A multi-heat source additive manufacturing method and system

Abstract

The present invention belongs to the field of additive manufacturing technology, and discloses a multi-heat source additive manufacturing method and system. The present invention provides a multi-heat source additive manufacturing method, including the steps of: S1, high-power fuse additive manufacturing; S2, temperature-controlled deformation additive forging; S3, low-power powder feeding compensation manufacturing; S4, overall post-processing. The present invention uses a control method for compensating the high-power fuse additive remelting area with low-power powder feeding additive, retains the deformed area of ​​fuse temperature-controlled additive forging, reduces the post-heat input of static recrystallization, and refines the additive forging surface to achieve high-efficiency, high-precision, and high-performance composite manufacturing. The present invention also provides a forming system that cooperates with this method, which can solve the contradiction between the high-performance additive large deformation residual height and the high-efficiency additive large heat input remelting in the existing additive composite manufacturing process, effectively suppress the growth of grains in the post-heat static recrystallization process, and successfully achieve high-efficiency, high-precision additive composite manufacturing of fine-grained forgings.

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, problems such as low production efficiency, low material utilization rate and high processing cost of traditional segmented forging and splicing manufacturing are becoming 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 (AM) technology utilizes a path planning code derived from slicing a solid 3D model to drive a motion mechanism, achieving layer-by-layer cladding of metal parts. This technology offers advantages such as high material utilization, high deposition efficiency, low manufacturing cost, and high part density, making it an effective method for the integral fabrication of load-bearing components. However, the macrostructure of a single AM ​​process exhibits a chaotic interweaving of columnar and equiaxed crystals, resulting in fatigue performance that rivals that of forged components. The introduction of isocratic forging (Isocratic forging) into the AM process can induce plastic deformation of the deposited material, break up dendrites, increase the heterogeneous nucleation rate, and thus promote grain refinement, and has been extensively studied in recent years. However, the significant conflict between the high-performance isocratic forging's low residual height during large deformations and the high-heat input remelting required for high-efficiency AM processes hinders the effective region for recrystallization. Furthermore, the greater the heat input, the deeper the remelting, leading to grain growth during post-heat static recrystallization, further weakening the grain refinement effect of Isocratic forging. Furthermore, issues with melt pool stability and deposited layer surface quality associated with high-efficiency AM processes can lead to insufficient manufacturing precision and lack of fusion defects.

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

[0005] The significant conflict between the high-performance, high-residual deformation of high-performance isotope materials and the high-heat-input remelting required for high-efficiency additive manufacturing hinders the effective zone for recrystallization during deformation. Furthermore, the greater the heat input, the deeper the remelting, leading to grain growth during post-heat static recrystallization, further weakening the grain refinement effect of isotope forging. Furthermore, issues with melt pool stability and deposited layer surface quality brought about by high-efficiency additive manufacturing can easily lead to insufficient manufacturing precision and lack of fusion defects. Summary of the Invention

[0006] In response to 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 achieved by a multi-heat source additive manufacturing method comprising:

[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 adopts an arc heat source or a laser-arc composite heat source, and the welding wire adopts a cold wire or a hot wire for single-wire or multi-wire feeding.

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

[0014] Furthermore, in step S3, the low-power powder feeding 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, the remaining 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 of the heat-affected zone of the last layer of additive manufacturing in step S1 is A. HAZ Only covers the bottom of the previous layer of 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] Furthermore, the overall post-processing in step S4 includes stress release and surface processing to remove the excess height and penetration depth of the last layer of low-power powder feeding compensation.

[0017] The laser heat source uses coaxial melt 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] First additive manufacturing unit, second additive manufacturing unit, equal material manufacturing unit, support unit, cleaning unit, heating unit, purification unit, monitoring unit, 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 workpiece to be additively forged is placed on a support unit, and the first additive manufacturing unit additively manufactures an additive layer on the substrate using a high-power fuse;

[0022] The isotropic manufacturing unit performs synchronous isotropic 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 the 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, which includes 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, causes 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 order to solve the serious contradiction between the low residual height of high-performance equal-material with large deformation and the serious remelting of high-efficiency additive 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, and solve the problems of insufficient retention of deformation recrystallization area and growth of recrystallized grains.

[0032] In order to address the problems of melt pool stability and deposited layer surface morphology quality caused by high-efficiency additive manufacturing, which can 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 to provide feedback on the deposited layer morphology after fine-tuning and deformation, thereby achieving efficient 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 wanted to solve but have never been able to successfully solve. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 This 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 structural diagram of a manufacturing system provided by an embodiment of the present invention.

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

[0037] Figure 4 This 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 solutions 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 intended to limit the present invention.

[0040] Example 1: Manufacturing of aircraft engine blades

[0041] Aircraft engine blades have complex curved geometry and strict mechanical performance requirements. This embodiment uses 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 ​​regionally heated and subjected to forging deformation, with special strengthening treatment being performed on 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 multiple times to cycle the above process until the entire blade shape and key parts are strengthened.

[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, and are suitable for small-batch customized production of complex geometries.

[0048] Example 2: Manufacturing of large ship propellers

[0049] Large marine propellers are typically manufactured from copper or titanium alloys, offering high strength, corrosion resistance, and complex three-dimensional curved surfaces. Traditional casting processes struggle to meet these high-precision and high-performance requirements. This embodiment utilizes a multi-heat-source additive composite manufacturing method to achieve efficient and refined processing.

[0050] Using high-power arc fuse equipment, the rough geometry of the propeller, including the blades and center hub section, was 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 edges and surfaces of the blades, low-power powder feeding technology is used to repair deformation errors 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 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 Fuse Filaments:

[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 multi-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, a Z-shaped free deposition method is used to compensate the surface area. The compensation deposition width is consistent with the high-power fuse deposition width in step S1, the penetration depth does not exceed 0.3mm, and the total height of the deposition residual height and penetration depth is consistent with the additive remelting depth in step S1 to optimize the surface morphology and accuracy.

[0063] S4. Repeat steps S1 to S3:

[0064] Repeat steps S1 to S3 in sequence according to the predetermined manufacturing path and number of layers until the entire component is manufactured;

[0065] S5. Overall post-processing:

[0066] The completed components are subjected to stress relief heat treatment to eliminate internal residual stress; at the same time, surface processing is carried out to remove the excess height and penetration of the last layer of low-power powder feeding compensation. The surface topography 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 filament additive manufacturing (FAM) is the core initial step of this method. Using a high-power heat source, a metal filament is rapidly heated to a molten state. Material is then deposited layer by layer along a precise path to build the base structure. This process offers high efficiency and material utilization, making it suitable for the rapid prototyping of large components. The heat input to the molten filament must be precisely controlled to ensure sufficient adhesion and geometric accuracy of the deposited layers.

[0068] After completing the base layer's fused filament fabrication, the temperature-controlled deformable material forging phase begins. By locally or globally heating the deposited structure and then applying mechanical forging pressure to plastically deform it, the internal grain size is refined, improving the material's density and mechanical properties. This process, combined with temperature control technology, avoids potential thermal cracking and uneven material properties during forging, while effectively reducing internal residual stresses.

[0069] After forging is complete, powder feeding and compensation manufacturing is performed using a low-power heat source. This step precisely compensates for geometric errors or surface defects that may occur during the fused filament additive manufacturing and forging processes using low heat input. The powder feeding equipment controls the powder flow rate and laser path to form a fine molten layer, ensuring the final component's appearance quality and dimensional accuracy.

[0070] The above steps (S1-S3) form a complete cycle, allowing for the gradual fabrication of complex shapes or large-scale components through multiple cycles. Each round of fused filament additive manufacturing and forging deformation further optimizes component performance, while compensating manufacturing ensures structural accuracy and integrity. The number of cycles is dynamically adjusted based on component design requirements and actual performance evaluation results.

[0071] After component manufacturing is complete, it undergoes comprehensive post-processing, including heat treatment, surface finishing, and performance testing. Heat treatment eliminates residual stresses and further optimizes material properties; surface finishing improves component surface quality through machining or coating techniques; and performance testing ensures that the final product meets applicable standards.

[0072] This method utilizes multiple heat sources in synergy, combining the advantages of additive manufacturing and forging deformation to achieve a highly efficient, precise, and high-performance composite manufacturing process. The combination of high-power and low-power heat sources meets the demands of rapid prototyping while ensuring precise detail. This method is particularly well-suited for the manufacture of complex components in aerospace, energy equipment, and other industries, and holds broad industrial application prospects.

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

[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 pre-set trajectory while controlling the welding wire 12 to melt at high temperatures generated by an arc 13, forming a first molten pool 14. This completes high-power fused wire additive manufacturing on the substrate. Through this process, the welding wire material accumulates layer by layer, forming a new additive layer, providing a foundation for subsequent processing. The unit's high power allows for rapid material deposition to build the initial additive layer.

[0075] The Iso-Material Manufacturing Unit (IMM) consists of a three-axis motion mechanism and a deformation mechanism 21. The deformation mechanism 21 is precisely positioned on the surface of the additive layer through X, Y, and Z motion of the three-axis motion mechanism. After the first AM unit completes a layer of additive manufacturing, the Iso-Material Manufacturing Unit simultaneously forges the newly generated additive layer. The deformation mechanism applies pressure to the material, densifying the internal structure of the additive material while improving its strength and surface quality.

[0076] The second additive manufacturing unit consists of a second six-axis robot and a second heat source. After the isotropic manufacturing unit completes forging, the second six-axis robot uses trajectory control to guide a laser head 31 to emit a laser beam 32, using powder 33 to form a second molten pool 35. The molten powder is then deposited onto the surface of the forged, deformed additive layer. The use of a low-power laser heat source enables precise control of the amount and area of ​​powder deposition, enabling surface compensation and dimensional correction of the additive layer.

[0077] Infrared thermal imager 22 and melt pool monitor 36 monitor the temperature distribution and dimensional changes of first and second melt pools 14, 35 in real time. This monitoring data is transmitted to the control center, which adjusts the power of first and second heat sources 11 based on the real-time feedback and optimizes the trajectories of the first and second six-axis robots. This allows for dynamic adjustments to ensure that the additive layer shape matches the target.

[0078] The cleaning unit promptly removes excess powder 33 and impurities generated during the deposition process, ensuring the cleanliness of the additive area. The heating unit preheats the substrate and additive area to reduce thermal stress during processing and improve material quality. The purification unit controls the purity of the ambient atmosphere to prevent oxidation and ensure stable transmission efficiency of the laser beam 32 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 works closely together to ultimately achieve 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 map 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 by 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, the remaining height L R and penetration L P Total height and additive remelting depth A in step S1 P consistent.

[0083] The S3 provided in the embodiment of the present invention is performed simultaneously. The depth A of the heat-affected zone of the latter layer of additive manufacturing in step S1 is HAZ Only covers the bottom of the previous layer of 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.

[0085] The laser heat source uses coaxial melt 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, an embodiment of the present invention provides a multi-heat source additive manufacturing system comprising:

[0087] First additive manufacturing unit, second additive manufacturing unit, equal material manufacturing unit, support unit, cleaning unit, heating unit, purification unit, monitoring unit, 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 workpiece to be additively forged is placed on a support unit, and the first additive manufacturing unit additively manufactures an additive layer on the substrate using a high-power fuse;

[0090] The isotropic manufacturing unit performs synchronous isotropic 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, which includes 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 additive manufacturing is carried out. The manufacturing environment uses a cleaning and purification system to maintain the water oxygen value below 50ppm.

[0097] The high-power fuse utilizes a laser-Tig arc 13 composite heat source, with a flat-top continuous laser power of 800W, a spot diameter of 3mm, and a Tig current of 210A. The welding wire 12 uses 1.2mm diameter TC4 titanium alloy cold wire, fed single-wire at a feed speed of 4m / min and a forming speed of 350mm / min. The uniform material forging utilizes mechanical rolling, with a 20mm diameter flat roller, a mechanical rolling temperature of 920-980°C, and a mechanical rolling pressure of 10,000N. The rolling position is adjusted in real time by online monitoring of the temperature at the contact point between the roller and the additive layer using an infrared thermal imager 22. The roller and the laser-arc 13 composite heat source follow a consistent and synchronized trajectory. Low-power powder feeding adopts 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, horizontal 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 This covers the bottom of the deformed melt depth (approximately 2mm) of the previous high-power fuse deposit, driving static recrystallization during isotropic forging. Simultaneously, the laser heat source utilizes coaxial melt pool monitoring for simultaneous surface topography monitoring, providing feedback on the deposited layer morphology after refinement of isotropic forging. Post-processing includes stress relief and surface finishing to remove the excess height and melt depth created by the final low-power powder feed compensation layer.

[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 radiographic inspection (detection accuracy 75μm), which meets the requirements for the use of forgings.

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

[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 pre-set trajectory while controlling the welding wire 12 to melt at high temperatures generated by an arc 13, forming a first molten pool 14. This completes high-power fused wire additive manufacturing on the substrate. Through this process, the welding wire material accumulates layer by layer, forming a new additive layer, providing a foundation for subsequent processing. The unit's high power allows for rapid material deposition to build the initial additive layer.

[0101] The Iso-Material Manufacturing Unit (IMM) consists of a three-axis motion mechanism and a deformation mechanism 21. The deformation mechanism 21 is precisely positioned on the surface of the additive layer through X, Y, and Z motion of the three-axis motion mechanism. After the first AM unit completes a layer of additive manufacturing, the Iso-Material Manufacturing Unit simultaneously forges the newly generated additive layer. The deformation mechanism applies pressure to the material, densifying the internal structure of the additive material while improving its strength and surface quality.

[0102] The second additive manufacturing unit consists of a second six-axis robot and a second heat source. After the isotropic manufacturing unit completes forging, the second six-axis robot uses trajectory control to guide a laser head 31 to emit a laser beam 32, using powder 33 to form a second molten pool 35. The molten powder is then deposited onto the surface of the forged, deformed additive layer. The use of a low-power laser heat source enables precise control of the amount and area of ​​powder deposition, enabling surface compensation and dimensional correction of the additive layer.

[0103] Infrared thermal imager 22 and melt pool monitor 36 monitor the temperature distribution and dimensional changes of first and second melt pools 14, 35 in real time. This monitoring data is transmitted to the control center, which adjusts the power of first and second heat sources 11 based on the real-time feedback and optimizes the trajectories of the first and second six-axis robots. This allows for dynamic adjustments to ensure that the additive layer shape matches the target.

[0104] The cleaning unit promptly removes excess powder 33 and impurities generated during the deposition process, ensuring the cleanliness of the additive area. The heating unit preheats the substrate and additive area to reduce thermal stress during processing and improve material quality. The purification unit controls the purity of the ambient atmosphere to prevent oxidation and ensure stable transmission efficiency of the laser beam 32 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 works closely together to ultimately achieve a high-precision, high-performance multi-heat source additive composite manufacturing process.

[0106] The above description is only a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications, equivalent substitutions and improvements made by any technician familiar with this technical field within the technical scope disclosed by the present invention and within the spirit and principles of the present invention should be covered by the scope of protection 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 Fuse Filaments: 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 multi-wire feeding method is used to deposit the metal material; S2, temperature controlled deformation and other 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, a Z-shaped free deposition method is used to compensate the surface area. The compensation deposition width is consistent with the high-power fuse deposition width in step S1, the penetration depth does not exceed 0.3mm, and the total height of the deposition residual height and penetration depth is consistent with the additive remelting depth in step S1 to optimize the surface morphology and accuracy. S4. Repeat steps S1 to S3: Repeat steps S1 to S3 in sequence according to the predetermined manufacturing path and number of layers until the entire component is manufactured; S5. Overall post-processing: The completed components are subjected to stress relief heat treatment to eliminate internal residual stress; at the same time, surface processing is carried out to remove the excess height and penetration of the last layer of low-power powder feeding compensation. The surface topography 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, wherein: In step S3, the low-power powder feeding adopts a laser heat source, and the compensation manufacturing adopts a Z-shaped 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, the remaining height L R and penetration L P Total height and additive remelting depth A in step S1 P consistent.

3. The multi-heat source additive manufacturing method according to claim 2, characterized in that: The depth A of the heat-affected zone of the last layer of additive manufacturing in step S1 HAZ Only covers the bottom of the previous layer of deformation depth outside the compensation manufacturing remelting in step S3, high power melting depth A P + Residual height after high power deformation A h -Low power melting depth L P , used to completely drive the static recrystallization of the medium material forging in step S2.

4. The multi-heat source additive manufacturing method according to claim 1, wherein: The overall post-processing in step S5 includes stress release and surface processing to remove the excess height and penetration depth of the last layer of low-power powder feeding compensation; The laser heat source uses coaxial melt 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.

5. A multi-heat source additive manufacturing system for implementing the multi-heat source additive manufacturing method according to any one of claims 1 to 4, characterized in that: The multi-heat source additive manufacturing system includes: First additive manufacturing unit, second additive manufacturing unit, equal material manufacturing unit, support unit, cleaning unit, heating unit, purification unit, monitoring unit, 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 part to be additively forged is placed on the support unit, and the first additive manufacturing unit additively manufactures an additive layer on the substrate using a high-power fuse; The isotropic manufacturing unit performs synchronous isotropic 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 isotropic manufacturing unit includes a three-axis motion mechanism and a deformation mechanism connected to each other; The three-axis motion mechanism can move along the 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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