Metal additive manufacturing part repairing and forming method and device

Abstract

The invention provides a metal additive manufacturing part repairing method and device. The device is composed of a basic motion platform, a quantitative powder falling mechanism, a powder box forming system, a laser melting mechanism and a vibration uniformizing mechanism. The basic motion platform provides basic motion and overall support, the quantitative powder falling mechanism achieves quantitative powder falling, the powder box forming system provides a damaged part repairing and forming platform, the laser melting mechanism achieves repairing of a damaged area according to slicing information, and the vibration uniformizing mechanism achieves uniform scattering of powder piles falling into damaged parts. A three-dimensional model of a damaged area is generated, the quantitative powder falling mechanism is adjusted to perform quantitative powder falling, the laser melting mechanism is controlled to repair the interior of the damaged area layer by layer until the interior of the damaged area is repaired, and then the exterior of the damaged area is repaired through metal 3D printing. According to the method, the repairing precision and quality of the internal damaged area are improved, and the development of repairing the damaged part through metal 3D printing is promoted.

Description

Technical Field

[0001] The present invention belongs to the field of complex parts repair, relates to the field of metal additive manufacturing, and particularly to a method and device for repairing and forming metal additive manufactured parts. Background Art

[0002] Metal additive manufacturing has significant advantages over traditional manufacturing, including high design freedom, high material utilization, reduced processing steps, rapid prototyping, support for personalized and customized production, reduced inventory requirements, and lightweight design. These advantages enable additive manufacturing to produce parts with complex geometries and internal structures, reduce waste and production cycles, and accelerate product development.

[0003] Damaged parts repair technology is currently widely used in aerospace, automobile manufacturing, heavy machinery, medical equipment, oil and gas and energy production and other fields. By repairing high-value and key components such as aircraft engines, automobile engines and gearbox components, key parts of engineering machinery, surgical instruments, drilling equipment and power equipment, it not only extends the service life and reliability of equipment and reduces replacement costs, but also improves overall efficiency and safety, which has significant economic and environmental significance.

[0004] The development of damaged parts repair technology covers a variety of methods such as traditional welding, mechanical processing, modern 3D printing, laser cladding, cold spraying, self-healing materials and intelligent sensing, and is widely used in aviation, automobiles, heavy machinery and medical equipment. Its significance lies in reducing costs, extending equipment life, reducing resource consumption and waste generation, promoting technological innovation and cross-domain applications, and improving equipment safety and production efficiency, thereby achieving the dual goals of economic benefits and environmental protection. In view of the fact that the process control of powder repair for metal additive repair parts on the market is relatively complex, the powder is unevenly spread, the single layer of powder is insufficient or excessive during the powder spreading process, and the laser uniform sintering of the powder spreading area cannot be completed, making it difficult to achieve effective repair of complex parts by metal additive. Summary of the invention

[0005] To solve the above problems, the present invention discloses a method and device for repairing and forming metal additively manufactured parts. In order to achieve effective metal additive manufacturing repair of complex parts, the development of repairing damaged parts through metal 3D printing is promoted, and the multi-region application of metal 3D printing is further promoted.

[0006] The present invention provides a method and device for repairing and forming metal additive manufacturing parts, which is composed of a basic motion platform, a quantitative powder dropping mechanism, a powder box forming system, a laser melting mechanism and a vibration uniformity mechanism. The basic motion platform is composed of a support frame, a square bracket and a module one, the module one is installed on the support frame, and the square frame is fixed on the module one; the quantitative powder dropping mechanism is composed of a module two, a powder box, a funnel, a butterfly valve controller one, a butterfly valve controller two, a micro vibrator and a funnel bracket, the powder box is fixed on the square frame, the butterfly valve controller one and the butterfly valve controller two are fixed on the cylinder on the powder box, the butterfly valve controller one is above the butterfly valve controller two, and the two butterfly valve controllers mainly realize the control of the powder amount. Module 2 is installed on the square frame, the funnel is installed on module 2, and the micro vibrator is fixed on the funnel. The powder pile falls on the damaged parts through high-frequency and low-amplitude vibration. The powder box forming system consists of a powder box forming chamber and a lifting system. The powder box forming chamber provides a damaged part forming platform. The lifting system adjusts the height of the damaged part and the powder box forming chamber descends according to the layer thickness when the damaged part is repaired externally. The laser melting mechanism consists of module 3 and a laser generator. Module 3 is installed on the square frame. The laser generator is fixed on module 3 and moves with module 3. The vibration uniformity mechanism consists of a vibration plate, a damaged part, a fixture sleeve, a matrix probe, a support connecting plate, a micro vibration motor and an elastic connector. The support connecting plate is installed on the lifting system. Four elastic connectors are fixedly connected to the support connecting plate and the vibration plate. The micro vibration motor is fixed on the lower side of the vibration plate. The powder pile in the damaged area is evenly dispersed through high-frequency and low-amplitude vibration. The fixture sleeve is fixed on the vibration plate, and the matrix probe is installed in the fixture sleeve. The matrix probe fixes the damaged part through air pressure.

[0007] Furthermore, the bottom opening diameter of the funnel is 2 mm, and the taper is greater than twice the natural accumulation angle of the powder;

[0008] Furthermore, the butterfly valve controller 1 and the butterfly valve controller 2 are equipped with weight sensors, and the controller opens and then closes after a certain weight of powder is accumulated.

[0009] Furthermore, the micro vibrator is a micro brushless motor with a vibration frequency of 1000 Hz and an amplitude of 0.2 to 0.4 mm. The micro vibration motor has a vibration frequency of 1000 Hz and an amplitude of 0.5 to 1 mm;

[0010] Furthermore, the control range of the matrix probe is larger than the range of the damaged parts, and a silicone soft cover is used at the front end of the probe to prevent secondary damage to the damaged parts.

[0011] Furthermore, the two ends of the elastic connector are metal plates, and the middle is a metal spring, and the spring plays a shock-absorbing role.

[0012] A method for repairing parts by metal additive manufacturing, wherein the damaged parts are observed to determine whether they meet the requirements of metal 3D printing, and if they meet the requirements, the damaged areas inside the parts are scanned and an internal three-dimensional model is generated, and an external three-dimensional model is generated according to the external missing areas in the original three-mode model of the parts. The damaged parts are placed on a vibration plate, and the damaged parts are fixed using a matrix probe; metal powder is placed in a powder box, and the metal powder is controlled to fall on butterfly valve controller 2 by butterfly valve controller 1, and then a quantitative amount of metal powder is dropped on a funnel by butterfly valve controller 2, and the funnel is controlled to move above the damaged area of ​​the damaged parts by module 2, and a micro vibrator is turned on to make the metal powder fall on the damaged area inside the damaged parts. The micro vibration motor is started to evenly spread the powder in the damaged area, and a laser melting mechanism is used to perform regional melting according to the internal three-dimensional model slices, and the above steps are repeated until the internal printing of the damaged parts is completed; the outside of the damaged parts is filled with metal powder, and the external area of ​​the damaged parts is generated layer by layer by metal 3D printing until the overall repair of the damaged parts is completed.

[0013] Furthermore, metal 3D printing requires that the internal cross-sectional area of ​​the damaged area is ≤ the internal cross-sectional area of ​​the previous layer, and the previous layer cannot block the area of ​​the next layer. In non-compliant areas, the damaged area needs to be cut to meet the metal 3D printing requirements.

[0014] Furthermore, the mass of the metal powder is M, the packing density of the metal powder is P, and the single-layer volume of the internal damaged area is V, which has the following relationship:

[0015] M=P×V,

[0016] P = m / v,

[0017] V=S×H,

[0018] Wherein, m is the mass of a certain amount of metal powder deposited in the measuring cylinder, v is the volume of a certain amount of metal powder deposited, S is the cross-sectional area of ​​the slice at the printing area, and H is the printing layer thickness;

[0019] Furthermore, the damaged area of ​​the damaged part is an inner area of ​​the part, and the inner damaged area is surrounded by metal.

[0020] Furthermore, the optical instrument scanning includes blue light scanning, structured light scanning and other optical instruments that can generate three-dimensional models.

[0021] After adopting the above technical solution, the beneficial effects of the present invention are:

[0022] 1. The device can adjust the amount of powder falling on the damaged area each time according to the three-mode model of the damaged area. At the same time, the powder pile in the damaged area can be evenly dispersed through vibration to achieve quantitative and accurate powder spreading on the damaged area;

[0023] 2. This method can realize the classified forming repair of the inside and outside of the damaged area, improve the repair accuracy and quality of the internal damaged area, and thus achieve high-precision and high-quality repair of damaged parts;

[0024] 3. The device and method achieve high-quality repair of damaged areas by introducing three-dimensional scanning, high-frequency and low-amplitude vibration mechanisms, and butterfly valve controllers that accurately control the quality of powder piles, promoting the development of repairing damaged parts through metal 3D printing and further promoting multi-region applications of metal 3D printing. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 Structural diagram of the repair and forming device for metal additive manufacturing parts;

[0026] Figure 2 This is the left view of the metal additive manufacturing part repair forming device;

[0027] Figure 3 Right view of the metal additive manufacturing part repair forming device;

[0028] Figure 4 Top view of the metal additive manufacturing part repair forming device;

[0029] Figure 5 for Figure 4 Screenshot at the middle AA;

[0030] Figure 6 for Figure 4 Screenshot from the middle BB;

[0031] Figure 7 A magnified image of the vibrating uniform powder layer in the metal additive manufacturing part repair forming device;

[0032] Figure 8 Schematic diagram of the distribution of micro vibrators in the metal additive manufacturing part repair forming device;

[0033] Fig. 9 Flow chart of the repair forming method for metal additive manufacturing parts;

[0034] Fig.10 It is a schematic diagram of the process of the metal additive manufacturing part repair forming method;

[0035] Fig.11 A flow chart for obtaining a three-mode model of the inner and outer damaged area in a metal additive manufacturing part repair forming method;

[0036] Description of the drawings: 101, support frame; 102, module one; 103, square bracket; 201, module two; 202, powder box; 203, funnel; 204, butterfly valve control 1; 205, butterfly valve controller two; 206, funnel bracket; 207, micro vibrator; 301, powder box forming chamber; 302, lifting system; 401, module three; 402, laser generator; 501, vibration plate; 502, damaged parts; 503, fixture set; 504, matrix probe; 505, support connecting plate; 506, micro vibration motor; 507, elastic connector. DETAILED DESCRIPTION

[0037] The present invention is further explained below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention. It should be noted that the words "front", "rear", "left", "right", "upper" and "lower" used in the following description refer to directions in the accompanying drawings, and the words "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0038] like Figure 1-8As shown, the metal additive manufacturing repair parts device of this embodiment, the metal additive manufacturing repair parts device, the device consists of a basic motion platform, a quantitative powder dropping mechanism, a powder box forming system, a laser melting mechanism and a vibration uniformity mechanism; the basic motion platform consists of a support frame 101, a square bracket 103 and a module 1 102, the module 1 102 is installed on the support frame 101, and the square frame is fixed on the module 1 102; the quantitative powder dropping mechanism consists of a module 2 201, a powder box 202, a funnel 203, a butterfly valve controller 1 204, a butterfly valve controller 2 205, a micro vibrator 207 and a funnel bracket 206, the powder box 202 is fixed on the square frame, the butterfly valve controller 1 204 and the butterfly valve controller 2 205 are fixed on the cylinder on the powder box 202; the module 2 201 is installed on the square frame, the funnel 203 is installed on the module 2 203, and the micro vibrator 207 is fixed on the funnel 203, through the high frequency Low-amplitude vibration causes the powder pile to fall on the damaged parts; the powder box forming system is composed of a powder box forming chamber 301 and a lifting system 302, the laser melting mechanism is composed of a module three 401 and a laser generator 402, the module three 401 is installed on a square frame, the laser generator 402 is fixed on the module three 401, and moves with the module three 401; the vibration uniformity mechanism is composed of a vibration plate 501, a damaged part 502, a fixture sleeve 503, a matrix probe 504, a support connecting plate 505, a micro vibration motor 506 and an elastic connector 507, the support connecting plate 505 is installed on the lifting system 302, four elastic connectors 507 are fixedly connected to the support connecting plate 505 and the vibration plate 501, the micro vibration motor 506 is fixed on the lower side of the vibration plate 501, the fixture sleeve 503 is fixed on the vibration plate 501, the matrix probe 504 is installed in the fixture sleeve 503, and the matrix probe is fixed to the damaged part by air pressure.

[0039] The butterfly valve controller 1 204 is above the butterfly valve controller 2 205, and the butterfly valve controller 1 204 and the butterfly valve controller 2 205 realize the control of the powder amount. The bottom opening diameter of the funnel 203 is 2mm, and the taper is greater than twice the natural accumulation angle of the powder. The butterfly valve controller 1 204 and the butterfly valve controller 2 205 are equipped with weight sensors, and the controller opens and closes after the powder accumulates a certain weight.

[0040] The micro vibrator 207 is a micro brushless motor with a vibration frequency of 1000 Hz and an amplitude of 0.2-0.4 mm; the micro vibration motor 506 has a vibration frequency of 1000 Hz and an amplitude of 0.5-1 mm. The control range of the matrix probe 504 is larger than the range of the damaged parts, and the front end of the matrix probe 504 adopts a silicone soft sleeve. The two ends of the elastic connector 507 are metal plates, and the middle is a metal spring.

[0041] A method for repairing parts by metal additive manufacturing, wherein the damaged parts are observed to determine whether they meet the requirements of metal 3D printing, and if they meet the requirements, the damaged areas inside the parts are scanned and an internal three-dimensional model is generated, and an external three-dimensional model is generated according to the external missing areas in the original three-mode model of the parts. The damaged parts are placed on a vibration plate, and the damaged parts are fixed using a matrix probe; metal powder is placed in a powder box, and the metal powder is controlled to fall on butterfly valve controller 2 by butterfly valve controller 1, and then a quantitative amount of metal powder is dropped on a funnel by butterfly valve controller 2, and the funnel is controlled to move above the damaged area of ​​the damaged parts by module 2, and a micro vibrator is turned on to make the metal powder fall on the damaged area inside the damaged parts. The micro vibration motor is started to evenly spread the powder in the damaged area, and a laser melting mechanism is used to perform regional melting according to the internal three-dimensional model slices, and the above steps are repeated until the internal printing of the damaged parts is completed; the outside of the damaged parts is filled with metal powder, and the external area of ​​the damaged parts is generated layer by layer by metal 3D printing until the overall repair of the damaged parts is completed.

[0042] Among them, the metal 3D printing requirement is that the internal cross-sectional area of ​​the damaged area is ≤ the internal cross-sectional area of ​​the previous layer, and the previous layer cannot block the area of ​​the next layer. If the area does not meet the requirements, the damaged area needs to be cut to meet the metal 3D printing requirements;

[0043] Wherein, the certain mass of metal powder is M, the packing density of the metal powder is P, and the single layer volume of the internal damaged area is V, which has the following relationship:

[0044] M=P×V,

[0045] P = m / v,

[0046] V=S×H,

[0047] m is the mass of a certain amount of metal powder deposited in the measuring cylinder, v is the volume of a certain amount of metal powder deposited, S is the cross-sectional area of ​​the slice at the printing area, and H is the printing layer thickness;

[0048] Wherein, the damaged area of ​​the damaged part is the inner area of ​​the part, and the inner damaged area is surrounded by metal;

[0049] The optical instrument scanning includes blue light scanning, structured light scanning and other optical instruments that can generate three-dimensional models.

[0050] The damaged parts were successfully repaired through the above-mentioned devices and methods, and the performance met the use requirements of the parts, but further finishing and surface treatment were still needed to improve the overall accuracy and strength.

[0051] The technical means disclosed in the scheme of the present invention are not limited to the technical means disclosed in the above-mentioned implementation mode, but also include technical schemes composed of any combination of the above technical features.

Claims

1. A metal additive manufacturing device for repairing parts, characterized in that: The device is composed of a basic motion platform, a quantitative powder dropping mechanism, a powder box forming system, a laser melting mechanism and a vibration uniformity mechanism; the basic motion platform is composed of a support frame (101), a module one (102) and a square bracket (103), the module one (102) is installed on the support frame (101), and the square bracket (103) is fixed on the module one (102); the quantitative powder dropping mechanism is composed of a module two (201), a powder box (202), a funnel (203), a butterfly valve controller one (204), a butterfly valve The invention is composed of a controller 2 (205), a micro vibrator (207) and a funnel bracket (206); a powder box (202) is fixed on a square frame; a butterfly valve controller 1 (204) and a butterfly valve controller 2 (205) are fixed on a cylinder on the powder box (202); a module 2 (201) is installed on the square frame; a funnel (203) is installed on the module 2 (203); a micro vibrator (207) is fixed on the funnel (203); and powder is deposited on the damaged parts through high-frequency and low-amplitude vibration; the powder box The forming system is composed of a powder box forming chamber (301) and a lifting system (302); the laser melting mechanism is composed of a module three (401) and a laser generator (402); the module three (401) is installed on a square frame; the laser generator (402) is fixed on the module three (401) and moves with the module three (401); the vibration uniformity mechanism is composed of a vibration plate (501), a damaged part (502), a fixture sleeve (503), a matrix probe (504), a supporting connecting plate (505), a micro vibration The micro vibration motor (506) is composed of a dynamic motor (506) and an elastic connector (507), a supporting connecting plate (505) is installed on the lifting system (302), four elastic connectors (507) are fixedly connected to the supporting connecting plate (505) and the vibration plate (501), the micro vibration motor (506) is fixed on the lower side of the vibration plate (501), the clamp sleeve (503) is fixed on the vibration plate (501), the matrix probe (504) is installed in the clamp sleeve (503), and the matrix probe is fixed to the damaged parts by air pressure.

2. The metal additive manufacturing repair parts device according to claim 1, characterized in that: The butterfly valve controller 1 (204) is above the butterfly valve controller 2 (205), and the butterfly valve controller 1 (204) and the butterfly valve controller 2 (205) realize the control of the powder amount.

3. The metal additive manufacturing repair parts device according to claim 1, characterized in that: The bottom opening diameter of the funnel (203) is 2 mm, and the taper is greater than twice the natural accumulation angle of the powder.

4. The metal additive manufacturing repair parts device according to claim 1, characterized in that: The butterfly valve controller 1 (204) and the butterfly valve controller 2 (205) are equipped with weight sensors, and the controller opens and then closes when a certain weight of powder is accumulated.

5. The metal additive manufacturing repair parts device according to claim 1, characterized in that: The micro vibrator (207) is a micro brushless motor with a vibration frequency of 1000 Hz and an amplitude of 0.2 to 0.4 mm; the micro vibration motor (506) has a vibration frequency of 1000 Hz and an amplitude of 0.5 to 1 mm.

6. The metal additive manufacturing repair parts device according to claim 1, characterized in that: The control range of the matrix probe (504) is larger than the range of the damaged parts, and the front end of the matrix probe (504) adopts a silicone soft sleeve.

7. The metal additive manufacturing repair parts device according to claim 1, characterized in that: The two ends of the elastic connector (507) are metal plates, and the middle is a metal spring.

8. A method for repairing parts by metal additive manufacturing, characterized in that: Observe the damaged parts to see if they meet the requirements for metal 3D printing, including the following steps: Step 1: Scan the damaged area inside the component if necessary and generate an internal 3D model. At the same time, generate an external 3D model based on the external missing area in the original three-mode model of the part. Step 2: Place the damaged part on the vibration plate and use the matrix probe to fix the damaged part; Step 3: Put metal powder in the powder box, control the metal powder to fall on butterfly valve controller 2 through butterfly valve controller 1, and then use butterfly valve controller 2 to realize the quantitative metal powder falling on the funnel, use module 2 to control the funnel to move above the damaged area of ​​the damaged part, and turn on the micro vibrator to make the metal powder fall on the damaged area inside the damaged part. Step 4: Start the micro-vibration motor to evenly spread the powder in the damaged area, use the laser melting mechanism to melt the area according to the internal 3D model slices, and repeat the above steps until the internal printing of the damaged part is completed; Step 5: Fill the outside of the damaged part with metal powder, and use metal 3D printing to generate the outer area of ​​the damaged part layer by layer until the entire damaged part is repaired.

9. The metal additive manufacturing method for repairing parts according to claim 8, characterized in that: The metal 3D printing requirement is that the internal cross-sectional area of ​​the damaged area is ≤ the internal cross-sectional area of ​​the previous layer, and the previous layer cannot block the area of ​​the next layer. The non-compliant area needs to be cut in the damaged area to meet the metal 3D printing requirements; the damaged area of ​​the damaged part is the inner area of ​​the part, and the internal damaged area is surrounded by metal; the optical instrument scanning includes blue light scanning, structured light scanning and other optical instruments that can generate three-dimensional models.

10. The metal additive manufacturing method for repairing parts according to claim 7, characterized in that: The mass of the metal powder is M, the packing density of the metal powder is P, and the single-layer volume of the internal damaged area is V, which has the following relationship: M=P×V, P=m / v, V=S×H, Among them, m is the mass of a certain amount of metal powder deposited in the measuring cylinder, v is the volume of a certain amount of metal powder deposited, S is the cross-sectional area of ​​the slice at the printing area, and H is the printing layer thickness.

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