Electric arc-laser composite synchronous in-situ micro-rolling additive manufacturing device and method
Through the arc-laser composite synchronous in-situ micro-rolling additive manufacturing device, the laser heat source is used to increase the heat input and regulate the melt pool. Combined with synchronous micro-rolling, the problems of precision and coarse grains in arc additive manufacturing are solved, and efficient and high-quality additive manufacturing effects are achieved.
Patent Information
- Application Number
- CN202510549635.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-28
- Publication Date
- 2025-07-04
AI Technical Summary
The existing arc additive manufacturing technology has low energy density and large heat-affected zones, resulting in low manufacturing accuracy and coarse grains of finished parts, making it difficult to meet the manufacturing requirements of high-quality, efficient and low-cost in actual production.
The arc-laser composite synchronous in-situ micro-rolling additive manufacturing device is adopted to increase the heat input through the laser heat source as an auxiliary heat source, and the melt pool is regulated by a galvanometer, combined with synchronous micro-rolling technology, high-efficiency and high-quality additive manufacturing is achieved.
It significantly improves the deposition efficiency of additive manufacturing, reduces the number of pores, realizes grain refinement, improves the strength and formation quality of the material, and simplifies the subsequent processing process.
Smart Images
Figure CN120244258A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of additive manufacturing technology, and particularly to an arc-laser composite synchronous in-situ micro-rolling additive manufacturing device and method. Background Art
[0002] Compared with traditional manufacturing technologies, additive manufacturing, as a technology that directly manufactures digital models into three-dimensional solid parts in a layer-by-layer stacking manner, has the advantages of high speed and low cost. Using additive manufacturing technology, the integrated additive manufacturing of complex parts can be realized. For difficult-to-machine materials, additive manufacturing shortens the manufacturing cycle of workpieces due to its advantage of small manufacturing allowance. Therefore, additive manufacturing technology is currently of great significance in occasions where difficult-to-machine materials are widely used, such as the aerospace field. As an important branch technology of metal additive manufacturing, arc additive manufacturing is widely used in the additive manufacturing industry due to its low cost and high efficiency. However, its low energy density and large heat-affected zone result in low manufacturing accuracy, large grains in the finished parts, and mechanical properties inferior to those of forgings. It is difficult to meet the manufacturing requirements of high quality, high efficiency, and low cost in the actual production process. Summary of the Invention
[0003] The purpose of this application is to provide an arc-laser composite synchronous in-situ micro-rolling additive manufacturing device and method, which utilize a laser composite heat source, perform laser regulation while increasing the energy density, and achieve high-efficiency, high-quality, and short-process additive manufacturing.
[0004] To achieve the above purpose, this application provides the following solutions:
[0005] In the first aspect, this application provides an arc-laser composite synchronous in-situ micro-rolling additive manufacturing device, including: a main heat source, a laser heat source, a welding wire, and a rolling device;
[0006] The main heat source, the laser heat source, the welding wire, and the rolling device are arranged on the same structure, and the main heat source, the laser heat source, the welding wire, and the rolling device move synchronously;
[0007] The laser heat source includes a galvanometer;
[0008] The galvanometer is used to make the laser emitted by the laser heat source swing.
[0009] Optionally, the galvanometer includes: an X-axis galvanometer and a Y-axis galvanometer; the amplitude of the galvanometer is 0 - 5 mm;
[0010] The relative position between the laser heat source and the welding wire can be adjusted;
[0011] The laser power of the laser heat source is 0 - 3000 w; the included angle between the laser incident angle and the main heat source is 30 - 60°.
[0012] Optionally, the main heat source, the laser heat source, the welding wire, and the rolling equipment are installed on the machine tool spindle and move synchronously with the machine tool spindle.
[0013] Optionally, the welding wire is located directly below the main heat source and is fixed to the same moving unit as the main heat source;
[0014] The rolling equipment is located behind the main heat source and is fixed to the same moving unit as the main heat source; the rolling equipment is used to perform in-situ synchronous rolling on the formed weld bead.
[0015] Optionally, the main heat source is a welding torch; the welding current of the welding torch is 0 - 300A;
[0016] The rolling equipment is a rolling mill.
[0017] Optionally, it further includes: an infrared thermal imager, a line laser detector, and a CCD camera;
[0018] The infrared thermal imager is used to monitor the temperature of the additive workpiece in real time during the forming process;
[0019] The line laser detector and the CCD camera are used to monitor the surface flatness and surface defects of the additive workpiece in real time during the forming process.
[0020] In a second aspect, the present application provides an arc-laser composite synchronous in-situ micro-rolling additive manufacturing method, including:
[0021] Obtain a forming path;
[0022] Generate a synchronous control instruction according to the forming path; the synchronous control instruction is used to control the synchronous movement of the main heat source, the laser heat source, the welding wire, and the rolling equipment;
[0023] After a molten pool is formed below the main heat source, control the laser heat source to emit laser light to the molten pool and make the laser light swing by controlling the galvanometer on the laser heat source;
[0024] After the molten pool solidifies, control the main heat source, the laser heat source, the welding wire, and the rolling equipment to perform in-situ synchronous hot rolling.
[0025] Optionally, after controlling the main heat source, the laser heat source, the welding wire, and the rolling equipment to perform in-situ synchronous hot rolling when the molten pool solidifies, it further includes:
[0026] Detect the additive workpiece obtained after in-situ synchronous hot rolling by using a line laser measuring instrument or a CCD camera;
[0027] When a defect is detected in the additive workpiece, control the laser light source to remelt the additive workpiece.
[0028] Optionally, when the temperature of the additive workpiece is lower than a preset threshold, the laser heat source is controlled to heat the additive workpiece.
[0029] Optionally, during the in-situ synchronous hot rolling process:
[0030] The main heat source current is controlled to be 160 - 260 A, the laser power of the laser heat source is 500 - 1500 W, the wire feeding speed of the welding wire is 2 - 4 m / min, and the rolling force of the hot rolling is 15 - 30 kN.
[0031] According to the specific embodiments provided by the present application, the following technical effects are disclosed in the present application:
[0032] The present application provides an arc-laser composite synchronous in-situ micro-rolling additive manufacturing device and method. The device includes: a main heat source, a laser heat source, a welding wire, and a rolling device; the main heat source, the laser heat source, the welding wire, and the rolling device are arranged on the same structure, and the main heat source, the laser heat source, the welding wire, and the rolling device move synchronously; wherein, the laser heat source includes a galvanometer; the galvanometer is used to swing the laser emitted by the laser heat source; the laser heat source is used to regulate the molten pool formed by the main heat source. In the present application, the laser heat source is used as an auxiliary heat source, so as to increase the heat input during the additive manufacturing process, significantly improve the deposition efficiency during the additive manufacturing process. At the same time, a galvanometer is provided in the laser heat source, and the laser emitted by the laser heat source is swung through the galvanometer, so as to regulate the molten pool formed by the main heat source, make the molten pool more uniform, and the oscillating laser accelerates the flow of the molten pool, enabling the small micropores generated in the molten pool during the additive manufacturing process to overflow from the molten pool faster, reducing the pore size and quantity during the additive forming process, and effectively improving the forming quality of the additive workpiece. Therefore, the present application uses a laser composite heat source and synchronous micro-rolling to perform laser regulation while increasing the energy density, realizing high-efficiency, high-quality, and short-process additive manufacturing. Description of the Drawings
[0033] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required to be used in the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.
[0034] Figure 1 Schematic structural diagram of a laser light source with X-direction and Y-direction galvanometers provided in an embodiment of the present application.
[0035] Figure 2 Schematic working principle diagram of an arc-laser composite synchronous in-situ micro-rolling additive manufacturing device provided in an embodiment of the present application.
[0036] Figure 3 Schematic diagram of the printing path formation process provided by an embodiment of the present application.
[0037] Figure 4 Schematic diagram of the defect detection process provided by an embodiment of the present application. Specific embodiments
[0038] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present application without creative efforts shall fall within the protection scope of the present application.
[0039] The present application realizes high-efficiency, high-quality and short-process additive manufacturing by using laser compounding and synchronous micro-rolling. The laser is used as an auxiliary heat source to increase the heat input and improve the forming efficiency of additive manufacturing. At the same time, the oscillating laser is used to regulate the molten pool, making the molten pool more uniform, and the oscillating laser accelerates the flow of the molten pool, enabling the small micropores generated in the molten pool during the additive manufacturing process to overflow from the molten pool faster.
[0040] In an exemplary embodiment, an arc-laser composite synchronous in-situ micro-rolling additive manufacturing device is provided, including: a main heat source, a laser heat source, a welding wire and a rolling device.
[0041] The main heat source, the laser heat source, the welding wire and the rolling device are arranged on the same structure, and the main heat source, the laser heat source, the welding wire and the rolling device move synchronously;
[0042] Among them, the laser heat source includes a galvanometer; the galvanometer is used to swing the laser emitted by the laser heat source; the laser heat source is used to regulate the molten pool formed by the main heat source.
[0043] The galvanometer in this embodiment includes: an X-direction galvanometer and a Y-direction galvanometer; the amplitude of the galvanometer is 0-5 mm. As Figure 1 shown, Figure 1 galvanometer 1 in is the X-direction galvanometer, and galvanometer 2 is the Y-direction galvanometer.
[0044] In this embodiment, the relative position of the laser heat source and the welding wire can be adjusted; the laser power of the laser heat source is 0-3000 w; the included angle between the laser incident angle and the main heat source is 30-60°.
[0045] The main heat source, the laser heat source, the welding wire and the rolling equipment are installed on the machine tool spindle and move synchronously with the machine tool spindle. In this embodiment, specifically, the welding torch, the wire feeder head, the laser head and the rolling mill are arranged on the machine tool spindle, and other larger structures such as the laser emitter and the arc emitter can be adaptively arranged.
[0046] The welding wire is located directly below the main heat source and is fixed to the same moving unit as the main heat source; the rolling equipment is located behind the main heat source and is fixed to the same moving unit as the main heat source; the rolling equipment is used for in-situ synchronous rolling of the formed weld bead.
[0047] In this embodiment, the main heat source is a welding torch; the welding current of the welding torch is 0 - 300A; the rolling equipment is a rolling mill.
[0048] When applying the above device for additive manufacturing, its working principle is as Figure 2 shown, and specifically, the following method can be selected:
[0049] During the manufacturing process, the moving unit drives the composite heat source (main heat source + laser heat source), the welding wire, and the rolling mill to move along the preset path. The laser head of the laser heat source and the welding torch melt the welding wire as heat sources, causing it to deposit on the substrate to form an additive workpiece. The rolling mill rolls the formed weld bead to improve its forming quality. The welding torch, as the main heat source during the manufacturing process, can use an arc welding torch / plasma arc welding torch. The welding wire should be fed directly below the welding torch, with a wire feeding speed of 0 - 6m / min, and is fixed to the same moving unit as the welding torch. The rolling mill is located behind the welding torch and is fixed to the same moving unit as the welding torch, performing in-situ synchronous rolling on the formed weld bead, with the rolling force ranging from 0 - 30000N. The forming method should be equipped with an infrared thermal imager, a line laser detector, and a CCD camera as detection devices to monitor the temperature, surface flatness, and surface defects during the forming process in real time.
[0050] This application utilizes synchronous micro-rolling to achieve synchronous grain refinement during the additive manufacturing process, realizes the additive manufacturing of equiaxed fine-grained parts, and comprehensively improves the strength and toughness of the material. Moreover, by means of synchronous in-situ micro-rolling, the performance of the formed product is enhanced, and post-treatment such as subsequent die forging or hot isostatic pressing is not required. At the same time, the surface is smoother after rolling, layer milling is not needed, and continuous forming can be achieved. In-situ synchronous micro-rolling of the weld bead after additive forming can subject the material to hot rolling after forming, resulting in dynamic recrystallization, transforming the initial coarse grains into fine equiaxed grains and realizing the grain refinement effect. There are existing technologies using synchronous micro-rolling to refine grains, but most of them are ultrasonic impact.
[0051] Compared with the prior art, this embodiment has the following remarkable features and advantages:
[0052] In this embodiment, the heat input during the additive manufacturing process can be increased by an arc-laser hybrid heat source, significantly improving the deposition efficiency during the additive manufacturing process.
[0053] In this embodiment, the molten pool is regulated by introducing an oscillating laser, accelerating the overflow of bubbles during the forming process, and reducing the size and quantity of pores during the additive forming process.
[0054] In this embodiment, the introduction of synchronous micro-rolling plays a role in grain refinement during the additive manufacturing process, and the comprehensive strength and toughness of the material are improved by obtaining ultrafine equiaxed fine grains.
[0055] Based on the same inventive concept, the embodiment of the present application also provides an arc-laser composite synchronous in-situ micro-rolling additive manufacturing method. The composite heat source, wire, and roller are driven by a motion unit to move along a preset path. The laser head and welding torch are used as heat sources to melt the wire, which is deposited on the substrate to form an additive workpiece. The roller rolls the formed weld bead to improve its forming quality, mainly including the following steps:
[0056] S1. Obtain the forming path.
[0057] S2. Generate a synchronous control instruction according to the forming path; the synchronous control instruction is used to control the synchronous movement of the main heat source, laser heat source, wire, and rolling equipment.
[0058] S3. After a molten pool is formed under the main heat source, control the laser heat source to emit laser light to the molten pool, and make the laser oscillate by controlling the galvanometer on the laser heat source.
[0059] S4. After the molten pool solidifies, control the main heat source, laser heat source, wire, and rolling equipment to perform in-situ synchronous hot rolling.
[0060] As a specific implementation manner, the following method can be selected in this embodiment to specifically complete the additive manufacturing process:
[0061] During the additive manufacturing process, the equipment first reads the forming path to determine the movement path of the equipment. Subsequently, an arc is formed between the welding torch and the substrate or the additive workpiece. The welding wire is fed into the arc and melted to form a molten pool directly below the welding torch. After the molten pool is formed, the laser is irradiated into the molten pool, and the galvanometer inside the laser head is used to swing the laser to control the molten pool (wherein, the galvanometer is installed inside the laser head, and the laser swings along the movement direction or perpendicular to the movement direction through the X-axis and Y-axis galvanometers and is irradiated into the molten pool, which can accelerate the flow of the molten pool and play a role in stirring the molten pool), accelerating the overflow of pores in the molten pool. The amplitude of the galvanometer is 0 - 5 mm, and the swing frequency is 0 - 500 Hz. The included angle between the laser incident angle and the welding torch is 30 - 60°. After the molten pool solidifies to form a weld bead, the rolling mill synchronously performs in-situ synchronous hot rolling on the weld bead (the rolling mill descends and rolls the just-formed weld bead according to the preset rolling force to achieve grain refinement of the weld bead and make the formed surface smoother). During the in-situ synchronous hot rolling process, the forming current is 160 - 260 A, the laser power is 500 - 1500 W, the wire feeding speed of the welding wire is 2 - 4 m / min, the forming walking speed is 200 - 400 mm / min, and the rolling force of the hot rolling is 15 - 30 kN.
[0062] The welding torch, laser head, welding wire, and rolling mill synchronously move according to the preset motion program and deposit layer by layer to finally form the required additive part. Among them, the welding torch generates an arc as the main heat source to melt the welding wire and form a molten pool. The laser head generates a laser and irradiates the laser into the molten pool formed by the arc to control the molten pool. The rolling mill rolls the already formed weld bead. The formation process of the printing path is as Figure 3 shown.
[0063] At the beginning of printing, the slicing software first slices the bottom layer of the input printing model (the slicing software extracts the STL file of the input model and identifies its printing direction, intercepts the bottom surface of the model with a plane perpendicular to the printing direction, and extracts its contour as the first-layer slice). After obtaining the printing shape, the filling path is generated, and the G code is generated to drive the synchronous movement of the welding torch, laser head, welding wire, and rolling mill. After printing one layer is completed, the printed layer is scanned with a line laser to read the current printing layer height. Based on the layer height information, the STL file is sliced again to generate a new printing path. The parts formed by using the above process parameters can achieve high strength, high toughness, and high fatigue performance.
[0064] At the initial stage of additive manufacturing or during the additive manufacturing process, if the machine stops for a long time due to special circumstances, the initial temperature of the additive workpiece or substrate is relatively low. In this case, a small-power laser (not exceeding 600w) can be used by the laser head as an auxiliary heat source to preheat the substrate or the additive workpiece. After the preheating is completed, the infrared thermal imager is used to identify the temperature of the substrate and determine whether it meets the preset requirements. The infrared thermal imager is installed on the forming equipment and does not have a motion module, and it monitors the temperature of the substrate and the additive workpiece after forming in real time. After reaching the preset requirements, the additive manufacturing process can be carried out. If the preset requirements are not met, preheating needs to be carried out again. This method can reduce the temperature gradient during the additive manufacturing process, ensure uniform temperature during the forming process, and improve the forming quality.
[0065] Please refer to Figure 4 , when unevenness or defects are detected by a line laser measuring instrument or a CCD camera after the additive workpiece is formed, the unevenness or defects can be solved by wire melting, or the wire feeding can be stopped, and an arc is formed between the welding torch and the additive workpiece as the main heat source to remelt the weld bead along the forming path. During the remelting process, no arc is used, and a small-power laser of 300-500w is used to melt the surface of the weld bead. The remelting speed is 200-400mm / min. During the remelting process, only the Y-axis galvanometer is used, with an amplitude of 5mm and a frequency of 100Hz, so as to achieve the purpose of remelting the surface defects or unevenness again. At the same time, the roll performs in-situ hot rolling on the weld bead again to further eliminate surface defects and improve the flatness of the weld bead. The line laser measuring instrument or the CCD camera is installed on the head of the additive manufacturing equipment and can move synchronously with the head. After each layer is printed, the surface topography after forming is scanned by the drive of the equipment head.
[0066] Generally speaking, this embodiment includes a welding torch, a laser head, a wire, and a roll. The above four components are installed on the head of the additive manufacturing equipment, and the four move synchronously during the forming process; the welding torch is used as the main heat source during the manufacturing process, and an arc welding torch / plasma arc welding torch can be used. The laser head is used as an auxiliary heat source, equipped with X-axis and Y-axis galvanometers, and the relative position with the wire can be adjusted. The wire should be fed under the welding torch and fixed on the same motion unit as the welding torch. The roll is located behind the welding torch and fixed on the same motion unit as the welding torch to perform in-situ synchronous rolling on the formed weld bead.
[0067] In this embodiment, laser is introduced to regulate the molten pool during the arc additive manufacturing process to increase the heat input during the forming process, and the surface defects generated during the additive manufacturing process are eliminated in the form of laser remelting. In addition, in-situ synchronous rolling is introduced during the arc additive manufacturing process.
[0068] Through this embodiment, the comprehensive improvement of the strength, toughness, and fatigue performance of the arc additive parts can be realized.
[0069] The technical features of the above embodiments can be combined arbitrarily. For the sake of concise description, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered as the scope recorded in this specification.
[0070] Specific examples are used in this article to elaborate on the principles and implementation manners of this application. The description of the above embodiments is only used to help understand the method and its core idea of this application; at the same time, for those of ordinary skill in the art, according to the idea of this application, there will be changes in the specific implementation manners and application scopes. In summary, the content of this specification should not be construed as a limitation to this application.
Claims
1. An arc-laser composite synchronous in-situ micro-rolling additive manufacturing device, characterized in that, Including: A main heat source, a laser heat source, a welding wire, and a rolling device; The main heat source, the laser heat source, the welding wire, and the rolling device are arranged on the same structure, and the main heat source, the laser heat source, the welding wire, and the rolling device move synchronously; The laser heat source includes a galvanometer; The galvanometer is used to make the laser emitted by the laser heat source swing; The laser heat source is used to regulate the molten pool formed by the main heat source.
2. The arc-laser composite synchronous in-situ micro-rolling additive manufacturing device according to claim 1, wherein The galvanometer includes: an X-axis galvanometer and a Y-axis galvanometer; the amplitude of the galvanometer is 0 - 5 mm; The relative position of the laser heat source and the welding wire can be adjusted; The laser power of the laser heat source is 0 - 3000 w; the included angle between the laser incident angle and the main heat source is 30 - 60°.
3. The arc-laser composite synchronous in-situ micro-rolling additive manufacturing device according to claim 1, characterized in that The main heat source, the laser heat source, the welding wire, and the rolling device are installed on the machine tool spindle and move synchronously with the machine tool spindle.
4. The arc-laser composite synchronous in-situ micro-rolling additive manufacturing device according to claim 1, wherein The welding wire is located directly below the main heat source and is fixed to the same moving unit as the main heat source; The rolling device is located behind the main heat source and is fixed to the same moving unit as the main heat source; the rolling device is used to perform in-situ synchronous rolling on the formed weld bead.
5. The arc-laser composite synchronous in-situ micro-rolling additive manufacturing device according to claim 1, wherein The main heat source is a welding torch; the welding current of the welding torch is 0 - 300 A; The rolling device is a rolling mill.
6. The arc-laser composite synchronous in-situ micro-rolling additive manufacturing device according to claim 1, wherein It further includes: An infrared thermal imager, a line laser detector, and a CCD camera; The infrared thermal imager is used to monitor the temperature of the additive manufacturing workpiece in real time during the forming process; The line laser detector and the CCD camera are used to monitor the surface flatness and surface defects of the additive manufacturing workpiece in real time during the forming process.
7. An arc-laser composite synchronous in-situ micro-rolling additive manufacturing method, characterized in that, Including: Obtain the forming path; Generate a synchronous control instruction according to the forming path; the synchronous control instruction is used to control the synchronous movement of the main heat source, the laser heat source, the welding wire, and the rolling device; After a molten pool is formed below the main heat source, control the laser heat source to emit laser to the molten pool, and make the laser swing by controlling the galvanometer on the laser heat source; After the molten pool solidifies, control the main heat source, the laser heat source, the welding wire, and the rolling device to perform in-situ synchronous hot rolling.
8. The arc-laser composite synchronous in-situ micro-rolling additive manufacturing method according to claim 7, wherein After controlling the main heat source, the laser heat source, the welding wire, and the rolling device to perform in-situ synchronous hot rolling when the molten pool solidifies, it further includes: Detect the additive manufacturing workpiece obtained after in-situ synchronous hot rolling by using a line laser measuring instrument or a CCD camera; When a defect is detected in the additive manufacturing workpiece, control the laser light source to remelt the additive manufacturing workpiece.
9. The arc-laser composite synchronous in-situ micro-rolling additive manufacturing method according to claim 7, wherein When the temperature of the additive manufacturing workpiece is lower than a preset threshold, control the laser heat source to heat the additive manufacturing workpiece.
10. The arc-laser composite synchronous in-situ micro-rolling additive manufacturing method according to claim 7, characterized in that, During the in-situ synchronous hot rolling process: Control the main heat source current to be 160 - 260 A, the laser power of the laser heat source to be 500 - 1500 W, the wire feeding speed of the welding wire to be 2 - 4 m / min, and the rolling force of the hot rolling to be 15 - 30 kN.