Complex curved surface welding repair method based on multi-source ultrasonic action

Abstract

The invention discloses a complex curved surface welding repair method based on multi-source ultrasonic action, and belongs to the field of repair and remanufacturing. The problems that in the existing repair process of a large component with a complex curved surface, due to the fact that large heat input is adopted, the structure of a repair area is coarse, large residual stress and deformation are generated around the repair area, meanwhile, performance of base metal near a repair interface is weakened due to heat influence, and even secondary cracks are generated are solved. The method comprises the following steps: 1, defect pretreatment; 2, preparing equipment; 3, welding repair; and fourthly, repairing is completed. In the repairing process of the method, high-frequency pulsed arc self-excitation ultrasound is adopted to improve the physical property of a melt, an external ultrasonic energy field is combined, the fusing process of a repairing area is cooperatively optimized, and the structure performance of the repairing area is regulated and controlled. The method is used for complex curved surface welding repair based on the multi-source ultrasonic action.

Description

Technical Field

[0001] The invention belongs to the field of repair and remanufacturing. Background Art

[0002] During the use of large metal components, local cracking, wear and even fracture often occur due to original manufacturing defects or special service conditions, which become potential or direct factors for the overall failure of the components. Given the high cost of replacing large components as a whole, it is particularly important to use repair welding to maintain structural integrity and delay further failure. Tungsten inert gas welding is the main method for defect repair welding due to its low cost, convenience and flexibility. However, this technology currently has many limitations.

[0003] In the repair process of large components with complex curved surfaces, due to the uneven thickness and discontinuous geometric dimensions of the complex curved surface structure, the conventional repair welding method is difficult to adjust the process, stress concentration is easy to occur, and in order to ensure that the curved surface repair area is fully melted, a large welding heat input is often used to ensure the fluidity of the molten pool. However, a large heat input will cause the repair area to be coarse, and generate large residual stress and deformation around the repair area. At the same time, the parent material near the repair interface is affected by heat and weakened, and even secondary cracks are directly generated under the action of residual stress.

[0004] The existing technology still has significant deficiencies in the microstructure and properties of the repaired area, interface matching, residual stress control, etc. It is urgent to develop a new welding method to achieve high-quality and efficient welding repair of complex curved surface components. Summary of the invention

[0005] The present invention aims to solve the problem that the existing repair process of large components with complex curved surfaces uses a large heat input, which will lead to coarse structure in the repair area, generate large residual stress and deformation around the repair area, and cause the parent material near the repair interface to be affected by heat and weaken its performance, and even produce secondary cracks, thereby providing a complex curved surface welding repair method based on multi-source ultrasonic action.

[0006] A complex curved surface welding repair method based on multi-source ultrasonic action is carried out in the following steps:

[0007] 1. Defect preprocessing:

[0008] Pre-treat the defect or crack area of ​​the complex surface to be repaired to remove the defect or crack, obtain the area to be repaired, and then determine the repair path;

[0009] 2. Equipment preparation:

[0010] Connect the welding gun to the ultrasonic frequency pulse welding power source, and then fix the welding gun to the moving end of the repair robot. The mechanical ultrasonic roller is located behind the welding gun and fits the area to be repaired.

[0011] 3. Welding repair:

[0012] Start the mechanical ultrasonic system, the mechanical ultrasonic roller continuously outputs mechanical vibration, start the ultrasonic frequency pulse welding power supply, feed the filler wire synchronously, and move the welding gun along the repair path to repair the defect. The filler wire and the base material are melted under the heating of the ultrasonic frequency pulse arc heat source to form a molten pool which solidifies and deposits at the defect location;

[0013] 4. Repair completed:

[0014] After the defect repair is completed, turn off the ultrasonic frequency pulse welding power supply, wait for the molten pool to completely solidify, and then turn off the mechanical ultrasonic system to complete the complex curved surface welding repair method based on multi-source ultrasonic action.

[0015] The beneficial effects of the present invention are:

[0016] Ultrasonic excitation of ultrasonic frequency pulse current and regulation of molten pool physical properties: Under the action of ultrasonic frequency pulse current, compared with conventional welding arc, ultrasonic frequency pulse arc shrinks due to thermal delay effect and electromagnetic contraction effect, which makes its heat source energy concentrated, arc pressure increased, and arc stiffness improved. The optimization of arc stiffness improves the directionality of arc as a melting heat source; the increase in heat source energy density also further improves the heating efficiency of molten pool metal, so that the overall temperature of molten pool metal increases. The temperature change of molten pool metal will reduce its viscosity and make it easier to flow; the increase in pressure gradient caused by the increase in arc pressure will promote greater tangential pressure and further promote the flow of molten pool. In addition, since arc plasma has a wide frequency band response range, when the current pulse frequency is modulated to ultrasonic frequency, the plasma as a whole will change at ultrasonic frequency. At this time, arc plasma is similar to ultrasonic transducer. Under the excitation of ultrasonic frequency pulse current, arc ultrasound is excited and acts on the molten pool.

[0017] Finally, under the action of ultrasonic frequency pulse current, the directivity of the heat source increases, the heating efficiency is improved, and the same effect as the conventional welding repair method can be obtained under the condition of small heat input.

[0018] Coordinated regulation of solidification process by multi-source ultrasound: under the action of mechanical vibration ultrasound, the wheel-type horn transmits ultrasonic vibration to the inside of the workpiece. When the ultrasonic energy propagates along the solid phase of the parent material to the front of the solid-liquid interface of the molten pool, acoustic reflection and refraction will occur. At this time, the ultrasonic energy will be transmitted into the molten pool. Since the liquid cannot vibrate, a large sound pressure will be generated at the front of the liquid phase at the solid-liquid interface. At the same time, the ultrasonic energy and the ultrasonic energy transmitted into the molten pool by arc excitation ultrasound act together on the liquid metal in the molten pool, promoting the ultrasonic frequency vibration of the liquid phase molecules at the front of the liquid phase at the solid-liquid interface. During the vibration process, the metal molecules will be displaced and promote the generation of cavitation bubbles. Under the continuous action of ultrasonic energy, the cavitation bubbles at the front of the solid-liquid interface will be annihilated, causing local high temperature and high pressure, impacting the solidified grains at the front of the solid-liquid interface, and increasing the larger temperature gradient range and increasing the supercooling of the composition. The solid phase front at the solid-liquid interface will also vibrate under the continuous action of ultrasound, and stress concentration will occur on its surface, thereby forming local microcracks and finally cracking, realizing the dendrite fragmentation during the solidification process.

[0019] Finally, under the synergistic effect of multi-source ultrasound, the solidification behavior at the solid-liquid interface front of the molten pool in the repaired area is affected. On the one hand, multi-source ultrasound promotes the cavitation behavior of the molten pool liquid phase and the fracture of the solid phase grains. On the other hand, it causes local supercooling at the solid-liquid interface front. Together, they regulate the solidification behavior and promote grain refinement.

[0020] Multi-source ultrasonic grain coordinated deformation and residual stress relief: Based on the regulation of solidification behavior by multi-source ultrasound, relatively small solidified grains will be produced. Small grain size is easier to rotate, making the flow of liquid metal between grains easier and easier to reflux and heal, thereby reducing the shrinkage deformation resistance during the solidification process. At the same time, since the wheel-type amplitude rod of the mechanical ultrasound follows behind the welding gun, during the solidification process of the molten pool metal, the mechanical ultrasound will continuously act on the weld structure to cause stress relaxation. It can better suppress the occurrence of secondary thermal cracks on thin-walled complex curved surfaces, thereby improving the qualified rate of repair welding.

[0021] The invention is used for a complex curved surface welding repair method based on multi-source ultrasonic action. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 Schematic diagram of the equipment for complex curved surface welding repair based on multi-source ultrasonic action of the present invention, (1) repair welding head, (2) wire feeding mechanism, (3) welding gun, (4) wheel-type ultrasonic horn, (5) fixed platform, (6) workpiece to be repaired, (7) repair robot, (8) mechanical ultrasonic output power supply, (9) ultrasonic frequency pulse current welding power supply;

[0023] Figure 2This is a physical picture of the repair area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 1;

[0024] Figure 3 This is a microstructure diagram of the repair area interface of the complex curved surface welding repair method based on multi-source ultrasonic action in Example 1;

[0025] Figure 4 This is a diagram showing the interface hardness distribution of the repair area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 1;

[0026] Figure 5 This is a physical picture of the repair area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 2;

[0027] Figure 6 This is a microstructure diagram of the repaired area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 2;

[0028] Figure 7 This is a diagram of the tensile properties of the repaired area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 2. DETAILED DESCRIPTION

[0029] Specific implementation method 1, combined with Figure 1 Specific description: This embodiment is a complex curved surface welding repair method based on multi-source ultrasonic action, which is carried out in the following steps:

[0030] 1. Defect preprocessing:

[0031] Pre-treat the defect or crack area of ​​the complex surface to be repaired to remove the defect or crack, obtain the area to be repaired, and then determine the repair path;

[0032] 2. Equipment preparation:

[0033] Connect the welding gun to the ultrasonic frequency pulse welding power source, and then fix the welding gun to the moving end of the repair robot. The mechanical ultrasonic roller is located behind the welding gun and fits the area to be repaired.

[0034] 3. Welding repair:

[0035] Start the mechanical ultrasonic system, the mechanical ultrasonic roller continuously outputs mechanical vibration, start the ultrasonic frequency pulse welding power supply, feed the filler wire synchronously, and move the welding gun along the repair path to repair the defect. The filler wire and the base material are melted under the heating of the ultrasonic frequency pulse arc heat source to form a molten pool which solidifies and deposits at the defect location;

[0036] 4. Repair completed:

[0037] After the defect repair is completed, turn off the ultrasonic frequency pulse welding power supply, wait for the molten pool to completely solidify, and then turn off the mechanical ultrasonic system to complete the complex curved surface welding repair method based on multi-source ultrasonic action.

[0038] The mechanical ultrasonic vibration part of this specific embodiment includes an ultrasonic transducer and a horn, which converts the electrical signal output by the ultrasonic power supply into mechanical vibration through the ultrasonic transducer and transmits it to the metal component through the wheel-type horn. The ultrasonic frequency pulse arc output part adopts a pulse welding power supply based on SiC power devices, and its pulse output frequency range is 20kHz to 100kHz. The repair robot part is used to fix the welding gun so that it moves along a predetermined trajectory to achieve repair welding.

[0039] This specific implementation method couples arc-excited ultrasound with mechanical ultrasonic vibration to regulate the energy distribution of the welding heat source and the flow / solidification behavior of the molten pool metal, achieves efficient filling under low heat input conditions, and optimizes the organizational properties of the repair area. Specifically, this specific implementation method modulates the arc pulse frequency to the ultrasonic frequency to achieve fine regulation of the heat source energy, thereby adjusting the physical properties of the molten pool metal during the repair welding of complex curved surface components, promoting the flow behavior of the molten pool, and reducing the melt acoustic impedance coefficient. The arc excites ultrasound under the excitation of ultrasonic frequency pulse current, and the synergistic effect of mechanical ultrasonic vibration repairs the molten pool in the area, causing it to be subjected to multi-dimensional disturbances, further promoting the flow behavior of the molten pool metal, improving the solidification process and solidification structure, thereby improving the repair quality, optimizing the organizational properties of the repair area, improving the interface relationship between the fusion line of the repair area and the parent material area, improving the bonding strength between the repair area and the parent material, reducing the repair of secondary defects, and especially having significant effects in controlling pores, cracks and residual stresses.

[0040] This specific implementation method introduces multi-source ultrasound assistance into the repair and remanufacturing process of complex curved surface components, and regulates the formation, expansion, solidification and other key stages of the molten pool in the repair area to ensure sufficient flow, uniform solidification and grain refinement of the molten pool. At the same time, multi-source ultrasound can effectively weaken the impact on the heat-affected zone of the parent material during the repair process and reduce the residual stress generated during the repair process.

[0041] The beneficial effects of this embodiment are:

[0042] Ultrasonic excitation of ultrasonic frequency pulse current and regulation of molten pool physical properties: Under the action of ultrasonic frequency pulse current, compared with conventional welding arc, ultrasonic frequency pulse arc shrinks due to thermal delay effect and electromagnetic contraction effect, which makes its heat source energy concentrated, arc pressure increased, and arc stiffness improved. The optimization of arc stiffness improves the directionality of arc as a melting heat source; the increase in heat source energy density also further improves the heating efficiency of molten pool metal, so that the overall temperature of molten pool metal increases. The temperature change of molten pool metal will reduce its viscosity and make it easier to flow; the increase in pressure gradient caused by the increase in arc pressure will promote greater tangential pressure and further promote the flow of molten pool. In addition, since arc plasma has a wide frequency band response range, when the current pulse frequency is modulated to ultrasonic frequency, the plasma as a whole will change at ultrasonic frequency. At this time, arc plasma is similar to ultrasonic transducer. Under the excitation of ultrasonic frequency pulse current, arc ultrasound is excited and acts on the molten pool.

[0043] Finally, under the action of ultrasonic frequency pulse current, the directivity of the heat source increases, the heating efficiency is improved, and the same effect as the conventional welding repair method can be obtained under the condition of small heat input.

[0044] Coordinated regulation of solidification process by multi-source ultrasound: under the action of mechanical vibration ultrasound, the wheel-type horn transmits ultrasonic vibration to the inside of the workpiece. When the ultrasonic energy propagates along the solid phase of the parent material to the front of the solid-liquid interface of the molten pool, acoustic reflection and refraction will occur. At this time, the ultrasonic energy will be transmitted into the molten pool. Since the liquid cannot vibrate, a large sound pressure will be generated at the front of the liquid phase at the solid-liquid interface. At the same time, the ultrasonic energy and the ultrasonic energy transmitted into the molten pool by arc excitation ultrasound act together on the liquid metal in the molten pool, promoting the ultrasonic frequency vibration of the liquid phase molecules at the front of the liquid phase at the solid-liquid interface. During the vibration process, the metal molecules will be displaced and promote the generation of cavitation bubbles. Under the continuous action of ultrasonic energy, the cavitation bubbles at the front of the solid-liquid interface will be annihilated, causing local high temperature and high pressure, impacting the solidified grains at the front of the solid-liquid interface, and increasing the larger temperature gradient range and increasing the supercooling of the composition. The solid phase front at the solid-liquid interface will also vibrate under the continuous action of ultrasound, and stress concentration will occur on its surface, thereby forming local microcracks and finally cracking, realizing the dendrite fragmentation during the solidification process.

[0045] Finally, under the synergistic effect of multi-source ultrasound, the solidification behavior at the solid-liquid interface front of the molten pool in the repaired area is affected. On the one hand, multi-source ultrasound promotes the cavitation behavior of the molten pool liquid phase and the fracture of the solid phase grains. On the other hand, it causes local supercooling at the solid-liquid interface front. Together, they regulate the solidification behavior and promote grain refinement.

[0046] Multi-source ultrasonic grain coordinated deformation and residual stress relief: Based on the regulation of solidification behavior by multi-source ultrasound, relatively small solidified grains will be produced. Small grain size is easier to rotate, making the flow of liquid metal between grains easier and easier to reflux and heal, thereby reducing the shrinkage deformation resistance during the solidification process. At the same time, since the wheel-type amplitude rod of the mechanical ultrasound follows behind the welding gun, during the solidification process of the molten pool metal, the mechanical ultrasound will continuously act on the weld structure to cause stress relaxation. It can better suppress the occurrence of secondary thermal cracks on thin-walled complex curved surfaces, thereby improving the qualified rate of repair welding.

[0047] Specific implementation method 2: This implementation method is different from specific implementation method 1 in that the material of the complex curved surface to be repaired in step 1 is nickel-based alloy, aluminum alloy, magnesium alloy or stainless steel. The rest is the same as specific implementation method 1.

[0048] Specific implementation method three: This implementation method is different from specific implementation methods one or two in that in step one, the defect or crack part of the complex curved surface to be repaired is pre-treated to remove the defect or crack and form a spherical cap notch. The rest is the same as specific implementation methods one or two.

[0049] Specific implementation method 4: This implementation method is different from specific implementation methods 1 to 3 in that the distance between the mechanical ultrasonic roller and the welding gun in step 2 is 10 mm to 80 mm. Other aspects are the same as specific implementation methods 1 to 3.

[0050] Specific embodiment 5: This embodiment is different from specific embodiments 1 to 4 in that: in step 3, the average current of the ultrasonic pulse welding power source is 100A to 300A, wherein the base current is 50A to 200A, the amplitude current is 10A to 100A, the peak value accounts for 10% to 50%, and the pulse arc frequency is 20kHz to 40kHz. The rest is the same as specific embodiments 1 to 4.

[0051] Specific implementation example 6: This implementation example is different from specific implementation examples 1 to 5 in that the vibration frequency of the mechanical ultrasonic roller in step 3 is 20kHz to 50kHz, and the vibration power is 100W to 2600W. The rest is the same as specific implementation examples 1 to 5.

[0052] Specific embodiment 7: This embodiment differs from specific embodiments 1 to 6 in that the wire feeding speed of the filling wire in step 3 is 1000 mm / min to 2500 mm / min, and the moving speed of the welding gun is 100 mm / min to 300 mm / min. The rest is the same as specific embodiments 1 to 6.

[0053] Specific embodiment 8: This embodiment differs from specific embodiments 1 to 7 in that the welding atmosphere in step 3 is argon gas, and the introduction rate of the welding atmosphere is 15L / min to 20L / min. The rest is the same as specific embodiments 1 to 7.

[0054] Specific embodiment 9: This embodiment is different from specific embodiments 1 to 8 in that the diameter of the filling wire described in step 3 is 1.2 mm to 2.4 mm. The rest is the same as specific embodiments 1 to 8.

[0055] Specific embodiment 10: This embodiment differs from specific embodiments 1 to 9 in that: in step 3, layered deposition technology is used to repair defects, and the thickness of each layer is 0.3 mm to 2 mm. Other aspects are the same as specific embodiments 1 to 9.

[0056] The following examples are used to verify the beneficial effects of the present invention:

[0057] Embodiment 1:

[0058] A complex curved surface welding repair method based on multi-source ultrasonic action is carried out in the following steps:

[0059] 1. Defect preprocessing:

[0060] Pre-process the defective parts of the complex curved surface to be repaired to remove the defects, form a 1 / 4 spherical crown notch with a diameter of 10mm, and obtain the area to be repaired. Then use a 3D scanner to scan the area to be repaired, generate a 3D point cloud model, preliminarily analyze the stress state of the repair area, obtain typical defect classification characteristics and repair area characteristics, and determine the repair path;

[0061] The complex curved surface to be repaired is a thin-walled magnesium alloy engine with a thickness of 10 mm, made of ZM6, and the defective part is located on the surface of the engine;

[0062] 2. Equipment preparation:

[0063] Connect the welding gun to the ultrasonic frequency pulse welding power source, and then fix the welding gun to the moving end of the repair robot. The mechanical ultrasonic roller is located behind the welding gun and fits the area to be repaired.

[0064] The distance between the mechanical ultrasonic roller and the welding gun is 50 mm;

[0065] Three welding repairs:

[0066] Start the mechanical ultrasonic system, the mechanical ultrasonic roller continuously outputs mechanical vibration, start the ultrasonic frequency pulse welding power supply, feed the filler wire synchronously, and move the welding gun along the repair path to repair the defect. The filler wire and the base material are melted under the heating of the ultrasonic frequency pulse arc heat source to form a molten pool which solidifies and deposits at the defect location;

[0067] The average current of the ultrasonic pulse welding power supply is 150A, of which the base current is 100A, the amplitude current is 100A, the peak current = base current + amplitude current = 200A, the peak value accounts for 50%, the welding voltage is 14V, and the pulse arc frequency is 20kHz;

[0068] The vibration frequency of the mechanical ultrasonic roller is 28kHz and the vibration power is 500W;

[0069] The wire feeding speed of the filler wire is 1800 mm / min, and the moving speed of the welding gun is 200 mm / min;

[0070] The welding atmosphere is argon, and the welding atmosphere introduction rate is 15L / min;

[0071] Filled with ZM6 matching wire, 1.6mm in diameter;

[0072] The defect repair is carried out using layered deposition technology, with each layer deposited with a thickness of 1.2 mm;

[0073] 4. Repair completed:

[0074] After the defect repair is completed, turn off the ultrasonic frequency pulse welding power supply, wait for the molten pool to completely solidify, and then turn off the mechanical ultrasonic system to complete the complex curved surface welding repair method based on multi-source ultrasonic action.

[0075] Figure 2 This is a real picture of the repair area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 1; as can be seen from the figure, the surface of the repair area is relatively smooth, and no obvious defects such as lack of fusion are observed.

[0076] Figure 3 This is the interface microstructure diagram of the repair area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 1; as can be seen from the figure, the lower left side is the base material area, and the upper right side is the repair area. Due to the adjustment of the solidification process by multi-source composite ultrasound, the grain size of the repair area is relatively small. Although the grain size of the base material area is relatively large, the difference between the two is not large, and good coordinated deformation can occur when bearing load. At the same time, there are no obvious defects such as pores and cracks at the repair interface, and it has relatively good organizational consistency.

[0077] Figure 4 This is a diagram showing the interface hardness distribution of the repair area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 1; as can be seen from the figure, from left to right is the base material to the repair area, wherein the hardness of the repair area is higher than that of the base material area, and the hardness of the repair area is higher than that of the repair area by the conventional method, indicating that multi-source ultrasound has a better regulating effect on the hardness performance of the repair area.

[0078] Embodiment 2: This embodiment is different from Embodiment 1 in that: the complex curved surface to be repaired component described in step 1 is an aluminum alloy flat plate component with a thickness of 50 mm and a material of ZL205; in step 1, a laser scanner scans the area to be repaired to generate a high-resolution three-dimensional model and determine the repair path;

[0079] In step 3, the average current of the ultrasonic pulse welding power supply is 160A, wherein the base current is 110A, the amplitude current is 100A, the peak current = base current + amplitude current = 210A, the peak value accounts for 50%, the welding voltage is 14V, and the pulse arc frequency is 20kHz;

[0080] In step 3, the vibration frequency of the mechanical ultrasonic roller is 20kHz and the vibration power is 600W;

[0081] In step 3, the wire feeding speed of the filling wire is 2000 mm / min, and the moving speed of the welding gun is 100 mm / min;

[0082] In step 3, the welding atmosphere is argon, and the introduction speed of the welding atmosphere is 20Lmin / mm;

[0083] In step 3, the wire material filled with ZL205 material has a diameter of 1.2 mm;

[0084] In step 3, the defect repair is performed using a layered deposition technique, and the thickness of each layer is 1.8 mm. Other steps are the same as those in embodiment 1.

[0085] Figure 5 This is a real picture of the repair area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 2; as can be seen from the figure, the repair area is filled relatively fully, and there are no obvious defects on the surface, and the surfacing layer is continuous.

[0086] Figure 6 This is a microstructure diagram of the repair area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 2; as can be seen from the figure, there are no obvious defects inside the repair area, the structure is dense, and the second phase distribution inside is relatively uniform.

[0087] The test is carried out according to the national standard of tensile properties of metal materials, and multiple specimens are tested in parallel; Figure 7 This is a tensile performance diagram of the repair area of ​​the complex curved surface welding repair method based on multi-source ultrasonic action in Example 2; as can be seen from the figure, the average tensile strength of the repair area is 345MPa, the average yield strength is 280MPa, and the average elongation is 5.9%, reaching the cast performance level of the material and meeting the repair requirements.

Claims

1. A complex curved surface welding repair method based on multi-source ultrasonic action, characterized in that It is carried out in the following steps:

1. Defect preprocessing: Pre-treat the defect or crack area of ​​the complex surface to be repaired to remove the defect or crack, obtain the area to be repaired, and then determine the repair path; 2. Equipment preparation: Connect the welding gun to the ultrasonic frequency pulse welding power source, and then fix the welding gun to the moving end of the repair robot. The mechanical ultrasonic roller is located behind the welding gun and fits the area to be repaired.

3. Welding repair: Start the mechanical ultrasonic system, the mechanical ultrasonic roller continuously outputs mechanical vibration, start the ultrasonic frequency pulse welding power supply, feed the filler wire synchronously, and move the welding gun along the repair path to repair the defect. The filler wire and the base material are melted under the heating of the ultrasonic frequency pulse arc heat source to form a molten pool which solidifies and deposits at the defect location; 4. Repair completed: After the defect repair is completed, turn off the ultrasonic frequency pulse welding power supply, wait for the molten pool to completely solidify, and then turn off the mechanical ultrasonic system to complete the complex curved surface welding repair method based on multi-source ultrasonic action.

2. A complex curved surface welding repair method based on multi-source ultrasonic action according to claim 1, characterized in that The material of the complex curved surface to be repaired described in step 1 is nickel-based alloy, aluminum alloy, magnesium alloy or stainless steel.

3. The complex curved surface welding repair method based on multi-source ultrasonic action according to claim 1 is characterized in that In step 1, the defect or crack part of the complex curved surface to be repaired is pre-treated to remove the defect or crack and form a spherical crown gap.

4. The complex curved surface welding repair method based on multi-source ultrasonic action according to claim 1 is characterized in that The distance between the mechanical ultrasonic roller and the welding gun described in step 2 is 10 mm to 80 mm.

5. The complex curved surface welding repair method based on multi-source ultrasonic action according to claim 1 is characterized in that In step three, the average current of the ultrasonic pulse welding power supply is 100A-300A, of which the base current is 50A-200A, the amplitude current is 10A-100A, the peak value accounts for 10%-50%, and the pulse arc frequency is 20kHz-40kHz.

6. The complex curved surface welding repair method based on multi-source ultrasonic action according to claim 1 is characterized in that In step 3, the vibration frequency of the mechanical ultrasonic roller is 20kHz to 50kHz, and the vibration power is 100W to 2600W.

7. The complex curved surface welding repair method based on multi-source ultrasonic action according to claim 1 is characterized in that In step 3, the wire feeding speed of the filling wire is 1000 mm / min to 2500 mm / min, and the moving speed of the welding gun is 100 mm / min to 300 mm / min.

8. The complex curved surface welding repair method based on multi-source ultrasonic action according to claim 1 is characterized in that In step three, the welding atmosphere is argon, and the introduction rate of the welding atmosphere is 15L / min to 20L / min.

9. The complex curved surface welding repair method based on multi-source ultrasonic action according to claim 1 is characterized in that The diameter of the filling wire described in step 3 is 1.2 mm to 2.4 mm.

10. The complex curved surface welding repair method based on multi-source ultrasonic action according to claim 1, characterized in that In step three, the defect is repaired by using layered deposition technology, and the thickness of each layer is 0.3 mm to 2 mm.

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