Amorphous alloy manufacturing method and system based on laser preheating and ultrasonic shot peening impact
By combining laser preheating with ultrasonic shot peening, the stress state in L-PBF technology is controlled layer by layer, solving the cracking problem caused by thermal stress accumulation in amorphous alloys and achieving high-precision forming and improved mechanical properties of amorphous alloys.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- NINGBO INST OF MATERIALS TECH & ENG CHINESE ACAD OF SCI
- Filing Date
- 2023-11-29
- Publication Date
- 2026-06-16
AI Technical Summary
In the process of preparing amorphous alloys, the L-PBF technology causes cracks due to the accumulation of thermal stress, which limits the three-dimensional dimensions and forming quality of the amorphous alloys.
By combining laser preheating with ultrasonic shot peening, and adjusting process parameters layer by layer, the stress state is monitored and optimized in real time to avoid thermal stress accumulation, eliminate crack defects, and improve forming accuracy and surface quality.
It effectively reduces cracks and pores in the forming process of amorphous alloys, improves the mechanical properties and forming accuracy of the workpiece, expands the machinable area and process window, and optimizes the comprehensive mechanical properties of amorphous alloys.
Smart Images
Figure CN117862532B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of amorphous alloy manufacturing, and in particular to a method and system for manufacturing amorphous alloys based on laser preheating and ultrasonic shot peening. Background Technology
[0002] Amorphous alloys possess excellent mechanical, magnetic, and catalytic properties, making them invaluable for research and application. However, the formation of the amorphous phase requires a high cooling rate. In traditional preparation techniques, the cooling rate in the central region of the sample gradually decreases as the three-dimensional size of the sample increases, making it difficult for the amorphous phase to form in the central region. This limits the three-dimensional size of amorphous alloy workpieces.
[0003] Additive manufacturing technology employs a point-by-point, layer-by-layer fabrication process, eliminating the reliance on molds and other components in traditional manufacturing techniques. It overcomes the limitation of traditional fabrication techniques where the central region of the sample cannot maintain a high cooling rate as the three-dimensional size of the sample increases, thus offering a potential solution to the three-dimensional size constraints in the manufacture of amorphous alloys and their composites. Amorphous alloy additive manufacturing technologies mainly include laser selective melting (L-PBF), laser direct energy deposition (L-DED), fused wire additive manufacturing (FFF), thermal spray additive manufacturing (TSAM), and ultrasonic additive manufacturing (UAM). Among these, L-PBF technology, with its relatively high molten pool solidification and cooling rate, has gradually become an important method for manufacturing large-size amorphous alloys and their composites.
[0004] Amorphous alloys lack crystalline structural defects such as dislocations and grain boundaries, making shear bands prone to rapid propagation into cracks, resulting in a lack of macroscopic plasticity at room temperature. Furthermore, the L-PBF forming process involves significant thermal stress, which accumulates and exceeds the crack initiation threshold as the sample size increases, leading to cracking in the amorphous alloy. This problem severely restricts the development of L-PBF technology for amorphous alloy preparation. Therefore, a method for stress control during the L-PBF amorphous alloy preparation process is urgently needed. Summary of the Invention
[0005] Because of the significant thermal stress present during the L-PBF forming process, as the size of the prepared sample increases, the thermal stress accumulates and exceeds the crack initiation threshold, leading to cracks in the prepared amorphous alloy. To address this technical problem, this invention proposes an amorphous alloy manufacturing method based on laser preheating and ultrasonic shot peening, applied to an additive manufacturing system, comprising the following steps:
[0006] S1: Construct a stress control process parameter library through additive manufacturing experiments. Specifically, this involves: manufacturing amorphous alloys layer by layer using an additive manufacturing system, and conducting single stress control experiments or multiple stress control experiments with different process parameters layer by layer during the manufacturing process (multiple sets of different process parameters can be preset). The stress control experiments include: laser preheating control and ultrasonic shot peening impact stress control; acquiring experimental data corresponding to each stress control experiment, and obtaining analysis results from the experimental data; the analysis results include the overall stress, local stress, strain evolution law and distribution characteristics of the amorphous alloy; constructing a stress control process parameter library based on the analysis results and experimental data; the experimental data includes the process parameters corresponding to laser preheating control and ultrasonic shot peening impact stress control.
[0007] S2: Real-time monitoring of the morphology parameters and temperature information of the powder bed, molten pool and workpiece during the manufacturing of amorphous alloys using an additive manufacturing system;
[0008] S3: Set the set of layers to be adjusted; the set of layers to be adjusted includes the number of layers corresponding to one or more layers for which stress regulation is to be performed;
[0009] S4: Determine whether the additive manufacturing system has completed the manufacturing of the current layer. If yes, determine whether the current layer belongs to the set of layers to be adjusted. If yes, proceed to the next step; otherwise, jump to step S7.
[0010] S5: The additive manufacturing process is simulated using the morphological parameters and temperature information of the powder bed, molten pool and workpiece through finite element analysis software to predict the overall stress, local stress, strain evolution law and distribution characteristics of the workpiece, and the corresponding process parameters are retrieved from the stress control process parameter library based on the prediction results.
[0011] S6: Based on the retrieved process parameters, perform laser preheating and stress control on the current layer, and acquire real-time monitoring information during the control process. Then, adjust the current laser preheating process through the real-time monitoring information so that the real-time monitoring information is close to or equal to the corresponding retrieved process parameters.
[0012] S7: Determine if the current layer is the last layer for workpiece manufacturing. If not, start manufacturing the next layer and return to step S4.
[0013] Furthermore, the process parameters for laser preheating control include: preheating temperature, area, and time; the process parameters for stress control include: ultrasonic shot peening impact frequency, power, amplitude, and pressure.
[0014] Furthermore, the real-time monitoring information includes the workpiece's temperature information and preheating area.
[0015] Furthermore, in step S1, a stress control process parameter library is constructed by analyzing the results and experimental data, specifically as follows:
[0016] Among the multiple analysis results corresponding to each layer, the optimal analysis result is obtained based on the values of overall stress and local stress; the corresponding stress matching range is set according to the overall stress and local stress in the optimal analysis result; and a stress control process parameter library is constructed by combining the optimal analysis result and its corresponding stress matching range with experimental data.
[0017] Furthermore, the step of obtaining the optimal analysis result based on the values of overall stress and local stress from multiple analysis results corresponding to each layer specifically involves:
[0018] Based on the influence of overall stress and local stress on the quality of the final formed amorphous alloy workpiece, the weights corresponding to the overall stress and local stress of the amorphous alloy are set.
[0019] The weight values corresponding to each analysis result are calculated based on the weights and numerical values corresponding to the overall stress and local stress of the amorphous alloy.
[0020] The analysis result corresponding to the minimum weight value is set as the optimal analysis result.
[0021] Furthermore, based on the overall stress and local stress in the optimal analysis results, corresponding stress matching ranges are set, specifically as follows:
[0022] By setting corresponding upper and lower limits with the overall stress and local stress as intermediate values, the overall stress matching range and the local stress matching range are obtained;
[0023] The numerical ranges of the overall stress matching range for each layer and the numerical ranges of the local stress matching range for each layer are both continuous.
[0024] Furthermore, in step S5, the corresponding process parameters are retrieved from the stress control process parameter library based on the prediction results, specifically as follows:
[0025] Based on the preset weights corresponding to the overall stress and local stress, the weight values corresponding to the overall stress and local stress in the prediction results are obtained. The stress matching range corresponding to the larger weight value is obtained, and the analysis result corresponding to the stress matching range is obtained as the target result. The process parameters of laser preheating control and stress control in the experimental data corresponding to the target result are set as the process parameters for controlling the current layer.
[0026] This invention also proposes an amorphous alloy manufacturing system based on laser preheating and ultrasonic shot peening, comprising:
[0027] The parameter library construction module is used to build a stress control process parameter library through additive manufacturing experiments. Specifically, it involves manufacturing amorphous alloys point-by-point and layer-by-layer using an additive manufacturing system, and conducting single or multiple stress control experiments layer by layer during the manufacturing process. These stress control experiments include laser preheating control and ultrasonic shot peening impact stress control. Experimental data corresponding to each stress control experiment is acquired, and analysis results are obtained from the experimental data. The analysis results include the overall stress, local stress, strain evolution law, and distribution characteristics of the amorphous alloy. A stress control process parameter library is constructed using the analysis results and experimental data. The experimental data includes the process parameters corresponding to laser preheating control and ultrasonic shot peening impact stress control.
[0028] The monitoring module is used to monitor in real time the morphology parameters and temperature information of the powder bed, molten pool and workpiece during the manufacturing of amorphous alloys using an additive manufacturing system.
[0029] The setting module is used to set the set of layers to be adjusted; the set of layers to be adjusted includes the number of layers corresponding to one or more layers for which stress regulation is to be performed;
[0030] The logic judgment module includes a first logic judgment unit and a second logic judgment unit; the first logic judgment unit is used to determine whether the additive manufacturing system has completed the manufacturing of the current layer; the second logic judgment unit is used to determine whether the current layer belongs to the set of layers to be adjusted when the manufacturing of the current layer has been completed.
[0031] The retrieval module is used to simulate the additive manufacturing process using the morphological parameters and temperature information of the powder bed, molten pool and workpiece through finite element analysis software when the current layer belongs to the set of layers to be adjusted. This is to predict the overall stress, local stress, strain evolution law and distribution characteristics of the workpiece, and retrieve the corresponding process parameters from the stress control process parameter library based on the prediction results.
[0032] The control module is used to perform laser preheating and stress control on the current layer based on the retrieved process parameters. During the control process, it acquires real-time monitoring information and controls the current laser preheating process through the real-time monitoring information so that the real-time monitoring information is close to or equal to the corresponding retrieved process parameters.
[0033] The final layer judgment module is used to determine whether the current layer is the last layer of workpiece manufacturing. If not, the manufacturing of the next layer begins and the logic judgment module continues to be executed.
[0034] Furthermore, the monitoring module specifically includes:
[0035] The structured light device and the infrared thermal imaging device are used to monitor in real time the morphological parameters and temperature information of the powder bed, molten pool, and workpiece during the process of manufacturing amorphous alloys point by point and layer by layer using an additive manufacturing system.
[0036] Furthermore, in the parameter library construction module, a stress control process parameter library is constructed by analyzing the results and experimental data, specifically as follows:
[0037] Among the multiple analysis results corresponding to each layer, the optimal analysis result is obtained based on the values of overall stress and local stress; the corresponding stress matching range is set according to the overall stress and local stress in the optimal analysis result; and a stress control process parameter library is constructed by combining the optimal analysis result and its corresponding stress matching range with experimental data.
[0038] Compared with the prior art, the present invention has at least the following beneficial effects:
[0039] (1) This invention manufactures amorphous alloys layer by layer using an additive manufacturing system. During the manufacturing process, multiple stress control experiments with different process parameters are conducted layer by layer to obtain experimental data corresponding to each stress control experiment. The analysis results are obtained through the experimental data. A stress control process parameter library is constructed based on the analysis results and experimental data. A set of layers to be controlled is set. When the manufacturing of the current layer is completed and the current layer belongs to the set of layers to be controlled, the additive manufacturing process is simulated using the morphological parameters and temperature information of the powder bed, molten pool and workpiece through finite element analysis software to predict the overall stress, local stress, strain evolution law and distribution characteristics of the workpiece. Based on the prediction results, the corresponding process parameters in the stress control process parameter library are retrieved. Based on the retrieved process parameters, laser preheating and stress control are performed on the current layer. That is, after each layer or multiple layers are completed, the local material of the workpiece is softened by laser preheating, which reduces the yield strength and deformation resistance. On this basis, ultrasonic shot peening is performed at the same time to achieve stress state control, avoid the accumulation of thermal stress and eliminate crack defects that occur in the amorphous alloy forming process.
[0040] (2) After each layer or multiple layers are completed, the present invention softens the local material of the workpiece by laser preheating, reduces the yield strength and deformation resistance, which is beneficial to control and expand the machinable area and process window, prefabricates a deeper compressive stress layer, eliminates cracks and pore defects, and improves the mechanical properties, forming accuracy and surface quality of the workpiece.
[0041] (3) This invention uses laser preheating and ultrasonic shot peening to perform multiple stress regulation, optimizes the control of local and overall deformation of amorphous alloy workpieces, and improves the forming accuracy and surface quality of amorphous alloy workpieces.
[0042] (4) Based on the real-time acquired information on the morphology and temperature of the powder bed, molten pool and workpiece, this invention repeatedly controls the compressive stress deformation generated during the manufacturing process, effectively reducing the porosity defects of amorphous alloys and improving the comprehensive mechanical properties of amorphous alloys.
[0043] (5) In the manufacturing process, stress is controlled by laser preheating and ultrasonic shot peening. On this basis, compressive stress and shear bands are pre-formed in the amorphous alloy, which improves the degree of structural rejuvenation of the amorphous alloy and the comprehensive mechanical properties of the amorphous alloy.
[0044] (6) During the control process, the present invention acquires real-time monitoring information and controls the current laser preheating process through the real-time monitoring information, so that the real-time monitoring information is close to or equal to the corresponding process parameters; further improving the mechanical properties, forming accuracy and surface quality of the workpiece. Attached Figure Description
[0045] Figure 1 This is a flowchart of a method for manufacturing amorphous alloys based on laser preheating and ultrasonic shot peening.
[0046] Figure 2 This is a structural diagram of an amorphous alloy manufacturing system based on laser preheating and ultrasonic shot peening.
[0047] In the picture:
[0048] 1. Laser source of L-PBF additive manufacturing system; 2. Motion system of L-PBF additive manufacturing system; 3. Structured light device; 4. Infrared thermal imaging device; 5. Laser preheating device; 6. Ultrasonic shot peening; 7. Control system of L-PBF additive manufacturing system; 8. Amorphous alloy workpiece. Detailed Implementation
[0049] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.
[0050] Example 1
[0051] As the size of the prepared samples increases, thermal stress accumulates during the preparation of amorphous alloys using the L-PBF technique, exceeding the crack initiation threshold and causing cracks to appear in the prepared amorphous alloys. To address this technical problem, such as... Figure 1 As shown, this invention proposes a method for manufacturing amorphous alloys based on laser preheating and ultrasonic shot peening, comprising the following steps:
[0052] S1: Construct a stress control process parameter library through additive manufacturing experiments. Specifically, this involves: manufacturing amorphous alloys layer by layer using an additive manufacturing system, and conducting single stress control experiments or multiple stress control experiments with different process parameters layer by layer during the manufacturing process (pre-setting multiple sets of different process parameters, and conducting stress control experiments corresponding to each set of process parameters layer by layer). The stress control experiments include: laser preheating control and ultrasonic shot peening impact stress control; acquiring experimental data corresponding to each stress control experiment, and obtaining analysis results from the experimental data; the analysis results include the overall stress, local stress, strain evolution law and distribution characteristics of the amorphous alloy; constructing a stress control process parameter library based on the analysis results and experimental data; the experimental data includes the process parameters corresponding to laser preheating control and ultrasonic shot peening impact stress control.
[0053] The process parameters for laser preheating control include: preheating temperature, area, and time; the process parameters for stress control include: ultrasonic shot peening impact frequency, power, amplitude, and pressure.
[0054] In step S1, a stress control process parameter library is constructed by analyzing the results and experimental data, specifically as follows:
[0055] When performing multiple stress control experiments with different process parameters layer by layer, the optimal analysis result is obtained from the multiple analysis results corresponding to each layer based on the values of overall stress and local stress. The corresponding stress matching range is set according to the overall stress and local stress in the optimal analysis result. When performing a single stress control experiment layer by layer, the analysis result of the stress control experiment corresponding to the current layer is the optimal analysis result for that layer. A stress control process parameter library is constructed by combining the optimal analysis result and its corresponding stress matching range with the experimental data.
[0056] The process of obtaining the optimal analysis result based on the values of overall stress and local stress from multiple analysis results corresponding to each layer is as follows:
[0057] Based on the degree of influence of overall stress and local stress on the final quality of the amorphous alloy workpiece (obtained from prior experience), the weights corresponding to the overall stress and local stress of the amorphous alloy are set.
[0058] The weight values corresponding to each analysis result are calculated based on the weights and numerical values corresponding to the overall stress and local stress of the amorphous alloy.
[0059] The analysis result corresponding to the minimum weight value is set as the optimal analysis result;
[0060] This embodiment uses one of the analysis results (analysis result 1) as an example for illustration:
[0061] weight value 分析结果1 =Overall stress分析结果1 *Weight 整体应力 +local stress 分析结果1 *Weight 局部应力 ;
[0062] It should be noted here that there may be multiple local stresses (e.g., local stress 1, local stress 2, local stress 3), and each local stress is assigned a corresponding weight. Therefore:
[0063] weight value 分析结果1 =Overall stress 分析结果1 *Weight 整体应力 +Local stress 1 分析结果1 *Weight 局部应力1 +Local stress 2 分析结果1 *Weight 局部应力2 +Local stress 3 分析结果1 *Weight 局部应力3 ;
[0064] Based on the overall stress and local stress in the optimal analysis results, the corresponding stress matching range is set as follows:
[0065] By setting corresponding upper and lower limits with the overall stress and local stress as intermediate values, the overall stress matching range and the local stress matching range are obtained;
[0066] The numerical ranges of the overall stress matching range for each layer and the numerical ranges of the local stress matching range for each layer are both continuous, ensuring that the most suitable stress matching range can be found. For example:
[0067] The overall stress matching range corresponding to the first layer is: [1,5);
[0068] The overall stress matching range corresponding to the second layer is: [5,8);
[0069] The overall stress matching range corresponding to the third layer is: [8, 15)...
[0070] S2: Real-time monitoring of the morphology parameters and temperature information of the powder bed, molten pool and workpiece during the manufacturing of amorphous alloys using an additive manufacturing system;
[0071] S3: Set the set of layers to be adjusted; the set of layers to be adjusted includes the number of layers corresponding to one or more layers for which stress regulation is to be performed;
[0072] S4: Determine whether the additive manufacturing system has completed the manufacturing of the current layer. If yes, determine whether the current layer belongs to the set of layers to be adjusted. If yes, proceed to the next step; otherwise, jump to step S7.
[0073] S5: The additive manufacturing process is simulated using the morphological parameters and temperature information of the powder bed, molten pool and workpiece through finite element analysis software to predict the overall stress, local stress, strain evolution law and distribution characteristics of the workpiece, and the corresponding process parameters are retrieved from the stress control process parameter library based on the prediction results.
[0074] In step S5, the corresponding process parameters are retrieved from the stress control process parameter library based on the prediction results, specifically as follows:
[0075] Based on the preset weights corresponding to the overall stress and local stress, the weight values corresponding to the overall stress and local stress in the prediction results are obtained, the stress matching range corresponding to the larger weight value is obtained, and the analysis result corresponding to the stress matching range is obtained as the target result. The process parameters of laser preheating control and stress control in the experimental data corresponding to the target result are set as the process parameters for controlling the current layer.
[0076] S6: Based on the retrieved process parameters, perform laser preheating and stress control on the current layer, and acquire real-time monitoring information during the control process. Then, adjust the current laser preheating process based on the real-time monitoring information so that the real-time monitoring information is close to or equal to the corresponding retrieved process parameters. The real-time monitoring information includes the workpiece temperature information and the preheating area.
[0077] S7: Determine if the current layer is the last layer for workpiece manufacturing. If not, start manufacturing of the next layer and return to step S4. If yes, end manufacturing.
[0078] It should be noted that the amorphous alloy manufacturing method in this embodiment is not only applicable to L-PBF additive manufacturing technology, but also to other manufacturing technologies such as L-DED, FFF, and TSAM.
[0079] This invention manufactures amorphous alloys layer by layer using an additive manufacturing system. During the manufacturing process, multiple stress control experiments with different process parameters are conducted layer by layer to obtain experimental data for each stress control experiment. Analysis results are obtained from the experimental data. A stress control process parameter library is constructed using the analysis results and experimental data. A set of layers to be controlled is set. When the current layer is completed and its layer number belongs to the set of layers to be controlled, the additive manufacturing process is simulated using finite element analysis software with the morphological parameters and temperature information of the powder bed, molten pool, and workpiece. This simulates the overall stress, local stress, strain evolution, and distribution characteristics of the workpiece. Based on the prediction results, the corresponding process parameters from the stress control process parameter library are retrieved. Based on the retrieved process parameters, laser preheating and stress control are performed on the current layer. In other words, after each layer or multiple layers are completed, laser preheating softens the local material of the workpiece, reducing yield strength and deformation resistance. Simultaneously, ultrasonic shot peening is performed to control the stress state, avoiding the accumulation of thermal stress and eliminating crack defects that occur during the amorphous alloy forming process.
[0080] Example 2
[0081] like Figure 2 As shown, this invention also proposes an amorphous alloy manufacturing system based on laser preheating and ultrasonic shot peening, comprising:
[0082] An additive manufacturing system (which includes a laser source 1, a motion system 2 and a control system 7) is used to manufacture amorphous alloy workpieces 8 point by point and layer by layer. It should be noted that the additive manufacturing system in this embodiment is an L-PBF additive manufacturing system, an L-DED manufacturing system, an FFF manufacturing system or a TSAM manufacturing system, etc.
[0083] The parameter library construction module is used to build a stress control process parameter library through additive manufacturing experiments. Specifically, it involves manufacturing amorphous alloys point-by-point and layer-by-layer using an additive manufacturing system, and conducting single or multiple stress control experiments layer by layer during the manufacturing process. These stress control experiments include laser preheating control and ultrasonic shot peening impact stress control. Experimental data corresponding to each stress control experiment is acquired, and analysis results are obtained from the experimental data. The analysis results include the overall stress, local stress, strain evolution law, and distribution characteristics of the amorphous alloy. A stress control process parameter library is constructed using the analysis results and experimental data. The experimental data includes the process parameters corresponding to laser preheating control and ultrasonic shot peening impact stress control.
[0084] In the parameter library construction module, a stress control process parameter library is constructed by analyzing the results and experimental data, specifically as follows:
[0085] When performing multiple stress control experiments with different process parameters layer by layer, the optimal analysis result is obtained from the multiple analysis results corresponding to each layer based on the values of overall stress and local stress. The corresponding stress matching range is set according to the overall stress and local stress in the optimal analysis result. When performing a single stress control experiment layer by layer, the analysis result of the stress control experiment corresponding to the current layer is the optimal analysis result for that layer. A stress control process parameter library is constructed by combining the optimal analysis result and its corresponding stress matching range with the experimental data.
[0086] The monitoring module is used to monitor in real time the morphology parameters and temperature information of the powder bed, molten pool and workpiece during the manufacturing of amorphous alloys using an additive manufacturing system.
[0087] The monitoring module specifically includes:
[0088] The structured light device 3 and the infrared thermal imaging device 4 are used to monitor in real time the morphological parameters and temperature information of the powder bed, molten pool and workpiece during the process of manufacturing amorphous alloys point by point and layer by layer using the L-PBF additive manufacturing system.
[0089] It should be noted that this embodiment is not limited to structured light device 3 and infrared thermal imaging device 4. The structured light device 3 can also be replaced with a CCD camera or laser line scanner, and the infrared thermal imaging device 4 can be replaced with a dual-color pyrometer or photodiode, etc., all of which can achieve the purpose of morphology and temperature monitoring.
[0090] The setting module is used to set the set of layers to be adjusted; the set of layers to be adjusted includes the number of layers corresponding to one or more layers for which stress regulation is to be performed;
[0091] The logic judgment module includes a first logic judgment unit and a second logic judgment unit; the first logic judgment unit is used to determine whether the additive manufacturing system has completed the manufacturing of the current layer; the second logic judgment unit is used to determine whether the current layer belongs to the set of layers to be adjusted when the manufacturing of the current layer has been completed.
[0092] The retrieval module is used to simulate the additive manufacturing process using the morphological parameters and temperature information of the powder bed, molten pool and workpiece through finite element analysis software when the current layer belongs to the set of layers to be adjusted. This is to predict the overall stress, local stress, strain evolution law and distribution characteristics of the workpiece, and retrieve the corresponding process parameters from the stress control process parameter library based on the prediction results.
[0093] The control module includes a control unit, a laser preheating device 5, and an ultrasonic shot peening device 6. The control unit is used to perform laser preheating and stress control on the current layer based on the retrieved process parameters using the laser preheating device 5 and the ultrasonic shot peening device 6, respectively. During the control process, real-time monitoring information is acquired, and the current laser preheating process is controlled through the real-time monitoring information so that the real-time monitoring information is close to or equal to the corresponding retrieved process parameters.
[0094] The final layer judgment module is used to determine whether the current layer is the last layer of workpiece manufacturing. If not, the manufacturing of the next layer begins and the logic judgment module continues to be executed.
[0095] In this embodiment, the functions of the parameter library construction module, setting module, logic judgment module, control unit, and final layer judgment module are all integrated into the control system 7 of the L-PBF additive manufacturing system. Furthermore, in the stress control process of this embodiment, it is not limited to the laser preheating device 5; the laser source of the additive manufacturing system, or auxiliary heat sources such as ion arc or induction heating can also be used.
[0096] The amorphous alloy manufacturing system proposed in this embodiment is not only applicable to the manufacturing of amorphous alloys, but also to the manufacturing of amorphous composite materials and other brittle alloy materials.
[0097] This invention utilizes laser preheating and ultrasonic shot peening to perform multiple stress adjustments, thereby optimizing the control of local and overall deformation of amorphous alloy workpieces and improving their forming accuracy and surface quality.
[0098] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.
[0099] Furthermore, in this invention, descriptions involving terms such as "first," "second," and "a" are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.
[0100] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.
[0101] Furthermore, the technical solutions of the various embodiments of the present invention can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by the present invention.
Claims
1. A method for manufacturing amorphous alloys based on laser preheating and ultrasonic shot peening, applied to an additive manufacturing system, characterized in that, Including the following steps: S1: A stress control process parameter library is constructed through additive manufacturing experiments. Specifically, amorphous alloys are manufactured point-by-point and layer-by-layer using an additive manufacturing system. During the manufacturing process, single or multiple stress control experiments are conducted layer by layer. The stress control experiments include laser preheating control and ultrasonic shot peening impact stress control. Experimental data corresponding to each stress control experiment are acquired, and analysis results are obtained from the experimental data. The analysis results include the overall stress, local stress, strain evolution law, and distribution characteristics of the amorphous alloy. A stress control process parameter library is constructed based on the analysis results and experimental data. The experimental data includes the process parameters corresponding to laser preheating control and ultrasonic shot peening impact stress control. S2: Real-time monitoring of the morphology parameters and temperature information of the powder bed, molten pool and workpiece during the manufacturing of amorphous alloys using an additive manufacturing system; S3: Set the set of layers to be adjusted; the set of layers to be adjusted includes the number of layers corresponding to one or more layers for which stress regulation is to be performed; S4: Determine whether the additive manufacturing system has completed the manufacturing of the current layer. If yes, determine whether the current layer belongs to the set of layers to be adjusted. If yes, proceed to the next step; otherwise, jump to step S7. S5: The additive manufacturing process is simulated using the morphological parameters and temperature information of the powder bed, molten pool and workpiece through finite element analysis software to predict the overall stress, local stress, strain evolution law and distribution characteristics of the workpiece, and the corresponding process parameters are retrieved from the stress control process parameter library based on the prediction results. S6: Based on the retrieved process parameters, perform laser preheating and stress control on the current layer, and acquire real-time monitoring information during the control process. Then, adjust the current laser preheating process through the real-time monitoring information so that the real-time monitoring information is close to or equal to the corresponding retrieved process parameters. S7: Determine if the current layer is the last layer for workpiece manufacturing. If not, start manufacturing the next layer and return to step S4.
2. The method for manufacturing amorphous alloys based on laser preheating and ultrasonic shot peening according to claim 1, characterized in that, The process parameters for laser preheating control include: preheating temperature, area, and time; the process parameters for stress control include: ultrasonic shot peening impact frequency, power, amplitude, and pressure.
3. The method for manufacturing amorphous alloys based on laser preheating and ultrasonic shot peening according to claim 2, characterized in that, The real-time monitoring information includes the workpiece's temperature and preheating area.
4. The method for manufacturing amorphous alloys based on laser preheating and ultrasonic shot peening according to claim 3, characterized in that, In step S1, a stress control process parameter library is constructed by analyzing the results and experimental data, specifically as follows: Among the multiple analysis results corresponding to each layer, the optimal analysis result is obtained based on the values of overall stress and local stress; the corresponding stress matching range is set according to the overall stress and local stress in the optimal analysis result; and a stress control process parameter library is constructed by combining the optimal analysis result and its corresponding stress matching range with experimental data.
5. The method for manufacturing amorphous alloys based on laser preheating and ultrasonic shot peening according to claim 4, characterized in that, The process of obtaining the optimal analysis result based on the values of overall stress and local stress from multiple analysis results corresponding to each layer is specifically as follows: Based on the influence of overall stress and local stress on the quality of the final formed amorphous alloy workpiece, the weights corresponding to the overall stress and local stress of the amorphous alloy are set. The weight values corresponding to each analysis result are calculated based on the weights and numerical values corresponding to the overall stress and local stress of the amorphous alloy. The analysis result corresponding to the minimum weight value is set as the optimal analysis result.
6. The method for manufacturing amorphous alloys based on laser preheating and ultrasonic shot peening according to claim 5, characterized in that, Based on the overall stress and local stress in the optimal analysis results, the corresponding stress matching range is set as follows: By setting corresponding upper and lower limits with the overall stress and local stress as intermediate values, the overall stress matching range and the local stress matching range are obtained; The numerical ranges of the overall stress matching range for each layer and the numerical ranges of the local stress matching range for each layer are both continuous.
7. The method for manufacturing amorphous alloys based on laser preheating and ultrasonic shot peening according to claim 6, characterized in that, In step S5, the corresponding process parameters are retrieved from the stress control process parameter library based on the prediction results, specifically as follows: Based on the preset weights corresponding to the overall stress and local stress, the weight values corresponding to the overall stress and local stress in the prediction results are obtained. The stress matching range corresponding to the larger weight value is obtained, and the analysis result corresponding to the stress matching range is obtained as the target result. The process parameters of laser preheating control and stress control in the experimental data corresponding to the target result are set as the process parameters for controlling the current layer.
8. An amorphous alloy manufacturing system based on laser preheating and ultrasonic shot peening, characterized in that, include: The parameter library construction module is used to build a stress control process parameter library through additive manufacturing experiments. Specifically, it involves manufacturing amorphous alloys point-by-point and layer-by-layer using an additive manufacturing system, and conducting single or multiple stress control experiments layer by layer during the manufacturing process. These stress control experiments include laser preheating control and ultrasonic shot peening impact stress control. Experimental data corresponding to each stress control experiment is acquired, and analysis results are obtained from the experimental data. The analysis results include the overall stress, local stress, strain evolution law, and distribution characteristics of the amorphous alloy. A stress control process parameter library is constructed using the analysis results and experimental data. The experimental data includes the process parameters corresponding to laser preheating control and ultrasonic shot peening impact stress control. The monitoring module is used to monitor in real time the morphology parameters and temperature information of the powder bed, molten pool and workpiece during the manufacturing of amorphous alloys using an additive manufacturing system. The setting module is used to set the set of layers to be adjusted; the set of layers to be adjusted includes the number of layers corresponding to one or more layers for which stress regulation is to be performed; The logic judgment module includes a first logic judgment unit and a second logic judgment unit; the first logic judgment unit is used to determine whether the additive manufacturing system has completed the manufacturing of the current layer; the second logic judgment unit is used to determine whether the current layer belongs to the set of layers to be adjusted when the manufacturing of the current layer has been completed. The retrieval module is used to simulate the additive manufacturing process using the morphological parameters and temperature information of the powder bed, molten pool and workpiece through finite element analysis software when the current layer belongs to the set of layers to be adjusted. This is to predict the overall stress, local stress, strain evolution law and distribution characteristics of the workpiece, and retrieve the corresponding process parameters from the stress control process parameter library based on the prediction results. The control module is used to perform laser preheating and stress control on the current layer based on the retrieved process parameters. During the control process, it acquires real-time monitoring information and controls the current laser preheating process through the real-time monitoring information so that the real-time monitoring information is close to or equal to the corresponding retrieved process parameters. The final layer judgment module is used to determine whether the current layer is the last layer of workpiece manufacturing. If not, the manufacturing of the next layer begins and the logic judgment module continues to be executed.
9. The amorphous alloy manufacturing system based on laser preheating and ultrasonic shot peening according to claim 8, characterized in that, The monitoring module specifically includes: The structured light device and the infrared thermal imaging device are used to monitor in real time the morphological parameters and temperature information of the powder bed, molten pool, and workpiece during the process of manufacturing amorphous alloys point by point and layer by layer using an additive manufacturing system.
10. The amorphous alloy manufacturing system based on laser preheating and ultrasonic shot peening according to claim 9, characterized in that, In the parameter library construction module, a stress control process parameter library is constructed by analyzing the results and experimental data, specifically as follows: Among the multiple analysis results corresponding to each layer, the optimal analysis result is obtained based on the values of overall stress and local stress; the corresponding stress matching range is set according to the overall stress and local stress in the optimal analysis result; and a stress control process parameter library is constructed by combining the optimal analysis result and its corresponding stress matching range with experimental data.