In-situ intelligent repair system and method for first wall component of nuclear fusion device

Abstract

The invention discloses an in-situ intelligent repair system and method for a first wall part of a nuclear fusion device, and relates to the technical field of magnetic confinement fusion devices, and the in-situ intelligent repair system comprises a mechanical arm module, an in-situ performance examination module and a multi-fiber laser cooperation device. The multi-fiber laser cooperative device comprises a path of damage clearing and preheating laser, a path of main repairing laser and a path of local impact laser, the main repairing laser is provided with a coaxial powder feeding device, and the coaxial powder feeding device is used for conveying repairing powder to a damaged area. According to the in-situ intelligent repair system and method for the first wall component of the nuclear fusion device, a comprehensive solution is provided for in-situ repair of the first wall component of the nuclear fusion device, the repair efficiency and the repair effect can be remarkably improved, resource waste caused by component replacement is reduced, and the in-situ intelligent repair system and method are not only suitable for the nuclear fusion device but also suitable for in-situ repair of the first wall component of the nuclear fusion device. The method can also be applied to the fields of aerospace, nuclear power equipment and the like needing restoration in an extreme environment, and has wide application prospects and market value.

Description

Technical Field

[0001] The present invention relates to the technical field of magnetic confinement fusion devices, and in particular to an in-situ intelligent repair system and method for a first wall component of a nuclear fusion device. Background Art

[0002] The first wall of a nuclear fusion reactor is directly exposed to high-temperature plasma and neutron irradiation, and its surface and internal materials are prone to irradiation damage. This damage will significantly reduce the thermal properties and fracture toughness of the material, thereby affecting the operating safety of the device, while weakening the reliability of experimental data, and posing challenges to the long-term stable operation of the nuclear fusion device.

[0003] The first wall component of a nuclear fusion reactor is a composite structure consisting of a first wall material, a supporting structure and a transition material, wherein the first wall material is usually tungsten or molybdenum with a high melting point and high radiation resistance, the supporting structure is usually low-activation steel or other high-strength alloys, and the transition material is usually oxygen-free copper or chromium-zirconium copper, which is used to alleviate the thermal expansion mismatch problem between the first wall material and the supporting structure.

[0004] Current repair methods mainly rely on disassembling damaged parts for repair or replacement, which is not only complex, time-consuming, but also costly.

[0005] Laser additive manufacturing technology, with its advantages of high energy density, high material utilization rate and high-precision forming, has shown great potential in the field of complex structure and material repair. However, in view of the need to repair complex curved surfaces, large areas and multi-directional damage in nuclear fusion devices, existing technologies still face the following bottlenecks: the inability to accurately transport repair powder to the curved surface damage area; low powder utilization rate; insufficient bonding strength and density between the repair layer and the base material, making it difficult to meet the service requirements under high heat load environments; lack of technical means to observe and evaluate the performance of the repair layer in real time, making it difficult to ensure the reliability of the repair effect.

[0006] The composite structure of the first wall component places higher demands on the in-situ repair technology. On the one hand, the differences in physical properties between the first wall material, transition material and support structure, such as differences in thermal expansion coefficient, melting point and thermal conductivity, lead to stress concentration and damage at the interface; on the other hand, the thermal stability and compatibility of multiple materials need to be considered simultaneously during the repair process to avoid introducing new defects or further weakening the performance of the component due to the repair. In addition, since composite structures usually have complex curved surfaces and multi-directional connection forms, this also brings additional difficulties to the design and operation of repair equipment.

[0007] In the industrial field, multi-degree-of-freedom manipulators have been widely used for high-precision operations in complex environments. However, in the high-radiation environment and complex curved surface conditions of nuclear fusion devices, the coordinated control and trajectory planning of manipulators still face many technical challenges. These limitations require further research and technological breakthroughs to meet the needs of efficient, precise and intelligent repair of internal components of nuclear fusion devices. Summary of the invention

[0008] The purpose of the present invention is to provide an in-situ intelligent repair system and method for the first wall component of a nuclear fusion device, so as to solve the problem of repairing complex curved surface, large area and multi-directional structural damage of the first wall component caused by high temperature plasma, high heat flux density and neutron irradiation environment.

[0009] To achieve the above-mentioned objectives, the present invention provides an in-situ intelligent repair system for the first wall component of a nuclear fusion device, comprising a robotic arm module, an in-situ performance assessment module and a multi-fiber laser collaborative device, wherein the multi-fiber laser collaborative device comprises a damage removal and preheating laser, a main repair laser and a local impact laser, wherein the main repair laser is equipped with a coaxial powder feeding device, which is used to transport repair powder to the damaged area.

[0010] Preferably, the coaxial powder feeding device optimizes the nozzle outlet shape, carrier gas flow rate, spraying height and spraying amount through multiphase flow numerical model simulation.

[0011] Preferably, the multi-fiber laser collaborative device achieves high-density deposition of the repair layer by adjusting laser power, scanning strategy, scanning speed and building direction.

[0012] Preferably, the in-situ performance assessment module generates natural laser speckle marks on the surface of the repair area by using a low-power laser.

[0013] The method for an in-situ intelligent repair system for a first wall component of a nuclear fusion device comprises the following steps: Step S1, damage identification: using a high-resolution detection method to determine the damage area and microscopic characteristics of the first wall structure damage sample; Step S2, repair preparation: selecting repair powder and laser process parameters according to damage characteristics, and adjusting the working modes of the coaxial powder feeding device and the multi-fiber laser coordination device; Step S3, repair process: using a multi-fiber laser collaborative device to perform damage cleaning and preheating, main repair and local impact treatment, while transporting repair powder through a coaxial powder feeding device; Step S4, performance assessment: using an in-situ assessment module to measure the mechanical and thermal properties of the repair layer under high thermal load.

[0014] Preferably, the high-resolution detection method in step S1 is to use a profilometer and a spectrometer to identify the structural damage of the first wall structure damage sample to obtain the geometric morphology and material composition information of the damaged area.

[0015] Preferably, in step S4, the in-situ assessment module observes the strain field changes of the repair area in real time by laser speckle digital image correlation method, and measures the temperature field distribution by infrared thermal imaging method.

[0016] Therefore, the present invention adopts the above-mentioned in-situ intelligent repair system and method for the first wall component of the nuclear fusion device, providing a comprehensive solution for the in-situ repair of the first wall component of the nuclear fusion device, which can significantly improve the repair efficiency and repair effect, and reduce the waste of resources caused by component replacement. It is not only suitable for nuclear fusion devices, but also can be applied to aerospace, nuclear power equipment and other fields that require repair in extreme environments. It has broad application prospects and market value.

[0017] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a structural schematic diagram of an embodiment of an in-situ intelligent repair system and method for a first wall component of a nuclear fusion device according to the present invention; Figure 2 It is a flow chart of the in-situ intelligent repair system and method for the first wall component of a nuclear fusion device of the present invention; Figure 3 A schematic diagram of repair preparation for an in-situ intelligent repair system and method for a first wall component of a nuclear fusion device according to the present invention; Figure 4 It is a schematic diagram of the in-situ intelligent repair system and method for the first wall component of a nuclear fusion device based on a high-power multi-fiber laser collaborative energy deposition repair technology solution of the present invention; Figure 5 It is a structural schematic diagram of a coaxial powder feeding device of the in-situ intelligent repair system and method for the first wall component of a nuclear fusion device of the present invention; Figure 6 It is a schematic diagram of a high-efficiency in-situ detection technology for mechanical and heat transfer properties of a repair layer of an in-situ intelligent repair system and method for a first wall component of a nuclear fusion device according to the present invention; Figure numerals: 1. Robotic arm module; 2. In-situ performance assessment module; 3. Multi-fiber laser collaborative device; 4. Profilometer and spectrometer; 5. First wall structural damage sample; 6. Structural damage; 7. Molten pool; 8. Main repair laser; 9. Damage removal and preheating laser; 10. Local impact laser; 11. Protective gas; 12. Repair powder; 13. Deposition trajectory; 14. Heat affected zone; 15. Computer; 16. Infrared thermal imaging equipment; 17. Repair area; 18. High-speed photography; 19. Filter; 20. Low-power laser. DETAILED DESCRIPTION

[0019] The technical solution of the present invention is further described below through the accompanying drawings and embodiments.

[0020] Unless otherwise defined, the technical terms or scientific terms used in the present invention should be understood by people with ordinary skills in the field to which the present invention belongs. The words "first", "second" and similar words used in the present invention do not indicate any order, quantity or importance, but are only used to distinguish different components. "Include" or "comprise" and similar words mean that the elements or objects appearing before the word include the elements or objects listed after the word and their equivalents, without excluding other elements or objects. "Connect" or "connected" and similar words are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "Up", "down", "left", "right" and the like are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0021] Example See also Figure 1-6 The present invention provides an in-situ intelligent repair system for the first wall component of a nuclear fusion device, including a mechanical arm module 1, an in-situ performance assessment module 2, and a multi-fiber laser coordination device 3. The system combines the flexible operation capability of multiple mechanical arms, the high-density forming capability of laser additive manufacturing, and the non-contact online performance detection technology to achieve efficient and accurate repair of the first wall component of a nuclear fusion device under complex environments. The repair method covers steps such as damage identification, repair preparation, energy deposition repair, and repair performance assessment, and can adapt to a variety of working conditions and ensure the reliability of the performance of the repair area.

[0022] The robot module 1 is used for precise positioning and motion control under complex surfaces and multi-directional structures. Combined with the multi-degree-of-freedom control function of the robot arm, through path planning and motion control algorithms, the robot arm can automatically adjust the position and angle of the repair equipment to achieve precise positioning and flexible operation of the repair equipment. It is suitable for damage repair on complex surfaces, large areas and high-radioactivity environments, and can adapt to the repair needs of different damaged areas.

[0023] The multi-fiber laser collaborative device 3 includes a cleaning and preheating laser 9, a main repair laser 8 and a local impact laser 10, which can collaboratively complete the energy distribution, material deposition repair and microstructure optimization of the damaged area, realize the precise energy distribution of the repair area 17, and combine with the protective gas to reduce powder leakage to improve the repair efficiency. The multi-fiber laser collaborative device 3 achieves high-density deposition in the repair area 17 by adjusting the laser power, scanning strategy, scanning speed and construction direction, so that the density is ≥98%.

[0024] The main repair laser 8 is equipped with a coaxial powder feeding device, which is used to transport the repair powder 12 to the damaged area. The coaxial powder feeding device optimizes the nozzle outlet shape, carrier gas flow rate, spraying height and spraying amount through multiphase flow numerical model simulation to ensure the stable transportation of the repair powder 12 and reduce environmental pollution. The powder feeding system has advantages such as multiple powder channels and multiple powder supply barrels. The powder feeding system combines protective gas to reduce the leakage of the repair powder 12, and adapts to the repair needs of complex curved surfaces and asymmetric structures by adjusting parameters such as spraying height and carrier gas flow rate.

[0025] The in-situ performance assessment module 2 monitors the strain field and temperature field of the repair area 17 in real time and evaluates the repair quality and performance based on digital image correlation technology (DIC) and infrared thermal imaging technology. The in-situ performance assessment module 2 generates natural laser speckle marks on the surface of the repair area 17 through a low-power laser 20, provides guidance for optimizing the performance of the repair area 17, and improves the measurement accuracy of the digital image correlation technology.

[0026] The method for the in-situ intelligent repair system of the first wall component of the nuclear fusion device comprises the following steps: Step S1, damage identification: using a high-resolution detection method to determine the damage area and its microscopic features of the first wall structure damage sample 5. The high-resolution detection method uses a profilometer and a spectrometer 4 to identify the damage of the first wall component and obtain the geometric morphology and material composition information of the damage area.

[0027] Step S2, repair preparation: select suitable repair powder 12 and laser process parameters according to the damage characteristics, and adjust the working mode of the coaxial powder feeding device and the multi-fiber laser cooperative device 3 to ensure accurate material delivery and uniform melting.

[0028] Step S3, repair process: using the multi-fiber laser cooperative device 3 to perform damage cleaning and preheating, main repair and local impact treatment, while the coaxial powder feeding device is used to transport the repair powder 12 to complete the repair of the damaged area layer by layer.

[0029] Step S4, performance assessment: After the repair is completed, the mechanical and thermal properties of the repaired area 17 under high heat load are measured using the in-situ assessment module. Specifically, the in-situ assessment module observes the strain field changes of the repaired area 17 in real time through the laser speckle digital image correlation method, and measures the temperature field distribution through the infrared thermal imaging method.

[0030] The technical solution is further described in conjunction with the following embodiments.

[0031] like Figure 1 As shown, the system of this embodiment is mainly composed of a robot arm module 1, a multi-fiber laser cooperative device 3 and an in-situ assessment module.

[0032] The steps to implement the repair method are as follows: Figure 2 shown.

[0033] First, a first wall structural damage sample 5 with structural damage 6 is prepared.

[0034] Then, the material surface is observed to obtain the pit profile and microstructure characteristic parameters, and the first wall component is scanned by high-resolution detection technology to identify the location, shape and depth of the damaged area. The microscopic characteristic parameters of the damaged location, such as crack size and damage distribution, are obtained to provide a basis for the formulation of the repair process.

[0035] Then, according to the damage characteristics, select appropriate repair powder 12 (such as tungsten powder or molybdenum powder) and determine the particle size to be between 10µm and 50µm. Adjust the laser power, scanning speed and scanning trajectory of the multi-fiber laser cooperative device 3, and optimize the powder supply and spraying parameters of the coaxial powder feeding device to ensure accurate material delivery and uniform melting in the repair area 17.

[0036] After that, multi-fiber laser collaborative energy deposition shaping repair is carried out, and the following steps are carried out in sequence: (1) Damage cleaning and preheating: Use the damage cleaning and preheating laser to clean the surface of the damaged area and increase the substrate temperature to 200℃-400℃; (2) Main repair: The main repair laser 8 cooperates with the coaxial powder feeding device to deposit repair powder layer by layer to form a repair area 17, with a layer thickness of 0.1 mm to 0.3 mm; (3) Local impact: Use local impact laser to dynamically strengthen the repair area 17 to improve the bonding strength between the repair area 17 and the substrate.

[0037] Subsequently, digital image correlation method and infrared thermal imaging technology were used to observe the thermal strain field / temperature field of the repaired area 17 under low-power laser irradiation, with the strain field measurement accuracy reaching 10µm and the temperature resolution being 0.1°C. The mechanical / thermal properties of the repaired area 17 were assessed.

[0038] Finally, the in-situ repair technology of the first wall structure based on multi-fiber laser collaborative energy deposition is comprehensively integrated to form an in-situ integrated intelligent repair technology system for the first wall components.

[0039] like Figure 3 As shown, when the cladding structure is damaged, it is necessary to consider the type and structure of the substrate tissue and determine the repair plan, which mainly includes: process parameters, performance control and powder design. Among them, the process parameters specifically include preheating temperature, laser power, scanning speed, scanning spacing and delivery speed. Performance control specifically includes density, mechanical properties and thermal properties. Powder design specifically includes powder composition, powder particle size and fluidity. The feedback results of the repair performance and damage characteristics are applied to the formulation of the next round of repair plans to achieve continuous improvement of the repair process and ensure that the final performance of the repair area 17 meets the design requirements.

[0040] like Figure 4 As shown, the multi-fiber laser device is composed of three lasers. The cleaning and preheating laser 9 is used to remove impurities on the surface of the damaged area and heat the substrate to reduce the thermal mismatch between the repair area 17 and the substrate; the main repair laser 8 is used to deposit energy to repair the powder and complete the deposition forming. The laser power range is 500W-2000W, and the scanning speed range is 1mm / s-10mm / s to ensure that the density of the repair area 17 is ≥98%; the local impact laser 10 is used to strengthen the bonding strength between the repair area 17 and the substrate and optimize the microstructure. The molten pool 7 is a liquid area formed by the laser energy acting on the surface of the repair area 17 to locally melt the repair powder 12 and the substrate material. The molten pool 7 can promote the full mixing of the repair powder and the substrate material, thereby forming a high-density, high-strength bonding layer. The main repair laser 8 is the main driving force for the formation of the molten pool 7. By concentrating the laser energy in the repair area 17, the repair powder and the substrate material are directly melted to form a liquid molten pool. The control of laser power and scanning speed determines the depth and width of the molten pool, affecting the density, bonding strength and microstructure of the repair layer.

[0041] like Figure 5 As shown, the coaxial powder feeding device combines multiple powder channels with multiple powder supply barrels, and combines the protective gas 11 to reduce powder leakage, ensure the precise delivery of the repair powder 12, and form a deposition track 13 and a heat-affected zone 14 on the first wall structure damage sample 5. The outlet shape of the nozzle can be dynamically adjusted according to the geometric characteristics of the repair area 17, the spraying height range is 10mm-50mm, and the flow rate of the protective gas 11 is 10m / s-30m / s to meet the repair needs of complex curved surfaces.

[0042] like Figure 6As shown, the in-situ performance assessment module 2 measures the strain field and temperature field distribution of the repair area 17 in real time through digital image correlation technology (DIC) and infrared thermal imaging technology. DIC technology generates natural speckle marks on the surface of the repair area 17 through low-power laser 20 to achieve high-precision non-contact measurement. Infrared thermal imaging technology is used to capture the temperature changes of the repair area 17 under high heat load and comprehensively evaluate the mechanical and heat transfer properties of the repair area 17. The specific implementation process is as follows: the computer 15 is responsible for receiving and processing the measurement data of the high-speed photography 18 and the infrared thermal imaging device 16, calculating the strain field and temperature field distribution of the repair area 17, and performing comprehensive performance analysis. Under the natural speckle marks generated by the low-power laser 20, the high-speed photography 18 records the dynamic deformation process of the speckle with strain at a high frame rate. The filter 19 is installed at the front end of the high-speed photography 18 to filter the interference of ambient light and ensure that the speckle image is clear and reliable. The infrared thermal imaging device 16 monitors the temperature changes of the repair area 17 in real time, senses the intensity of infrared radiation, obtains temperature field data and transmits it to the computer 15 for comprehensive evaluation, thereby achieving accurate monitoring of the mechanical and thermal properties of the repair area 17 under high heat load.

[0043] The schematic diagram of the component structure of this embodiment is as follows Figure 1 As shown, it includes three core links: identification, repair and detection, combining a variety of advanced equipment and technologies to form a closed-loop repair process.

[0044] The identification process includes: using optical measurements such as a profilometer and a spectrometer 4 to accurately identify the structural damage 6 of the first wall structural damage sample 5, obtaining the geometric morphology and material composition information of the damaged area, and providing data support for the formulation of a repair plan.

[0045] The repair process includes: using multi-channel collaborative energy deposition technology to integrate damage cleaning, preheating, main repair and local strengthening functions; the main repair laser 8 is combined with a coaxial powder feeding device to achieve high-precision, high-density layer-by-layer material deposition to ensure the mechanical and thermal properties of the repair area.

[0046] The detection process includes: using laser speckle digital image correlation technology (DIC) to monitor the strain field and temperature field of the repair layer in real time, and evaluate the mechanical and thermal properties of the repair layer.

[0047] The entire system integrates intelligent robotic arms, high-precision detection equipment, and multi-channel laser collaborative technology to achieve full-process automation and intelligence from damage identification to repair detection, and can adapt to the needs of first-wall component repair under complex curved surfaces and high-radioactivity environments.

[0048] Therefore, the present invention adopts the above-mentioned in-situ intelligent repair system and method for the first wall component of the nuclear fusion device, providing a comprehensive solution for the in-situ repair of the first wall component of the nuclear fusion device, which can significantly improve the repair efficiency and repair effect, and reduce the waste of resources caused by component replacement. It is not only suitable for nuclear fusion devices, but also can be applied to aerospace, nuclear power equipment and other fields that require repair in extreme environments. It has broad application prospects and market value.

[0049] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that they can still modify or replace the technical solution of the present invention with equivalents, and these modifications or equivalent replacements cannot cause the modified technical solution to deviate from the spirit and scope of the technical solution of the present invention.

Claims

1. An in-situ intelligent repair system for the first wall component of a nuclear fusion device, characterized in that: It includes a robotic arm module, an in-situ performance assessment module and a multi-fiber laser collaborative device. The multi-fiber laser collaborative device includes a damage removal and preheating laser, a main repair laser and a local impact laser. The main repair laser is equipped with a coaxial powder feeding device, which is used to transport the repair powder to the damaged area.

2. The in-situ intelligent repair system for the first wall component of a nuclear fusion device according to claim 1, characterized in that: The coaxial powder feeding device optimizes the nozzle outlet shape, carrier gas flow rate, spraying height and spraying amount through multiphase flow numerical model simulation.

3. The in-situ intelligent repair system for the first wall component of a nuclear fusion device according to claim 2, characterized in that: The multi-fiber laser cooperative device achieves high-density deposition of the repair layer by adjusting laser power, scanning strategy, scanning speed and building direction.

4. The in-situ intelligent repair system for the first wall component of a nuclear fusion device according to claim 3, characterized in that: The in-situ performance assessment module generates natural laser speckle marks on the surface of the repair area through a low-power laser.

5. A method for applying the in-situ intelligent repair system for the first wall component of a nuclear fusion device as described in any one of claims 1 to 4, characterized in that: The following steps are involved: Step S1, damage identification: using a high-resolution detection method to determine the damage area and microscopic characteristics of the first wall structure damage sample; Step S2, repair preparation: selecting repair powder and laser process parameters according to damage characteristics, and adjusting the working modes of the coaxial powder feeding device and the multi-fiber laser coordination device; Step S3, repair process: using a multi-fiber laser collaborative device to perform damage cleaning and preheating, main repair and local impact treatment, while transporting repair powder through a coaxial powder feeding device; Step S4, performance assessment: using an in-situ assessment module to measure the mechanical and thermal properties of the repair layer under high thermal load.

6. The method for the in-situ intelligent repair system of the first wall component of a nuclear fusion device according to claim 5, characterized in that: The high-resolution detection method in step S1 is to use a profilometer and a spectrometer to identify the structural damage of the first wall structure damage sample to obtain the geometric morphology and material composition information of the damaged area.

7. The method for the in-situ intelligent repair system of the first wall component of a nuclear fusion device according to claim 6, characterized in that: In step S4, the in-situ assessment module observes the strain field changes of the repair area in real time by laser speckle digital image correlation method, and measures the temperature field distribution by infrared thermal imaging method.

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