Additive and subtractive composite shape follow-up runner integrated manufacturing system and method

Abstract

The invention relates to the technical field of shape follow-up runner manufacturing, and discloses an additive and subtractive composite shape follow-up runner integrated manufacturing system and method.The system comprises a laser additive manufacturing module, a laser additive manufacturing module and a laser additive manufacturing module, and the laser additive manufacturing module is used for cladding metal powder through laser beams to form a shape follow-up runner structure layer by layer; the physical field auxiliary module is integrated in a processing area of the laser additive manufacturing module; the subtractive machining module is used for cutting the inner surface and the characteristic structure of the formed runner after the additive manufacturing is completed; the information acquisition module is used for acquiring the molten pool peak temperature at the laser beam acting point in the manufacturing process in real time and tracking and measuring the dynamic cooling rate of the solidification front edge of the molten pool; the intelligent control module adjusts the laser beam output power according to the peak temperature of the molten pool; and controlling on-off of an ultrasonic wave generating device and a pulsed magnetic field generating device in the physical field auxiliary module according to the dynamic cooling rate. According to the invention, the forming quality and the manufacturing reliability of the conformal runner are improved.

Description

Technical Field

[0001] This invention relates to the field of conformal flow channel manufacturing technology, and more specifically, to an integrated manufacturing system and method for conformal flow channels using additive and subtractive materials. Background Technology

[0002] Conformal flow channels are widely used in aerospace, automotive engines, and mold cooling systems. Their internal structure is complex and their surfaces are varied. Traditional subtractive machining methods, such as milling or electrical discharge machining, have limitations when machining complex internal cavities or curved flow channels.

[0003] While traditional additive manufacturing can construct complex shapes through layer-by-layer deposition, it is prone to abnormal crystal nucleus growth, crystallization defects, and porosity during molten pool solidification, thus affecting material microstructure and forming density. Furthermore, existing additive manufacturing methods lack effective real-time information acquisition and feedback control during processing, making it impossible to precisely monitor molten pool temperature and cooling rate. This results in difficulties in dynamically adjusting energy input and solidification behavior, thereby impacting forming consistency and reliability.

[0004] Therefore, it is necessary to provide an integrated manufacturing system and method for conformal flow channels in additive and subtractive manufacturing to solve the problems of abnormal growth of crystal nuclei, crystallization defects and porosity during the solidification process of the molten pool, which affect the material properties and forming density. Furthermore, the lack of effective real-time information acquisition and feedback control means in the processing process makes it impossible to accurately monitor the molten pool temperature and cooling rate, and it is difficult to dynamically adjust the energy input and solidification behavior, thereby affecting the consistency and reliability of forming. Summary of the Invention

[0005] In view of this, the present invention proposes an integrated manufacturing system and method for conformal flow channels combining additive and subtractive materials, aiming to solve the problems of abnormal growth of crystal nuclei, crystallization defects and porosity that easily occur during the solidification process of the molten pool in traditional additive manufacturing, which affect the material properties and forming density. Furthermore, the lack of effective real-time information acquisition and feedback control means in the processing process makes it impossible to accurately monitor the molten pool temperature and cooling rate, and it is difficult to dynamically adjust the energy input and solidification behavior, thereby affecting the consistency and reliability of forming.

[0006] On one hand, this invention proposes an integrated manufacturing system for conformal flow channels using additive and subtractive materials, comprising: A laser additive manufacturing module is used to clad metal powder with a laser beam to form conformal flow channel structures layer by layer. A physical field auxiliary module, integrated into the processing area of ​​the laser additive manufacturing module, includes an ultrasonic generator and a pulsed magnetic field generator. The physical field auxiliary module is used to apply a physical field during the solidification process of the molten pool to suppress crystallization. The subtractive machining module is used to perform cutting machining on the formed inner surface of the flow channel and the feature structure after additive manufacturing is completed; The information acquisition module is used to collect the peak temperature of the molten pool at the point of laser beam action during the manufacturing process in real time and to track and measure the dynamic cooling rate of the molten pool solidification front. The intelligent control module is used to adjust the laser beam output power according to the peak temperature of the molten pool; and to control the opening and closing of the ultrasonic generator and pulse magnetic field generator in the physical field auxiliary module according to the dynamic cooling rate.

[0007] Furthermore, when the information acquisition module is used to acquire the peak temperature of the molten pool at the laser beam's point of application during the manufacturing process in real time and to track and measure the dynamic cooling rate of the molten pool's solidification front, it includes: The highest temperature value formed on the surface of the molten pool by the center position of the laser beam spot is tracked and collected in real time by the infrared temperature measurement unit and recorded as the peak temperature of the molten pool. The infrared thermal imaging unit tracks and calculates the product of the temperature gradient and the interface movement velocity in the direction of solid-liquid interface movement in real time in the region behind the laser beam scanning path, which is recorded as the dynamic cooling rate of the solidification front.

[0008] Furthermore, the intelligent control module includes: The judgment unit is used to compare the peak temperature of the molten pool with the preset temperature range, and determine whether to adjust the output power of the laser beam based on the comparison result; The power control unit is used to adjust the laser beam output power based on historical data when it is determined that the laser beam output power needs to be adjusted. The crystallization control unit is used to obtain the dynamic cooling rate within a preset time period, construct a cooling rate sequence, and control the opening and closing of the current ultrasonic generator and / or pulse magnetic field generator according to the cooling rate sequence.

[0009] Furthermore, the determination unit is used to compare the peak temperature of the molten pool with a preset temperature range, and to determine whether to adjust the laser beam output power based on the comparison result, including: The peak temperature of the molten pool is compared with the preset temperature range. If the peak temperature of the molten pool is within the preset temperature range, it is determined that the laser beam output power will not be adjusted. If the peak temperature of the molten pool is not within the preset temperature range, it is determined that the output power of the laser beam should be adjusted.

[0010] Furthermore, when the power control unit determines that the laser beam output power needs to be adjusted, and adjusts the laser beam output power based on historical data, it includes: Calculate the difference between the peak temperature of the molten pool and the preset temperature range, and record it as the temperature difference. Obtain the laser beam output power adjustment amount corresponding to the temperature difference in historical data, calculate the average value of all output power adjustment amounts, and record it as the average adjustment value. Adjust the current laser beam output power according to the average adjustment value so that the peak temperature of the molten pool is within the preset temperature range.

[0011] Furthermore, the current laser beam output power is adjusted based on the average adjustment value to ensure that the peak temperature of the molten pool is within a preset temperature range, including: If the peak temperature of the molten pool is still not within the preset temperature range after adjustment, the deviation between the peak temperature of the molten pool after adjustment and the preset temperature range is calculated and recorded as the temperature deviation. An adjustment coefficient is set according to the temperature deviation, and the laser beam output power is adjusted several times in sequence until the peak temperature of the molten pool falls into the preset temperature range.

[0012] Furthermore, when adjusting the laser beam output power sequentially several times based on the temperature deviation adjustment coefficient, the process includes: Set a deviation range, where the minimum value of the deviation range is greater than zero; take the absolute value of the temperature deviation to obtain the absolute value of the deviation; The absolute value of the deviation is compared with the deviation range. If the absolute value of the deviation is less than or equal to the minimum value of the deviation range, the adjustment coefficient is set as the first coefficient. If the absolute value of the deviation is within the deviation range, the adjustment coefficient is set as the second coefficient. If the absolute value of the deviation is greater than the maximum value of the deviation range, the adjustment coefficient is set as the third coefficient. Wherein, 0 < first coefficient < second coefficient < third coefficient < 0.3. If the temperature deviation is greater than zero, calculate the difference between 1 and the adjustment coefficient, and record it as the final difference. The laser beam output power after the second adjustment is the product of the laser beam output power after the first adjustment and the final difference. If the temperature deviation is less than zero, calculate the sum of 1 and the adjustment coefficient, and record it as the final sum. The laser beam output power after the second adjustment is the product of the laser beam output power after the first adjustment and the final sum. If the laser beam output power after readjustment is still not within the preset temperature range, iterative adjustments will be made using the final difference or final sum until the peak temperature of the molten pool falls within the preset temperature range.

[0013] Furthermore, when the crystallization control unit is used to obtain the dynamic cooling rate within a preset time period and construct a cooling rate sequence, it includes: Multiple time sampling points are set within a preset time period to collect the dynamic cooling rate of each time sampling point. The dynamic cooling rates are then arranged in order of time to form a cooling rate sequence.

[0014] Furthermore, when the crystallization control unit controls the on / off state of the current ultrasonic generator and / or pulsed magnetic field generator according to the cooling rate sequence, it includes: Calculate the mean of the cooling rate sequence and filter out the minimum value in the cooling rate sequence; The mean and minimum values ​​are weighted and summed to obtain the comprehensive cooling rate evaluation value; If the cooling rate assessment value is less than the preset rate, then it is determined that the ultrasonic generator and / or pulse magnetic field generator will be turned on. Specifically, the difference between the preset rate and the cooling rate evaluation value is calculated and recorded as the cooling difference; a difference limit is set, and if the cooling difference is less than the difference limit, it is determined that the ultrasonic generator or the pulse magnetic field generator is turned on; if the cooling difference is greater than or equal to the difference limit, it is determined that the ultrasonic generator and the pulse magnetic field generator are turned on simultaneously.

[0015] Compared with existing technologies, the advantages of this invention are as follows: By integrating laser additive manufacturing, physical field-assisted control, subtractive finishing, and information sensing and intelligent control, this invention improves the forming quality and manufacturing reliability of conformal flow channels. On the one hand, by using a laser beam to clad metal powder layer by layer to form conformal flow channel structures, complex internal cavities and curved flow channels can be formed in one step, breaking through the structural limitations of traditional subtractive processing in the manufacturing of internal channels. On the other hand, by introducing physical fields such as ultrasonic waves and pulsed magnetic fields into the additive manufacturing process, active intervention is made in the material structure during the solidification stage of the molten pool, suppressing abnormal growth of crystal nuclei and the generation of crystallization defects, thereby improving the performance of the formed structure from the source. At the same time, the information acquisition module acquires the peak temperature of the molten pool and the dynamic cooling rate at the solidification front in real time, giving the processing process a perceptible and quantifiable state feedback basis. Combined with the intelligent control module's dynamic adjustment of laser power and the opening and closing of the physical field, closed-loop control of the molten pool energy input and solidification behavior is achieved. Furthermore, after additive manufacturing is completed, the inner surface and key features of the flow channel are precision machined by combining the subtractive manufacturing module. This not only ensures dimensional accuracy and surface quality, but also avoids the quality instability problems caused by a single manufacturing method. As a result, the integrated manufacturing effect of conformal flow channels with high precision, high density and high consistency is achieved as a whole.

[0016] On the other hand, this application also provides an integrated manufacturing method for conformal flow channels using additive and subtractive materials, comprising: A conformal flow channel structure is formed layer by layer by cladding metal powder with a laser beam; After additive manufacturing is completed, the inner surface of the formed flow channel and the feature structure are machined. Real-time acquisition of the peak temperature of the molten pool at the point of laser beam action during the manufacturing process and tracking and measuring the dynamic cooling rate at the solidification front of the molten pool; The laser beam output power is adjusted according to the peak temperature of the molten pool; the opening and closing of the ultrasonic generator and pulse magnetic field generator in the physical field auxiliary module are controlled according to the dynamic cooling rate.

[0017] It is understood that the additive and subtractive composite conformal flow channel integrated manufacturing system and method provided in this application have the same beneficial effects, which will not be elaborated here. Attached Figure Description

[0018] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 Functional block diagram of the conformal flow channel integrated manufacturing system for additive and subtractive materials provided in the embodiments of the present invention; Figure 2 A flowchart of an integrated manufacturing system for conformal flow channels with additive and subtractive materials, provided in an embodiment of the present invention. Detailed Implementation

[0019] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the disclosure to those skilled in the art. It should be noted that, unless otherwise specified, embodiments and features in the embodiments of the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0020] In some embodiments of this application, see Figure 1 As shown, this embodiment provides an integrated manufacturing system for conformal flow channels using additive and subtractive materials, comprising: A laser additive manufacturing module is used to clad metal powder with a laser beam to form conformal flow channel structures layer by layer. A physical field auxiliary module, integrated into the processing area of ​​the laser additive manufacturing module, includes an ultrasonic generator and a pulsed magnetic field generator. The physical field auxiliary module is used to apply a physical field during the solidification process of the molten pool to suppress crystallization. The subtractive machining module is used to perform cutting machining on the formed inner surface of the flow channel and the feature structure after additive manufacturing is completed; The information acquisition module is used to collect the peak temperature of the molten pool at the point of laser beam action during the manufacturing process in real time and to track and measure the dynamic cooling rate of the molten pool solidification front. The intelligent control module is used to adjust the laser beam output power according to the peak temperature of the molten pool; and to control the opening and closing of the ultrasonic generator and pulse magnetic field generator in the physical field auxiliary module according to the dynamic cooling rate.

[0021] It is understandable that this invention improves the forming quality and manufacturing reliability of conformal flow channels by integrating laser additive manufacturing, physical field-assisted control, subtractive finishing, and information sensing and intelligent control. On the one hand, by using a laser beam to clad metal powder layer by layer to form conformal flow channel structures, complex internal cavities and curved flow channels can be formed in one step, breaking through the structural limitations of traditional subtractive processing in the manufacturing of internal channels. On the other hand, physical fields such as ultrasonic waves and pulsed magnetic fields are introduced into the additive manufacturing process to actively intervene in the material structure during the solidification stage of the molten pool, suppressing abnormal growth of crystal nuclei and the generation of crystallization defects, thereby improving the performance of the formed structure from the source. At the same time, the information acquisition module acquires the peak temperature of the molten pool and the dynamic cooling rate at the solidification front in real time, giving the processing process a perceptible and quantifiable state feedback basis. Combined with the intelligent control module's dynamic adjustment of laser power and the opening and closing of the physical field, closed-loop control of the molten pool energy input and solidification behavior is achieved. Furthermore, after additive manufacturing is completed, the inner surface and key features of the flow channel are precision machined by combining the subtractive manufacturing module. This not only ensures dimensional accuracy and surface quality, but also avoids the quality instability problems caused by a single manufacturing method. As a result, the integrated manufacturing effect of conformal flow channels with high precision, high density and high consistency is achieved as a whole.

[0022] In some embodiments of this application, when the information acquisition module is used to acquire the peak temperature of the molten pool at the laser beam application point during the manufacturing process in real time and to track and measure the dynamic cooling rate of the molten pool solidification front, it includes: The highest temperature value formed on the surface of the molten pool by the center position of the laser beam spot is tracked and collected in real time by the infrared temperature measurement unit and recorded as the peak temperature of the molten pool. The infrared thermal imaging unit tracks and calculates the product of the temperature gradient and the interface movement velocity in the direction of solid-liquid interface movement in real time in the region behind the laser beam scanning path, which is recorded as the dynamic cooling rate of the solidification front.

[0023] It is understood that this invention, by setting up an infrared temperature measurement unit and an infrared thermal imaging unit in the information acquisition module, synchronously and in real-time acquires the peak temperature of the molten pool and the dynamic cooling rate of the solidification front, which is beneficial for comprehensively and accurately characterizing the thermal behavior of the laser additive manufacturing process. Specifically, the infrared temperature measurement unit directly tracks the highest temperature at the center of the laser beam spot, enabling accurate and rapid sensing of the molten pool's energy input state, thereby avoiding defects such as spatter, collapse, or incomplete fusion caused by local overheating or insufficient energy. Simultaneously, the infrared thermal imaging unit acquires the temperature field distribution at the solid-liquid interface in the region behind the laser scanning path, and calculates the dynamic cooling rate of the solidification front by combining the temperature gradient and interface movement speed, transforming the material solidification process from invisible to quantifiable and analyzable. By simultaneously mastering these two key thermal parameters—the peak temperature of the molten pool and the dynamic cooling rate—not only is a reliable basis provided for subsequent laser power adjustment and physical field activation / deactivation control, but it also reflects the molten pool's solidification behavior and microstructure evolution trend, thereby improving the accuracy and stability of additive manufacturing process control and reducing the risk of microstructure inhomogeneity and crystallization defects.

[0024] In some embodiments of this application, the intelligent control module includes: The judgment unit is used to compare the peak temperature of the molten pool with the preset temperature range, and determine whether to adjust the output power of the laser beam based on the comparison result; The power control unit is used to adjust the laser beam output power based on historical data when it is determined that the laser beam output power needs to be adjusted. The crystallization control unit is used to obtain the dynamic cooling rate within a preset time period, construct a cooling rate sequence, and control the opening and closing of the current ultrasonic generator and / or pulse magnetic field generator according to the cooling rate sequence.

[0025] Understandably, by setting up a judgment unit, a power control unit, and a crystallization control unit in the intelligent control module, hierarchical decision-making and coordinated regulation of the laser additive manufacturing process are achieved, which is beneficial to improving the stability and controllability of the manufacturing process. Specifically, the judgment unit compares the real-time peak temperature of the molten pool with a preset temperature range, triggering power adjustment only when the temperature deviates from the reasonable range, avoiding unnecessary frequent control operations and thus improving the stability of system operation. The power control unit incorporates historical data as a reference when adjustment is needed, making targeted adjustments to the laser beam output power so that power changes are more consistent with the actual process evolution, reducing the risk of molten pool fluctuations caused by excessive single adjustments. Meanwhile, the crystallization control unit does not rely on a single instantaneous parameter, but constructs a cooling rate sequence based on the dynamic cooling rate within a preset time period, comprehensively reflecting the solidification state of the molten pool from a time dimension, and intelligently controls the opening and closing of the ultrasonic generator and / or pulsed magnetic field generator accordingly, achieving proactive intervention in the solidified structure. Through the above modular, data-driven control method, energy input regulation and structure control work together to suppress the generation of crystallization defects and improve the consistency and reliability of conformal flow channel additive manufacturing quality.

[0026] In some embodiments of this application, when the determination unit compares the peak temperature of the molten pool with a preset temperature range and determines whether to adjust the laser beam output power based on the comparison result, the following is included: The peak temperature of the molten pool is compared with the preset temperature range. If the peak temperature of the molten pool is within the preset temperature range, it is determined that the laser beam output power will not be adjusted. If the peak temperature of the molten pool is not within the preset temperature range, it is determined that the output power of the laser beam should be adjusted.

[0027] Understandably, the judgment unit compares the real-time peak temperature of the molten pool with a preset temperature range and determines whether to adjust the laser beam output power accordingly, thus providing clear and stable triggering conditions for laser energy control. When the peak temperature of the molten pool is within the preset temperature range, no laser power adjustment is made, which helps maintain the continuity and stability of the molten pool state and avoids problems such as energy fluctuations, molten pool disturbances, and inconsistent forming quality caused by frequent adjustments. When the peak temperature of the molten pool exceeds the preset temperature range, timely determination of the need for power adjustment can quickly correct overheating or insufficient energy, preventing defects such as splashing, collapse, and incomplete fusion. By adopting a range-based judgment method rather than a single threshold trigger, the control logic is more consistent with the temperature fluctuation characteristics in the actual processing process, enhancing the system's fault tolerance to changes in operating conditions, thereby improving the reliability of molten pool temperature control and overall forming quality in laser additive manufacturing.

[0028] In some embodiments of this application, the power control unit is used to adjust the laser beam output power based on historical data when it is determined that adjustment of the laser beam output power is necessary, including: Calculate the difference between the peak temperature of the molten pool and the preset temperature range, and record it as the temperature difference. Obtain the laser beam output power adjustment amount corresponding to the temperature difference in historical data, calculate the average value of all output power adjustment amounts, and record it as the average adjustment value. Adjust the current laser beam output power according to the average adjustment value so that the peak temperature of the molten pool is within the preset temperature range.

[0029] Understandably, the power control unit incorporates historical data to guide the adjustment process. By calculating the temperature difference between the current peak temperature of the molten pool and the preset temperature range, and retrieving the corresponding laser power adjustment amount from historical data, the average of multiple adjustment amounts is used as the basis for the current power adjustment. This helps improve the rationality and stability of power adjustment, fully utilizes the effective adjustment experience verified in previous processing, and avoids excessive influence of single abnormal fluctuations or measurement noise on the power adjustment results, thereby reducing the risk of large-scale laser power oscillations. By using the average adjustment value to correct the current laser beam output power, the peak temperature of the molten pool gradually returns to the preset temperature range, which helps to achieve smooth and gradual energy input control, maintain the continuous stability of the molten pool morphology and thermal state, and thus improve the consistency and reliability of forming quality in the additive manufacturing process.

[0030] In one specific embodiment of this application, the system presets the peak temperature range of the molten pool to be 1500℃~1600℃. When the current peak temperature of the molten pool is detected to be 1630℃ in real time, the temperature difference is calculated to be 30℃. The power control unit retrieves multiple sets of laser power adjustment records corresponding to the 30℃ temperature difference from the historical database. For example, the corresponding power adjustment amounts are -4%, -5%, and -6%, respectively, and the average adjustment amount is calculated to obtain an average adjustment value of -5%. Subsequently, the power control unit reduces the current laser beam output power by 5% based on this average adjustment value, thereby reducing the energy input to the molten pool. After adjustment, the system continuously monitors the change in the peak temperature of the molten pool. The peak temperature of the molten pool gradually decreases and stabilizes at around 1550℃, entering the preset temperature range. This achieves stable control of the thermal state of the molten pool while avoiding drastic fluctuations in laser power, ensuring the stability of the microstructure and dimensional quality during additive manufacturing.

[0031] In some embodiments of this application, adjusting the current laser beam output power based on an average adjustment value to ensure the peak temperature of the molten pool is within a preset temperature range includes: If the peak temperature of the molten pool is still not within the preset temperature range after adjustment, the deviation between the peak temperature of the molten pool after adjustment and the preset temperature range is calculated and recorded as the temperature deviation. An adjustment coefficient is set according to the temperature deviation, and the laser beam output power is adjusted several times in sequence until the peak temperature of the molten pool falls into the preset temperature range.

[0032] In some embodiments of this application, when adjusting the laser beam output power sequentially several times based on the temperature deviation adjustment coefficient, the following steps are included: Set a deviation range, where the minimum value of the deviation range is greater than zero; take the absolute value of the temperature deviation to obtain the absolute value of the deviation; The absolute value of the deviation is compared with the deviation range. If the absolute value of the deviation is less than or equal to the minimum value of the deviation range, the adjustment coefficient is set as the first coefficient. If the absolute value of the deviation is within the deviation range, the adjustment coefficient is set as the second coefficient. If the absolute value of the deviation is greater than the maximum value of the deviation range, the adjustment coefficient is set as the third coefficient. Wherein, 0 < first coefficient < second coefficient < third coefficient < 0.3. If the temperature deviation is greater than zero, calculate the difference between 1 and the adjustment coefficient, and record it as the final difference. The laser beam output power after the second adjustment is the product of the laser beam output power after the first adjustment and the final difference. If the temperature deviation is less than zero, calculate the sum of 1 and the adjustment coefficient, and record it as the final sum. The laser beam output power after the second adjustment is the product of the laser beam output power after the first adjustment and the final sum. If the laser beam output power after readjustment is still not within the preset temperature range, iterative adjustments will be made using the final difference or final sum until the peak temperature of the molten pool falls within the preset temperature range.

[0033] Understandably, by introducing a multi-iterative adjustment mechanism based on temperature deviation after correcting the average adjustment value, the control process of the laser beam output power possesses adaptive and progressively convergent characteristics. When the peak temperature of the molten pool still does not enter the preset temperature range after one adjustment, the system calculates the temperature deviation and sets a corresponding adjustment coefficient, adjusting the laser power in stages according to the magnitude of the deviation. This means a smaller adjustment range is used when the temperature deviation is small, and a relatively larger adjustment range is used when the deviation is large, thus balancing adjustment efficiency and control stability. Simultaneously, by distinguishing between the positive and negative directions of the temperature deviation and multiplicatively adjusting the laser power accordingly, different operating conditions such as molten pool overheating or insufficient energy can be accurately matched, avoiding adjustment imbalances caused by simple addition and subtraction. Furthermore, the laser power is continuously corrected through multiple iterations, gradually bringing the peak temperature of the molten pool closer to and eventually stabilizing within the preset temperature range. This effectively suppresses power overshoot and repeated oscillations, enhancing the robustness and precision of molten pool thermal state control, thereby improving the consistency of forming quality and the reliability of the process in additive manufacturing.

[0034] In one specific embodiment of this application, taking a metal conformal flow channel laser additive manufacturing process as an example, the system presets the peak temperature range of the molten pool to be 1550℃~1650℃. After correcting the laser beam output power once using the average adjustment value, the current peak temperature of the molten pool is detected to be 1680℃, exceeding the upper limit of the preset temperature range. Therefore, the calculated temperature deviation is 30℃. The absolute value of the temperature deviation is then taken and compared with a preset deviation range of 10℃~40℃. Since the absolute value of the deviation is within this range, a second coefficient is selected as the adjustment coefficient, for example, 0.15. Because the temperature deviation value is greater than zero, it indicates that the molten pool is in an overheated state. The system calculates the difference between 1 and the adjustment coefficient, i.e., 0.85, and multiplies the initially adjusted laser beam output power by 0.85 to obtain the re-adjusted laser beam output power. If the peak temperature of the molten pool is still detected to be higher than the preset temperature range, the above deviation judgment and coefficient selection process is repeated. The laser power is further reduced through successive iterations until the peak temperature of the molten pool stabilizes within the range of 1550℃ to 1650℃. This ensures the adjustment efficiency while effectively avoiding power overshoot, and achieves stable and precise control of the thermal state of the molten pool.

[0035] In some embodiments of this application, when the crystallization control unit is used to obtain the dynamic cooling rate within a preset time period and construct a cooling rate sequence, it includes: Multiple time sampling points are set within a preset time period to collect the dynamic cooling rate of each time sampling point. The dynamic cooling rates are then arranged in order of time to form a cooling rate sequence.

[0036] In some embodiments of this application, when the crystallization control unit is used to control the on / off of the current ultrasonic generator and / or pulsed magnetic field generator according to the cooling rate sequence, it includes: Calculate the mean of the cooling rate sequence and filter out the minimum value in the cooling rate sequence; The mean and minimum values ​​are weighted and summed to obtain the comprehensive cooling rate evaluation value; If the cooling rate assessment value is less than the preset rate, then it is determined that the ultrasonic generator and / or pulse magnetic field generator will be turned on. Specifically, the difference between the preset rate and the cooling rate evaluation value is calculated and recorded as the cooling difference; a difference limit is set, and if the cooling difference is less than the difference limit, it is determined that the ultrasonic generator or the pulse magnetic field generator is turned on; if the cooling difference is greater than or equal to the difference limit, it is determined that the ultrasonic generator and the pulse magnetic field generator are turned on simultaneously.

[0037] Understandably, the crystallization control unit, by sampling the dynamic cooling rate at multiple time points within a preset time period and constructing a cooling rate sequence, transforms the judgment of the molten pool solidification process from a single instantaneous value to a comprehensive assessment based on time evolution characteristics. This facilitates a more realistic reflection of the overall trend of material solidification behavior. Furthermore, by simultaneously introducing the mean and minimum values ​​of the cooling rate sequence for weighted calculation, it can characterize the overall cooling level and sensitively capture local or short-term low cooling rate risks, thereby avoiding misjudgments caused by occasional fluctuations or measurement noise. Based on this, according to the difference between the comprehensive cooling rate assessment value and the preset rate, the ultrasonic generator and / or pulsed magnetic field generator are controlled in stages to match the intensity of physical field intervention with the degree of crystallization risk. This helps reduce unnecessary energy and equipment investment when the crystallization risk is low, and enhances the intervention effect in a timely manner when the crystallization risk is high. This achieves precise control of the molten pool solidification structure, reduces the probability of crystallization defects, and improves the stability and microstructure consistency of the additive manufacturing process.

[0038] In one specific embodiment of this application, the crystallization control unit sets a preset duration of 50ms and sets five equally spaced sampling points within this duration to collect the dynamic cooling rate at the corresponding time, for example, 1.2×10⁻⁶. 5 K / s, 1.1×10 5 K / s, 0.9×10 5 K / s, 1.0×10 5 K / s and 0.8×10 5 The cooling rate sequence was constructed using K / s and ordered chronologically. The mean of this cooling rate sequence was then calculated to be 1.0 × 10⁻⁶. 5 K / s, and filtered to obtain the minimum value of 0.8 × 10 5 K / s, the mean and minimum values ​​are weighted and summed according to preset weights to obtain a comprehensive cooling rate evaluation value of 0.92×10. 5 K / s. When the preset rate is set to 1.0 × 10 5 At K / s, the calculated cooling difference is 0.08 × 10⁻⁶. 5 K / s, if the system-set difference limit is 0.05 × 10 5 If the temperature difference is K / s, it is determined that both the ultrasonic generator and the pulsed magnetic field generator should be activated simultaneously to enhance intervention in the solidification process of the molten pool. If the cooling difference is less than the difference limit in subsequent evaluations, only the ultrasonic generator or the pulsed magnetic field generator should be activated, thereby dynamically adjusting the physical field intervention method according to the degree of crystallization risk. Specifically, the sum of the weights of the mean and the minimum is 1. In this specific embodiment, the weights of the mean and the minimum are 0.6 and 0.4, respectively.

[0039] On the other hand, see Figure 2As shown, this application also provides an integrated manufacturing method for conformal flow channels using additive and subtractive material composites, applied to the aforementioned integrated manufacturing system for conformal flow channels using additive and subtractive material composites, comprising the following steps: S100: Metal powder is clad with a laser beam to form a conformal flow channel structure layer by layer; S200. After additive manufacturing is completed, the inner surface of the formed flow channel and the feature structure are machined by cutting. S300: Real-time acquisition of the peak temperature of the molten pool at the point of laser beam action during the manufacturing process and tracking and measuring the dynamic cooling rate of the molten pool solidification front. S400: Adjust the laser beam output power according to the peak temperature of the molten pool; control the opening and closing of the ultrasonic generator and pulse magnetic field generator in the physical field auxiliary module according to the dynamic cooling rate.

[0040] Understandably, this invention achieves precise control over the flow channel forming process by combining laser additive manufacturing, subtractive processing, real-time information acquisition, and intelligent control. In S100, conformal flow channels are formed by cladding metal powder layer by layer with a laser beam, enabling high-degree-of-freedom manufacturing of complex geometries and providing a solid foundation for subsequent precision machining. In S200, subtractive processing further optimizes the surface quality and characteristic structure of the flow channel, improving dimensional accuracy and surface finish, which is beneficial for enhancing overall hydrodynamic performance. S300 collects the peak temperature of the molten pool and the dynamic cooling rate at the solidification front in real time, obtaining instantaneous information on the thermal state of the molten pool and the evolution characteristics of solidification behavior, providing accurate basis for intelligent control. S400 feeds back the molten pool temperature and dynamic cooling rate to the laser power adjustment and physical field auxiliary modules, achieving adaptive control of laser energy input and auxiliary intervention, ensuring that the molten pool temperature remains stable within a preset range while suppressing crystallization defects. Overall, this method can improve the stability and consistency of the manufacturing process, reduce the risk of defects, and achieve efficient synergy between additive and subtractive composite processes while ensuring the forming quality and dimensional accuracy of complex conformal channels. This significantly improves the reliability and precision of additive manufacturing processes.

[0041] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program goods. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program goods embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0042] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program goods according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0043] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0044] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0045] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A composite additive and subtractive material conformal flow channel integrated manufacturing system, characterized in that, include: A laser additive manufacturing module is used to clad metal powder with a laser beam to form conformal flow channel structures layer by layer. A physical field auxiliary module, integrated into the processing area of ​​the laser additive manufacturing module, includes an ultrasonic generator and a pulsed magnetic field generator. The physical field auxiliary module is used to apply a physical field during the solidification process of the molten pool to suppress crystallization. The subtractive machining module is used to perform cutting machining on the formed inner surface of the flow channel and the feature structure after additive manufacturing is completed; The information acquisition module is used to collect the peak temperature of the molten pool at the point of laser beam action during the manufacturing process in real time and to track and measure the dynamic cooling rate of the molten pool solidification front. The intelligent control module is used to adjust the laser beam output power according to the peak temperature of the molten pool; and to control the opening and closing of the ultrasonic generator and pulse magnetic field generator in the physical field auxiliary module according to the dynamic cooling rate.

2. The integrated manufacturing system for conformal flow channels with additive and subtractive materials as described in claim 1, characterized in that, The information acquisition module is used to acquire the peak temperature of the molten pool at the laser beam's point of application during the manufacturing process in real time and to track and measure the dynamic cooling rate of the molten pool's solidification front. This includes: The highest temperature value formed on the surface of the molten pool by the center position of the laser beam spot is tracked and collected in real time by the infrared temperature measurement unit and recorded as the peak temperature of the molten pool. The infrared thermal imaging unit tracks and calculates the product of the temperature gradient and the interface movement velocity in the direction of solid-liquid interface movement in real time in the region behind the laser beam scanning path, which is recorded as the dynamic cooling rate of the solidification front.

3. The integrated manufacturing system for conformal flow channels with additive and subtractive materials according to claim 2, characterized in that, The intelligent control module includes: The judgment unit is used to compare the peak temperature of the molten pool with the preset temperature range, and determine whether to adjust the output power of the laser beam based on the comparison result; The power control unit is used to adjust the laser beam output power based on historical data when it is determined that the laser beam output power needs to be adjusted. The crystallization control unit is used to obtain the dynamic cooling rate within a preset time period, construct a cooling rate sequence, and control the opening and closing of the current ultrasonic generator and / or pulse magnetic field generator according to the cooling rate sequence.

4. The integrated manufacturing system for conformal flow channels with additive and subtractive materials according to claim 3, characterized in that, The judgment unit is used to compare the peak temperature of the molten pool with a preset temperature range, and to determine whether to adjust the laser beam output power based on the comparison result, including: The peak temperature of the molten pool is compared with the preset temperature range. If the peak temperature of the molten pool is within the preset temperature range, it is determined that the laser beam output power will not be adjusted. If the peak temperature of the molten pool is not within the preset temperature range, it is determined that the output power of the laser beam should be adjusted.

5. The integrated manufacturing system for conformal flow channels with additive and subtractive materials according to claim 4, characterized in that, The power control unit is used to adjust the laser beam output power based on historical data when it is determined that adjustment of the laser beam output power is necessary, including: Calculate the difference between the peak temperature of the molten pool and the preset temperature range, and record it as the temperature difference. Obtain the laser beam output power adjustment amount corresponding to the temperature difference in historical data, calculate the average value of all output power adjustment amounts, and record it as the average adjustment value. Adjust the current laser beam output power according to the average adjustment value so that the peak temperature of the molten pool is within the preset temperature range.

6. The integrated manufacturing system for conformal flow channels with additive and subtractive materials according to claim 5, characterized in that, Adjusting the current laser beam output power based on the average adjustment value to ensure the peak temperature of the molten pool is within a preset temperature range includes: If the peak temperature of the molten pool is still not within the preset temperature range after adjustment, the deviation between the peak temperature of the molten pool after adjustment and the preset temperature range is calculated and recorded as the temperature deviation. An adjustment coefficient is set according to the temperature deviation, and the laser beam output power is adjusted several times in sequence until the peak temperature of the molten pool falls into the preset temperature range.

7. The integrated manufacturing system for conformal flow channels with additive and subtractive materials according to claim 6, characterized in that, When adjusting the laser beam output power sequentially several times based on the temperature deviation by setting an adjustment coefficient, the process includes: Set a deviation range, where the minimum value of the deviation range is greater than zero; take the absolute value of the temperature deviation to obtain the absolute value of the deviation; The absolute value of the deviation is compared with the deviation range. If the absolute value of the deviation is less than or equal to the minimum value of the deviation range, the adjustment coefficient is set as the first coefficient. If the absolute value of the deviation is within the deviation range, the adjustment coefficient is set as the second coefficient. If the absolute value of the deviation is greater than the maximum value of the deviation range, the adjustment coefficient is set as the third coefficient. Wherein, 0 < first coefficient < second coefficient < third coefficient < 0.

3. If the temperature deviation is greater than zero, calculate the difference between 1 and the adjustment coefficient, and record it as the final difference. The laser beam output power after the second adjustment is the product of the laser beam output power after the first adjustment and the final difference. If the temperature deviation is less than zero, calculate the sum of 1 and the adjustment coefficient, and record it as the final sum. The laser beam output power after the second adjustment is the product of the laser beam output power after the first adjustment and the final sum. If the laser beam output power after readjustment is still not within the preset temperature range, iterative adjustments will be made using the final difference or final sum until the peak temperature of the molten pool falls within the preset temperature range.

8. The integrated manufacturing system for conformal flow channels with additive and subtractive materials according to claim 3, characterized in that, When the crystallization control unit is used to obtain the dynamic cooling rate within a preset time period and construct a cooling rate sequence, it includes: Multiple time sampling points are set within a preset time period to collect the dynamic cooling rate of each time sampling point. The dynamic cooling rates are then arranged in order of time to form a cooling rate sequence.

9. The integrated manufacturing system for conformal flow channels with additive and subtractive materials according to claim 8, characterized in that, When the crystallization control unit is used to control the on / off of the current ultrasonic generator and / or pulse magnetic field generator according to the cooling rate sequence, it includes: Calculate the mean of the cooling rate sequence and filter out the minimum value in the cooling rate sequence; The mean and minimum values ​​are weighted and summed to obtain the comprehensive cooling rate evaluation value; If the cooling rate assessment value is less than the preset rate, then it is determined that the ultrasonic generator and / or pulse magnetic field generator will be turned on. Specifically, the difference between the preset rate and the cooling rate evaluation value is calculated and recorded as the cooling difference; a difference limit is set, and if the cooling difference is less than the difference limit, it is determined that the ultrasonic generator or the pulse magnetic field generator is turned on; if the cooling difference is greater than or equal to the difference limit, it is determined that the ultrasonic generator and the pulse magnetic field generator are turned on simultaneously.

10. A method for integrated manufacturing of conformal flow channels using additive and subtractive materials, applied to the integrated manufacturing system for conformal flow channels using additive and subtractive materials as described in any one of claims 1-9, characterized in that, include: A conformal flow channel structure is formed layer by layer by cladding metal powder with a laser beam; After additive manufacturing is completed, the inner surface of the formed flow channel and the feature structure are machined. Real-time acquisition of the peak temperature of the molten pool at the point of laser beam action during the manufacturing process and tracking and measuring the dynamic cooling rate at the solidification front of the molten pool; The laser beam output power is adjusted according to the peak temperature of the molten pool; the opening and closing of the ultrasonic generator and pulse magnetic field generator in the physical field auxiliary module are controlled according to the dynamic cooling rate.

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