Array laser additive-measurement-subtractive multi-field synergistic composite manufacturing system

Abstract

The application provides an array laser additive-subtractive-multiphase synergistic composite manufacturing system, which comprises a forming chamber, a forming cylinder, a powder supply cylinder, a powder laying mechanism, a cooling system and an atmosphere system, and further comprises: an array laser area printing module for performing multi-laser partition scanning sintering forming; a defect detection image field module for monitoring defects of each layer of the sintering forming, identifying defect types and defect positions; and a femtosecond laser defect removal subtractive module capable of scanning a femtosecond laser beam at the defect positions through a subtractive scanning galvanometer according to the defects, the defect types and the defect positions detected by the defect detection image field module, and removing the defects in situ according to the defect types, so as to realize integrated integration of laser additive manufacturing, defect detection and defect subtractive removal, and realize high-efficiency and high-quality component manufacturing.

Description

Technical Field

[0001] This invention relates to the field of laser additive manufacturing technology, and more specifically to an array laser augmentation-measurement-subtraction multi-field collaborative composite manufacturing system. Background Technology

[0002] Laser additive manufacturing often suffers from various manufacturing problems such as metallurgical defects and poor forming quality, affecting the structural performance of components. Integrating laser additive manufacturing, defect detection, and defect removal functions to achieve online closed-loop defect removal can improve the forming quality of components. Developing integrated equipment with regional printing, online monitoring, and defect subtraction capabilities, along with the coordinated control of additive and subtractive processes, to achieve integrated intelligent control of the entire manufacturing process, is an important guarantee for the high-quality and efficient printing of key components. Summary of the Invention

[0003] In view of the defects and shortcomings of existing additive and subtractive composite manufacturing systems, the purpose of this invention is to provide a composite manufacturing system that integrates regional additive manufacturing, online inspection, and femtosecond defect removal, realizing the integrated management of laser additive manufacturing, defect detection, and defect subtractive removal, and the coordination and control of additive and subtractive processes, providing a reliable implementation plan for high-efficiency regional printing, online defect detection, and closed-loop in-situ repair.

[0004] According to a first aspect of the present invention, an array laser augmentation-measurement-subtraction multi-field collaborative composite manufacturing system is provided, comprising a forming chamber, a forming cylinder, a powder supply cylinder, a powder spreading mechanism, and an atmosphere system, characterized in that it further comprises:

[0005] The array laser area printing module has an array laser scanning optical system consisting of an additive laser and an additive scanning galvanometer. It is installed above the forming chamber and uses the additive scanning galvanometer to scan the laser beam in sections within the forming chamber to sinter the powder spread on the sintering area of ​​the substrate surface in the forming cylinder.

[0006] The defect detection image field module has four cameras, which are respectively set in the molding chamber and located at the four upper corners. It is used to monitor defects in each layer of the sintering process and identify the defect type and defect location.

[0007] The femtosecond laser defect removal subtractive module has a femtosecond laser optical system consisting of a femtosecond laser and a subtractive scanning galvanometer. It is installed above the forming chamber. Based on the defects detected by the defect detection image field module, as well as the defect type and defect location, the femtosecond laser beam is scanned at the defect location through the subtractive scanning galvanometer, and in-situ defect removal is performed according to the defect type.

[0008] The array laser area printing module adopts a galvanometer splicing method, splicing together additive scanning galvanometers distributed in a 3*2 array. The sintering of each layer adopts a spliced ​​partitioned scanning method, and six laser beams are used for partitioned scanning to sinter powder into shape.

[0009] The femtosecond laser beam emitted by the femtosecond laser of the femtosecond laser defect removal subtractive module enters the subtractive scanning galvanometer through the coupling optical path, and the middle pair of additive scanning galvanometers distributed in the 3*2 array constitute the subtractive scanning galvanometer, realizing the reuse of the scanning galvanometer.

[0010] As an optional embodiment, in the array laser scanning optical system, the size of the overlapping area of ​​the six laser beams scanning in the partition is adjustable.

[0011] As an optional embodiment, the overlap range of each layer during sintering is adjustable within the overlap area.

[0012] As an optional embodiment, the laser beams output by six additive scanning galvanometers arranged in a 3*2 grid form a laser spot on the substrate surface that fully covers the entire sintering area.

[0013] As an optional embodiment, the intermediate pair of additive scanning galvanometers multiplexed by the femtosecond laser and the additive laser is used by only one laser in area additive processing or femtosecond defect removal.

[0014] As an optional embodiment, the additive laser of the array laser area printing module includes two first lasers and six second lasers, and the coupling optical path includes a first coupling optical path and a second coupling optical path; the power of the first laser is greater than the power of the second laser;

[0015] The two first lasers are coupled to a pair of additive scanning galvanometers in the middle of a 3*2 array via a first coupling optical path and a second coupling optical path, respectively, forming two fast scanning filling optical paths.

[0016] The six second lasers are respectively connected to additive scanning mirrors distributed in a 3*2 array through shaping optical paths, forming six fine scanning optical paths for regional contours.

[0017] As an optional embodiment, the femtosecond laser defect removal subtractive module includes two femtosecond lasers. The laser beams emitted by the two femtosecond lasers are coupled to a pair of additive scanning galvanometers in the middle of a 3*2 array through a first coupling optical path and a second coupling optical path, respectively, to form two femtosecond laser defect removal optical paths.

[0018] As an optional embodiment, the image fields of the four cameras provide full coverage of the interior of the forming chamber, enabling scanning imaging of each layer located in the additive and subtractive processing areas to monitor the printing quality of each layer.

[0019] As an optional embodiment, based on the defects detected by the defect detection image field module, as well as the defect type and location, a femtosecond laser beam is scanned at the defect location using a subtractive scanning galvanometer, and in-situ defect removal processing is performed according to the defect type, including:

[0020] For defects and their locations identified by imaging at any layer, based on the identified defect type, a femtosecond laser beam is scanned at the defect location using a subtractive scanning galvanometer to perform in-situ defect removal. Specifically:

[0021] If the defect is identified as a protrusion / bulge type defect, the protrusion / bulge is removed by femtosecond laser beam, and imaging detection is performed again after the defect removal process, so that the protrusion / bulge type defect is effectively removed.

[0022] If the defect is identified as a concave defect, it is repaired by a femtosecond laser beam. This includes smoothing the transition of a predetermined area around the concave defect and re-scanning and sintering the concave defect area. After the defect repair is completed, imaging is performed again to ensure that the concave defect is effectively repaired.

[0023] As an optional embodiment, the criterion for effectively removing the protrusion / bulge defect is: the size of the protrusion / bulge location is less than a set size threshold.

[0024] The criterion for determining whether a concave defect has been effectively repaired is that the curvature change at the edge of the concave location is less than a set curvature threshold.

[0025] The array laser area printing module of the present invention adopts an array design, such as a 3*2 distribution, with the six scanning galvanometers divided in terms of function and layout:

[0026] Two of the scanning mirrors are connected to a high-power laser to form a filling optical path, which is used for rapid scanning and filling of large areas.

[0027] The six scanning galvanometers are connected to the six low-power lasers through corresponding shaping optical paths, forming six laser beams for zoned scanning, which is used for fine scanning of the region contour.

[0028] The two scanning galvanometers arranged in the middle are multiplexed scanning lenses, which are connected to two femtosecond lasers respectively through the coupling optical paths on both sides (the first coupling optical path and the second coupling optical path) for in-situ removal of defects.

[0029] This design not only improves printing accuracy but also significantly enhances printing efficiency.

[0030] The array laser additive-detection-subtractive multi-field collaborative composite manufacturing system of the present invention integrates the forming chamber, forming cylinder, powder supply cylinder, powder spreading mechanism, cooling system, and atmosphere system with the array laser area printing module, defect detection image field module, and femtosecond laser defect removal subtractive module, realizing modular collaborative manufacturing of area additive / defect detection / defect removal subtractive, improving the flexibility of the equipment, and enabling each module to respond and switch quickly as needed, thereby improving manufacturing efficiency.

[0031] It should be understood that all combinations of the foregoing concepts and the additional concepts described in more detail below may be considered part of the inventive subject matter of this disclosure, provided that such concepts do not contradict each other. Furthermore, all combinations of the claimed subject matter are considered part of the inventive subject matter of this disclosure.

[0032] The foregoing and other aspects, embodiments, and features of the teachings of the present invention will be more fully understood from the following description in conjunction with the accompanying drawings. Other additional aspects of the invention, such as features and / or beneficial effects of exemplary embodiments, will become apparent from the following description or may be learned through practice of specific embodiments according to the teachings of the present invention. Attached Figure Description

[0033] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component shown in the various figures may be denoted by the same reference numeral. For clarity, not every component is labeled in each figure. Embodiments of various aspects of the invention will now be described by way of example and with reference to the accompanying drawings.

[0034] Figure 1 This is an overall schematic diagram of an array laser augmentation-measurement-subtraction multi-field collaborative composite manufacturing system according to an embodiment of the present invention.

[0035] Figure 2 This is a schematic diagram of the array layout of the array laser area printing module according to an embodiment of the present invention.

[0036] Figure 3 This is a top view of the array layout of the array laser area printing module according to an embodiment of the present invention.

[0037] Figure 4 This is a schematic diagram of the region printing optics of the array laser region printing module according to an embodiment of the present invention.

[0038] Figure 5 This is a schematic diagram of the six laser beams scanning coverage area of ​​the array laser area printing module according to an embodiment of the present invention. Detailed Implementation

[0039] To better understand the technical content of the present invention, specific embodiments are described below in conjunction with the accompanying drawings.

[0040] Various aspects of the invention are described in this disclosure with reference to the accompanying drawings, which illustrate numerous illustrative embodiments. The embodiments of this disclosure are not necessarily intended to encompass all aspects of the invention. It should be understood that the various concepts and embodiments described above, as well as those described in more detail below, can be implemented in any of many ways, because the concepts and embodiments disclosed herein are not limited to any particular implementation. Furthermore, some aspects of the invention disclosed may be used alone or in any suitable combination with other aspects of the invention disclosed.

[0041] {Example 1}

[0042] Combination Figures 1-4 As shown, the array laser additive-measuring-subtracting multi-field collaborative composite manufacturing system according to an embodiment of the present invention includes a forming chamber, a forming cylinder, a powder supply cylinder, a powder spreading mechanism, a cooling system, and an atmosphere system. The powder spreading mechanism is located in the forming chamber. The powder supply cylinder supplies additive printing powder to the forming cylinder, and the powder spreading mechanism spreads the powder evenly onto the substrate surface of the forming cylinder.

[0043] It should be understood that the forming chamber, forming cylinder, powder supply cylinder, and powder spreading mechanism are mounted on the main frame to form the main unit of the equipment. The main unit of the equipment is also equipped with an optical path system located above the forming chamber, an atmosphere system connected to the air path of the forming chamber, a water cooling system for heat dissipation, a powder supply system for supplying powder, a mounting bracket for placing laser components, and an electrical control cabinet, etc., which can be implemented using existing commercial modules.

[0044] In the embodiments of the present invention, the above-mentioned main equipment and its supporting modules such as forming chamber, forming cylinder, powder supply cylinder, powder spreading mechanism, atmosphere system, water cooling system, powder supply system, mounting frame and electrical control cabinet can be designed and configured using existing powder spreading additive manufacturing methods.

[0045] In the multi-field collaborative composite manufacturing system design of the embodiments of the present invention, an array laser area printing module, a defect detection image field module, and a femtosecond laser defect removal subtractive material module are also included. As the main processing modules, they are used to realize the sintering and forming of powder, defect detection of the printed layer, and in-situ removal of defects using femtosecond lasers, respectively. This realizes the collaborative control of additive and subtractive material processing technology and defect detection, and achieves high-efficiency, high-quality area printing, online defect detection and closed-loop in-situ repair integrated intelligent component manufacturing.

[0046] As an optional embodiment, combined with Figure 2-4As shown, the array laser area printing module has an array laser scanning optical system consisting of an additive laser and an additive scanning galvanometer, which is installed above the forming chamber. The laser beam is scanned in sections within the forming chamber by the additive scanning galvanometer to sinter the powder spread on the sintering area of ​​the substrate surface in the forming cylinder.

[0047] In embodiments of the present invention, the powder spreading system is designed to spread powder in one or two directions, is compatible with rigid and soft scrapers, and can use a bottom-up powder spreading method to ensure uniform and stable powder supply.

[0048] For each layer of the sintering printing process, after receiving the printing control command, the powder supply cylinder supplies powder to the substrate surface of the forming cylinder according to the preset amount of powder required for each layer of printing. The powder spreading mechanism spreads the powder evenly on the substrate surface of the forming cylinder in one or two directions. Then, the array laser area printing module performs multi-laser partition scanning and sintering.

[0049] In embodiments of the present invention, such as Figure 2-4 As shown, the array laser area printing module adopts a galvanometer splicing and partitioned scanning method, splicing together additive scanning galvanometers distributed in a 3*2 array. The sintering of each layer is done in a spliced ​​manner, with six laser beams performing partitioned scanning for powder sintering. Thus, the laser beams output from the six additive scanning galvanometers, distributed in a 3*2 array, form laser spots on the substrate surface that fully cover the entire sintering area.

[0050] The defect detection imaging module has four cameras, which are located inside the molding chamber and at the four upper corners. They are used to monitor defects in each layer of the sintered molding process and identify the type and location of defects.

[0051] The image fields of the four cameras provide full coverage of the interior of the forming chamber, enabling scanning and imaging of each layer in the additive and subtractive processing areas to monitor the printing quality of each layer.

[0052] In conjunction with the aforementioned sintering and printing process, after each layer is sintered, real-time imaging and defect detection are performed using a defect detection imaging field module. In an optional embodiment, the defect detection imaging field module detects and identifies defects on the surface of each layer based on computer vision detection algorithms, including protrusion / bulge defects and depression defects.

[0053] As an optional embodiment, for each surface layer of the sintered printing, different intensities and directions of reflected light will be generated depending on the shape and reflective properties of the surface. For example, the reflection of light differs between smooth surfaces and defective surfaces (such as protrusions and depressions), providing a basis for defect identification.

[0054] For raised / bulging defects and recessed defects, they exhibit different visual characteristics in images. Raised / bulging defects appear as increased height in a localized area, contrasting with the surrounding normal printed surface, such as bright spots or areas (because the angle of light reflection on the raised portion may differ, leading to brightness variations). Recessed defects, conversely, appear as dark spots or areas in the image. This is due to the changed angle of light reflection in the recessed portion, resulting in reduced reflected light, and also exhibiting a certain change in surface curvature. These features, including brightness, texture, and shape, are extracted to identify and extract the defects.

[0055] As an optional embodiment, the defect detection algorithm used in this invention can be implemented using existing algorithms. For example, based on images captured by a camera, gradient operators and neural network models can be used to extract image feature information (such as edge features, shape features, etc.), and the feature information can be used to judge and identify defects. For example, a threshold-based method can be used, which can determine whether a defect exists based on pre-set grayscale thresholds, shape parameter thresholds, etc. For example, when the grayscale value of a certain area is higher than the grayscale value of the normal surface by a certain degree and the area reaches a certain size, it is judged as a bulge / bump type defect; when the grayscale value is lower than the normal surface and meets the shape characteristics of a depression, it is judged as a depression type defect. At the same time, based on the feature information, quantitative indicators such as the size, depth, or height of the defect area can be further determined.

[0056] In another embodiment, machine learning algorithms can be used to input the extracted feature vectors into a trained defect recognition network model. The defect recognition network model classifies the defects based on the learned patterns and outputs the type of defect (protrusion / bulge or depression) and the degree of defect (quantitative indicators such as the size, depth or height of the defect area).

[0057] Defect location identification can be achieved using coordinate positioning methods. By combining the relationship between the two-dimensional coordinate system of the printed layer surface and the actual size of the printed layer surface with the position of the defect in the image pixel coordinate system, the actual physical location of the defect on the printed layer surface can be determined.

[0058] As an optional example, the defect location identification process based on coordinate localization includes:

[0059] First, during the image acquisition stage, a two-dimensional coordinate system is established for the surface of the printed layer. For example, the origin can be a fixed point on the substrate (such as a corner), and the system is determined by the mapping relationship between the camera imaging principle and the actual position of the printed layer. For example, there is a certain proportional relationship between the pixel coordinates of the camera and the actual physical size of the printed layer. Assuming that the pixel resolution of the camera is m*n and the actual size of the printed layer is x*y, the actual length and width corresponding to each pixel can be calculated accordingly.

[0060] Then, for defects identified from the image, their actual physical location on the printing layer surface can be calculated based on their position in the image pixel coordinate system using the aforementioned proportional relationship. For example, if the defect's pixel coordinates in the image are (i,j), and each pixel corresponds to an actual length of a and a width of b, then the actual position coordinates of the defect on the printing layer surface are (a*i,b*j).

[0061] In another embodiment, defect location identification can also be based on feature point localization methods or deep learning network models for detection output.

[0062] In an embodiment of the present invention, the femtosecond laser defect removal subtractive module has a femtosecond laser optical system consisting of a femtosecond laser and a subtractive scanning galvanometer, which is installed above the forming chamber. Based on the defects detected by the defect detection image field module, as well as the defect type and defect location, the femtosecond laser beam is scanned at the defect location by the subtractive scanning galvanometer, and in-situ defect removal processing is performed according to the defect type.

[0063] Combination Figure 2-4 As shown, the femtosecond laser beam emitted by the femtosecond laser of the femtosecond laser defect removal subtractive module enters the subtractive scanning galvanometer through the coupling optical path, and the middle pair of additive scanning galvanometers distributed in the 3*2 array constitute the subtractive scanning galvanometer, realizing the reuse of the scanning galvanometer.

[0064] In an embodiment of the present invention, for defects and defect locations identified by imaging of any layer, the femtosecond laser defect removal subtractive processing module scans the femtosecond laser beam at the defect location using a subtractive scanning galvanometer to achieve in-situ removal of defects based on the identified defect type.

[0065] After the subtractive machining process, in-situ removal of defects, is completed and passes inspection, the forming cylinder is moved down one layer according to the additive manufacturing slab model, and the powder-spreading and printing process is carried out again.

[0066] As an optional embodiment, in the array laser scanning optical system, the overlap area size of the six laser beams scanning in zones is adjustable. For the sintering of each layer, the overlap range is adjustable within the overlap area.

[0067] Combination Figure 2-4 As shown, the additive laser of the array laser area printing module includes two first lasers and six second lasers, and the coupling optical path includes a first coupling optical path and a second coupling optical path; the power of the first laser is greater than the power of the second laser;

[0068] The two first lasers are coupled to a pair of additive scanning galvanometers in the middle of a 3*2 array via a first coupling optical path and a second coupling optical path, respectively, forming two fast scanning filling optical paths.

[0069] The six second lasers are respectively connected to additive scanning mirrors distributed in a 3*2 array through their respective shaping optical paths, forming six fine scanning optical paths for regional contours.

[0070] It should be understood that the aforementioned shaping optical path is used to perform beam shaping processing on the laser beam fed through the optical fiber, including, for example, collimation, beam expansion, and beam homogenization of the laser beam, outputting a collimated laser beam with a uniform intensity distribution, which is coupled to the corresponding additive scanning galvanometer. The additive scanning galvanometer performs beam deflection scanning to achieve powder sintering. The shaping optical path design can be implemented using existing optical path designs, but is not limited to shaping and adjusting the spot size, morphology, and intensity distribution of the laser beam.

[0071] Combination Figure 2-4 As shown, as an optional embodiment, the femtosecond laser defect removal subtractive module includes two femtosecond lasers. The laser beams emitted by the two femtosecond lasers are coupled to a pair of additive scanning galvanometers in the middle of a 3*2 array (entering through their corresponding shaping optical paths) via a first coupling optical path and a second coupling optical path, respectively, thus forming two femtosecond laser defect removal optical paths.

[0072] It should be understood that in the design of this invention, the intermediate pair of additive scanning galvanometers, which are multiplexed by a femtosecond laser and an additive laser, are used by only one laser in regional additive processing or femtosecond defect removal.

[0073] As shown in the accompanying drawings, the array laser area printing module of the present invention adopts an array design, for example, six scanning lenses distributed in a 3*2 pattern. The six scanning galvanometers are divided in terms of function and layout:

[0074] The two scanning mirrors in the middle are connected to a high-power laser through the first / second coupling optical path to form a filling optical path for rapid scanning and filling of large areas;

[0075] The six scanning galvanometers are connected to the six low-power lasers through corresponding shaping optical paths, forming six laser beams for zoned scanning, which is used for fine scanning of the region contour.

[0076] The two scanning galvanometers arranged in the middle form a multiplexed scanning galvanometer, which is connected to two femtosecond lasers respectively through the coupling optical paths on both sides (the first coupling optical path and the second coupling optical path) for in-situ removal of defects.

[0077] Combination Figure 3 , Figure 4 , Figure 5 As shown, examples are provided for filling optical paths, contouring optical paths (used for fine scanning of region contours), and femtosecond subtractive optical paths (used for in-situ removal of defects).

[0078] Femtosecond subtractive optical path:

[0079] Femtosecond subtractive optical path 1: Femtosecond laser A → Coupled optical path AC → Common dynamic focusing AC;

[0080] Femtosecond subtractive optical path 2: Femtosecond laser B → Coupled optical path BD → Common dynamic focusing BD.

[0081] Fill the optical path:

[0082] Filling optical path 1: AM laser C (high power, such as 3000W) → Coupled optical path AC → Common dynamic focusing AC;

[0083] Filling optical path 2: AM laser D (high power, such as 3000W) → Coupled optical path BD → Common dynamic focusing BD.

[0084] Outline the light path:

[0085] Outline optical path 1: AM laser E (low power, such as 500W) → single-mode dynamic focus E;

[0086] Outline optical path 2: AM laser F (low power, such as 500W) → single-mode dynamic focusing F;

[0087] Outline optical path 3: AM laser G (low power, such as 500W) → single-mode dynamic focusing G;

[0088] Outline optical path 4: AM laser H (low power, such as 500W) → single-mode dynamic focusing H;

[0089] Outline optical path 5: AM laser P (low power, such as 500W) → Coupled optical path AC → Common dynamic focusing AC;

[0090] Outline optical path 6: AM laser Q (low power, such as 500W) → Coupled optical path BD → Common dynamic focusing BD.

[0091] Therefore, the first and second coupling optical paths, which are symmetrically arranged on the two sides of the scanning galvanometers in the 3*2 array, both adopt a three-in-one-out optical path design.

[0092] The first coupled optical path receives laser beam inputs from femtosecond laser A and two additive lasers (i.e., high-power AM laser C and low-power AM laser P), and outputs to the common dynamic focusing AC (i.e., the combined optical path of shaping optical path + scanning galvanometer).

[0093] The second coupling optical path receives laser beam inputs from the femtosecond laser B and two additive lasers (i.e., high-power AM laser D and low-power AM laser Q), and outputs to the common dynamic focusing BD (i.e., the combined optical path of the shaping optical path and the scanning galvanometer).

[0094] Furthermore, for the first coupled optical path / second coupled optical path, optical path switching and coupling output are realized within it, allowing one path to be coupled and output at any time.

[0095] As an optional embodiment, two femtosecond lasers, two high-power lasers, and six low-power lasers can be installed in the mounting bracket of the laser assembly and connected to each other via optical fibers to guide the laser beam into the optical path system above the forming chamber.

[0096] like Figure 2 , Figure 3 In the example shown, through the optimized distribution of the workspace array, two femtosecond lasers are installed on the top of the molding chamber, and two other high-power lasers and six low-power lasers are installed in the mounting frame, each connected by optical fiber.

[0097] As an optional embodiment, based on the defects detected by the defect detection image field module, as well as the defect type and location, a femtosecond laser beam is scanned at the defect location using a subtractive scanning galvanometer, and in-situ defect removal processing is performed according to the defect type, including:

[0098] For defects and their locations identified by imaging at any layer, based on the identified defect type, a femtosecond laser beam is scanned at the defect location using a subtractive scanning galvanometer to perform in-situ defect removal. Specifically:

[0099] If the defect is identified as a protrusion / bulge type defect, the protrusion / bulge is removed by femtosecond laser beam, and imaging detection is performed again after the defect removal process, so that the protrusion / bulge type defect is effectively removed.

[0100] If the defect is identified as a concave defect, it is repaired by a femtosecond laser beam. This includes smoothing the transition of a predetermined area around the concave defect and re-scanning and sintering the concave defect area. After the defect repair is completed, imaging is performed again to ensure that the concave defect is effectively repaired.

[0101] As an optional embodiment, the criterion for effectively removing the protrusion / bulge defect is: the size of the protrusion / bulge location is less than a set size threshold.

[0102] The criterion for determining whether a concave defect has been effectively repaired is that the curvature change at the edge of the concave location is less than a set curvature threshold.

[0103] The array laser augmentation-measurement-subtraction multi-field collaborative composite manufacturing system described in the above embodiments of the present invention employs high-precision scanning galvanometers and six-mirror splicing technology to achieve full coverage of the entire sintering area by the laser spot. Each sintering layer is spliced, with six lasers performing zoned scanning, and the overlap area size is adjustable, achieving high-precision and high-efficiency sintering. Each sintered layer is monitored in real time by multiple cameras to identify potential defects, their types, and locations. Defects are then efficiently removed and repaired by coupling femtosecond lasers to multiplexed scanning galvanometers. Closed-loop control through online defect detection and in-situ femtosecond laser defect removal improves the quality of the sintered layer.

[0104] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Those skilled in the art can make various modifications and refinements without departing from the spirit and scope of the invention. Therefore, the scope of protection of the present invention shall be determined by the claims.

Claims

1. An array laser additive-subtractive-measure multi-field synergic hybrid manufacturing system, comprising a forming chamber, a forming cylinder, a powder supply cylinder, a powder laying mechanism and an atmosphere system, characterized in that, Also include: Array laser area printing module, with array laser scanning optical system composed of additive laser, additive scanning galvanometer, installed above the forming chamber, through the additive scanning galvanometer to scan the laser beam in the forming chamber, sintering the powder laid in the sintering area of the substrate surface of the forming cylinder; Defect detection image field module, with four cameras, respectively set in the forming chamber, and located in the four upper corner positions, for monitoring the defects of each layer of sintering forming, identifying the defect type and defect position; Femtosecond laser defect removal subtractive module, with femtosecond laser optical system composed of femtosecond laser and subtractive scanning galvanometer, installed above the forming chamber, according to the defects and defect types and defect positions detected by the defect detection image field module, the femtosecond laser beam is scanned at the defect position by the subtractive scanning galvanometer, and the in situ defect removal treatment is carried out according to the defect type; Wherein, the array laser area printing module adopts galvanometer splicing method, and the 3*2 array distributed additive scanning galvanometer is spliced, and the sintering of each layer adopts splicing type partition scanning, and six laser beams are used for partition scanning to sinter the powder; The femtosecond laser beam emitted by the femtosecond laser of the femtosecond laser defect removal subtractive module enters the subtractive scanning galvanometer through the coupling light path, and the middle pair of additive scanning galvanometers in the 3*2 array distribution constitutes the subtractive scanning galvanometer, realizing the multiplexing of scanning galvanometer; The additive laser of the array laser area printing module includes two first lasers and six second lasers, and the coupling light path includes first coupling light path and second coupling light path; The power of the first laser is greater than that of the second laser; The two first lasers respectively couple the laser beams emitted by the first laser to the middle pair of additive scanning galvanometers in the 3*2 array distribution through the first coupling light path and the second coupling light path, respectively, to constitute two fast scanning filling light paths; The six second lasers correspond to the 3*2 array distributed additive scanning galvanometers through the shaping light path respectively, to constitute six regional contour fine scanning light paths.

2. The array laser additive-subtractive-metrology multi-field synergic composite manufacturing system according to claim 1, wherein, In the array laser scanning optical system, the size of the overlap area of the six laser beams partition scanning is adjustable.

3. The array laser additive-subtractive-metrology multi-field synergic composite manufacturing system according to claim 2, wherein, For the sintering of each layer, the overlap range in the overlap area is adjustable.

4. The array laser additive-subtractive-metrology multi-field synergic composite manufacturing system of claim 1, wherein, The laser beams output by the six additive scanning galvanometers in the 3*2 splicing distribution fully cover the laser spots formed on the substrate surface.

5. The array laser additive-subtractive-metrology multi-field synergic composite manufacturing system of claim 1, wherein, The middle pair of additive scanning galvanometers multiplexed by the femtosecond laser and the additive laser are only used by one laser in the regional additive processing or femtosecond flaw removal.

6. The array laser additive-subtractive-metrology multi-field synergic composite manufacturing system of claim 1, wherein, The femtosecond laser defect removal subtractive module includes two femtosecond lasers, which respectively couple the laser beams emitted by the femtosecond laser to the middle pair of additive scanning galvanometers in the 3*2 array distribution through the first coupling light path and the second coupling light path, to constitute two femtosecond laser defect removal light paths.

7. The array laser additive-subtractive-metrology multi-field synergic composite manufacturing system of claim 1, wherein, The image field of the four cameras fully covers the inside of the forming chamber to realize scanning imaging of each layer in the additive processing area and the subtractive processing area, and monitor the printing quality of each layer.

8. The array laser additive-subtractive-metrology multi-field synergic composite manufacturing system of claim 1, wherein, According to the defects detected by the defect detection image field module and the defect type and defect position, the femtosecond laser beam is scanned at the defect position by subtractive scanning galvanometer, and in-situ defect removal processing is performed according to the defect type, including: For the defects and defect positions identified by imaging of any layer, the femtosecond laser beam is scanned at the defect position by subtractive scanning galvanometer according to the identified defect type, and in-situ defect removal processing is performed, wherein: If the identified defect is a protrusion / bulge type defect, protrusion / bulge removal processing is performed by the femtosecond laser beam, and imaging detection is performed again after the defect removal processing, so that the protrusion / bulge type defect is effectively removed; If the identified defect is a recess type defect, repair processing is performed by the femtosecond laser beam, including smooth transition processing of a predetermined area around the recess type defect and rescan sintering of the recess type defect area, and imaging detection is performed again after the defect repair processing, so that the recess type defect is effectively repaired.

9. The array laser additive-subtractive-metrology multi-field synergic composite manufacturing system according to claim 8, wherein, The judgment criterion for the protrusion / bulge type defect to be effectively removed is that the size of the protrusion / bulge position is less than a set size threshold; The judgment criterion for the recess type defect to be effectively repaired is that the curvature change of the edge of the recess position is less than a set curvature threshold.

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