Composite additive system based on programmable laser beam-double electric arcs and working method of composite additive system

Abstract

The invention discloses a composite additive system based on programmable laser beam-double arcs and a working method of the composite additive system. The composite additive system is mainly composed of a laser unit, a beam shaping unit, a deformation optical unit, a double-arc unit, a double-wire-feeding unit, a substrate unit and a light spot shape unit. According to the system, Gaussian laser is converted into a flat-topped beam through a pi Shaper collimation beam shaper, and the shape and intensity distribution of a light spot are dynamically regulated and controlled by combining an electromagnetic actuating self-adaptive optical element; the double arc units cooperate around the laser beam to achieve gradient deposition of heterogeneous materials such as titanium / aluminum and the like in cooperation with an independently-controlled wire feeding system. A closed-loop feedback mechanism is adopted, molten pool parameters are monitored in real time through an optical sensor, laser power, electric arc parameters and wire feeding speed are dynamically adjusted, and molten pool stability and metallurgical reaction control precision are remarkably improved. The system can meet the multi-material composite additive manufacturing requirements of multifunctional parts of complex structures, and is particularly suitable for efficient forming of high-performance titanium-aluminum alloy components in the aerospace field.

Description

Technical Field

[0001] The present invention belongs to the technical field of additive manufacturing, and in particular relates to a composite additive system based on a programmable laser beam and dual arcs and a working method thereof. Background Art

[0002] Additive Manufacturing (AM), as an efficient manufacturing method, has been widely used in aerospace, automotive, and medical fields. Laser AM is one of the most common technologies. A laser beam serves as the energy source, melting the material and depositing it layer by layer to gradually create parts with complex structures. However, in traditional laser AM methods, the laser's output spot exhibits a Gaussian distribution. However, the energy utilization rate of a Gaussian-distributed laser beam is very low, with 63% of the energy lost, leaving only 37% for processing. This low energy utilization leads to low production efficiency. Furthermore, the Gaussian distribution results in uneven energy distribution. Excessive energy in the intermediate regions can cause some low-melting-point alloying elements to vaporize, resulting in unstable melt pool behavior and impairing process stability. Furthermore, the outer boundaries of the Gaussian distribution often lack energy, leading to incomplete melting. Consequently, the laser beam's energy distribution and the melt pool temperature gradient are difficult to precisely control, which can easily lead to melt pool instability and poor build quality. Furthermore, when manufacturing complex structures and multi-material transitions, problems such as compositional inhomogeneity and sudden property changes often occur.

[0003] To address these issues, existing additive manufacturing methods based on laser beam shaping, laser control, and dual-arc assisted manufacturing have been proposed. However, these methods still face challenges in control accuracy, process adaptability, and multi-material manufacturing. Therefore, it is crucial to develop a novel additive manufacturing method that can precisely control laser energy distribution and melt pool temperature gradients while maintaining good process adaptability. Summary of the Invention

[0004] The purpose of the present invention is to provide a composite additive system based on programmable laser beam-dual arc and its working method, so as to solve the problems in traditional additive manufacturing technology such as single heat source, difficulty in precise control of heat input, limited material adaptability, and difficulty in manufacturing complex structures and multifunctional material parts, and to realize a high-precision, high-efficiency and highly flexible additive manufacturing process to meet the production needs of high-performance parts in the fields of aerospace, mechanical manufacturing, etc.

[0005] To achieve the purpose of the present invention, on the one hand, the present invention provides a composite additive system based on a programmable laser beam-dual arc, comprising a laser unit, a beam shaping unit, a deformation optical unit, a first arc unit, a second arc unit, a first wire feeding unit, a second wire feeding unit, a substrate unit, and a spot shape unit arranged in sequence;

[0006] The laser unit is used to generate a laser beam with specific power, wavelength and pulse frequency to provide an initial high-energy heat source for the composite additive process;

[0007] The beam shaping unit is used to adjust the spatial distribution and shape of the original laser beam output by the laser unit, thereby changing its spot size and energy density distribution;

[0008] The deformable optical unit is used to dynamically adjust the wavefront shape and propagation direction of the laser beam to achieve active control of the temperature gradient of the molten pool;

[0009] The first arc unit is used to generate a first arc, cooperate with the laser beam to form a composite heat source in the processing area, and adjust the current, voltage and arc length of the arc;

[0010] The second arc unit is used to generate a second arc, and optimize the flow state and metallurgical reaction of the molten pool by reasonably matching with the first arc and the laser beam;

[0011] The first wire feeding unit is used to feed a filler material wire to the active area of the first arc unit, and to feed the wire into the molten pool stably and evenly through a precise wire feeding drive mechanism and a speed control system;

[0012] The second wire feeding unit is used to feed another type of filler material wire to the active area of the second arc unit, thereby realizing independent feeding of wires of different materials or compositions, meeting the additive manufacturing requirements of complex structures and multifunctional materials, and realizing composite deposition of multiple materials by working in conjunction with the first wire feeding unit;

[0013] The base plate unit is used to serve as an electrode of the electric arc and to support the additively manufactured formed part;

[0014] The light spot shape unit is used for real-time monitoring and feedback of light spot shape information of the laser beam.

[0015] The beam shaping unit uses a πShaper collimating beam shaper to control the Gaussian distribution laser beam emitted by the laser unit into a collimated flat-top laser beam. The anamorphic optical unit dynamically adjusts the shape and laser intensity distribution of the collimated flat-top beam. The first arc unit and the second arc unit are arranged around the laser beam at a set angle and spacing, and dynamically adjust the arc output power and position to cooperate with the laser beam to heat the molten pool. The first arc unit generates a first arc, and the second arc unit generates a second arc. The two arcs work together with the laser beam to form a composite heat source. The first wire feeding unit delivers filler material wire to the active area of the first arc unit, and the second wire feeding unit delivers filler material wire of the same type or another type to the active area of the second arc unit. The substrate unit moves and positions as needed to cooperate with the layer-by-layer deposition process of additive manufacturing. The spot shaping unit uses optical sensors and image analysis technology to obtain parameters such as the size, shape, and energy distribution of the laser spot and transmits the data to a control system. The control system makes real-time adjustments to the laser unit, the beam shaping unit, and the anamorphic optical unit based on this feedback information.

[0016] The deformable optical unit adopts a high-performance adaptive optical element based on electromagnetic actuation, and generates the light spot shape unit by controlling multiple driving units to adjust the deformation of the mirror.

[0017] The first arc unit and the second arc unit are two independent arc generating devices, which dynamically adjust the arc current, voltage and relative position according to the part geometry and additive manufacturing requirements. By being arranged around the laser beam at a set angle, the arc current and voltage are adjusted in real time according to the shape and temperature of the molten pool, thereby enhancing the stability and filling efficiency of the molten pool.

[0018] The first wire feeding unit and the second wire feeding unit are two independently controlled wire feeding units, which respectively feed pure aluminum welding wire and pure titanium welding wire, and the deposition of titanium-aluminum alloy gradient material is achieved by adjusting the wire feeding speed ratio.

[0019] Adjust the wire feeding angles of the first wire feeding unit and the second wire feeding unit so that the angles between the two welding wires and the laser beam axis are both 45°.

[0020] On the other hand, the present invention also provides a working method of a programmable laser beam-dual arc composite additive system, comprising the following steps:

[0021] Step 1: Start the laser unit to emit a laser beam with a specific power, wavelength and pulse frequency. The laser beam enters the beam shaping unit and passes through the πShaper collimating beam shaper in the beam shaping unit to shape the original Gaussian distribution laser beam into a collimated flat-top laser beam.

[0022] Step 2: The spot shape unit starts working in real time, using its optical sensor and image analysis technology to monitor the spot shape, size, energy distribution and other parameters of the collimated flat-top laser beam after being shaped by the beam shaping unit, and promptly transmits the monitored data to the control system. The control system issues corresponding control instructions to the deformation optical unit based on the received spot data and pre-set manufacturing requirements. The deformation optical unit is based on a high-performance adaptive optical element actuated by electromagnetics. It adjusts the deformation of the mirror by precisely controlling multiple drive units, thereby dynamically adjusting the wavefront shape and propagation direction of the laser beam, thereby achieving effective control of the spot shape and laser intensity distribution.

[0023] Step 3: setting the initial output power, current, and voltage of the first arc unit and the second arc unit, starting the first arc unit and the second arc unit to generate arcs, arranging the first arc unit and the second arc unit around the collimated flat-top laser beam and synchronously adjusting the output power and position to form a stable molten pool;

[0024] Step 4: Start the first wire feeding unit and the second wire feeding unit, and feed the same or different types of welding wires into the molten pool respectively. The welding wires are rapidly melted under the combined heating action of the collimated flat-top laser beam and the arcs generated by the first arc unit and the second arc unit, and are deposited on the substrate unit, and begin to accumulate layer by layer to form the initial layer of the part.

[0025] Step 5: Real-time monitoring of the state of the molten pool, the stability of the arc, and the wire feeding status. Based on these real-time monitoring data, the control system dynamically adjusts the output power and pulse frequency of the laser unit, the fine-tuning parameters of the beam shaping unit, the spot control instructions of the anamorphic optical unit, the arc parameters of the first arc unit and the second arc unit, and the wire feeding speeds of the first wire feeding unit and the second wire feeding unit to manufacture parts layer by layer.

[0026] Step 6: After the part manufacturing is completed, the laser unit, the first arc unit, the second arc unit, the first wire feeding unit and the second wire feeding unit are turned off in a specific order to stop the operation of the additive manufacturing system.

[0027] Compared with the prior art, the significant progress of the present invention lies in: (1) The present invention utilizes the high energy density of the laser beam and the synergistic effect of the dual arcs, and effectively improves the stability and filling efficiency of the molten pool through the combined heating method of the laser and the dual arcs. Among them, the laser beam mainly provides high-precision energy input to regulate the temperature gradient of the molten pool; while the dual arc system enhances the stability and filling effect of the molten pool by increasing the heat input, avoiding the problem of uneven molten pool in traditional additive manufacturing; (2) The present invention can quickly and accurately regulate the energy distribution of the laser beam through a simple beam shaping unit and a deformable optical system, realize precise control of the molten pool temperature, and effectively reduce the temperature gradient of the heat-affected zone. It avoids overheating or burning of the material due to excessive temperature, and ensures the quality of the workpiece in the additive manufacturing process; (3) The present invention can flexibly adapt to the manufacturing requirements of multi-material or gradient material parts by precisely controlling the working parameters of the laser and the dual arcs. By selecting different welding wires and precisely controlling the wire feeding mechanism, it can achieve precise transition of material composition in different areas, improve the composition uniformity of the deposited layer and the overall performance of the part, and avoid the problems of sudden changes in material composition and uneven performance in traditional additive manufacturing.

[0028] In order to more clearly illustrate the functional characteristics and structural parameters of the present invention, further description is given below with reference to the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0030] Figure 1 It is a system schematic diagram of the present invention;

[0031] Figure 2 It is a schematic diagram of light spots of different modes obtained after the light beam of the present invention passes through the beam shaping unit and the deformation optical unit.

[0032] The reference numerals in the figure are: 1-laser unit, 2-beam shaping unit, 3-deformation optical unit, 4-first arc unit, 5-second arc unit, 6-first wire feeding unit, 7-second wire feeding unit, 8-substrate unit, 9-spot shape unit. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments; based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0034] The present invention is a composite additive system based on programmable laser beam-dual arc, combined with Figure 1 and Figure 2 , comprising a laser unit 1, a beam shaping unit 2, a deformation optical unit 3, a first arc unit 4, a second arc unit 5, a first wire feeding unit 6, a second wire feeding unit 7, a substrate unit 8, and a spot shape unit 9, which are arranged in sequence;

[0035] The laser unit 1 is used to generate a laser beam with specific power, wavelength and pulse frequency to provide an initial high-energy heat source for the composite additive process. The parameters of the laser beam can be precisely adjusted according to different additive manufacturing requirements;

[0036] The beam shaping unit 2 is used to adjust the spatial distribution and shape of the original laser beam output by the laser unit, thereby changing its spot size and energy density distribution;

[0037] The deformable optical unit 3 is used to dynamically adjust the wavefront shape and propagation direction of the laser beam to achieve active control of the temperature gradient of the molten pool, thereby optimizing the solidification process of the molten pool and the molding quality of the material;

[0038] The first arc unit 4 is used to generate a first arc, cooperate with the laser beam to form a composite heat source in the processing area, and adjust the current, voltage and arc length of the arc;

[0039] The second arc unit 5 is used to generate a second arc, further increasing the flexibility and controllability of heat input, and optimizing the flow state and metallurgical reaction of the molten pool through reasonable matching with the first arc and the laser beam;

[0040] The first wire feeding unit 6 is used to feed the filler material wire to the active area of the first arc unit 4, and to feed the wire stably and evenly into the molten pool through a precise wire feeding drive mechanism and a speed control system;

[0041] The second wire feeding unit 7 is used to feed another type of filler wire to the active area of the second arc unit 5, so as to realize independent feeding of wires of different materials or compositions, meet the additive manufacturing requirements of complex structures and multifunctional materials, and realize composite deposition of multiple materials by working in conjunction with the first wire feeding unit 6;

[0042] The base plate unit 8 is used to act as an electrode for the electric arc and to support the additively manufactured formed part;

[0043] The light spot shape unit 9 is used to monitor and feed back the light spot shape information of the laser beam in real time.

[0044] The beam shaping unit 2 adjusts the Gaussian distribution laser beam emitted by the laser unit 1 into a collimated flat-top laser beam through the πShaper collimated beam shaper; the collimated flat-top laser beam has a more uniform energy distribution, which can make the material more evenly heated when heated, and provide a good energy input basis for subsequent additive manufacturing; the deformation optical unit 3 dynamically adjusts the shape and laser intensity distribution of the collimated flat-top beam; the first arc unit 4 and the second arc unit 5 are arranged around the laser beam at a set angle and spacing, and dynamically adjust the arc output power and position to cooperate with the laser beam to heat the molten pool; the first arc unit 4 generates a first arc, and the second arc unit 5 generates a second arc, and the two arcs work together with the laser beam to form a composite heat source; the first wire feeding unit 6 transports the filler material wire to the action area of the first arc unit 4 The second wire feeding unit 7 delivers the same type or another type of filler material wire to the action area of the second arc unit 5, realizing independent delivery of wires of different materials or compositions, meeting the additive manufacturing requirements of complex structures and multifunctional materials, and realizing composite stacking of multiple materials by working in coordination with the first arc unit 4, the second arc unit 5 and the laser beam; the substrate unit 8 is moved and positioned as needed to cooperate with the layer-by-layer stacking process of additive manufacturing; the spot shape unit 9 obtains the parameters of the size, shape and energy distribution of the laser spot through optical sensors and image analysis technology, and transmits the data to the control system. The control system adjusts the laser unit 1, the beam shaping unit 2 and the deformation optical unit 3 in real time according to these feedback information to ensure that the laser spot always maintains an ideal shape and state to meet the requirements of different additive manufacturing processes.

[0045] The deformable optical unit 3 adopts a high-performance adaptive optical element based on electromagnetic actuation, and generates the light spot shape unit 9 by controlling multiple driving units to adjust the deformation of the mirror.

[0046] The first arc unit 4 and the second arc unit 5 are two independent arc generating devices, which dynamically adjust the arc current, voltage and relative position according to the part geometry and additive manufacturing requirements; by being arranged around the laser beam at a set angle, the arc current and voltage are adjusted in real time according to the shape and temperature of the molten pool, thereby enhancing the stability and filling efficiency of the molten pool.

[0047] The first wire feeding unit 6 and the second wire feeding unit 7 are two independently controlled wire feeding units, which respectively feed pure aluminum welding wire and pure titanium welding wire, and achieve the deposition of titanium-aluminum alloy gradient material by adjusting the wire feeding speed ratio.

[0048] The wire feeding angles of the first wire feeding unit 6 and the second wire feeding unit 7 are adjusted so that the angles between the two welding wires and the axis of the laser beam are both 45°.

[0049] A working method of a programmable laser beam-dual arc composite additive system according to the present invention comprises the following steps:

[0050] Step 1: Start the laser unit 1 to emit a laser beam with a specific power, wavelength and pulse frequency. The laser beam enters the beam shaping unit 2 and passes through the πShaper collimating beam shaper in the beam shaping unit 2 to shape the original Gaussian distribution laser beam into a collimated flat-top laser beam.

[0051] Step 2: The spot shape unit 9 starts working in real time, using its optical sensor and image analysis technology to monitor the spot shape, size, energy distribution and other parameters of the collimated flat-top laser beam after being shaped by the beam shaping unit 2, and promptly transmits the monitored data to the control system. The control system issues corresponding control instructions to the deformation optical unit 3 based on the received spot data and pre-set manufacturing requirements. The deformation optical unit 3 is based on a high-performance adaptive optical element actuated by electromagnetics. It adjusts the deformation of the mirror by precisely controlling multiple drive units, thereby dynamically adjusting the wavefront shape and propagation direction of the laser beam, thereby achieving effective control of the spot shape and laser intensity distribution to meet different manufacturing requirements;

[0052] Step 3: setting the initial output power, current, and voltage of the first arc unit 4 and the second arc unit 5, starting the first arc unit 4 and the second arc unit 5 to generate arcs, arranging the first arc unit 4 and the first arc unit 5 around the collimated flat-top laser beam and synchronously adjusting the output power and position to form a stable molten pool;

[0053] Step 4: Start the first wire feeding unit 6 and the second wire feeding unit 7, and feed the same type or different types of welding wires into the molten pool respectively. The welding wires are rapidly melted under the combined heating action of the collimated flat-top laser beam and the arcs generated by the first arc unit 4 and the second arc unit 5, and are deposited on the substrate unit 8, and begin to accumulate layer by layer to form the initial layer of the part;

[0054] Step 5: Real-time monitoring of the state of the molten pool, the stability of the arc, and the wire feeding status. Based on these real-time monitoring data, the control system dynamically adjusts the output power and pulse frequency of the laser unit 1, the fine-tuning parameters of the beam shaping unit 2, the spot control instructions of the deformable optical unit 3, the arc parameters of the first arc unit 4 and the second arc unit 5, and the wire feeding speeds of the first wire feeding unit 6 and the second wire feeding unit 7 to manufacture parts layer by layer.

[0055] Step 6: After the part manufacturing is completed, the laser unit 1, the first arc unit 4, the second arc unit 5, the first wire feeding unit 6 and the second wire feeding unit 7 are turned off in a specific order to stop the operation of the additive manufacturing system.

[0056] Example

[0057] Example 1

[0058] First, pre-treat the substrate unit 8 and clean it with anhydrous ethanol to remove oil stains on the surface. After cleaning, use a clamp to fix the substrate unit 8 on the workbench to ensure that it remains stable during the additive manufacturing process. Set the output power of the laser unit 1 to 3000W. The laser unit 1 emits a laser beam with a Gaussian distribution, which enters the beam shaping unit 2. The beam shaping unit 2 uses a collimating beam shaper to shape the Gaussian distributed laser beam into a flat-top beam with uniform energy distribution. At the same time, adjust the defocus amount so that the focal position of the laser beam is kept at a distance of +10mm from the surface of the substrate unit 8, and set the laser scanning speed to 1-2mm / s.

[0059] The flat top beam shaped by the beam shaping unit 2 enters the deformable optical unit 3. By controlling the multiple electromagnetic drive units in the deformable optical unit 3, the mirror surface is deformed, thereby generating a spot shape that meets the requirements of different processes. The deformed spot is precisely adjusted in the focusing unit, and finally an adjustable spot pattern is formed. Figure 2 As shown, dynamic regulation of laser intensity distribution is achieved.

[0060] Adjust the wire feeding angles of the first and second wire feeding units 6 and 7 so that both wires are at a 45° angle to the laser beam axis. Adjust the ends of the wires so that they are close to the surface of the substrate unit 8, centered at the laser spot, and maintain a distance of 1.5 mm between the ends of the wires and the surface of the substrate unit 8.

[0061] The first arc unit 4 and the second arc unit 5 were turned on, with the arc current set to 100 A and the arc voltage set to 15 V. At the same time, the side-blowing shielding gas device was activated to introduce pure argon shielding gas into the processing area at a gas flow rate of 25 L / min to prevent oxidation of the molten pool during the additive manufacturing process.

[0062] Perform the first additive manufacturing operation. After the first deposited layer is completed, use a vernier caliper to measure its build height. This height value is set as the offset for each layer in the additive manufacturing direction, providing an accurate parameter basis for subsequent layer-by-layer manufacturing. Additive manufacturing is performed layer by layer according to the set offset. After each layer is completed, wait for the deposited layer to cool below 40°C before proceeding to the next additive manufacturing layer to ensure the quality and performance of each deposited layer. Continue this process until the entire part is completed.

[0063] Example 2

[0064] A working method of a programmable laser beam-dual arc composite additive system, comprising the following steps:

[0065] First, the substrate unit 8 is pre-treated and cleaned with anhydrous ethanol to remove surface oil. After cleaning, the substrate unit 8 is firmly mounted on the workbench using a fixture to ensure that the substrate unit 8 remains stable and does not move during the additive manufacturing process.

[0066] The output power of laser unit 1 was set to 3000W. Laser unit 1 emitted a Gaussian-distributed laser beam, which then entered beam shaping unit 2. The collimated beam shaper within beam shaping unit 2 processed the laser beam, shaping it into a flat-top beam with uniform energy distribution. Simultaneously, the defocus was adjusted to maintain a distance of +10mm between the laser beam focal point and the surface of substrate unit 8, and the laser scanning speed was set to 12mm / s.

[0067] The flat top beam shaped by the beam shaping unit 2 enters the deformation optical unit 3. By controlling the multiple electromagnetic drive units in the deformation optical unit 3, the mirror surface is deformed, thereby generating a spot shape that meets the process requirements. The deformed spot is further precisely adjusted in the focusing unit to form an adjustable spot pattern, such as Figure 2 As shown, dynamic regulation of laser intensity distribution is achieved to adapt to subsequent additive manufacturing processes.

[0068] The core difference between this embodiment and embodiment 1 is reflected in this step. The welding wire material of the first wire feeding unit 6 is replaced with pure aluminum, and the welding wire material of the second wire feeding unit 7 is replaced with pure titanium. The wire feeding angles of the first wire feeding unit 6 and the second wire feeding unit 7 are adjusted so that the angles between the two welding wires and the axis of the laser beam are both 45°, and the ends of the welding wires are adjusted to be close to the surface of the substrate unit 8, located at the center of the laser spot, and the distance between the ends of the welding wires and the surface of the substrate unit 8 is maintained at 1.5 mm. At the same time, according to the composition requirements of the target titanium-aluminum alloy deposition layer, the initial wire feeding speeds of the first wire feeding unit 6 and the second wire feeding unit 7 are set in the control system.

[0069] Turn on the first arc unit 4 and the second arc unit 5, setting the arc current to 100A and the arc voltage to 15V. Simultaneously, start the side-blowing shielding gas device to introduce pure argon shielding gas into the processing area at a gas flow rate of 25L / min to prevent oxidation of the molten pool during the manufacturing process and ensure the smooth progress of the additive manufacturing process.

[0070] Perform additive manufacturing of the first layer. After the first deposited layer is completed, use a vernier caliper to measure its build height. This height value is set as the offset of each layer in the additive manufacturing direction, providing precise parameters for subsequent layer-by-layer manufacturing.

[0071] According to the set offset of each layer, additive manufacturing begins layer by layer. During the manufacturing process, the ratio of the wire feeding speeds of the first wire feeding unit 6 and the second wire feeding unit 7 is adjusted in real time according to different application requirements: when the wire feeding speeds of the first wire feeding unit 6 pure Al and the second wire feeding unit 7 pure Ti are equal, a deposited layer with an atomic ratio close to Ti-50Al is obtained;

[0072] When the wire feeding speed of the first wire feeding unit 6 is higher than that of the second wire feeding unit 7, the content of aluminum in the deposited layer increases;

[0073] When the wire feeding speed of the second wire feeding unit 7 is higher than that of the first wire feeding unit 6 , the titanium content in the deposited layer increases.

[0074] After each layer is completed, wait for the deposited layer to cool down to below 40°C before manufacturing the next layer. Continue the above operation until the entire part is completed, thereby realizing the preparation of titanium-aluminum alloy deposited layers with different compositions to meet diverse application requirements such as high temperature resistance, corrosion resistance, light weight and high strength.

[0075] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0076] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A composite additive system based on programmable laser beam and dual arc, characterized in that: It comprises a laser unit (1), a beam shaping unit (2), a deformation optical unit (3), a first arc unit (4), a second arc unit (5), a first wire feeding unit (6), a second wire feeding unit (7), a substrate unit (8), and a spot shape unit (9) which are arranged in sequence; The laser unit (1) is used to generate a laser beam with specific power, wavelength and pulse frequency to provide an initial high-energy heat source for the composite additive process; The beam shaping unit (2) is used to adjust the spatial distribution and shape of the original laser beam output by the laser unit, thereby changing its spot size and energy density distribution; The deformable optical unit (3) is used to dynamically adjust the wavefront shape and propagation direction of the laser beam to achieve active control of the temperature gradient of the molten pool; The first arc unit (4) is used to generate a first arc, cooperate with the laser beam to form a composite heat source in the processing area, and adjust the current, voltage and arc length of the arc; The second arc unit (5) is used to generate a second arc, and optimize the flow state and metallurgical reaction of the molten pool by reasonably matching with the first arc and the laser beam; The first wire feeding unit (6) is used to feed the filler material wire to the action area of the first arc unit (4), and to feed the wire into the molten pool stably and evenly through a precise wire feeding drive mechanism and a speed control system; The second wire feeding unit (7) is used to feed another type of filler wire to the action area of the second arc unit (5), thereby realizing independent feeding of wires of different materials or compositions, meeting the requirements of additive manufacturing of complex structures and multifunctional materials, and realizing composite stacking of multiple materials by working in conjunction with the first wire feeding unit (6); The base plate unit (8) is used to act as an electrode of the electric arc and to support the additively manufactured formed part; The light spot shape unit (9) is used for real-time monitoring and feedback of light spot shape information of the laser beam.

2. A programmable laser beam-dual arc composite additive system according to claim 1, characterized in that: The beam shaping unit (2) adjusts the Gaussian distribution laser beam emitted by the laser unit (1) into a collimated flat-top laser beam through a πShaper collimating beam shaper; the deformation optical unit (3) dynamically adjusts the shape and laser intensity distribution of the collimated flat-top beam; the first arc unit (4) and the second arc unit (5) are arranged around the laser beam at a set angle and spacing, and dynamically adjust the arc output power and position to cooperate with the laser beam to heat the molten pool; the first arc unit (4) generates a first arc, and the second arc unit (5) generates a second arc, and the two arcs work together with the laser beam to form a composite heat source; the first arc unit (4) and the second arc unit (5) generate a first arc, and the two arcs work together with the laser beam to form a composite heat source. The wire unit (6) delivers a filler material wire to the active area of the first arc unit (4), and the second wire feeding unit (7) delivers a filler material wire of the same type or another type to the active area of the second arc unit (5); the substrate unit (8) is moved and positioned as needed to cooperate with the layer-by-layer stacking process of additive manufacturing; the spot shape unit (9) obtains the parameters of the size, shape, and energy distribution of the laser spot through optical sensors and image analysis technology, and transmits the data to the control system, and the control system adjusts the laser unit (1), the beam shaping unit (2), and the deformation optical unit (3) in real time based on the feedback information.

3. The programmable laser beam-dual arc composite additive system according to claim 1, characterized in that: The deformation optical unit (3) adopts a high-performance adaptive optical element based on electromagnetic actuation, and generates the light spot shape unit (9) by controlling multiple driving units to adjust the deformation of the mirror surface.

4. The programmable laser beam-dual arc composite additive system according to claim 1, characterized in that: The first arc unit (4) and the second arc unit (5) are two independent arc generating devices, which dynamically adjust the arc current, voltage and relative position according to the geometric shape of the part and the requirements of additive manufacturing; by being arranged around the laser beam at a set angle, the arc current and voltage are adjusted in real time according to the shape and temperature of the molten pool, thereby enhancing the stability and filling efficiency of the molten pool.

5. The programmable laser beam-dual arc composite additive system according to claim 2, characterized in that: The first wire feeding unit (6) and the second wire feeding unit (7) are two independently controlled wire feeding units, which respectively feed pure aluminum welding wire and pure titanium welding wire, and achieve deposition of titanium-aluminum alloy gradient material by adjusting the wire feeding speed ratio.

6. The programmable laser beam-dual arc composite additive system according to claim 2, characterized in that: The wire feeding angles of the first wire feeding unit (6) and the second wire feeding unit (7) are adjusted so that the angles between the two welding wires and the laser beam axis are both 45°.

7. A method for operating a programmable laser beam-dual arc composite additive system according to any one of claims 1 to 6, characterized in that: The following steps are involved: Step 1: Start the laser unit (1) to emit a laser beam with a specific power, wavelength and pulse frequency. The laser beam enters the beam shaping unit (2). The laser beam originally having a Gaussian distribution is shaped into a collimated flat-top laser beam by the πShaper collimating beam shaper in the beam shaping unit (2). Step 2: The spot shape unit (9) starts working in real time, and uses its optical sensor and image analysis technology to monitor the parameters such as the spot shape, size, and energy distribution of the collimated flat-top laser beam after being shaped by the beam shaping unit (2), and transmits the monitored data to the control system in a timely manner. The control system issues corresponding control instructions to the deformation optical unit (3) based on the received spot data and pre-set manufacturing requirements. The deformation optical unit (3) is based on a high-performance adaptive optical element actuated by electromagnetics, and adjusts the deformation of the mirror by precisely controlling multiple driving units, thereby dynamically adjusting the wavefront shape and propagation direction of the laser beam, thereby achieving effective control of the spot shape and laser intensity distribution. Step 3, setting the initial output power, current and voltage of the first arc unit (4) and the second arc unit (5), starting the first arc unit (4) and the second arc unit (5) to generate arcs, arranging the first arc unit (4) and the first arc unit (5) around the collimated flat-top laser beam and synchronously adjusting the output power and position to form a stable molten pool; Step 4: Start the first wire feeding unit (6) and the second wire feeding unit (7), and feed the same type or different types of welding wires into the molten pool respectively. The welding wires are rapidly melted under the combined heating action of the collimated flat-top laser beam and the arcs generated by the first arc unit (4) and the second arc unit (5), and are deposited on the substrate unit (8), and begin to accumulate layer by layer to form the initial layer of the part. Step 5: Real-time monitoring of the state of the molten pool, the stability of the arc, and the wire feeding situation. The control system dynamically adjusts the output power and pulse frequency of the laser unit (1), the fine-tuning parameters of the beam shaping unit (2), the spot control instructions of the deformation optical unit (3), the arc parameters of the first arc unit (4) and the second arc unit (5), and the wire feeding speeds of the first wire feeding unit (6) and the second wire feeding unit (7) based on these real-time monitoring data, thereby manufacturing parts layer by layer. Step 6: When the part is manufactured, the laser unit (1), the first arc unit (4), the second arc unit (5), the first wire feeding unit (6) and the second wire feeding unit (7) are turned off in a specific order, and the operation of the additive manufacturing system is stopped.

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