Multi-heat-source equivalent material increasing composite manufacturing method and system

Abstract

The invention belongs to the technical field of additive manufacturing, and discloses a multi-heat-source additive manufacturing composite manufacturing method and system.The multi-heat-source additive manufacturing composite manufacturing method comprises the steps that S1, high-power fuse additive manufacturing is conducted; s2, performing temperature-controlled deformation equal-material forging; s3, low-power powder feeding compensation manufacturing; and S4, carrying out integral post-treatment. According to the regulation and control method for compensating the high-power fuse additive remelting area through low-power powder feeding additive, the deformed area of fuse temperature control equivalent material forging is reserved, post-heat input of static recrystallization is reduced, the equivalent material forging surface is refined, and high-efficiency, high-precision and high-performance composite manufacturing is achieved. The invention further provides a forming system matched with the method, the contradiction between high-performance equal-material large-deformation surplus and high-efficiency additive large-heat input remelting in the existing additive composite manufacturing process can be solved, and growth of crystal grains in the post-heat static recrystallization process is effectively inhibited; and high-efficiency and high-precision additive composite manufacturing of the fine-grain forge piece is successfully realized.

Description

Technical Field

[0001] The present invention belongs to the technical field of additive manufacturing, and in particular relates to a multi-heat source additive manufacturing method and system. Background Art

[0002] As the load-bearing components of high-end equipment develop towards lightweight, large-scale and integrated manufacturing, the problems of low production efficiency, low material utilization rate and high processing cost of traditional segmented forging and splicing manufacturing have become increasingly prominent, making it difficult to meet the R&D needs of rapid product iteration. The low-cost and high-efficiency manufacturing of high-performance, high-reliability and long-life large-scale integral lightweight forgings poses new challenges to manufacturing technology.

[0003] Additive manufacturing technology drives the motion mechanism through the path planning code obtained by slicing the solid three-dimensional model to achieve layer-by-layer cladding of metal parts. It has the advantages of high material utilization, high deposition efficiency, low manufacturing cost, and high part density. It is an effective method for the overall manufacture of load-bearing components. However, the macroscopic structure of single additive manufacturing is a chaotic columnar crystal and equiaxed crystal interweaving form, and the fatigue performance is difficult to match that of forgings. The introduction of isotope forging in the additive manufacturing process can cause plastic deformation of the deposited material, break dendrites, increase the heterogeneous nucleation rate, and thus promote grain refinement. It has been widely studied in recent years. However, the contradiction between the low residual height of high-performance isotope and the serious remelting of high-efficiency additive with large heat input affects the effective area retention of deformation recrystallization. The greater the heat input, the deeper the remelting, and the grain growth in the post-heat static recrystallization process, further weakening the fine grain effect of isotope forging. In addition, the stability of the molten pool and the surface morphology quality of the deposited layer brought by high-efficiency additives are prone to insufficient manufacturing accuracy and unfused defects.

[0004] Through the above analysis, the problems and defects of the prior art are as follows:

[0005] The contradiction between the large deformation residual height of high-performance equal materials and the high heat input remelting of high-efficiency additive materials affects the effective area retention of deformation recrystallization. The greater the heat input, the deeper the remelting, and the grain growth during the post-heat static recrystallization process, further weakening the fine grain effect of equal material forging. In addition, the stability of the molten pool and the quality of the surface morphology of the deposited layer brought about by high-efficiency additive materials can easily lead to insufficient manufacturing precision and unfused defects. Summary of the invention

[0006] In view of the problems existing in the prior art, the present invention provides a multi-heat source additive manufacturing method and system.

[0007] The present invention is implemented in this way: a multi-heat source additive manufacturing method comprises:

[0008] S1, Additive manufacturing of high-power fuses;

[0009] S2, temperature controlled deformed material forging;

[0010] S3, low power powder feeding compensation manufacturing;

[0011] S4, repeat steps S1 to S3 until the component manufacturing is completed and the overall post-processing is completed.

[0012] Furthermore, in step S1, the high-power fuse uses an arc heat source or a laser-arc composite heat source, and the welding wire uses a cold wire or a hot wire for single-wire or multi-wire feeding.

[0013] Further, in step S2, the material forging includes mechanical rolling, mechanical hammering or ultrasonic impact.

[0014] Further, in step S3, the low-power powder feeding adopts a laser heat source, and the compensation manufacturing adopts a Z-track free deposition, and the deposition width is consistent with the high-power fuse deposition width in step S1, and the melting depth L P No more than 0.3mm, residual height L R And penetration L P Total height and additive remelting depth A in step S1 P Consistent.

[0015] Furthermore, steps S1 to S3 are performed simultaneously, and the depth A of the heat-affected zone of the next layer of additive manufacturing in step S1 is HAZ Only cover to the bottom of the previous layer with deformation depth (high power melting depth A) outside the compensation manufacturing remelting in step S3 P + Residual height after high power deformation A h - Low power melting depth L P ), which is used to completely drive the static recrystallization of the medium material forging in step S2.

[0016] Further, the overall post-processing in step S4 includes stress release and surface processing to remove the excess height and fusion depth of the last layer of low-power powder feeding compensation manufacturing;

[0017] The laser heat source uses coaxial molten pool monitoring to perform synchronous surface morphology monitoring to provide feedback on the morphology of the deposited layer after deformation in the refinement step S2.

[0018] Another object of the present invention is to provide a multi-heat source additive manufacturing system comprising:

[0019] A first additive manufacturing unit, a second additive manufacturing unit, an equal material manufacturing unit, a support unit, a cleaning unit, a heating unit, a purification unit, a monitoring unit, and a control center;

[0020] The first additive manufacturing unit, the second additive manufacturing unit, the equal material manufacturing unit, the support unit, the cleaning unit, the heating unit, the purification unit and the monitoring unit are electrically connected to the control center respectively;

[0021] The substrate of the forged part to be additively manufactured is placed on a support unit, and a first additive manufacturing unit additively manufactures an additive layer on the substrate using a high-power fuse;

[0022] The isomaterial manufacturing unit performs synchronous isomaterial forging and compounding on the newly generated additive layer, and the second additive manufacturing unit performs synchronous low-power powder feeding additive manufacturing compensation layer on the additive layer after forging deformation;

[0023] The first additive manufacturing unit includes a first six-axis robot and a first heat source connected to each other, and the first six-axis robot controls the first heat source to move along a preset trajectory;

[0024] The material manufacturing unit includes a three-axis motion mechanism and a deformation mechanism connected to each other;

[0025] The three-axis motion mechanism can move along three dimensions of X, Y, and Z to control the deformation mechanism to cooperate with the first additive manufacturing unit to perform forging;

[0026] The second additive manufacturing unit includes a second six-axis robot and a second heat source connected to each other, and the second six-axis robot controls the second heat source to move along a preset trajectory.

[0027] Another object of the present invention is to provide a computer device, comprising a memory and a processor, wherein the memory stores a computer program, and when the computer program is executed by the processor, the processor executes the steps of the multi-heat source additive manufacturing method.

[0028] Another object of the present invention is to provide a computer-readable storage medium storing a computer program, which, when executed by a processor, enables the processor to execute the steps of the multi-heat source additive manufacturing method.

[0029] Another object of the present invention is to provide an information data processing terminal, characterized in that the information data processing terminal is used to implement the multi-heat source additive manufacturing system.

[0030] In combination with the above technical solutions and the technical problems solved, the advantages and positive effects of the technical solutions to be protected by the present invention are as follows:

[0031] In view of the serious contradiction between the low residual height of high-performance equal materials with large deformation and the serious remelting of high-efficiency additive materials with large heat input, a low-power laser powder feeding Z-shaped trajectory continuous additive compensation layer is used to make up for the remelting of the subsequent layer of high-power heat source fuse. At the same time, it can reduce the driving energy input of static recrystallization of equal material forging, solving the problems of insufficient retention of deformation recrystallization area and growth of recrystallized grains.

[0032] In order to solve the problems of melt pool stability and deposited layer surface morphology quality caused by high-efficiency additive manufacturing, which easily lead to insufficient manufacturing precision and unfused defects, coaxial melt pool monitoring is used to perform synchronous surface morphology monitoring during the low-power laser powder feeding additive compensation layer process. This is used to feedback the deposited layer morphology after fine-tuning and deformation, and to achieve high-efficiency and high-precision additive manufacturing of fine-grained forgings.

[0033] This system can realize self-correction of the manufacturing process, reduce post-processing time, further shorten the overall manufacturing cycle of the product, and solve the technical problem of efficient, high-precision and high-reliability direct manufacturing that people have always been eager to solve but have never succeeded in solving. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a flow chart of the multi-heat source additive manufacturing method provided by an embodiment of the present invention.

[0035] Figure 2 It is a schematic diagram of the structure of a manufacturing system provided by an embodiment of the present invention.

[0036] Figure 3 It is a schematic diagram of interlayer remelting compensation provided by an embodiment of the present invention.

[0037] Figure 4 It is a structural block diagram of a multi-heat source additive manufacturing system provided by an embodiment of the present invention.

[0038] In the figure: 11, first heat source; 12, welding wire; 13, electric arc; 14, first molten pool; 21, deformation mechanism; 22, infrared thermal imager; 31, laser head; 32, laser beam; 33, powder; 34, light spot; 35, second molten pool; 36, molten pool monitor. DETAILED DESCRIPTION

[0039] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0040] Example 1: Manufacturing of aircraft engine blades

[0041] The blades of aircraft engines have complex curved surface geometry and strict mechanical performance requirements. This embodiment adopts a multi-heat source additive composite manufacturing method to solve the problems of low efficiency, large material waste and difficult stress control in traditional manufacturing methods.

[0042] Using high-power laser fuse equipment, the basic geometric structure of the blade, including the root, middle part and tip, is quickly formed according to the three-dimensional design drawing of the blade.

[0043] The formed blade matrix is ​​subjected to regional heating and forging deformation, especially strengthening treatment for the root and middle of the blade to improve the internal grain structure and enhance fatigue resistance and strength.

[0044] The low-power laser powder feeding process is used to compensate for the blade surface and repair possible micro defects in the additive process, while achieving fine molding of complex aerodynamic surfaces.

[0045] Repeat steps S1 to S3 for multiple cycles to cycle the above process until the overall shape of the blade and the strengthening of key parts are completed.

[0046] The finished blades are heat treated to eliminate stress, and then surface polished and heat-resistant coated to ensure that the blades meet the requirements of high-temperature and high-speed operating environments.

[0047] The blades manufactured by this method reach the level of traditional forged blades in performance, while reducing material costs and production cycles, making it suitable for small-batch customized production of complex geometries.

[0048] Example 2: Manufacturing of large ship propellers

[0049] Large ship propellers are usually made of copper alloy or titanium alloy, which have high strength, corrosion resistance and complex three-dimensional curved surface. Traditional casting processes are difficult to meet their high precision and high performance requirements. This embodiment uses a multi-heat source additive composite manufacturing method to achieve high efficiency and refined processing.

[0050] Using high-power arc fuse equipment, the rough geometry of the propeller, including the blades and center hub section, is quickly constructed.

[0051] Temperature-controlled forging is performed on the blade root and center hub areas to improve the material density and fatigue resistance of these high-stress areas.

[0052] On the edge and surface of the blade, low-power powder feeding technology is used to repair the deformation error during additive manufacturing, and the surface morphology is further optimized to meet hydrodynamic requirements.

[0053] Repeat steps S1 to S3, and repeat the cycle of additive manufacturing and forging compensation multiple times according to the size and design requirements of the propeller to ensure the overall strength and accuracy.

[0054] The propellers are heat treated to improve overall performance, and are surface polished and coated with corrosion-resistant coatings to ensure long-term stability in seawater environments.

[0055] This method solves the problem of refined manufacturing of large and complex structures that is difficult to achieve with traditional casting, while improving the performance of key parts of the blades and meeting the requirements of efficient propulsion and durability.

[0056] like Figure 1 As shown, a multi-heat source additive manufacturing method provided by an embodiment of the present invention includes the following steps:

[0057] S1. Additive manufacturing of high-power fuses:

[0058] An arc heat source or a laser-arc composite heat source is used to melt the welding wire, which can be a cold wire or a hot wire, and a single wire or multiple wire feeding method is used to deposit the metal material;

[0059] S2. Temperature controlled deformed material forging:

[0060] After completing the additive manufacturing of each layer of high-power fuse, the deposited layer is subjected to temperature-controlled deformation forging. The forging process includes mechanical rolling, mechanical hammering or ultrasonic impact. The forging temperature is controlled within the material recrystallization temperature range to achieve microstructure refinement, eliminate residual stress and improve interlayer bonding strength.

[0061] S3, low power powder feeding compensation manufacturing:

[0062] Using a laser heat source, the surface area is compensated by a Z-track free deposition method. The deposition width of the compensation manufacturing is consistent with the deposition width of the high-power fuse in step S1, the melting depth does not exceed 0.3mm, and the total height of the deposition residual height and the melting depth is consistent with the additive remelting depth in step S1, so as to optimize the surface morphology and accuracy;

[0063] S4, repeat steps S1 to S3:

[0064] Repeating steps S1 to S3 in sequence according to a predetermined manufacturing path and number of layers until the overall manufacturing of the component is completed;

[0065] S5. Overall post-processing:

[0066] The finished components are subjected to stress release heat treatment to eliminate internal residual stress. At the same time, surface processing is carried out to remove the excess height and melting depth of the last layer of low-power powder feeding compensation manufacturing. The surface morphology is refined through the laser heat source combined with coaxial molten pool monitoring to ensure that the components meet the preset dimensional accuracy and quality requirements.

[0067] High-power fused wire additive manufacturing is the core starting step of this method. By using a high-power heat source, the metal wire is quickly heated to a molten state, and the material is deposited layer by layer through a precise moving path to build the basic structure. This step has the characteristics of high efficiency and high material utilization, and is suitable for rapid prototyping of large components. The heat input of the molten metal wire needs to be precisely controlled to ensure that the deposited layer has sufficient adhesion strength and geometric accuracy.

[0068] After completing the manufacturing of the fuse of the base layer, the temperature-controlled deformed material forging stage begins. By heating the deposited structure locally or as a whole, and then applying mechanical forging pressure for plastic deformation, the internal grains of the structure are refined, and the material density and mechanical properties are improved. This process, combined with temperature control technology, avoids the problems of thermal cracks or uneven material properties that may occur during the forging process, while effectively improving the internal residual stress.

[0069] After forging is completed, powder feeding compensation manufacturing is carried out through a low-power heat source. This step accurately compensates for geometric errors or surface defects that may occur during filament additive and forging processes through low heat input. The powder feeding equipment can form a fine molten layer by controlling the powder flow and laser path to ensure the appearance quality and dimensional accuracy of the final component.

[0070] The above steps (S1-S3) form a complete cycle process, and complex shapes or large-sized components can be gradually manufactured through multiple cycles. Each round of fused additive manufacturing and forging deformation will further optimize the performance of the component, while compensating manufacturing ensures the accuracy and integrity of the structure. The number of cycles is dynamically adjusted according to the design requirements of the component and the actual performance evaluation results.

[0071] After the component is manufactured, it needs to be post-processed as a whole, including heat treatment, surface finishing and performance testing. Heat treatment is used to eliminate residual stress and further optimize material properties; surface finishing can improve the surface quality of the component through machining or surface coating technology; performance testing ensures that the final product meets the use standards.

[0072] This method realizes a high-efficiency, high-precision and high-performance composite manufacturing process by combining the advantages of additive manufacturing and forging deformation through the collaborative work of multiple heat sources. The combination of high-power and low-power heat sources not only meets the needs of rapid prototyping, but also ensures the accuracy of details. This method is particularly suitable for the manufacture of aerospace, energy equipment and complex parts, and has broad industrial application prospects.

[0073] The substrate to be processed is placed on the support unit, which ensures the stability of the substrate during the manufacturing process through precise positioning. The support unit not only provides mechanical support, but also ensures that the substrate is always within the working range of the first six-axis robot and the first heat source 11 through fine-tuning function, so that the first molten pool 14 formed by the welding wire 12 and the arc 13 on the substrate has a high-quality initial combination.

[0074] The first additive manufacturing unit consists of a first six-axis robot and a first heat source 11. The first six-axis robot moves along a preset trajectory and controls the welding wire 12 to melt at high temperature through the arc 13 to form a first molten pool 14, completing high-power fused wire additive manufacturing on the substrate. Through this process, the welding wire material is accumulated layer by layer to form a new additive layer, providing a basis for subsequent processing. The high-power characteristics of this unit can quickly deposit materials to build the initial additive layer.

[0075] The iso-material manufacturing unit is composed of a three-axis motion mechanism and a deformation mechanism 21. The deformation mechanism 21 is accurately positioned on the surface of the additive layer by moving the three-axis motion mechanism in the X, Y and Z directions. After the first additive manufacturing unit completes a layer of additive manufacturing, the iso-material manufacturing unit synchronously forges the newly generated additive layer, applies pressure to the material through the deformation mechanism, makes the internal structure of the additive material more compact, and improves the strength and surface quality of the material.

[0076] The second additive manufacturing unit consists of a second six-axis robot and a second heat source. After the isomaterial manufacturing unit completes forging, the second six-axis robot guides the laser head 31 to emit a laser beam 32 through trajectory control, uses powder 33 to form a second molten pool 35, and deposits the molten powder on the surface of the additive layer after forging deformation. The application of a low-power laser heat source can accurately control the amount and area of ​​powder deposition, thereby performing surface compensation and size correction on the additive layer.

[0077] The infrared thermal imager 22 and the molten pool monitor 36 monitor in real time the temperature distribution and size change of the first molten pool 14 and the second molten pool 35. The monitoring data is transmitted to the control center, which adjusts the power of the first heat source 11 and the second heat source according to the real-time feedback, and optimizes the trajectory of the first six-axis robot and the second six-axis robot, thereby achieving dynamic adjustment to ensure that the shape of the additive layer is consistent with the target.

[0078] The cleaning unit promptly cleans the excess powder 33 and impurities generated during the deposition process to ensure the cleanliness of the additive area. The heating unit preheats the substrate and the additive area to reduce the impact of thermal stress during the processing and improve the material quality. The purification unit controls the purity of the atmosphere to avoid oxidation and ensure that the laser beam 32 maintains a stable transmission efficiency during the melting process of the powder 33.

[0079] Through the high-power additive manufacturing of the first heat source 11, the synchronous forging of the deformation mechanism 21, the low-power compensation manufacturing of the second heat source and the real-time regulation of the monitoring unit, each unit cooperates closely and finally realizes a high-precision, high-performance multi-heat source additive composite manufacturing process.

[0080] The high-power fuse provided in the embodiment of the present invention adopts an arc 13 heat source or a laser-arc 13 composite heat source, and the welding wire 12 adopts a cold wire or a hot wire for single-wire or multi-wire feeding.

[0081] The equal material forging provided in the embodiment of the present invention includes mechanical rolling, mechanical hammering or ultrasonic impact. The matching forging pressure and forging temperature are determined by combining the thermal processing diagram and macro-microstructure simulation, and the infrared thermal imager 22 is used to monitor the surface temperature of the additive layer online to adjust the forging position in real time.

[0082] The low-power powder feeding provided in the embodiment of the present invention adopts a laser heat source, and the compensation manufacturing adopts a Z-shaped track free deposition, and the deposition width is consistent with the high-power fuse deposition width in step S1, and the melting depth L P No more than 0.3mm, residual height L R And penetration L P Total height and additive remelting depth A in step S1 P Consistent.

[0083] S3 provided in the embodiment of the present invention is performed synchronously, and the depth A of the heat-affected zone of the next layer of additive manufacturing in step S1 is HAZ Only cover to the bottom of the previous layer with deformation depth (high power melting depth A) outside the compensation manufacturing remelting in step S3 P + Residual height after high power deformation A h - Low power melting depth L P ), which is used to completely drive the static recrystallization of the medium material forging in step S2.

[0084] The overall post-processing in step S4 provided in the embodiment of the present invention includes stress release and surface processing, and removes the excess height and penetration of the last layer of low-power powder feeding compensation manufacturing;

[0085] The laser heat source uses coaxial molten pool monitoring to perform synchronous surface morphology monitoring to provide feedback on the morphology of the deposited layer after deformation in the refinement step S2.

[0086] like Figure 2 , 4 As shown, a multi-heat source additive manufacturing system provided by an embodiment of the present invention includes:

[0087] A first additive manufacturing unit, a second additive manufacturing unit, an equal material manufacturing unit, a support unit, a cleaning unit, a heating unit, a purification unit, a monitoring unit, and a control center;

[0088] The first additive manufacturing unit, the second additive manufacturing unit, the equal material manufacturing unit, the support unit, the cleaning unit, the heating unit, the purification unit and the monitoring unit are electrically connected to the control center respectively;

[0089] The substrate of the forged part to be additively manufactured is placed on a support unit, and a first additive manufacturing unit additively manufactures an additive layer on the substrate using a high-power fuse;

[0090] The isomaterial manufacturing unit performs synchronous isomaterial forging and compounding on the newly generated additive layer, and the second additive manufacturing unit performs synchronous low-power powder feeding additive manufacturing compensation layer on the additive layer after forging deformation;

[0091] The first additive manufacturing unit includes a first six-axis robot and a first heat source 11 connected to each other, and the first six-axis robot controls the first heat source 11 to move along a preset trajectory;

[0092] The material manufacturing unit includes a three-axis motion mechanism and a deformation mechanism 21 connected to each other;

[0093] The three-axis motion mechanism can move along the three dimensions of X, Y, and Z to control the deformation mechanism 21 to cooperate with the first additive manufacturing unit to perform forging;

[0094] The second additive manufacturing unit includes a second six-axis robot and a second heat source connected to each other, and the second six-axis robot controls the second heat source to move along a preset trajectory.

[0095] Another object of the present invention is to provide a computer device, comprising a memory and a processor, wherein the memory stores a computer program, and when the computer program is executed by the processor, the processor executes the steps of the multi-heat source additive manufacturing method.

[0096] For details, see Figure 2-Figure 3 A two-axis positioner is used to clamp the substrate, a stainless steel brush (cleaning unit) is used to remove the oxide layer on the surface of the substrate and wipe it with anhydrous alcohol, a cleaning and purification system (purification unit) is used to seal and purify the cabin until the water oxygen value is lower than 50ppm, and finally a bottom heating plate (heating unit) is used to preheat the substrate until the upper surface temperature reaches 100℃ before multi-heat source material composite manufacturing is carried out. A cleaning and purification system is used in the manufacturing environment to maintain the water oxygen value below 50ppm.

[0097] The high-power fuse uses a laser-Tig arc 13 composite heat source, a flat-top distribution continuous laser power of 800W, a spot diameter of 3mm, a Tig current of 210A, and a 1.2mm wire diameter TC4 titanium alloy cold wire for single wire feeding. The wire feeding speed is 4m / min and the forming speed is 350mm / min. The equal material forging uses mechanical rolling, the rolling flat roller diameter is 20mm, the mechanical rolling temperature is 920-980℃, and the mechanical rolling pressure is 10000N. The rolling position is adjusted in real time by online monitoring of the temperature of the roller and the additive layer contact entrance position by an infrared thermal imager 22. The roller and the laser-arc 13 composite heat source have the same trajectory and move synchronously. Low-power powder feeding uses a flat-top distributed laser heat source, continuous laser power 1200W, powder feeding speed 6g / min, spot diameter 3mm, Z-shaped track free deposition, forming speed 350mm / min, lateral scanning speed 500mm / min, scanning width is consistent with high-power fuse deposition width, melting depth L P About 0.2mm, residual height L R And penetration L P Total height and additive remelting depth A P The depth of the heat affected zone of the last layer of high power fuse deposition is A. HAZ Cover the bottom of the previous layer of high-power fuse deposition (about 2mm) that has been deformed and melted, and drive the static recrystallization of isotropic forging. Synchronously, the laser heat source uses coaxial molten pool monitoring to perform synchronous surface morphology monitoring, which is used to feedback the morphology of the deposited layer after fine-tuning isotropic forging. The overall post-processing includes stress release and surface processing to remove the excess height and melt depth of the last layer of low-power powder feeding compensation.

[0098] The titanium alloy forgings formed by the above-mentioned multi-heat source material addition composite manufacturing method have uniform grain size (about 180μm), and no defects are shown in X-ray detection (detection accuracy 75μm), which meets the use requirements of forgings.

[0099] The substrate to be processed is placed on the support unit, which ensures the stability of the substrate during the manufacturing process through precise positioning. The support unit not only provides mechanical support, but also ensures that the substrate is always within the working range of the first six-axis robot and the first heat source 11 through fine-tuning function, so that the first molten pool 14 formed by the welding wire 12 and the arc 13 on the substrate has a high-quality initial combination.

[0100] The first additive manufacturing unit consists of a first six-axis robot and a first heat source 11. The first six-axis robot moves along a preset trajectory and controls the welding wire 12 to melt at high temperature through the arc 13 to form a first molten pool 14, completing high-power fused wire additive manufacturing on the substrate. Through this process, the welding wire material is accumulated layer by layer to form a new additive layer, providing a basis for subsequent processing. The high-power characteristics of this unit can quickly deposit materials to build the initial additive layer.

[0101] The iso-material manufacturing unit is composed of a three-axis motion mechanism and a deformation mechanism 21. The deformation mechanism 21 is accurately positioned on the surface of the additive layer by moving the three-axis motion mechanism in the X, Y and Z directions. After the first additive manufacturing unit completes a layer of additive manufacturing, the iso-material manufacturing unit synchronously forges the newly generated additive layer, applies pressure to the material through the deformation mechanism, makes the internal structure of the additive material more compact, and improves the strength and surface quality of the material.

[0102] The second additive manufacturing unit consists of a second six-axis robot and a second heat source. After the isomaterial manufacturing unit completes forging, the second six-axis robot guides the laser head 31 to emit a laser beam 32 through trajectory control, uses powder 33 to form a second molten pool 35, and deposits the molten powder on the surface of the additive layer after forging deformation. The application of a low-power laser heat source can accurately control the amount and area of ​​powder deposition, thereby performing surface compensation and size correction on the additive layer.

[0103] The infrared thermal imager 22 and the molten pool monitor 36 monitor in real time the temperature distribution and size change of the first molten pool 14 and the second molten pool 35. The monitoring data is transmitted to the control center, which adjusts the power of the first heat source 11 and the second heat source according to the real-time feedback, and optimizes the trajectory of the first six-axis robot and the second six-axis robot, thereby achieving dynamic adjustment to ensure that the shape of the additive layer is consistent with the target.

[0104] The cleaning unit promptly cleans the excess powder 33 and impurities generated during the deposition process to ensure the cleanliness of the additive area. The heating unit preheats the substrate and the additive area to reduce the impact of thermal stress during the processing and improve the material quality. The purification unit controls the purity of the atmosphere to avoid oxidation and ensure that the laser beam 32 maintains a stable transmission efficiency during the melting process of the powder 33.

[0105] Through the high-power additive manufacturing of the first heat source 11, the synchronous forging of the deformation mechanism 21, the low-power compensation manufacturing of the second heat source and the real-time regulation of the monitoring unit, each unit cooperates closely and finally realizes a high-precision, high-performance multi-heat source additive composite manufacturing process.

[0106] The above description is only a specific implementation mode of the present invention, but the protection scope of the present invention is not limited thereto. Any modifications, equivalent substitutions and improvements made by any technician familiar with the technical field within the technical scope disclosed by the present invention and within the spirit and principle of the present invention should be covered by the protection scope of the present invention.

Claims

1. A multi-heat source additive manufacturing method, characterized in that: The following steps are involved: S1. Additive manufacturing of high-power fuses: An arc heat source or a laser-arc composite heat source is used to melt the welding wire, which can be a cold wire or a hot wire, and a single wire or multiple wire feeding method is used to deposit the metal material; S2. Temperature controlled deformed material forging: After completing the additive manufacturing of each layer of high-power fuse, the deposited layer is subjected to temperature-controlled deformation forging. The forging process includes mechanical rolling, mechanical hammering or ultrasonic impact. The forging temperature is controlled within the material recrystallization temperature range to achieve microstructure refinement, eliminate residual stress and improve interlayer bonding strength. S3, low power powder feeding compensation manufacturing: Using a laser heat source, the surface area is compensated by a Z-track free deposition method. The deposition width of the compensation manufacturing is consistent with the deposition width of the high-power fuse in step S1, the melting depth does not exceed 0.3mm, and the total height of the deposition residual height and the melting depth is consistent with the additive remelting depth in step S1, so as to optimize the surface morphology and accuracy; S4, repeat steps S1 to S3: Repeating steps S1 to S3 in sequence according to a predetermined manufacturing path and number of layers until the overall manufacturing of the component is completed; S5. Overall post-processing: The finished components are subjected to stress release heat treatment to eliminate internal residual stress. At the same time, surface processing is carried out to remove the excess height and melting depth of the last layer of low-power powder feeding compensation manufacturing. The surface morphology is refined through the laser heat source combined with coaxial molten pool monitoring to ensure that the components meet the preset dimensional accuracy and quality requirements.

2. The multi-heat source additive manufacturing method according to claim 1, characterized in that: In step S1, the high-power fuse uses an arc heat source or a laser-arc composite heat source, and the welding wire uses a cold wire or a hot wire to be fed in single wire or multiple wires.

3. The multi-heat source additive manufacturing method according to claim 1, characterized in that: In step S2, the material forging includes mechanical rolling, mechanical hammering or ultrasonic impact.

4. The multi-heat source additive manufacturing method according to claim 1, characterized in that: In step S3, the low-power powder feeding adopts a laser heat source, and the compensation manufacturing adopts a Z-track free deposition. The deposition width is consistent with the high-power fuse deposition width in step S1, and the melting depth L P No more than 0.3mm, residual height L R And penetration L P Total height and additive remelting depth A in step S1 P Consistent.

5. The multi-heat source additive manufacturing method according to claim 1, characterized in that: Steps S1 to S3 are performed simultaneously. In step S1, the depth of the heat-affected zone of the next layer of additive manufacturing is A. HAZ Only cover to the bottom of the previous layer with deformation depth (high power melting depth A) outside the compensation manufacturing remelting in step S3 P + Residual height after high power deformation A h - Low power melting depth L P ), which is used to completely drive the static recrystallization of the medium material forging in step S2.

6. The multi-heat source additive manufacturing method according to claim 1, characterized in that: The overall post-processing in step S4 includes stress release and surface processing to remove the excess height and fusion depth of the last layer of low-power powder feeding compensation manufacturing; The laser heat source uses coaxial molten pool monitoring to perform synchronous surface morphology monitoring to provide feedback on the morphology of the deposited layer after deformation in the refinement step S2.

7. A multi-heat source additive manufacturing system for implementing the multi-heat source additive manufacturing method according to any one of claims 1 to 6, characterized in that: The multi-heat source additive manufacturing system comprises: A first additive manufacturing unit, a second additive manufacturing unit, an equal material manufacturing unit, a support unit, a cleaning unit, a heating unit, a purification unit, a monitoring unit, and a control center; The first additive manufacturing unit, the second additive manufacturing unit, the equal material manufacturing unit, the support unit, the cleaning unit, the heating unit, the purification unit and the monitoring unit are electrically connected to the control center respectively; The substrate of the forged part to be additively manufactured is placed on a support unit, and a first additive manufacturing unit additively manufactures an additive layer on the substrate using a high-power fuse; The isomaterial manufacturing unit performs synchronous isomaterial forging and compounding on the newly generated additive layer, and the second additive manufacturing unit performs synchronous low-power powder feeding additive manufacturing compensation layer on the additive layer after forging deformation; The first additive manufacturing unit includes a first six-axis robot and a first heat source connected to each other, and the first six-axis robot controls the first heat source to move along a preset trajectory; The material manufacturing unit includes a three-axis motion mechanism and a deformation mechanism connected to each other; The three-axis motion mechanism can move along three dimensions of X, Y, and Z to control the deformation mechanism to cooperate with the first additive manufacturing unit to perform forging; The second additive manufacturing unit includes a second six-axis robot and a second heat source connected to each other, and the second six-axis robot controls the second heat source to move along a preset trajectory.

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