A crack ultrasonic testing apparatus for additive manufacturing of metallic materials

Abstract

The application discloses a kind of crack ultrasonic detection equipment for additive manufacturing metal material, comprising: conveying pipeline, pretreatment component, dryer, pressing assembly, cutting assembly, ultrasonic detector, data analyzer, wherein the pressing assembly, cutting assembly, ultrasonic detector are connected by moving manipulator, simultaneously the data analyzer is connected on the ultrasonic detector, for processing the data detected by ultrasonic detector;The conveying pipeline, pretreatment component, dryer, pressing assembly are connected by first connection conveying belt, by the present application, the removal work of different impurities, oil stains etc. of additive manufacturing metal parts can be effectively completed, meanwhile the uniformity of the granularity of output material can be guaranteed, so as to reduce the error of block making process, improve the accuracy of detection result.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing technology, and more specifically to an ultrasonic crack detection device for additive manufacturing of metallic materials. Background Technology

[0002] Additive manufacturing, also known as 3D printing, is based on the principle of building objects by layering materials. It involves stacking raw materials (such as metal powder, plastic filaments, etc.) layer by layer based on a 3D model data to ultimately form a complete part or object. The advantages of additive manufacturing lie in its high flexibility, enabling the creation of complex and personalized products while saving materials and reducing manufacturing time. Furthermore, additive manufacturing can create products with complex internal structures and voids, achieving product designs that are impossible with traditional methods. In metal additive manufacturing, metal materials typically undergo a series of rigorous tests to ensure their quality and performance. Ultrasonic testing, which involves emitting ultrasonic waves into the material and receiving the reflected signals, can detect internal defects, cracks, pores, and other problems.

[0003] However, oil stains, impurities, dryness, and particle size uniformity in metallic materials can all affect the testing of the materials. At the same time, for powdered materials, they need to be processed into test blocks. Factors such as the smoothness of the surface of the test blocks can affect the propagation and reception of ultrasonic waves to a certain extent, thus affecting the test results. Existing ultrasonic testing equipment usually requires complicated preparation work to eliminate interference factors before testing. However, this method is not only time-consuming and laborious, but also causes errors in the test results to a certain extent, which in turn affects the subsequent manufacturing process.

[0004] Therefore, it is necessary to provide an ultrasonic testing device for cracks in additively manufactured metallic materials to solve the above problems. Summary of the Invention

[0005] To achieve the above objectives, the present invention provides the following technical solution: an ultrasonic crack detection device for additive manufacturing of metallic materials, comprising:

[0006] The system includes a conveying pipeline, a pretreatment component, a dryer, a pressing component, a cutting component, an ultrasonic detector, and a data analyzer. The pressing component, the cutting component, and the ultrasonic detector are connected by a mobile robotic arm, and the data analyzer is connected to the ultrasonic detector to process the data detected by the ultrasonic detector.

[0007] The conveying pipeline, pretreatment component, dryer, and pressing component are connected by a first connecting conveyor belt.

[0008] Furthermore, preferably, the preprocessing component includes:

[0009] The second connecting conveyor belt is a section of the first connecting conveyor belt and is connected to a material washing machine. A detergent tank is fixedly mounted on the upper end of the material washing machine. One end of the material washing machine is connected to a secondary washing tank, and the other end is connected to a density screening component. A connecting pipe is provided between the secondary washing tank and the density screening component. A tertiary washing tank is connected to the other side of the density screening component, and a particle size screening component is connected to the other side of the tertiary washing tank. The other end of the particle size screening component is connected to the first connecting conveyor belt.

[0010] Furthermore, preferably, the pressing component includes:

[0011] The third connecting conveyor belt is a section of the first connecting conveyor belt, and a forming mold is fixed at its other end. A fixing group is provided below the forming mold, a forming machine is provided above the forming mold, and a demolding powder tank is provided on one side of the forming machine.

[0012] Furthermore, preferably, the molding die includes:

[0013] A clamping column is clamped and fixed on a fixed assembly. A fixed plate is fixedly installed above the clamping column. Four sets of telescopic cylinders are vertically fixedly mounted on the fixed plate. Two sets of coaxially arranged variable mold wall assemblies are fixedly mounted on the upper end of the four sets of telescopic cylinders. Two sets of fixed mold wall assemblies are coaxially arranged on the lower end of the two sets of variable mold wall assemblies. Four sets of fixing rods are provided on the two sets of fixed mold wall assemblies. The four sets of fixing rods are fixedly mounted on the fixed plate.

[0014] Furthermore, preferably, the variable mold wall assembly includes:

[0015] The fixed connecting blocks are provided in four sets, which are respectively fixedly assembled on the four sets of telescopic cylinders. The inner side of the four sets of fixed connecting blocks is fixedly connected to a first hydraulic cylinder. The other end of the first hydraulic cylinder is fixedly connected to a mold wall connecting block. The inner side of each set of mold wall connecting blocks is fixedly embedded with two sets of second hydraulic cylinders. The other end of the two sets of second hydraulic cylinders is fixedly connected to the mold wall.

[0016] Furthermore, as a preferred embodiment, the two sets of second hydraulic cylinders on the same mold wall connecting block are parallel to the central axis of the first hydraulic cylinder.

[0017] Furthermore, as a preferred embodiment, compared with the variable mold wall assembly, the fixed mold wall assembly only includes a mold wall connecting block, a second hydraulic cylinder, and a mold wall, and the outer surface of the mold wall connecting block of the variable mold wall assembly is provided with a fitting groove.

[0018] Furthermore, preferably, the cutting assembly includes:

[0019] A fixed support frame is placed between the pressing component and the ultrasonic detector. A sliding shaft assembly is provided on the fixed support frame. A sliding block is slidably arranged on the right side of the sliding shaft assembly, and a clamping and fixing assembly is fixedly arranged on the left side of the sliding shaft assembly. Clamping assemblies are fixedly and rotatably arranged inside both the sliding block and the clamping and fixing assembly, and the two clamping assemblies are coaxial. A movable blade assembly is slidably arranged in the middle of the sliding shaft assembly, and a coolant pipe is fixedly arranged on the movable blade assembly. A waste chip collection tank and a control panel are fixedly arranged on the fixed support frame.

[0020] Furthermore, as a preferred embodiment, a conversion hydraulic cylinder is fixedly assembled inside the clamping and fixing assembly and the sliding block, and a centering end is fixedly assembled inside the conversion hydraulic cylinder.

[0021] Furthermore, as a preferred embodiment, a drive component is fixedly disposed inside the clamping and fixing assembly and the sliding block, the output shaft of the drive component is fixedly connected to the clamping assembly, and an automatic clamping drive assembly is disposed on the clamping assembly.

[0022] Compared with the prior art, the present invention provides an ultrasonic crack detection device for additive manufacturing of metallic materials, which has the following beneficial effects:

[0023] In this invention, the pre-processing components effectively remove various impurities and oil stains, while ensuring the uniformity of the particle size of the output material. This reduces errors in the block-making process and improves the accuracy of the test results. Furthermore, the molding die can be adjusted according to actual conditions, resulting in finer test blocks and further ensuring experimental results. The device also includes a cutting component to remove surface material to a certain extent, ensuring a smooth and flat surface for ultrasonic testing. Through automated operation, the device achieves a complete testing process while maintaining accuracy, further saving production costs and improving production efficiency. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of an ultrasonic crack detection device for additive manufacturing of metallic materials.

[0025] Figure 2 This is a schematic diagram of the preprocessing component's operation.

[0026] Figure 3 This is a schematic diagram illustrating the operation of the compression component;

[0027] Figure 4 This is a schematic diagram of the molding die structure;

[0028] Figure 5 This is a schematic diagram of a variable mode wall assembly;

[0029] Figure 6This is a schematic diagram of the cutting assembly structure;

[0030] Figure 7 This is an enlarged view of a portion of the cutting assembly structure;

[0031] In the diagram: 1. Conveying pipeline; 2. Pretreatment component; 3. Dryer; 4. Pressing component; 5. Moving robot; 6. Cutting component; 7. Ultrasonic detector; 8. Data analyzer; 9. First connecting conveyor belt; 21. Second connecting conveyor belt; 22. Material washing machine; 23. Detergent tank; 24. Secondary washing tank; 25. Density sieving component; 26. Tertiary washing tank; 27. Particle size sieving component; 41. Third connecting conveyor belt; 42. Demolding powder tank; 43. Molding mold; 44. Molding machine; 431. Clamping column; 432. Fixing plate ; 433, Telescopic cylinder; 434, Variable mold wall assembly; 435, Fixed mold wall assembly; 436, Fixed rod; 437, Fitting groove; 4342, Fixed connecting block; 4343, First hydraulic cylinder; 4344, Mold wall connecting block; 4345, Second hydraulic cylinder; 4346, Mold wall; 61, Fixed support frame; 62, Sliding shaft assembly; 63, Clamping and fixing assembly; 64, Sliding block; 65, Clamping assembly; 66, Moving cutter assembly; 67, Coolant pipe; 68, Waste chip recovery tank; 69, Control panel; 610, Centering end; 611, Conversion hydraulic cylinder. Detailed Implementation

[0032] Please see Figures 1-7 This invention provides an ultrasonic crack detection device for additively manufactured metallic materials, comprising:

[0033] The system includes a conveying pipeline 1, a pretreatment component 2, a dryer 3, a pressing component 4, a cutting component 6, an ultrasonic detector 7, and a data analyzer 8. The pressing component 4, the cutting component 6, and the ultrasonic detector 7 are connected to each other via a mobile robotic arm 5. The data analyzer 8 is connected to the ultrasonic detector 7 and is used to process the data detected by the ultrasonic detector 7.

[0034] The conveying pipeline 1, pretreatment component 2, dryer 3, and pressing component 4 are connected by a first connecting conveyor belt 9;

[0035] In a preferred embodiment, the metal material to be tested is fed into the pretreatment component 2 through the conveying pipe 1. The pretreatment component 2 performs operations such as decontamination, impurity removal, and sieving to ensure that the pure metal material of suitable particle size enters the dryer 3 through the first connecting conveyor belt 9. The dryer 3 dries the moisture on the surface of the metal material to prevent it from causing errors in the test results. The dried metal material enters the pressing component 4 through the first connecting conveyor belt 9. The pressing component 4 presses it into a test block of a suitable size. The moving robot arm 5 places the test block into the cutting component 6 for processing. After processing, the moving robot arm 5 places it on the internal ultrasonic detector 7. The ultrasonic detector 7 uploads the detected data to the data analyzer 8 for analysis and processing. Then, the moving robot arm 5 removes the test block from the device, completing the test.

[0036] Furthermore, the preprocessing component 2 includes:

[0037] The second connecting conveyor belt 21 is a section of the first connecting conveyor belt 9. It is connected to a material washing machine 22. A detergent tank 23 is fixedly mounted on the upper end of the material washing machine 22. One end of the material washing machine 22 is connected to a secondary washing tank 24, and the other end is connected to a density screening component 25. A connecting pipe is provided between the secondary washing tank 24 and the density screening component 25. The other side of the density screening component 25 is connected to a tertiary washing tank 26. The other side of the tertiary washing tank 26 is connected to a particle size screening component 27. The other end of the particle size screening component 27 is connected to the first connecting conveyor belt 9.

[0038] As a preferred embodiment, different metal materials may contain different amounts of oil, impurities, etc. Before pretreatment, technicians need to conduct preliminary testing to confirm the required steps and select appropriate impurity removal components based on the type of impurities. For example, the detergent tank 23 contains various types of detergents to remove stains that may be present on the material surface. Meanwhile, the density sieving component 25 can adjust the concentration within a certain range to configure the solution concentration according to the approximate density of the impurities, thereby removing the impurities. The particle size sieving component 27 removes excessively large or small metal materials to prevent them from affecting the properties of the test blocks after they are made, thus causing errors in the test results.

[0039] Furthermore, the suppression component 4 includes:

[0040] The third connecting conveyor belt 41 is a section of the first connecting conveyor belt 9, and a forming mold 43 is fixed at its other end. A fixing group is provided below the forming mold 43, a forming machine 44 is provided above the forming mold 43, and a demolding powder tank 42 is provided on one side of the forming machine 44.

[0041] As a preferred embodiment, the shape and size of the test block are determined according to the specific testing requirements and the type of ultrasonic probe. (The design of the test block should ensure that ultrasonic waves can effectively propagate within the test block and reflect the true condition of the material.) Based on the shape and size of the test block, a corresponding mold is made. (The mold can be made using 3D printing or CNC machining to ensure its precision and durability.) Powdered metal material is placed into the mold, and appropriate pressure is applied by the molding machine 44 to tightly bond them together to form a test block. (During the pressing process, it is necessary to ensure that the pressure is evenly distributed to avoid internal defects or cracks.) At the same time, the molding machine 44 can also perform curing treatment on the pressed test block according to the material type and process requirements, such as heating or cooling. In actual use, the amount and type of the release powder can maintain a certain friction between the test block and the molding mold 43 without sticking together, so that the two do not rotate relative to each other.

[0042] Furthermore, the molding die 43 includes:

[0043] A clamping column 431 is clamped and fixed on a fixed assembly. A fixed plate 432 is fixedly installed above the clamping column 431. Four sets of telescopic cylinders 433 are vertically fixedly mounted on the fixed plate 432. Two sets of coaxially arranged variable mold wall assemblies 434 are fixedly mounted on the upper end of the four sets of telescopic cylinders 433. Two sets of fixed mold wall assemblies 435 are coaxially arranged on the lower end of the two sets of variable mold wall assemblies 434. Four sets of fixing rods 436 are provided on the two sets of fixed mold wall assemblies 435. The four sets of fixing rods 436 are fixedly mounted on the fixed plate 432.

[0044] In a preferred embodiment, an appropriate number of variable mold wall groups 434 and fixed mold wall groups 435 can be selected according to the size of the test block, and the number of both is equal. The initial state of the molding mold 43 is shown in the figure. After the molding operation of the test block is completed, the mobile robot arm 5 will clamp the test block and the molding mold 43 onto the cutting component 6. The cutting component 6 clamps the clamping column 431. At the same time, the lowermost variable mold wall group 434 deforms and detaches from the test block. Simultaneously, the four sets of telescopic cylinders 433 retract, causing the uppermost variable mold wall group 434 to descend and overlap with the uppermost fixed mold wall group 435. At this time, the upper end of the test block will be exposed, which facilitates the cutting component 6 to cut the surface of the test block, thereby keeping the surface of the test block flat and smooth, which is convenient for the detection of the ultrasonic detector 7. After the upper end of the test block is cut, the above operation is repeated until all variable mold wall groups 434 have been retracted. The cutting component 6 clamps the cut part of the test block, and then the mobile robot arm 5 removes the molding mold 43, thereby completing the subsequent cutting work of the test block.

[0045] Furthermore, the variable wall assembly 434 includes:

[0046] Four sets of fixed connecting blocks 4342 are provided, which are respectively fixedly assembled on four sets of telescopic cylinders 433. A first hydraulic cylinder 4343 is fixedly connected to the inner side of the four sets of fixed connecting blocks 4342. The other end of the first hydraulic cylinder 4343 is fixedly connected to a mold wall connecting block 4344. Two sets of second hydraulic cylinders 4345 are fixedly installed on the inner side of each set of mold wall connecting blocks 4344. The other end of the two sets of second hydraulic cylinders 4345 is fixedly connected to a mold wall 4346.

[0047] In a preferred embodiment, the dimensions of the mold wall 4346 can be adjusted according to the actual situation of the test block, and the radius of the mold wall 4346 is the sum of the actual radius of the test block and the cutting thickness. When the variable mold wall assembly 434 contracts, both the second hydraulic cylinder 4345 and the first hydraulic cylinder 4343 are in a contracted state.

[0048] Furthermore, the two sets of second hydraulic cylinders 4345 on the same mold wall connecting block 4344 are parallel to the central axis of the first hydraulic cylinder 4343, which facilitates the replacement, installation and retraction of the mold wall 4346.

[0049] Furthermore, compared with the variable mold wall assembly 434, the fixed mold wall assembly 435 only includes the mold wall connecting block 4344, the second hydraulic cylinder 4345, and the mold wall 4346, and the outer side surface of the mold wall connecting block 4344 of the variable mold wall assembly 434 is provided with a fitting groove 437.

[0050] In a preferred embodiment, the fitting groove 437 allows the first hydraulic cylinder 4343 in its contracted state to overlap with the fitting groove 437, thereby further saving space and facilitating the adjustment of the variable mold wall assembly 434. The second hydraulic cylinder 4345, while replacing and installing mold walls 4346 of different sizes, also facilitates the separation of the mold wall 4346 from the test block.

[0051] Furthermore, the cutting assembly 6 includes:

[0052] A fixed support frame 61 is placed between the pressing component 4 and the ultrasonic detector 7. A sliding shaft assembly 62 is provided on the fixed support frame 61. A sliding block 64 is slidably provided on the right side of the sliding shaft assembly 62. A clamping and fixing assembly 63 is fixedly provided on the left side of the sliding shaft assembly 62. A clamping assembly 65 is fixedly and rotatably provided on the inner side of both the sliding block 64 and the clamping and fixing assembly 63. The two clamping assemblies 65 are coaxial. A movable blade assembly 66 is slidably provided in the middle of the sliding shaft assembly 62. A coolant pipe 67 is fixedly provided on the movable blade assembly 66. A waste chip collection tank 68 and a control panel 69 are fixedly provided on the fixed support frame 61.

[0053] In a preferred embodiment, the arrangement of two sets of clamping groups 65 enables the cutting assembly 6 to complete the cutting work of the test block more efficiently.

[0054] Furthermore, a conversion hydraulic cylinder 611 is fixedly assembled inside the clamping and fixing assembly 63 and the sliding block 64, and a centering end 610 is fixedly assembled inside the conversion hydraulic cylinder 611.

[0055] In a preferred embodiment, the centering end 610 ensures that the center of the test block is on the same straight line, guaranteeing its coaxiality. Simultaneously, the centering end 610 minimizes test block vibration during cutting, further ensuring cutting performance and laying the foundation for subsequent testing. The conversion hydraulic cylinder 611 allows the centering end 610 to extend out of the corresponding clamping group 65, facilitating test block fixation while preventing friction and collision between the clamping group 65 and the test block in the non-clamping state, thus avoiding damage to the device or the test block.

[0056] Furthermore, a drive assembly is fixedly installed inside the clamping and fixing group 63 and the sliding block 64. The output shaft of the drive assembly is fixedly connected to the clamping group 65, and an automatic clamping drive group is installed on the clamping group 65.

[0057] The specific implementation includes the following steps: Based on the specific testing requirements and the type of ultrasonic probe, determine the shape and size of the test block. Simultaneously, according to the designed shape and size of the test block, fabricate and adjust the corresponding mold. Input the metal material to be tested into the pretreatment component 2 through the conveying pipe 1. The pretreatment component 2 performs decontamination, impurity removal, and sieving operations, allowing pure metal material of suitable particle size to enter the dryer 3 via the first connecting conveyor belt 9. The dryer 3 dries the surface moisture of the metal material to prevent errors in the testing results. The dried metal material enters the pressing component 4 via the first connecting conveyor belt 9. The pressing component 4 presses it into a test block of suitable size. The moving robot arm 5 places the test block into the cutting component 6 for processing. After processing, the moving robot arm 5 places it onto the internal ultrasonic detector 7. The ultrasonic detector 7 uploads the detected data to the data analyzer 8 for analysis and processing. Finally, the moving robot arm 5 removes the test block from the device, completing the testing.

[0058] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An ultrasonic crack detection device for additive manufacturing of metallic materials, characterized in that: include: The delivery pipeline (1), pretreatment component (2), dryer (3), pressing component (4), cutting component (6), ultrasonic detector (7), and data analyzer (8) are connected to each other via a mobile robot (5), and the data analyzer (8) is connected to the ultrasonic detector (7) to process the data detected by the ultrasonic detector (7). The conveying pipeline (1), pretreatment component (2), dryer (3), and pressing component (4) are connected by a first connecting conveyor belt (9); The preprocessing component (2) includes: The second connecting conveyor belt (21) is a section of the first connecting conveyor belt (9). It is connected to a material washing machine (22). A detergent tank (23) is fixedly mounted on the upper end of the material washing machine (22). One end of the material washing machine (22) is connected to a secondary washing tank (24), and the other end is connected to a density screening component (25). A connecting pipe is provided between the secondary washing tank (24) and the density screening component (25). The other side of the density screening component (25) is connected to a tertiary washing tank (26). The other side of the tertiary washing tank (26) is connected to a particle size screening component (27). The other end of the particle size screening component (27) is connected to the first connecting conveyor belt (9). The suppression component (4) includes: The third connecting conveyor belt (41) is a section of the first connecting conveyor belt (9), and a forming mold (43) is fixed at its other end. A fixing group is provided below the forming mold (43), a forming machine (44) is provided above the forming mold (43), and a demolding powder tank (42) is provided on one side of the forming machine (44). The molding die (43) includes: A clamping column (431) is clamped and fixed on a fixed assembly. A fixed plate (432) is fixedly installed above the clamping column (431). Four sets of telescopic cylinders (433) are vertically fixedly mounted on the fixed plate (432). Two sets of coaxially arranged variable mold wall assemblies (434) are fixedly mounted on the upper end of the four sets of telescopic cylinders (433). Two sets of fixed mold wall assemblies (435) are coaxially arranged on the lower end of the two sets of variable mold wall assemblies (434). Four sets of fixed rods (436) are provided on the two sets of fixed mold wall assemblies (435). The four sets of fixed rods (436) are fixedly mounted on the fixed plate (432). The cutting assembly (6) includes: A fixed support frame (61) is placed between the pressing assembly (4) and the ultrasonic detector (7). A sliding shaft assembly (62) is provided on the frame. A sliding block (64) is slidably provided on the right side of the sliding shaft assembly (62). A clamping and fixing assembly (63) is fixedly provided on the left side of the sliding shaft assembly (62). A clamping assembly (65) is fixedly and rotatably provided inside both the sliding block (64) and the clamping and fixing assembly (63). The two clamping assemblies (65) are coaxial. A movable blade assembly (66) is slidably provided in the middle of the sliding shaft assembly (62). A coolant pipe (67) is fixedly provided on the movable blade assembly (66). A waste chip collection tank (68) and a control panel (69) are fixedly provided on the fixed support frame (61).

2. The ultrasonic crack detection device for additive manufacturing metallic materials according to claim 1, characterized in that: The variable wall assembly (434) includes: The fixed connecting blocks (4342) are provided in four sets, which are respectively fixedly assembled on the four sets of telescopic cylinders (433). The first hydraulic cylinder (4343) is fixedly connected to the inner side of the four sets of fixed connecting blocks (4342). The other end of the first hydraulic cylinder (4343) is fixedly connected to the mold wall connecting block (4344). Two sets of second hydraulic cylinders (4345) are fixedly installed on the inner side of each set of mold wall connecting blocks (4344). The other end of the two sets of second hydraulic cylinders (4345) is fixedly connected to the mold wall (4346).

3. The ultrasonic crack detection device for additive manufacturing metallic materials according to claim 2, characterized in that: The two sets of second hydraulic cylinders (4345) on the same mold wall connecting block (4344) are parallel to the central axis of the first hydraulic cylinder (4343).

4. The ultrasonic crack detection device for additive manufacturing metallic materials according to claim 2, characterized in that: Compared with the variable mold wall assembly (434), the fixed mold wall assembly (435) only includes a mold wall connecting block (4344), a second hydraulic cylinder (4345), and a mold wall (4346), and the outer side surface of the mold wall connecting block (4344) of the variable mold wall assembly (434) is provided with a fitting groove (437).

5. The ultrasonic crack detection device for additive manufacturing metallic materials according to claim 1, characterized in that: The clamping and fixing assembly (63) and the sliding block (64) are fixedly assembled with a conversion hydraulic cylinder (611), and the conversion hydraulic cylinder (611) is fixedly assembled with a centering end (610) inside.

6. The ultrasonic crack detection device for additive manufacturing metallic materials according to claim 5, characterized in that: The clamping and fixing group (63) and the sliding block (64) are equipped with a drive component, the output shaft of which is fixedly connected to the clamping group (65), and the clamping group (65) is equipped with an automatic clamping drive group.

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