A method for welding and repairing complex curved surfaces based on multi-source ultrasonic action

Abstract

The application discloses a complex curved surface welding repair method based on multi-source ultrasonic action and belongs to the field of repair and remanufacture.The application aims to solve the problem that in the existing repair process of large components with complex curved surfaces, large heat input will lead to coarse structure of the repair area, large residual stress and deformation around the repair area, performance weakening of the base material near the repair interface due to thermal influence, and even secondary crack. The method comprises the following steps: one, defect pretreatment; two, equipment preparation; three, welding repair; and four, repair completion. In the repair process, the method adopts high-frequency pulse arc self-excitation ultrasonic to improve the physical properties of the melt, combines with an external ultrasonic energy field, and cooperatively optimizes the repair area melting process, so that the structure and performance of the repair area are controlled. The application is used for the complex curved surface welding repair based on multi-source ultrasonic action.

Description

Technical Field

[0001] This invention belongs to the field of repair and remanufacturing. Background Technology

[0002] Large metal components often experience localized cracking, wear, or even fracture during use due to original manufacturing defects or special service conditions, becoming potential or direct factors contributing to overall component failure. Given the high cost of replacing large components entirely, repair welding to maintain structural integrity and delay further failure is crucial. Tungsten inert gas (TIG) welding, due to its low cost and flexibility, is a primary method for defect repair. However, this technology currently has several limitations.

[0003] In the repair of large components with complex curved surfaces, the uneven thickness and discontinuous geometric dimensions of the complex curved surface structure make conventional welding methods difficult to adjust, and stress concentration is prone to occur. Furthermore, to ensure sufficient penetration in the repaired area, a large welding heat input is often used to maintain the fluidity of the molten pool. However, a large heat input can lead to coarse microstructure in the repaired area, generating significant residual stress and deformation around the repaired area. Simultaneously, it weakens the properties of the base material near the repair interface due to heat, and may even directly induce secondary cracks under the influence of residual stress.

[0004] Existing technologies still have significant shortcomings in terms of the microstructure and properties of the repaired area, interface matching, and residual stress control. There is an urgent need to develop a new welding repair method to achieve high-quality and efficient welding repair of complex curved surface components. Summary of the Invention

[0005] This invention aims to address the problem that the large heat input used in the repair process of large components with complex curved surfaces leads to coarse microstructure in the repair area, resulting in large residual stress and deformation around the repair area. At the same time, the base material near the repair interface is affected by heat, causing performance weakening and even secondary cracking. Therefore, this invention provides a welding repair method for complex curved surfaces based on multi-source ultrasonic action.

[0006] A method for welding and repairing complex curved surfaces based on multi-source ultrasonic action, comprising the following steps:

[0007] I. Defect Pre-processing:

[0008] Pre-process the defective or cracked areas of the complex curved surface to be repaired to remove the defects or cracks, obtain the area to be repaired, and then determine the repair path;

[0009] II. Equipment Preparation:

[0010] Connect the welding torch to the ultrasonic pulse welding power source, then fix the welding torch to the end of the repair robot's movement, with the mechanical ultrasonic roller positioned behind the welding torch and in contact with the area to be repaired;

[0011] III. Welding Repair:

[0012] The mechanical ultrasonic system is started, and the mechanical ultrasonic roller continuously outputs mechanical vibration. The ultrasonic frequency pulse welding power supply is started, and the filler wire is fed in synchronously. The welding torch moves along the repair path to repair the defect. The filler wire and the base material melt under the heating of the ultrasonic frequency pulse electric arc heat source, forming a molten pool and solidifying and depositing at the defect location.

[0013] IV. Repair complete:

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

[0015] The beneficial effects of this invention are:

[0016] Ultrasonic Excitation and Molten Pool Property Modulation by Ultrasonic Pulsed Current: Under the action of ultrasonic pulsed current, compared with conventional welding arcs, ultrasonic pulsed arcs contract due to thermal delay and electromagnetic contraction effects, concentrating their heat source energy, increasing arc pressure, and improving arc stiffness. Optimized arc stiffness improves the directional nature of the arc as a melting heat source; the increased heat source energy density further enhances the heating efficiency of the molten pool metal, causing an overall increase in the molten pool metal temperature. The temperature change experienced by the molten pool metal reduces its viscosity, making it easier to flow; the increased pressure gradient resulting from the increased arc pressure promotes greater tangential pressure, further promoting molten pool flow. Furthermore, because arc plasma has a wide frequency response range, when the current pulse frequency is modulated to the ultrasonic frequency, the plasma as a whole changes at the ultrasonic frequency. At this time, the arc plasma acts like an ultrasonic transducer, exciting arc ultrasound under the excitation of ultrasonic pulsed current and acting on the molten pool.

[0017] Ultimately, under the action of ultrasonic pulsed current, the directionality of the heat source increases and the heating efficiency improves, achieving the same effect as conventional welding repair methods with low heat input.

[0018] Multi-source ultrasonic synergistic regulation of the solidification process: Under the action of mechanical vibration ultrasound, a wheeled amplitude transformer transmits ultrasonic vibration to the interior of the workpiece. When the ultrasonic energy propagates along the solid phase of the base material to the front of the solid-liquid interface of the molten pool, acoustic reflection and refraction 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 liquid phase front of the solid-liquid interface. Simultaneously, this ultrasonic energy and the ultrasonic energy transmitted into the molten pool by the arc-excited ultrasound work together to promote the ultrasonic frequency vibration of the liquid phase molecules at the liquid phase front of the solid-liquid interface. During this vibration, displacement will occur between metal molecules, thereby promoting the generation of cavitation bubbles. Under the continuous action of ultrasonic energy, the cavitation bubbles at the solid-liquid interface front will annihilate, creating local high temperature and high pressure, impacting the solidified grains at the solidification front of the solidification interface, and increasing the temperature gradient range, thus increasing compositional supercooling. 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, leading to the formation of local microcracks, which will eventually crack, achieving dendrite fragmentation during the solidification process.

[0019] Ultimately, under the synergistic effect of multi-source ultrasound, the solidification behavior at the solid-liquid interface front of the molten pool in the repaired region was affected. On the one hand, multi-source ultrasound promoted cavitation behavior of the liquid phase in the molten pool and fracture of solid grains; on the other hand, it caused local supercooling at the solid-liquid interface front. Together, they regulated the solidification behavior and promoted grain refinement.

[0020] Multi-source ultrasonic grain-coordinated deformation and residual stress relief: Based on the control of solidification behavior by multi-source ultrasound, finer solidified grains are generated. These smaller grains are easier to rotate, facilitating the flow of liquid metal between grains and promoting reflow healing, thereby reducing shrinkage deformation resistance during solidification. Simultaneously, because the mechanical ultrasonic transducer follows the welding torch, the mechanical ultrasound continuously acts on the weld structure during the solidification of the molten pool, causing stress relaxation. This effectively suppresses the generation of secondary hot cracks on thin-walled complex curved surfaces, thus improving the weld repair success rate.

[0021] This invention relates to a method for repairing complex curved surfaces by welding based on multi-source ultrasonic action. Attached Figure Description

[0022] Figure 1 The following is a schematic diagram of the equipment for welding and repairing complex curved surfaces based on multi-source ultrasonic action according to the present invention: (1) Repair welding head, (2) Wire feeding mechanism, (3) Welding gun, (4) Wheel-type ultrasonic amplitude transformer, (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 image of the repair area in Example 1, which illustrates the complex curved surface welding repair method based on multi-source ultrasonic action.

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

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

[0026] Figure 5 This is a physical image of the repair area in Example 2, which describes a complex curved surface welding repair method based on multi-source ultrasonic action.

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

[0028] Figure 7 This is a tensile property diagram of the repair area in Example 2, which is a complex curved surface welding repair method based on multi-source ultrasonic action. Detailed Implementation

[0029] Specific implementation method one, combined with Figure 1 Detailed explanation: This embodiment describes a method for welding and repairing complex curved surfaces based on multi-source ultrasonic action, which is carried out according to the following steps:

[0030] I. Defect Pre-processing:

[0031] Pre-process the defective or cracked areas of the complex curved surface to be repaired to remove the defects or cracks, obtain the area to be repaired, and then determine the repair path;

[0032] II. Equipment Preparation:

[0033] Connect the welding torch to the ultrasonic pulse welding power source, then fix the welding torch to the end of the repair robot's movement, with the mechanical ultrasonic roller positioned behind the welding torch and in contact with the area to be repaired;

[0034] III. Welding Repair:

[0035] The mechanical ultrasonic system is started, and the mechanical ultrasonic roller continuously outputs mechanical vibration. The ultrasonic frequency pulse welding power supply is started, and the filler wire is fed in synchronously. The welding torch moves along the repair path to repair the defect. The filler wire and the base material melt under the heating of the ultrasonic frequency pulse electric arc heat source, forming a molten pool and solidifying and depositing at the defect location.

[0036] IV. Repair complete:

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

[0038] The mechanical ultrasonic vibration section of this specific embodiment includes an ultrasonic transducer and an amplitude transformer. The ultrasonic transducer converts the electrical signal output from the ultrasonic power supply into mechanical vibration, which is then transmitted to the metal component via the wheeled amplitude transformer. The ultrasonic frequency pulse arc output section uses a pulse welding power supply based on SiC power devices, with a pulse output frequency range of 20kHz to 100kHz. The repair robot section is used to fix the welding torch, allowing it to move along a predetermined trajectory to achieve repair welding.

[0039] This specific embodiment achieves efficient filling under low heat input conditions and optimizes the microstructure of the repaired area by coupling arc-excited ultrasound with mechanical ultrasonic vibration, thereby controlling the energy distribution of the welding heat source and the flow / solidification behavior of the molten pool. Specifically, this embodiment modulates the arc pulse frequency to the ultrasonic frequency to achieve precise control of the heat source energy, thereby adjusting the physical properties of the molten pool during the repair welding process of complex curved components, promoting molten pool flow behavior, and reducing the acoustic impedance coefficient of the melt. The arc, excited by ultrasonic frequency pulsed current, excites ultrasound, and the synergistic effect of the ultrasonic vibration on the molten pool in the repaired area subjectes it to multidimensional disturbance, further promoting the flow behavior of the molten pool, improving the solidification process and solidification microstructure, thereby improving the repair quality, optimizing the microstructure of the repaired area, improving the interface relationship between the fusion line of the repaired area and the base material, increasing the bonding strength between the repaired area and the base material, and reducing secondary defects in the repair, especially showing significant effects in controlling porosity, cracks, and residual stress.

[0040] This specific implementation introduces multi-source ultrasonic assistance into the repair and remanufacturing process of complex curved surface components. It regulates the formation, expansion, and solidification of the molten pool in the repair area during key stages, ensuring sufficient flow, uniform solidification, and grain refinement of the molten pool. Simultaneously, multi-source ultrasound effectively mitigates the impact on the heat-affected zone of the base material during repair, reducing residual stress generated during the repair process.

[0041] The beneficial effects of this embodiment are:

[0042] Ultrasonic Excitation and Molten Pool Property Modulation by Ultrasonic Pulsed Current: Under the action of ultrasonic pulsed current, compared with conventional welding arcs, ultrasonic pulsed arcs contract due to thermal delay and electromagnetic contraction effects, concentrating their heat source energy, increasing arc pressure, and improving arc stiffness. Optimized arc stiffness improves the directional nature of the arc as a melting heat source; the increased heat source energy density further enhances the heating efficiency of the molten pool metal, causing an overall increase in the molten pool metal temperature. The temperature change experienced by the molten pool metal reduces its viscosity, making it easier to flow; the increased pressure gradient resulting from the increased arc pressure promotes greater tangential pressure, further promoting molten pool flow. Furthermore, because arc plasma has a wide frequency response range, when the current pulse frequency is modulated to the ultrasonic frequency, the plasma as a whole changes at the ultrasonic frequency. At this time, the arc plasma acts like an ultrasonic transducer, exciting arc ultrasound under the excitation of ultrasonic pulsed current and acting on the molten pool.

[0043] Ultimately, under the action of ultrasonic pulsed current, the directionality of the heat source increases and the heating efficiency improves, achieving the same effect as conventional welding repair methods with low heat input.

[0044] Multi-source ultrasonic synergistic regulation of the solidification process: Under the action of mechanical vibration ultrasound, a wheeled amplitude transformer transmits ultrasonic vibration to the interior of the workpiece. When the ultrasonic energy propagates along the solid phase of the base material to the front of the solid-liquid interface of the molten pool, acoustic reflection and refraction 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 liquid phase front of the solid-liquid interface. Simultaneously, this ultrasonic energy and the ultrasonic energy transmitted into the molten pool by the arc-excited ultrasound work together to promote the ultrasonic frequency vibration of the liquid phase molecules at the liquid phase front of the solid-liquid interface. During this vibration, displacement will occur between metal molecules, thereby promoting the generation of cavitation bubbles. Under the continuous action of ultrasonic energy, the cavitation bubbles at the solid-liquid interface front will annihilate, creating local high temperature and high pressure, impacting the solidified grains at the solidification front of the solidification interface, and increasing the temperature gradient range, thus increasing compositional supercooling. 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, leading to the formation of local microcracks, which will eventually crack, achieving dendrite fragmentation during the solidification process.

[0045] Ultimately, under the synergistic effect of multi-source ultrasound, the solidification behavior at the solid-liquid interface front of the molten pool in the repaired region was affected. On the one hand, multi-source ultrasound promoted cavitation behavior of the liquid phase in the molten pool and fracture of solid grains; on the other hand, it caused local supercooling at the solid-liquid interface front. Together, they regulated the solidification behavior and promoted grain refinement.

[0046] Multi-source ultrasonic grain-coordinated deformation and residual stress relief: Based on the control of solidification behavior by multi-source ultrasound, finer solidified grains are generated. These smaller grains are easier to rotate, facilitating the flow of liquid metal between grains and promoting reflow healing, thereby reducing shrinkage deformation resistance during solidification. Simultaneously, because the mechanical ultrasonic transducer follows the welding torch, the mechanical ultrasound continuously acts on the weld structure during the solidification of the molten pool, causing stress relaxation. This effectively suppresses the generation of secondary hot cracks on thin-walled complex curved surfaces, thus improving the weld repair success rate.

[0047] Specific Implementation Method Two: This implementation method differs from Specific Implementation Method One in that the material of the complex curved surface to be repaired in step one is a nickel-based alloy, aluminum alloy, magnesium alloy, or stainless steel. Everything else is the same as in Specific Implementation Method One.

[0048] Specific Implementation Method Three: This implementation method differs from Specific Implementation Method One or Two in that: in step one, the defective or cracked areas of the complex curved surface to be repaired are pre-treated to remove the defects or cracks, forming a spherical crown notch. Everything else is the same as in Specific Implementation Method One or Two.

[0049] Specific Implementation Method Four: This implementation method differs from Specific Implementation Methods One to Three in that the distance between the mechanical ultrasonic roller and the welding torch in step two is 10mm to 80mm. Everything else is the same as in Specific Implementation Methods One to Three.

[0050] Specific Implementation Method Five: This implementation method differs from Specific Implementation Methods One to Four in that: in step three, the average current of the ultrasonic pulse welding power source is 100A to 300A, with a base current of 50A to 200A, an amplitude current of 10A to 100A, a peak current ratio of 10% to 50%, and a pulse arc frequency of 20kHz to 40kHz. Everything else is the same as in Specific Implementation Methods One to Four.

[0051] Specific Implementation Method Six: This implementation method differs from Specific Implementation Methods One to Five in that the vibration frequency of the mechanical ultrasonic roller in step three is 20kHz to 50kHz, and the vibration power is 100W to 2600W. Everything else is the same as in Specific Implementation Methods One to Five.

[0052] Specific Implementation Method Seven: This implementation method differs from Specific Implementation Methods One to Six in that the wire feeding speed of the filler wire in step three is 1000 mm / min to 2500 mm / min, and the moving speed of the welding torch is 100 mm / min to 300 mm / min. Everything else is the same as in Specific Implementation Methods One to Six.

[0053] Specific Implementation Method Eight: This implementation method differs from Specific Implementation Methods One to Seven in that the welding atmosphere in step three is argon, and the injection rate of the welding atmosphere is 15 L / min to 20 L / min. Everything else is the same as in Specific Implementation Methods One to Seven.

[0054] Specific Implementation Method Nine: This implementation method differs from Specific Implementation Methods One to Eight in that the diameter of the filler filament in step three is 1.2mm to 2.4mm. Everything else is the same as in Specific Implementation Methods One to Eight.

[0055] Specific Implementation Method Ten: This implementation method differs from Specific Implementation Methods One to Nine in that: in step three, a layered deposition technique is used for defect repair, with each layer having a deposition thickness of 0.3 mm to 2 mm. Everything else is the same as in Specific Implementation Methods One to Nine.

[0056] The beneficial effects of the present invention are verified using the following embodiments:

[0057] Example 1:

[0058] A method for welding and repairing complex curved surfaces based on multi-source ultrasonic action, comprising the following steps:

[0059] I. Defect Pre-processing:

[0060] The defective parts of the complex curved surface to be repaired are pre-processed to remove defects and form a 1 / 4 spherical cap notch with a diameter of 10mm to obtain the area to be repaired. Then, the area to be repaired is scanned with a 3D scanner to generate a 3D point cloud model. The stress state of the repair area is preliminarily analyzed to obtain typical defect classification characteristics and repair area characteristics, and the repair path is determined.

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

[0062] II. Equipment Preparation:

[0063] Connect the welding torch to the ultrasonic pulse welding power source, then fix the welding torch to the end of the repair robot's movement, with the mechanical ultrasonic roller positioned behind the welding torch and in contact with the area to be repaired;

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

[0065] Three-welding repair:

[0066] The mechanical ultrasonic system is started, and the mechanical ultrasonic roller continuously outputs mechanical vibration. The ultrasonic frequency pulse welding power supply is started, and the filler wire is fed in synchronously. The welding torch moves along the repair path to repair the defect. The filler wire and the base material melt under the heating of the ultrasonic frequency pulse electric arc heat source, forming a molten pool and solidifying and depositing 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 current accounts for 50%, the welding voltage is 14V, and the pulse arc frequency is 20kHz.

[0068] The mechanical ultrasonic roller has a vibration frequency of 28kHz and a vibration power of 500W.

[0069] The feed rate of the filler wire is 1800 mm / min, and the moving speed of the welding torch is 200 mm / min.

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

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

[0072] Defect repair was performed using a layered deposition technique, with each layer having a thickness of 1.2 mm.

[0073] IV. Repair complete:

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

[0075] Figure 2 The image shows a physical view 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 image, the surface of the repair area is relatively flat and there are no obvious defects such as lack of fusion.

[0076] Figure 3 This is a microstructure diagram of the repair area interface in the complex curved surface welding repair method based on multi-source ultrasonic action in Example 1. As shown in the figure, the lower left is the base material area and the upper right 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. They can undergo good coordinated deformation when subjected to load. At the same time, there are no obvious defects such as pores and cracks at the repair interface, and the microstructure is relatively consistent.

[0077] Figure 4 The figure shows the interface hardness distribution of the repair area in the complex curved surface welding repair method based on multi-source ultrasound in Example 1. As can be seen from the figure, from left to right, it is from the base material to the repair area. 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 conventional methods. This indicates that multi-source ultrasound has a good control effect on the hardness performance of the repair area.

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

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

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

[0081] In step three, the wire feeding speed of the filler wire is 2000 mm / min, and the moving speed of the welding torch is 100 mm / min;

[0082] In step three, the welding atmosphere is argon, and the rate of introduction of the welding atmosphere is 20 L / min / mm.

[0083] In step three, fill the gap with ZL205 material wire with a diameter of 1.2mm;

[0084] In step three, a layered deposition technique is used for defect repair, with each layer having a thickness of 1.8 mm. Everything else is the same as in Example 1.

[0085] Figure 5 The image shows a physical view of the repair area in Example 2, which is based on the multi-source ultrasonic welding repair method for complex curved surfaces. As can be seen from the image, the repair area is fully filled and there are no obvious defects on the surface, and the weld overlay is continuous.

[0086] Figure 6 This is a microstructure diagram of the repair area in Example 2, which is based on the multi-source ultrasonic welding repair method for complex curved surfaces. As can be seen from the figure, there are no obvious defects inside the repair area, the structure is dense, and the internal second phase is relatively uniformly distributed.

[0087] The tensile properties of metallic materials were tested in accordance with national standards, and multiple samples were tested in parallel. Figure 7 The figure shows the tensile properties of the repaired area in 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 repaired area is 345 MPa, the average yield strength is 280 MPa, and the average elongation is 5.9%, which reaches the as-cast performance level of the material and meets the repair requirements.

Claims

1. A method for repairing a complex curved surface based on multi-source ultrasonic action, characterized in that It is carried out in the following steps: I. Defect pretreatment: The defect or crack site of the complex curved surface to be repaired is pretreated to remove the defect or crack, form a spherical cap gap, obtain the to-be-repaired area, and then determine the repair path; II. Equipment preparation: Connect the welding gun with the ultrasonic frequency pulse welding power supply, then fix the welding gun at the end of the motion of the repair robot, and the mechanical ultrasonic roller is located behind the welding gun and adheres to the to-be-repaired area; The distance between the mechanical ultrasonic roller and the welding gun is 50mm~80mm; III. Welding repair: Start the mechanical ultrasonic system, the mechanical ultrasonic roller continuously outputs mechanical vibration, start the ultrasonic frequency pulse welding power supply, synchronously feed the filler wire, the welding gun moves according to the repair path to repair the defect, and the filler wire and the base material are melted under the heating of the ultrasonic frequency pulse arc heat source, forming a molten pool and solidifying and depositing at the defect position; The average current of the ultrasonic frequency pulse welding power supply is 100A~300A, the base current is 50A~200A, the amplitude current is 10A~100A, the peak value ratio is 10%~50%, and the pulse arc frequency is 20kHz~40kHz; The vibration frequency of the mechanical ultrasonic roller is 20kHz~50kHz, and the vibration power is 500W~2600W; The wire feeding speed of the filler wire is 1800mm / min~2500mm / min, and the moving speed of the welding gun is 100mm / min~300mm / min; The welding atmosphere is argon, and the inlet speed of the welding atmosphere is 15L / min~20L / min; The defect repair is carried out by using the layer-by-layer deposition technology, and the deposition thickness of each layer is 0.3mm~2mm; IV. Repair completion: After the defect repair is completed, the ultrasonic frequency pulse welding power supply is turned off, and after the molten pool is completely solidified, the mechanical ultrasonic system is turned off, and the complex curved surface welding repair method based on multi-source ultrasonic action is completed.

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 in step I is nickel-based alloy, aluminum alloy, magnesium alloy or stainless steel.

3. The method of claim 1, wherein the method is based on multi-source ultrasonic action. The diameter of the filler wire in step III is 1.2mm~2.4mm.

Images