Droplet arc-laser induced additive and subtractive integrated manufacturing system and method

Abstract

The invention discloses a molten drop arc-laser induced additive and subtractive integrated manufacturing system and method. The method comprises the steps that raw materials are heated through one or more energy sources to form molten drops; multiple kinds of energy are synchronously applied to molten drops to form a composite molten pool, in-situ coupling of additive and subtractive materials is achieved, and material removal is conducted on a cladding layer while material adding is conducted in the composite molten pool; dynamically adjusting the energy ratio and spatial-temporal distribution of each energy field, and optimizing the droplet transition and metallurgical quality; when the temperature of the cladding layer is reduced to a solid-liquid mixing interval or a thermoplastic deformation interval, shaping and surface processing are carried out, and the ideal component shape and surface smoothness are achieved; energy field parameters are dynamically adjusted based on real-time feedback of multi-sensor data, residual stress is inhibited in combination with a heating compensation technology, the heating compensation technology is used for effectively controlling heat input and stress release, and it is ensured that the stress state of a component in the manufacturing process is effectively managed.

Description

Technical Field

[0001] The present invention belongs to the field of metal material processing technology, and specifically relates to a droplet arc-laser induced additive and subtractive manufacturing integrated manufacturing system and method, which is particularly suitable for high-precision, high-performance integrated forming and processing scenarios of complex metal components. Background Art

[0002] Metal material processing occupies a vital position in modern manufacturing. With the continuous development of science and technology, higher and higher requirements are placed on the shape complexity, dimensional accuracy, mechanical properties, etc. of metal components. Traditional metal processing technology faces many challenges.

[0003] Arc additive manufacturing (AM) utilizes an electric arc as a heat source to melt metal wire and deposit it layer by layer to form components. While this technology offers advantages such as high deposition efficiency and low equipment costs, it also has some significant drawbacks. Due to the relatively wide energy distribution of the arc, the size and shape of the molten pool are difficult to precisely control, resulting in low molding accuracy and poor component surface quality, often requiring extensive subsequent processing to meet application requirements. Furthermore, the high heat input generated during the AM process can easily lead to significant residual stresses within the component, causing defects such as deformation and cracking, impacting the component's mechanical properties and reliability.

[0004] Laser cladding technology uses a high-energy-density laser beam to melt alloy powder or wire and clad it on the surface of the substrate to achieve material accumulation and shaping. Laser cladding has advantages such as high-quality cladding layer, low dilution rate, and small heat-affected zone. However, laser cladding has relatively low deposition efficiency, and for the manufacture of large components, the production cycle is long and the cost is high. Moreover, the cooling rate of the molten pool during the laser cladding process is extremely fast, which can easily lead to defects such as pores and cracks within the cladding layer. It can also make the structure and properties of the cladding layer uneven, affecting the overall performance of the component.

[0005] In traditional additive manufacturing processes, a single energy field is mostly used. A single energy field cannot simultaneously meet multiple requirements such as droplet transfer control, metallurgical quality optimization, and subsequent processing efficiency. In addition, additive manufacturing and subtractive processing are usually carried out separately in this process. The components are first stacked and formed using additive manufacturing technology, and then subtractive processing is carried out. This separation of additive and subtractive processes has many disadvantages. On the one hand, the components after additive manufacturing need to be re-clamped on the subtractive processing equipment, which inevitably introduces clamping errors and affects the processing accuracy of the components. On the other hand, the separation of additive and subtractive processes leads to complex processes, long production cycles, large equipment investments, and high production costs.

[0006] A Chinese patent application (Application No. CN201710203286.7, Application Date: March 30, 2017, Publication No. CN106925787A) discloses an arc-assisted coating additive manufacturing system and method for aluminum alloys. This system uses an arc as a heat source and utilizes a gas supply system, crucible, enclosed glove box, and mobile platform to produce high-quality aluminum alloy workpieces. However, the use of the arc as a single heat source results in concentrated heat input, uneven heating of the parts, and significant deformation. Furthermore, droplet transfer control is difficult, resulting in a rough surface finish and hindering the formation of precision components. Another Chinese patent application (Application No. CN202210685948.X, Application Date: June 16, 2022, Publication No. CN114951689A) provides a method for fabricating titanium alloy gradient composite materials for marine applications using arc additive manufacturing. This method utilizes a TIG arc to achieve a gradient distribution of reinforcement particles within the matrix through a wire / powder synchronization process, resulting in the fabrication of titanium alloy gradient composite components with excellent overall performance. However, its wire material is limited by the material's filamentation ability (high melting point / brittle material is difficult to process) and low deposition efficiency. Another Chinese patent document (application number: CN202110179615.5, application date: February 7, 2021, application publication number: CN112958915A) discloses a titanium alloy propeller arc laser composite additive manufacturing method and application based on multi-axis linkage, which adopts an arc laser composite additive process with cold metal transfer. Multi-axis linkage is used to ensure that the welding gun and the blade cutting plane with variable curvature and variable angle are coplanar in real time to achieve the forming and manufacturing of the propeller. However, it still requires subtractive processing afterwards, and integrated molding cannot be achieved. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide a molten droplet arc-laser induced additive and subtractive integrated manufacturing system and method to address the shortcomings of the above-mentioned existing technologies, so as to solve the bottleneck problems in molding accuracy, efficiency and quality of single energy field in additive manufacturing in the existing technology, as well as the technical problems of long production cycle and high cost caused by the separation of additive and subtractive processes.

[0008] The present invention adopts the following technical solutions: A droplet arc-laser induced additive and subtractive manufacturing method includes the following steps: heating the raw material to form molten droplets, wherein the molten droplets are formed by heating with one or more energy sources; Synchronously applying multiple energies to the molten droplets to form a composite molten pool, wherein the multiple energies include laser, arc and other energy sources that promote melting of raw materials; Achieve in-situ coupling of additive and subtractive processing, and remove material from the cladding layer while adding material in the composite molten pool; Dynamically adjust the energy proportion and spatiotemporal distribution of each energy field to optimize the droplet transfer and metallurgical quality; When the temperature of the cladding layer drops to a solid-liquid mixing range or a thermoplastic deformation range, shaping and surface processing are performed to achieve a component shape and surface smoothness; The energy field parameters are dynamically adjusted based on real-time feedback from multi-sensor data. The residual stress is suppressed by combining heating compensation technology to effectively control heat input and stress release, ensuring that the stress state of the component is effectively managed during the manufacturing process, and realizing integrated manufacturing of droplet arc-laser induced additive and subtractive materials.

[0009] Preferably, the droplet is pre-melted by continuous fiber laser.

[0010] Preferably, the heating comprises synchronous heating using a crucible induction heating coil and a molten pool induction heating coil.

[0011] Preferably, the heating parameters of the crucible induction heating coil and the molten pool induction heating coil are adjusted independently.

[0012] Preferably, the material removal process is performed by an extrusion wheel and a milling head carried by a five-axis linkage robot arm.

[0013] Preferably, the energy proportion and spatiotemporal distribution of each energy field are dynamically adjusted in real time based on the dynamics of the molten pool.

[0014] Preferably, infrared thermal imaging is used to monitor the surface temperature of the cladding layer, and when the temperature of the cladding layer drops to the solid-liquid mixing range of 0.7~0.9Tm or the thermoplastic deformation range of 0.5~0.7Tm, shaping and surface processing are performed.

[0015] Preferably, the heat input to the rear of the composite molten pool is dynamically compensated by induction heating, and the residual stress is reduced in combination with stress relief technology.

[0016] Another technical solution of the present invention is a droplet arc-laser induced additive and subtractive integrated manufacturing system, which adopts the method described above and includes: Crucible induction heating coil for melting raw materials; A laser emitter, used to emit molten droplets heated by the TIG welding gun and the crucible induction heating coil to form a composite molten pool; Infrared temperature sensor, used to obtain the temperature of the composite molten pool; The molten pool induction heating coil is used to dynamically adjust the temperature gradient of the composite molten pool; Robotic arm extrusion and processing tools are used for semi-solid extrusion and high-temperature milling.

[0017] Preferably, the system is suitable for the integrated manufacturing of various metal materials, including aluminum alloy, titanium alloy, and stainless steel.

[0018] Compared with the prior art, the present invention has at least the following beneficial effects: This integrated droplet arc-laser induced additive and subtractive manufacturing method uses a continuous fiber laser to scan the substrate surface to form an initial molten pool. The energy input is precisely controlled to optimize the molten pool shape and heat-affected zone. An arc heat source is simultaneously introduced to couple with the laser molten pool to form a composite molten pool. The crucible induction heating coil is used to melt the raw materials to form molten droplets, which are then heated and controlled by the molten pool induction heating coil to regulate the temperature gradient of the molten droplets and suppress defects such as pores and cracks. When the temperature of the cladding layer drops to the solid-liquid mixing range, the temperature sensor provides real-time feedback signals to trigger the equal material forming unit, and the extrusion wheel extrude the arc surfaces on both sides of the cladding layer at high speed to form a smooth interface and eliminate edge overflow defects. After the cladding layer solidifies, its surface temperature is monitored by infrared thermal imaging. When the temperature is in the thermoplastic deformation range, the five-axis linkage milling head efficiently mills the surface of the cladding layer, synchronously removes the oxide layer and uneven parts, and realizes dimensional accuracy control. The laser and arc energy are coupled in time and space. By adjusting the laser power, arc current and scanning speed, the depth and width of the molten pool are controlled to achieve coordinated optimization of the droplet transition stability and metallurgical bonding strength. At the same time, induction heating is dynamically compensated, and the induction coil current is adjusted in real time according to the temperature distribution of the molten pool to balance the local heat input and reduce residual stress.

[0019] Furthermore, the coordinated regulation of multiple energy fields and the energy complementarity of laser, arc and induction heating can achieve multi-objective optimization of droplet transfer, microstructure refinement and defect suppression.

[0020] Furthermore, in-situ additive and subtractive processing are integrated: additive deposition and subtractive processing are completed at the same workstation, reducing clamping errors and shortening production cycles.

[0021] Furthermore, intelligent temperature closed-loop control: a temperature feedback system based on multi-sensor fusion dynamically adjusts process parameters to ensure consistent molding quality.

[0022] Furthermore, laser pre-melting forms an initial molten pool, reducing the surface tension of the droplets and allowing them to transition to a composite molten pool at a stable frequency and size. Compared to pure arc melting, spatter is reduced by over 50%, droplet landing accuracy is improved, and edge forming consistency is significantly enhanced. Laser pre-melting generates localized high temperatures, thoroughly vaporizing impurities and refining the droplet structure. Combined with the subsequent arc energy field, the porosity within the molten pool is reduced to <0.5%, and strengthening phases such as θ-Al2Cu are uniformly distributed, improving the mechanical properties of the component.

[0023] Furthermore, the crucible coil is responsible for melting the raw materials, while the molten pool coil dynamically controls the temperature gradient of the composite molten pool (6). The two parameters are independently adjustable to avoid molten pool collapse or excessive heat-affected zone caused by excessive heat input. This is particularly suitable for highly thermally sensitive materials such as titanium alloys. The molten pool coil compensates for the cooling rate behind the molten pool in real time, extending the cooling time of the solid-liquid interval by 30% to 50%, promoting full filling of the liquid phase between dendrites and eliminating micro-shrinkage cavities. At the same time, it balances thermal stress, makes the residual stress distribution uniform, and reduces deformation by 60%.

[0024] Furthermore, the energy field ratio is adjusted in real time based on the dynamics of the melt pool. For example, when the infrared sensor detects an abnormal melt pool temperature, the laser ratio is instantly increased to stabilize the melt pool and avoid unfused defects. Extrusion at 0.7-0.9 Tm utilizes the semi-solid rheological properties of the material to repair interlayer gaps. Milling at 0.5-0.7 Tm leverages the material's high-temperature softening conditions, reducing tool wear by 40% and increasing processing efficiency by three times.

[0025] Furthermore, an induction coil applies a compensating heat source behind the composite molten pool, creating a reverse temperature gradient to offset shrinkage stress. Combined with mechanical vibration stress release technology, this reduces peak residual stress by 50% to 70%, particularly addressing the persistent deformation problem of large components.

[0026] In summary, the present invention achieves the simultaneous optimization of droplet transfer stability and metallurgical quality through the coordinated regulation of multi-energy fields, and utilizes the in-situ additive and subtractive material coupling process of semi-solidified extrusion and high-temperature milling to significantly improve the forming efficiency and dimensional accuracy of complex components.

[0027] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings to be used in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0029] Figure 1 It is a schematic diagram of the process of the present invention; Figure 2 Schematic diagram of the integrated manufacturing system of droplet arc-laser induced additive and subtractive material manufacturing of the present invention; Figure 3 This is the SEM image of the printed 2219 aluminum alloy sample, where white is θ-Al2Cu and black is α-Al phase; Figure 4 To print the finished cylinder.

[0030] Among them: 1. Crucible induction heating coil; 2. Laser emitter; 3. Infrared temperature sensor; 4. Molten droplet; 5. TIG welding gun; 6. Molten pool; 7. Deposition layer; 8. Substrate; 9. Base; 10. Molten pool induction heating coil; 11. Robotic arm extrusion and processing tool. DETAILED DESCRIPTION

[0031] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0032] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "one side", "one end", "one side" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0033] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0034] It will be understood that when used in this specification and the appended claims, the terms “comprises” and “comprising” indicate the presence of described features, integers, steps, operations, elements and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof.

[0035] It should also be understood that the terms used in the present specification are only for the purpose of describing particular embodiments and are not intended to limit the present invention. As used in the present specification and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms unless the context clearly indicates otherwise.

[0036] It should be further understood that the term "and / or" used in the present description and the appended claims refers to and includes any and all possible combinations of one or more of the associated listed items.

[0037] The accompanying drawings illustrate various schematic diagrams of structures according to embodiments disclosed herein. These figures are not drawn to scale; for clarity, some details are exaggerated and some details may be omitted. The shapes of the various regions and layers shown in the figures, as well as their relative sizes and positional relationships, are merely exemplary and may deviate in practice due to manufacturing tolerances or technical limitations. Those skilled in the art may design regions / layers with different shapes, sizes, and relative positions as needed.

[0038] The present invention provides an integrated manufacturing system and method for droplet arc-laser induced additive and subtractive materials, which heats raw materials to form droplets, and the droplets are formed by heating one or more energy sources; multiple energies are simultaneously applied to the droplets to form a composite molten pool, and the multiple energies include but are not limited to lasers, arcs and other energy sources that promote the melting of raw materials; in-situ coupling of additive and subtractive materials is achieved, and material is added to the composite molten pool while the cladding layer is removed; the energy proportion and spatiotemporal distribution of each energy field are dynamically adjusted to optimize the droplet transition and metallurgical quality; when the temperature of the cladding layer is reduced to the solid-liquid mixing range or the thermoplastic deformation range, shaping and surface processing are performed to achieve the ideal component shape and surface finish; energy field parameters are dynamically adjusted based on real-time feedback of multi-sensor data, and residual stress is suppressed in combination with heating compensation technology. The heating compensation technology is used to effectively control heat input and stress release to ensure that the stress state of the component during the manufacturing process is effectively managed.

[0039] See also Figure 1 The present invention provides a droplet arc-laser induced additive and subtractive integrated manufacturing method, comprising the following steps: S1, layering the sedimentary layer into a 3D model to obtain the movement path of each layer; S2. Aluminum alloy is selected as the deposition layer material; The metal is in any shape, including wire, granular, block and irregular shapes.

[0040] S3, the crucible induction heating coil melts the metal raw material (not limited to block, powder, etc.) ingot; S4, multi-energy field composite molten pool construction; Including laser, arc and induction heating and corresponding parameter settings.

[0041] S5. Manufacturing and forming with temperature feedback control Including semi-solid extrusion and interface high-temperature milling to achieve dimensional accuracy and control.

[0042] S6. Multi-energy field synergistic optimization This is achieved through energy coupling regulation, residual stress suppression and temperature closed-loop control S7. Print and process layer by layer according to the analyzed and set paths to output high-precision complex components.

[0043] See also Figure 2 The present invention provides a droplet arc-laser induced additive and subtractive integrated manufacturing system, comprising: Crucible induction heating coil 1 is used to melt the raw materials; The laser emitter 2 is used to emit laser light to form a composite molten pool 6 with the molten droplet 4 heated by the welding gun 5 and the crucible induction heating coil 1; The infrared temperature sensor 3 is used to obtain the temperature of the molten pool, which is convenient for changing parameters and thus performing closed-loop temperature control; The molten pool induction heating coil 10 is used to dynamically adjust the temperature gradient of the molten pool with the laser and the arc; The five-axis robot arm extrusion and processing tool 11 are used for semi-solidified extrusion and high-temperature milling to ensure surface roughness and flatness.

[0044] The specific working process is as follows: The deposition layer 7 is subjected to 3D model powder layer processing to obtain the moving path of each layer; aluminum alloy is selected as the deposition layer material; induction heating method is selected to melt the deposition layer material; aluminum alloy is selected as the substrate material, and the substrate 8 is fixed on the base 9; the parameters of the TIG welding gun 5, the molten pool induction heating coil 10 and the laser emitter 2 are set to generate a composite molten pool 8 on the surface of the substrate 8 with the molten droplet 4 heated by the crucible induction heating coil 1; the motion control system parameters are set to print according to the path of the first deposition layer; after one layer is about to be printed, the robot arm extrudes and the processing tool 11 extrude and cuts the layer, and the target aluminum alloy component can be obtained after all layers are completed.

[0045] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, 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 part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the present invention. 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.

[0046] Example 1 The crucible induction heating coil heats and melts the raw materials to form molten droplets. Through the composite processing platform integrating laser, arc and induction heating and the five-axis robotic arm, laser and arc pre-melting pools are simultaneously constructed on the surface of the substrate, and the temperature gradient is controlled by induction heating to form a composite molten pool. Infrared thermal imaging and temperature sensors are used to monitor the temperature of the cladding layer in real time. When the temperature drops to the solid-liquid mixing range, the edge is shaped by the extrusion wheel. When it drops to the thermoplastic range, the surface is milled at high temperature to achieve dimensional control. Based on multi-sensor data, the energy field parameters are dynamically adjusted to optimize the metallurgical quality of the molten pool. Induction heating is combined to compensate for heat input and stress release technology to suppress residual stress, ultimately achieving high-precision and high-efficiency integrated manufacturing of metal components, with the advantages of fast additive manufacturing speed, small molding error, and dense organization.

[0047] Example 2 For 6061 aluminum alloy welding wire and base material, the laser system was activated, with a power setting of 1500W, scanning the base material to form a pre-melted pool. Arc welding was simultaneously initiated, with a current of 180A and a wire feed speed of 5m / min. Molten droplets from the welding wire were deposited under the combined action of the laser and arc, forming a stable molten pool. An induction heating device continuously heated the periphery of the molten pool, balancing the temperature field and reducing solidification stress.

[0048] When the infrared temperature sensor monitors that the temperature of the cladding layer drops to 580°C (semi-solidified state), the robotic arm drives the extrusion wheel to extrude the outer edge of the annular component at a pressure of 0.8 MPa to eliminate the gap between layers, optimize surface flatness and enhance bonding strength.

[0049] The cladding layer was cooled to 400°C, and a diamond-coated milling cutter was used with a set speed of 8000 r / min and a feed speed of 1500 mm / min to mill the inner hole and outer circle. The dimensional accuracy was controlled to ±0.08 mm and the surface roughness Ra≤6.3 μm.

[0050] Example 3 For 7075 aluminum alloy welding wire and base material, the laser uses a 2000W pulse mode to reduce heat input, and the arc uses a TIG process (current 140A, wire feed speed 4.5m / min) to reduce heat accumulation. Induction heating balances the temperature gradient at the front of the molten pool, suppresses oxidation pores, and forms a high-quality molten pool.

[0051] The temperature sensor monitors the cladding layer until it drops to 600°C (semi-solidified state). The high-precision extrusion wheel dynamically adjusts the pressure (0.5-0.7MPa) according to the curvature of the thin wall, eliminating microcracks on the extrusion edge and improving the density.

[0052] When the temperature drops to 350°C, the five-axis milling equipment processes thin walls at a rotation speed of 10,000 r / min and a feed speed of 1,200 mm / min. By real-time monitoring of the milling force and adjusting the parameters, the wall thickness error is controlled to ±0.05 mm, meeting the precision requirements of aviation thin-walled components.

[0053] See also Figure 3 ,The figure clearly shows the black and white dual-phase structure, including: white phase θ-Al2Cu (aluminum alloy strengthening phase); black phase α-Al matrix; Distribution state: θ-Al2Cu particles are small (about 1~3μm) and evenly dispersed in the α-Al matrix without significant agglomeration or segregation.

[0054] Defect control: No typical additive defects such as pores and cracks were observed, and the interface was dense.

[0055] The synergistic use of multiple energy fields (laser pre-melting + arc deposition + induction temperature control) enables rapid melt pool cooling and optimized temperature gradients, promoting uniform precipitation of the θ-Al2Cu strengthening phase and avoiding dendritic segregation common in traditional arc additive manufacturing. The resulting fine, uniform θ-Al2Cu phase significantly enhances material strength, demonstrating the effectiveness of dynamically controlling the energy field to optimize metallurgical quality. The induction heating coil balances the melt pool's thermal cycle, extending the residence time in the solid-liquid zone and ensuring sufficient liquid filling between dendrites, eliminating microscopic shrinkage cavities and resolving the inherent drawback of rapid cooling-induced porosity in conventional laser cladding.

[0056] See also Figure 4 The side wall of the cylinder has high straightness and no visible bending deformation; the end face is flat, without overflow or collapse at the edge; the outer surface is smooth and uniform, without interlayer steps or molten droplet splash marks, and high-temperature milling textures are visible locally; there are no macro cracks or warping on the whole, which meets the requirements of high-precision components.

[0057] Semi-solid extrusion can trim the edge immediately when the temperature of the cladding layer drops to the solid-liquid mixing zone (580~600℃) to eliminate the gap between layers and achieve Figure 4High flatness of the center edge. High-temperature milling simultaneously removes the oxide layer and controls the dimensions, avoiding the secondary clamping errors of traditional processes. The absence of deformation in the cylinder demonstrates that induction heating compensation effectively suppresses residual stresses: by dynamically compensating for heat input behind the molten pool, shrinkage stress is offset, resolving the bottleneck of residual stress-induced deformation in arc additive manufacturing.

[0058] In summary, the present invention presents an integrated droplet arc-laser-induced additive and subtractive manufacturing system and method. Through intelligent closed-loop temperature control, process parameters are dynamically adjusted to effectively suppress defects and reduce residual stress, ultimately enabling the high-precision, high-efficiency manufacturing of high-performance metal components. Compared to traditional processes, this invention offers advantages such as high integration, simplified processes, and wide adaptability. It is suitable for the rapid manufacturing of complex components made of lightweight, high-strength materials in fields such as aerospace and new energy vehicles.

[0059] The above content is only for explaining the technical idea of ​​the present invention and cannot be used to limit the protection scope of the present invention. Any changes made on the basis of the technical solution in accordance with the technical idea proposed by the present invention shall fall within the protection scope of the claims of the present invention.

Claims

1. A droplet arc-laser induced additive and subtractive manufacturing method, characterized in that: The following steps are involved: heating the raw material to form molten droplets, wherein the molten droplets are formed by heating with one or more energy sources; Synchronously applying multiple energies to the molten droplets to form a composite molten pool, wherein the multiple energies include laser, arc and other energy sources that promote melting of raw materials; Achieve in-situ coupling of additive and subtractive processing, and remove material from the cladding layer while adding material in the composite molten pool; Dynamically adjust the energy proportion and spatiotemporal distribution of each energy field to optimize the droplet transfer and metallurgical quality; When the temperature of the cladding layer drops to a solid-liquid mixing range or a thermoplastic deformation range, shaping and surface processing are performed to achieve a component shape and surface smoothness; The energy field parameters are dynamically adjusted based on real-time feedback from multi-sensor data. The residual stress is suppressed by combining heating compensation technology to effectively control heat input and stress release, ensuring that the stress state of the component is effectively managed during the manufacturing process, and realizing integrated manufacturing of droplet arc-laser induced additive and subtractive materials.

2. The integrated manufacturing method of droplet arc-laser induced additive and subtractive material according to claim 1, characterized in that: The droplet is pre-melted by continuous fiber laser.

3. The integrated manufacturing method of droplet arc-laser induced additive and subtractive material according to claim 1, characterized in that: The heating includes simultaneous heating using a crucible induction heating coil and a molten pool induction heating coil.

4. The integrated manufacturing method of droplet arc-laser induced additive and subtractive material according to claim 3, characterized in that: The heating parameters of the crucible induction heating coil and the molten pool induction heating coil are adjusted independently.

5. The integrated manufacturing method of droplet arc-laser induced additive and subtractive material according to claim 1, characterized in that: The material removal process is carried out by the extrusion wheel and milling head carried by the five-axis linkage robot arm.

6. The integrated manufacturing method of droplet arc-laser induced additive and subtractive material according to claim 1, characterized in that: The energy proportion and spatiotemporal distribution of each energy field are dynamically adjusted in real time based on the dynamics of the molten pool.

7. The integrated manufacturing method of droplet arc-laser induced additive and subtractive material according to claim 1, characterized in that: Infrared thermal imaging is used to monitor the surface temperature of the cladding layer. When the temperature of the cladding layer drops to a solid-liquid mixing range of 0.7-0.9Tm or a thermoplastic deformation range of 0.5-0.7Tm, shaping and surface processing are performed.

8. The droplet arc-laser induced additive and subtractive integrated manufacturing method according to any one of claims 1 to 7, characterized in that: The heat input behind the composite molten pool is dynamically compensated by induction heating, and the residual stress is reduced by combining stress relief technology.

9. A droplet arc-laser induced additive and subtractive integrated manufacturing system, characterized in that: The method according to claim 1, comprising: Crucible induction heating coil (1) for melting raw materials; A laser emitter (2) for emitting molten droplets (4) heated by a TIG welding gun (5) and a crucible induction heating coil (1) to form a composite molten pool (6); an infrared temperature sensor (3) for obtaining the temperature of the composite molten pool (6); A molten pool induction heating coil (10) for dynamically adjusting the temperature gradient of the composite molten pool (6); A robotic arm extrusion and processing tool (11) is used for semi-solidified extrusion and high-temperature milling.

10. The droplet arc-laser induced additive and subtractive integrated manufacturing system according to claim 9, characterized in that: The system is suitable for the integrated manufacturing of various metal materials, including aluminum alloy, titanium alloy and stainless steel.

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