape, and if a protective layer is not added, the laser shock effect can be reduced, but the shock strengthening process can be simplified; the constraint layer is made of K9 glass or transparent polymer, and the impact strengthening effect is reduced when the constraint layer is not added, but the impact strengthening process can be simplified.
The online monitoring system comprises an X-ray emitter, a high-speed camera, a light filter, a wave motor, a slit and a necessary reflector, wherein X-rays enter an additive manufacturing working area through the slit and the shutter, and the high-speed camera is used for capturing the X-rays converted into visible light after the X-rays pass through a sample; the internal defects of the formed sample can be reconstructed in a computer through pictures shot by a high-speed camera, and the internal defects are used for determining the defect positions and the defect appearance of the sample.
Claims (1)
1. A method for eliminating pore defects of a metal additive manufacturing component based on-line monitoring is characterized by comprising the following steps: the device comprises a set of DED metal additive manufacturing system, a set of online monitoring system for monitoring the position of a pore defect in real time in the additive manufacturing process, a set of laser shock strengthening system for repairing the defect and a central control system for coordinating the additive manufacturing process, the online monitoring process and the laser shock strengthening process, wherein the central control system controls the laser shock strengthening system to carry out interlayer 3D shock strengthening on an additive manufacturing sample by using high-energy pulse laser according to a pore distribution model obtained by the online monitoring system, and eliminates the pore defect by firstly crushing a thin layer of metal above the defect and then controlling feeding in a subsequent forming process by the DED metal additive manufacturing system; for the cracks with the length direction parallel to the manufacturing direction, the central control system closes the cracks by applying residual compressive stress;
the method for eliminating the pore defects of the metal additive manufacturing component based on online monitoring comprises the following steps:
1) carrying out three-dimensional modeling through computer CAD software, and layering and path planning on the model by using DED metal additive manufacturing system slice layering software;
2) the DED metal additive manufacturing system carries out an additive manufacturing process, stacking and solidifying of the front n-layer material on the substrate are carried out, meanwhile, the online monitoring system continuously works, control parameters are fed back in real time, and the central control system corrects the additive manufacturing parameters according to the fed back parameters;
3) after the first n layers of materials are stacked, the online monitoring system feeds back the position, the shape and the size of an internal pore, and the central control system presets laser shock strengthening parameters according to a pore distribution model obtained by the online monitoring system;
4) the laser shock peening system starts to work, aiming at the distribution of internal pores, the laser shock peening system performs key shock peening on the part with the defects, crushes the surface of the part with the defects to expose the pores, and can perform shock peening on the side surface of the defect close to the side surface of the sample and directly repair the defect on the side surface;
5) the DED metal additive manufacturing system starts additive manufacturing of the (n + 1) th layer, repairs the defects according to the sizes and shapes of the defects, and gradually completes filling in the subsequent m-layer manufacturing process;
6) repeating the step 2) to the step 5) until the production of the sample is finished;
the laser shock peening system comprises Nd, YAG high-energy pulse laser, a restraint layer and an absorption layer, wherein the Nd is Nd applying Q-switch technology; the absorption layer is made of aluminum foil adhesive tape; the constraint layer is made of K9 glass or light-transmitting polymer; the diameter of the light spot is 0.1-20 mm, the longitudinal overlapping rate is 0-90%, the transverse overlapping rate is 0-90%, the pulse energy is 0.1-50J, and the repetition frequency is 0.5-10 Hz;
the DED metal additive manufacturing system comprises a LENS system and a WAAM system, and is respectively used for additive manufacturing of powder materials and wire materials; the LENS system comprises a fiber laser, a five-axis motion control system, a powder feeder, a coaxial distribution nozzle, an argon protection box and a water cooling machine; the WAAM system comprises a six-axis industrial robot integrated with an arc welding gun, a wire feeding system, a power supply system and a control system;
the online monitoring system comprises an X-ray emitter, a high-speed camera, a light filter, a wave motor, a slit and a reflector, wherein X-rays enter an additive manufacturing working area through the control of the slit and the shutter, and after the X-rays pass through a sample, the high-speed camera is used for capturing the X-rays converted into visible light; the internal defects of the formed sample can be reconstructed in a computer through pictures shot by a high-speed camera, and the internal defects are used for determining the defect positions and the defect appearance of the sample.
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