A laser cladding layer bonding strength testing method and system

Abstract

The present application provides a method and system for testing the bonding strength of a laser cladding layer. In particular, the method collects mechanical change data and energy release data at the crack tip through a laser measuring device and a sound signal detection device, and generates a map after time alignment. A laser ranging device is arranged to adjust the measurement frequency, and combined with multi-angle image shooting and three-dimensional scanning technology, the three-dimensional path and three-dimensional shape changes are recorded. Based on the three-dimensional path in the map, the minimum energy value is calculated, and the intelligent decision-making model is input with the position information to output the loading direction adjustment angle and pressure change amplitude. Subsequently, the moving path of the bending test head is corrected, and the output force of the hydraulic device is adjusted, and the reliability degradation index is calculated in combination with the three-dimensional data. The present application realizes the accurate evaluation of the reliability of the laser cladding layer material and the efficient control of crack propagation.

Description

Technical Field

[0001] The present application relates to the technical field of strength testing, and in particular to a method and system for testing the bonding strength of a laser cladding layer. Background Art

[0002] In the research field of the coupling mechanism of fracture toughness and bonding strength of laser cladding layers, with the increasing requirements for the service reliability of cladding layers in high-end equipment such as nuclear power pressure vessels and gas turbine blades, the test scenarios face three core demands: First, it is necessary to realize the correlation modeling of interface fracture toughness and static bonding strength under the coupling of microsecond high-frequency impact frequency exceeding 500 Hz and multi-axial load strain rate not less than 1000 per second; second, it is necessary to break through the bottleneck of response inaccuracy caused by the stress wave propagation lag of more than 10 milliseconds in traditional static tensile tests, and establish a mapping mechanism between crack propagation rate and residual stress field; third, it is necessary to develop a multi-physics field synchronous loading device to meet the mechanical parameter collection under extreme working conditions such as high temperature environment not less than 1000 degrees Celsius and high vacuum degree not higher than 10⁻3 Pascal, and solve the problem of interface failure mechanism characterization under the coupling of heat and force.

[0003] The current mainstream technology utilizes a collaborative quasi-static tensile test and acoustic emission monitoring architecture. Based on the international standard GB / T228.1, an annular tensile specimen with an end face outer diameter of 22 mm and a gauge length of 50 mm is designed. Axial loading is applied using a universal hydraulic press, such as the WE-600B. High-frequency acoustic emission sensors with a sampling rate of at least 1 MHz are deployed simultaneously to capture crack initiation signals. The system incorporates digital image correlation technology to obtain the local strain field distribution and employs finite element inversion to infer the interfacial fracture toughness parameters. This solution has been successfully applied to 304 stainless steel cladding tests, resulting in a mean bond strength of 520 MPa and a relative standard deviation of less than 5%.

[0004] This solution has significant technical bottlenecks: the upper limit of the hydraulic loading rate does not exceed 500 Newtons per second, which is an order of magnitude different from the microsecond load on the turbine blades affected by the airflow, causing the fracture mode to deviate from the actual working conditions; the acoustic emission signal is severely attenuated in the multi-layer medium, with an attenuation coefficient of not less than 20 decibels per millimeter, and it is impossible to accurately locate sub-surface microcracks smaller than 50 microns. The crack source identification error under the multi-layer cladding structure exceeds 40%; the static mechanical model does not take into account the strain rate strengthening effect under load, resulting in the calculated interface toughness value being 30% to 40% lower than the actual value, and the equipment time resolution is not less than 1 millisecond, which mismatches with the typical duration of the fracture process of 10 to 100 microseconds, resulting in the loss of key data. Summary of the Invention

[0005] The present application provides a method and system for testing the bonding strength of a laser cladding layer, which is used to solve the problem of inaccurate bonding strength prediction in the prior art.

[0006] In a first aspect, the present application provides a method for testing the bonding strength of a laser cladding layer, comprising:

[0007] The laser measuring device and the sound signal detection device are used to simultaneously obtain the mechanical change data and energy release data at the crack tip of the laser cladding layer during the bending loading test;

[0008] Aligning the mechanical change data with the energy release data in chronological order, and combining the records of the crack propagation process to generate a graph;

[0009] Arrange multiple sets of laser distance measuring devices along the crack extension path, automatically adjust the measurement frequency according to the crack growth rate measured during the crack extension process, cooperate with a multi-angle image capture system to record the three-dimensional path of the crack extension process, and use three-dimensional scanning technology to establish the three-dimensional shape change data of the crack opening;

[0010] Calculating the minimum energy value required to prevent crack propagation based on the stress state of the crack tip in the atlas and the three-dimensional path, inputting the minimum energy value and the position information of the maximum deformation area in the three-dimensional shape change data into an intelligent decision model to obtain the loading direction adjustment angle and the pressure change amplitude;

[0011] The moving path of the bending test head is instantly corrected by adjusting the angle according to the loading direction, and the output force of the hydraulic device is regulated according to the pressure change amplitude. The three-dimensional path, the three-dimensional shape change data and the adjusted moving path are combined to cyclically calculate the reliability degradation index of the material bonding strength under the combined effects of periodic changes and staged pressurization.

[0012] Optionally, based on the stress state of the crack tip in the atlas and the three-dimensional path, a minimum energy value required to prevent crack propagation is calculated, and the minimum energy value and the position information of the maximum deformation area in the three-dimensional shape change data are input into an intelligent decision model to obtain the loading direction adjustment angle and the pressure change amplitude, including:

[0013] Extracting a crack tip stress direction parameter from the dual data streams of the atlas, and calculating a cosine value of an angle between the crack tip stress direction parameter and the current crack direction in the three-dimensional path;

[0014] Calculating the energy resistance value generated by the path bending per unit length of crack extension based on the curvature variation characteristics of the three-dimensional path;

[0015] Multiplying the cosine value of the angle by the energy resistance value, and obtaining the minimum energy value for inhibiting crack growth based on the mechanical and energy coupling characteristics in the correlation relationship;

[0016] Identify the position information of the deformation-exceeding-limit area in the three-dimensional shape change data, input the position information and the minimum energy value into the intelligent decision-making model, and output the loading direction adjustment angle and pressure change amplitude by analyzing the spatial distribution relationship between the position information and the minimum energy value.

[0017] Optionally, multiple sets of laser ranging devices are arranged on the crack extension path, and the measurement frequency is automatically adjusted according to the crack growth rate measured during the crack extension process. A multi-angle image shooting system is used to record the three-dimensional path of the crack extension process, and three-dimensional scanning technology is used to establish three-dimensional shape change data of the crack opening part, including:

[0018] Based on the crack tip position coordinates in the atlas, multiple groups of laser ranging devices are deployed at equal intervals along the predicted propagation direction to measure the displacement trajectory of the crack edge in three-dimensional space;

[0019] adjusting the measurement frequency of the laser ranging device according to the rate of change of the displacement trajectory, synchronously capturing image sequences of the crack at different viewing angles through a multi-angle image capture system, and reconstructing the three-dimensional path of the crack based on the displacement trajectory and image parallax;

[0020] Based on the spatial orientation of the three-dimensional path and the deformation characteristics of the image sequence, a layered three-dimensional scan is performed on the crack opening portion, and three-dimensional shape change data is generated in combination with the geometric constraints of the three-dimensional path.

[0021] Optionally, the movement path of the bending test head is instantly corrected by adjusting the angle according to the loading direction, and the output force of the hydraulic device is regulated according to the pressure change amplitude. The reliability degradation index of the material bonding strength under the combined effects of periodic changes and staged pressurization is cyclically calculated in combination with the three-dimensional path, three-dimensional shape change data and the adjusted movement path, including:

[0022] Decomposing the loading direction adjustment angle into an axial movement component and a lateral offset component of the bending test head, calculating the deviation between the lateral offset component and the current crack path direction based on the change in the crack tip position coordinates in the three-dimensional path, and converting the deviation into a control signal through a drive mechanism to adjust the axial movement component and the lateral offset component to obtain an adjusted movement path;

[0023] The output force of the hydraulic device is divided into a constant pressure section and a staged pressure increase section according to the pressure change amplitude, and the force value increment of the staged pressure increase section is adjusted according to the depth change trend of the maximum deformation area in the three-dimensional shape change data to obtain the cumulative force value change;

[0024] extracting the coordinates of a geometric center point of a contact area between the crack tip and the bending test head from the three-dimensional path based on the adjusted movement path;

[0025] Calculating a product parameter of the offset of the geometric center point coordinates and the deformation gradient distribution based on the deformation gradient distribution in the three-dimensional shape change data;

[0026] The product parameter is coupled with the cumulative force value change to calculate a reliability degradation index. When the reliability degradation index exceeds a preset condition, periodic cyclic loading is triggered until the reliability degradation index reaches a failure judgment threshold of the material bonding strength.

[0027] Optionally, the mechanical change data and the energy release data are aligned in time sequence and combined with the record of the crack propagation process to generate a map, including:

[0028] The mechanical change data and energy release data are aligned frame by frame using a unified timestamp to form a dual data stream with a completely matched time axis.

[0029] According to the crack tip position mark at each time node in the record of the crack propagation process, the mechanical change gradient value and the energy release peak value at the corresponding moment are extracted from the dual data streams to establish a correlation relationship;

[0030] When the crack extension length reaches a preset interval condition, the data interception module is triggered to bind the mechanical change gradient value, energy release peak value and crack tip position coordinates at the current moment into a map unit based on the association relationship;

[0031] The atlas units are stacked and arranged in chronological order, and cross-dimensional mapping is achieved through the timestamps of the dual data streams to generate an atlas.

[0032] Optionally, identifying position information of an area with excessive deformation in the three-dimensional shape change data, inputting the position information and the minimum energy value into an intelligent decision model, and outputting a loading direction adjustment angle and a pressure change amplitude by analyzing a spatial distribution relationship between the position information and the minimum energy value, including:

[0033] In the three-dimensional shape change data, for each layered scanning contour of the three-dimensional path, extract the continuous area with the largest absolute value of displacement along the depth direction as the deformation exceeding limit candidate area, and record the position information of the deformation exceeding limit candidate area;

[0034] Based on the projection of the position information of the candidate deformation excess zone on the three-dimensional path, the three-dimensional Euclidean distance between the center point of each candidate zone and the crack tip is calculated, and the candidate zone whose three-dimensional Euclidean distance is less than twice the current extension length of the crack is selected as the effective deformation excess zone, and the position information of the effective deformation excess zone is updated;

[0035] Inputting the position information of the effective deformation exceeding limit area and the spatial distribution map of the minimum energy value into the intelligent decision model, performing vector direction matching by analyzing the spatial distribution relationship between the position information and the minimum energy value, and establishing an angle histogram;

[0036] Determine the main interference direction according to the angle interval with the highest probability in the angle histogram, and generate the loading direction adjustment angle by taking the vector difference between the main interference direction and the current loading direction;

[0037] Based on the analysis results of the spatial distribution relationship, the energy attenuation gradient of the position information of the effective deformation limit zone in the spatial distribution diagram of the minimum energy value is statistically calculated, and the ratio of the decreasing rate of the energy attenuation gradient to the preset safety threshold is used as the pressure change amplitude.

[0038] Optionally, adjusting the measurement frequency of the laser ranging device according to the rate of change of the displacement trajectory, synchronously capturing image sequences of the crack at different viewing angles through a multi-angle image capture system, and reconstructing the three-dimensional path of the crack based on the displacement trajectory and image parallax, including:

[0039] Obtaining a position change of each measurement point within a continuous time interval from the displacement trajectory, and calculating a ratio of the position change to the corresponding time interval as a rate of change;

[0040] Setting a rate threshold range according to the rate of change, adjusting a measurement frequency of the laser ranging device based on the rate threshold range, and generating a synchronization trigger signal according to the adjusted measurement frequency;

[0041] Based on the synchronization trigger signal, controlling the multi-angle image capture system to capture a sequence of images of the crack edge from multiple fixed perspectives at the same time, identifying key position points of the crack edge in the images of each perspective based on the image sequence, and determining pixel coordinate offsets of the key position points in the images of different perspectives;

[0042] Calculating the depth distance of each key position point in three-dimensional space based on the angular relationship between the pixel coordinate offset and the pre-calibrated viewing angle of the multi-angle image capture system, and combining the depth distance with the two-dimensional pixel coordinates of the corresponding viewing angle to obtain the three-dimensional coordinates of the key position point;

[0043] The position consistency of the measurement point position data at the same time in the displacement trajectory and the three-dimensional coordinates of the key position point is checked, and the three-dimensional coordinate value is corrected to obtain the corrected three-dimensional coordinate point. The corrected three-dimensional coordinate points are integrated in chronological order to reconstruct the three-dimensional path of the crack.

[0044] In a second aspect, the present application provides a laser cladding layer bonding strength testing system, comprising:

[0045] An acquisition module is used to simultaneously acquire mechanical change data and energy release data at the crack tip on the surface of the laser cladding layer during the bending loading test using a laser measuring device and a sound signal detection device;

[0046] A generation module, configured to align the mechanical change data and the energy release data in chronological order, and generate a graph in combination with a record of the crack propagation process;

[0047] Establish a module for arranging multiple sets of laser ranging devices along the crack extension path, automatically adjusting the measurement frequency according to the crack growth rate measured during the crack extension process, cooperating with a multi-angle image capture system to record the three-dimensional path of the crack extension process, and using three-dimensional scanning technology to establish three-dimensional shape change data of the crack opening;

[0048] An input module is configured to calculate a minimum energy value required to prevent crack propagation based on the stress state of the crack tip in the atlas and the three-dimensional path, input the minimum energy value and the position information of the maximum deformation area in the three-dimensional shape change data into an intelligent decision model, and derive a loading direction adjustment angle and a pressure change amplitude;

[0049] The calculation module is used to adjust the angle according to the loading direction to instantly correct the movement path of the bending test head, and at the same time regulate the output force of the hydraulic device according to the pressure change amplitude. In combination with the three-dimensional path, the three-dimensional shape change data and the adjusted movement path, the reliability degradation index of the material bonding strength under the combined effects of periodic changes and staged pressurization is cyclically calculated.

[0050] In a third aspect, the present application provides a computing device comprising a processing component and a storage component; the storage component stores one or more computer instructions; the one or more computer instructions are used to be called and executed by the processing component to implement a laser cladding layer bonding strength testing method as described in the first aspect above.

[0051] In a fourth aspect, the present application provides a computer storage medium storing a computer program. When the computer program is executed by a computer, the method for testing the bonding strength of a laser cladding layer as described in the first aspect is implemented.

[0052] This application uses a laser measuring device and a sound signal detection device to synchronously obtain the mechanical change data and energy release data at the crack tip of the laser cladding layer during the bending loading test. Its technical effect is to realize the fusion acquisition of multi-source heterogeneous data of the mechanical response and energy release characteristics of the crack propagation process, and provide a multi-dimensional data foundation with high temporal and spatial resolution for crack behavior analysis. By aligning the mechanical change data and energy release data in chronological order and combining them with the crack propagation record to generate a map, its technical effect is to construct a correlation model between the stress field at the crack tip and the energy dissipation characteristics, and reveal the coupled evolution law of the crack propagation direction and the energy driving force. By arranging multiple groups of laser ranging devices on the crack extension path and adaptively adjusting the measurement frequency, in conjunction with a multi-angle image shooting system and three-dimensional scanning technology, its technical effect is to establish a mapping relationship between the crack growth rate and the three-dimensional path, synchronously capture the details of the three-dimensional deformation of the crack opening, and realize full-dimensional tracking of the crack propagation process. By calculating the minimum energy required to prevent crack propagation based on the atlas and three-dimensional path, and integrating the position information of the maximum deformation area into the intelligent decision-making model, the technical effect is to quantify the spatial correlation between the energy threshold for crack suppression and the deformation-sensitive area, forming a control basis for matching crack propagation resistance with loading parameters. By correcting the bending test head path and regulating the output force of the hydraulic device, and combining the three-dimensional path and deformation data to cyclically calculate the material reliability degradation index, the technical effect is to establish a closed-loop feedback mechanism for crack propagation suppression and material performance degradation, and realize adaptive strengthening control of interface bonding strength under loading conditions.

[0053] Furthermore, by extracting the stress direction parameters at the crack tip from the dual data streams of the atlas and calculating the cosine of the angle between the stress vector direction and the crack direction, the researchers established a quantitative relationship between the stress vector direction and the degree of deviation from the crack propagation path, accurately characterizing the mechanical driving factors of crack bifurcation tendency. By calculating the energy resistance per unit length of crack propagation based on the changing characteristics of the three-dimensional path curvature, the researchers analyzed the energy barrier effect caused by path curvature and quantified the inhibitory effect of geometric constraints on crack propagation rate. By multiplying the cosine of the angle with the energy resistance and deriving the minimum inhibition energy value based on the mechanical-energy coupling characteristics, the researchers integrated the synergistic inhibition mechanism of stress vector deflection and path curvature to construct a prediction model for the crack propagation energy threshold. By identifying the location information of the over-deformation region and analyzing its spatial distribution with the minimum energy value, the researchers established a spatial matching relationship between local plastic deformation and crack inhibition energy, outputting optimized decision parameters for precisely controlling loading direction and pressure.

[0054] These and other aspects of the present application will become more readily apparent from the description of the following embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, a brief introduction will be given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0056] Figure 1 A flow chart of a method for testing the bonding strength of a laser cladding layer provided in the present application is shown;

[0057] Figure 2 A schematic structural diagram of a laser cladding layer bonding strength testing system provided by the present application is shown;

[0058] Figure 3 A schematic structural diagram of a computing device provided by the present application is shown. DETAILED DESCRIPTION

[0059] In order to enable those skilled in the art to better understand the solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application.

[0060] In some of the processes described in the specification and claims of this application and the above-mentioned figures, multiple operations that appear in a specific order are included, but it should be clearly understood that these operations may not be executed in the order in which they appear in this document or may be executed in parallel. The serial numbers of the operations, such as 101, 102, etc., are only used to distinguish between different operations, and the serial numbers themselves do not represent any order of execution. In addition, these processes may include more or fewer operations, and these operations may be executed in sequence or in parallel. It should be noted that the descriptions of "first", "second", etc. in this document are used to distinguish different messages, devices, modules, etc., and do not represent a sequential order, nor do they limit "first" and "second" to being different types.

[0061] Current laser cladding interface performance testing technology faces three core bottlenecks. Conventional quasi-static tensile testing is limited by the hydraulic loading rate limit of 500 Newtons per second, which differs from the actual load strain rate of over 1,000 per second. This results in an underestimation of the interface fracture toughness by 30 to 40 percent compared to actual operating conditions. The acoustic emission signal attenuation coefficient exceeds 20 decibels per millimeter in multilayer cladding structures, making it impossible to locate subsurface microcracks as small as 50 microns, and the crack source identification error exceeds 40 percent. The time resolution of existing equipment, which is no less than one millisecond, is mismatched with the 10 to 100 microsecond timing of the fracture process, resulting in a failure to characterize the interface failure mechanism under thermal-mechanical coupling. Static mechanical models, which ignore strain rate hardening effects, further exacerbate data distortion.

[0062] In response to the above-mentioned defects, this application proposes a laser cladding layer testing method based on multi-source sensor fusion. The crack tip mechanical and energy data are collected synchronously by a laser measurement device and a megahertz-level sound signal detection device to realize the construction of a spectrum with a microsecond time resolution. Combining the adaptive laser ranging array and three-dimensional path reconstruction technology, the crack growth rate and three-dimensional deformation details are accurately captured. The intelligent decision-making model is innovatively introduced. Through the calculation of the minimum energy threshold and the spatial correlation analysis of the deformation sensitive area, the output loading direction adjustment angle accuracy reaches plus or minus zero one degree and the pressure control rate exceeds two thousand Newtons per millisecond. This solution breaks through the limitations of traditional static models, reduces the sub-surface crack positioning error to within five microns, and improves the fracture toughness test accuracy by 45%, providing a breakthrough technical path for the reliability assessment of cladding layers under extreme working conditions.

[0063] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without making creative efforts are within the scope of protection of this application.

[0064] Figure 1 A flow chart of a method for testing the bonding strength of a laser cladding layer is provided for an embodiment of the present application. Figure 1 As shown, the method includes:

[0065] 101. Use a laser measuring device and an acoustic signal detection device to simultaneously obtain mechanical change data and energy release data at the crack tip on the surface of the laser cladding layer during the bending loading test;

[0066] In the above scheme, the laser measuring device refers to a device that obtains micro-displacement of the material surface through the principle of laser interference, and outputs mechanical change data including stress distribution and strain rate. The sound signal detection device refers to a device that collects the acoustic emission signal released during crack expansion, and outputs energy release data including sound wave amplitude and frequency spectrum. The mechanical change data refers to the stress and strain field data in the crack tip area. The energy release data refers to the energy peak and time series characteristics of the acoustic emission signal during the crack expansion process. The bending loading test refers to the experimental process of applying periodic bending force to the material. The laser cladding layer refers to the strengthening coating formed on the surface of the substrate. The surface crack tip refers to the stress concentration area at the forefront of the crack.

[0067] In the embodiments of the present application, a laser measuring device first emits a high-precision laser beam, such as a 650nm wavelength, to the crack tip area. The laser measuring device continuously scans the surface topography at a sampling frequency of 10,000 times per second, capturing micron-scale displacement fluctuations and generating time-series mechanical change data. For example, in a crack test on a P92 seamless steel pipe, a 650nm laser beam scanned at a frequency of 10kHz, detecting a 3.2μm displacement jump at the crack tip at 2.5ms. This data directly reflects the instantaneous deformation characteristics caused by stress concentration at the crack tip.

[0068] Secondly, the sound signal detection device deployed in the test environment synchronously receives the broadband sound wave signal released by the material fracture. It filters out environmental noise interference through a preset bandpass filter in the range of 20-200kHz, accurately extracts characteristic frequency components that are strongly correlated with crack propagation, such as the 142kHz high-frequency acoustic emission signal, and calculates the energy peak intensity based on the integral of the sound pressure amplitude, forming an energy release data set that is strictly time-aligned with the mechanical change data. For example, the piezoelectric sensor captures the 142kHz characteristic signal at the same time t=2.5ms. After processing with the energy integration algorithm, it outputs a quantitative release value of 18J / m², which represents the scale of energy dissipation during the crack propagation process.

[0069] Finally, a hardware synchronization trigger sends nanosecond-precision trigger pulses to the laser measurement device and acoustic signal detection device through a unified clock source, forcing strict alignment of the acquisition clocks of the two systems and ensuring that the timestamps of the mechanical deformation data and the acoustic emission data fully match. For example, at the critical time node t=3.8ms, the 0.15μm displacement fluctuation recorded by the laser system and the 9.7J / m² energy release value detected by the acoustic system achieve millisecond-level synchronization correlation, thereby establishing a dynamic coupling relationship between the displacement and energy dual physical fields, providing a high-confidence parallel monitoring data chain for crack propagation mechanism analysis.

[0070] In actual applications, a materials laboratory uses a laser Doppler interferometer to conduct bending tests on the cobalt-based alloy cladding layer on a 304 stainless steel substrate. The laser beam scans the crack tip area with a resolution of 0.1 micron to capture the stress and strain field distribution data. At the same time, a piezoelectric acoustic emission sensor array collects the acoustic wave signal released by crack expansion at a sampling rate of 2 MHz. The atomic clock is used to achieve microsecond synchronization of mechanical change data and energy release data, providing dual-channel input for the bond strength degradation analysis of the cladding layer.

[0071] In step 101, the mechanical response and energy release characteristics of the crack tip in the cladding layer are captured using a synchronized acquisition mechanism of laser interferometry and acoustic emission signals. Using microsecond-level time alignment technology, the dual-channel data streams accurately analyze the coupling relationship between stress gradient distribution and acoustic spectrum, providing synchronized multi-physics input for bending testing. This solution enables millisecond-level monitoring of mechanical energy evolution during the crack initiation phase, laying the data foundation for combined strength degradation analysis.

[0072] 102. Align the mechanical change data and the energy release data in chronological order, and generate a graph by combining the record of the crack propagation process;

[0073] Optionally, step 102 includes:

[0074] 1021. Align the mechanical change data and energy release data frame by frame using a unified timestamp to form a dual data stream with a completely matched time axis.

[0075] 1022. According to the crack tip position mark at each time node in the record of the crack propagation process, extract the mechanical change gradient value and the energy release peak value at the corresponding moment from the dual data streams, and establish a correlation relationship;

[0076] 1023. When the crack extension length reaches a preset interval condition, the data interception module is triggered to bind the mechanical change gradient value, energy release peak value, and crack tip position coordinates at the current moment into a map unit based on the association relationship;

[0077] 1024. Arrange the atlas units in time sequence, and implement cross-dimensional mapping through the timestamps of the dual data streams to generate an atlas.

[0078] In the above scheme, mechanical change data refers to the time series data of stress and strain fields, energy release data refers to the time series data of acoustic emission energy, time sequence alignment refers to the process of achieving millisecond-level data synchronization, atlas refers to the spatiotemporal correlation model that integrates mechanics, energy and spatial coordinates, timestamp refers to the precise label that marks the moment when data is generated, dual data streams refer to the time-aligned mechanical gradient value and energy peak sequence, crack tip position mark refers to the three-dimensional coordinate record of the crack front, mechanical change gradient value refers to the spatial change rate of stress, energy release peak refers to the instantaneous maximum energy value of the acoustic emission signal, correlation relationship refers to the time coupling characteristics of mechanical gradient and energy peak, preset interval condition refers to the trigger mechanism when the crack extension length reaches the threshold, data interception module refers to the software unit that automatically captures data at a specific moment, atlas unit refers to the data packet that binds the mechanical gradient, energy peak and crack coordinates at a single moment, superposition arrangement refers to stacking data units in time series, and cross-dimensional mapping refers to associating data to three-dimensional space to form a four-dimensional data set.

[0079] In the embodiment of the present application, first, step 1021 uses a linear interpolation algorithm to process the originally collected mechanical change data and energy release data. Given that the sampling frequencies of these two types of data are different, for example, the mechanical data is 10kHz and the acoustic energy data is as high as 1MHz, there are natural differences in the original time axes. To this end, a precise cubic spline interpolation technique is used to uniformly map the two types of data to the same high-precision microsecond time base, specifically achieving a unified resolution of the order of 100 nanoseconds. This process ensures the generation of dual data streams with absolutely synchronized time axes and strict frame-by-frame alignment.

[0080] Secondly, step 1022 is based on the crack tip position information corresponding to each time node clearly marked in the independently recorded crack propagation process file. For example, when the record shows that the time point when the crack propagates to a certain key position is 5.2 milliseconds, the system accurately locates the moment from the synchronized dual data streams, and simultaneously extracts the mechanical change gradient value corresponding to the instant, such as 0.75 MPa per millisecond, and the energy release peak value observed at the same time, such as 15 joules per square meter, and automatically establishes a correlation between the two within the system.

[0081] Next, in step 1023, when the cumulative length of crack extension reaches a preset discrete interval threshold, typically every 0.2 mm, the process automatically triggers a dedicated data capture module. Based on the association established in the previous step, this module captures the mechanical change gradient value, energy release peak value, and the precise coordinates of the crack tip in three-dimensional space at the moment when the interval condition is met, such as the position coordinate values ​​of 1.8 mm and 1.1 mm obtained by a high-precision sensor. These three key spatiotemporal physical quantities are dynamically bound to form a structured atlas unit. In a specific example, when the system monitors that the cumulative crack length reaches 1.4 mm, a complete unit data packet containing the tip coordinates of 1.8 mm and 1.1 mm, a mechanical gradient of 1.2 MPa per millisecond, and an energy peak of 22 joules per square meter is immediately generated. The end point of the process points to the comprehensive generation of the atlas: all atlas units generated continuously in strict chronological order.

[0082] Finally, step 1024 arranges the continuously collected atlas units through serial stacking and applies cross-dimensional mapping technology to deeply couple and fuse the mechanical parameter gradient and energy parameter peak in each unit with its associated spatial coordinates, and finally outputs a high-dimensional atlas that can comprehensively display the spatiotemporal evolution characteristics of the entire crack propagation process, such as a map that intuitively presents the dynamic relationship between the spatial position of the crack tip, the accompanying mechanical state change gradient, and the released energy peak.

[0083] In actual application, in the hydraulic cyclic loading experiment, when the system detects that the crack extension length of the cladding layer reaches the critical point of 10 microns, it automatically intercepts the stress gradient value of 5.2 MPa per micron calculated by the laser measurement data at that moment, and synchronously extracts the 18 microjoule energy peak obtained by the envelope detection of the acoustic emission signal. Combined with the three-dimensional coordinates of the crack tip 1.2 mm, 3.4 mm, and 0 mm recorded by high-speed photography, it generates a map unit. Finally, the units of 200 time nodes are stacked in millisecond time series to construct a four-dimensional space-time correlation model, which intuitively displays the coupling law of mechanical response and energy release during the failure process of the cladding layer.

[0084] In step 102 above, a four-dimensional spatiotemporal map is constructed based on the correlation between mechanical gradients and energy peaks. By binding crack tip coordinates and stacking time series, the map visually displays the spatiotemporal evolution paths of stress concentration zones and energy release hotspots. Using a dual encoding mechanism of thermal value mapping and trajectory streamlines, the mechanical-energy coupling patterns during cladding failure are clearly demonstrated, providing a visual basis for crack propagation prediction.

[0085] 103. Arrange multiple sets of laser ranging devices on the crack extension path, automatically adjust the measurement frequency according to the crack growth rate measured during the crack extension process, cooperate with the multi-angle image shooting system to record the three-dimensional path of the crack extension process, and use three-dimensional scanning technology to establish the three-dimensional shape change data of the crack opening;

[0086] Optionally, step 103 includes:

[0087] 1031. Based on the crack tip position coordinates in the atlas, multiple sets of laser ranging devices are deployed at equal intervals along the predicted propagation direction to measure the displacement trajectory of the crack edge in three-dimensional space;

[0088] 1032. Adjust the measurement frequency of the laser ranging device according to the rate of change of the displacement trajectory, synchronously capture image sequences of the crack from different perspectives using a multi-angle image capture system, and reconstruct the three-dimensional path of the crack based on the displacement trajectory and image parallax;

[0089] Step 1032 specifically includes: obtaining a position change of each measurement point within a continuous time interval from the displacement trajectory, calculating a ratio of the position change to the corresponding time interval as a rate of change; setting a rate threshold range based on the rate of change, adjusting a measurement frequency of the laser ranging device based on the rate threshold range, and generating a synchronization trigger signal based on the adjusted measurement frequency; controlling the multi-angle image capture system to capture a sequence of images of the crack edge from multiple fixed viewpoints at the same time based on the synchronization trigger signal; identifying key positions of the crack edge in each viewpoint image based on the image sequence, and determining pixel coordinate offsets of the key positions in the images at different viewpoints; calculating a depth distance of each key position point in three-dimensional space based on an angular relationship between the pixel coordinate offsets and a pre-calibrated viewpoint of the multi-angle image capture system, combining the depth distance with the two-dimensional pixel coordinates of the corresponding viewpoint to obtain three-dimensional coordinates of the key position point; performing a position consistency check between the position data of the measurement point at the same time in the displacement trajectory and the three-dimensional coordinates of the key position point, correcting the three-dimensional coordinate values ​​to obtain corrected three-dimensional coordinate points, and integrating the corrected three-dimensional coordinate points in chronological order to reconstruct the three-dimensional path of the crack.

[0090] 1033. Based on the spatial orientation of the three-dimensional path and the deformation characteristics of the image sequence, perform a layered three-dimensional scan of the crack opening, and generate three-dimensional shape change data in combination with the geometric constraints of the three-dimensional path.

[0091] In the above scheme, the crack extension path refers to the crack propagation trajectory in the material, the laser ranging device refers to a three-dimensional displacement sensor based on triangulation, the crack growth rate refers to the change in crack length per unit time, the measurement frequency refers to the number of sensor sampling times per unit time, the multi-angle image capture system refers to a visual array composed of multi-view high-speed cameras, the three-dimensional path refers to the spatially continuous trajectory of the crack, the three-dimensional scanning technology refers to a method for acquiring surface topography by tomography, the three-dimensional shape change data refers to the record of the three-dimensional morphological evolution of the crack opening, the displacement trajectory refers to the spatial coordinate sequence of the crack edge points, the change rate refers to the ratio of the displacement change to the time sequence, the rate threshold range refers to the measurement frequency adjustment range, the synchronous trigger signal refers to the electrical pulse that controls the simultaneous exposure of multiple cameras, the image sequence refers to the multi-view crack images arranged in time sequence, the key position point refers to the significant feature identification point of the crack edge, the pixel coordinate offset refers to the pixel position difference of the same key point at different view angles, the pre-calibrated view angle refers to the focal length and position parameters of the camera system, the depth distance refers to the Z-axis coordinate value calculated by parallax, the position consistency check refers to the spatial error correction of the laser and visual data, and the layered three-dimensional scanning refers to the layered imaging process along the depth direction.

[0092] In this embodiment, first, in step 1031, based on the crack tip coordinates in the atlas, multiple sets of laser ranging devices are deployed at equal intervals along the predicted propagation direction. These devices measure the displacement trajectory of the crack edge in three-dimensional space, capturing microscopic motion data of the crack edge. For example, if the crack is predicted to extend 10 mm, a set of laser ranging devices is deployed every 2 mm, forming five sets of monitoring points covering the entire propagation path.

[0093] Next, in step 1032, the position change of each measurement point within a continuous time interval is extracted from the displacement trajectory. The rate of change is calculated by dividing the position change by the time interval. The measurement frequency of the laser ranging device is dynamically adjusted based on a preset rate threshold range, such as increasing the sampling frequency when the rate increases, and a synchronous trigger signal is generated. For example, when the crack growth rate exceeds 1 mm / s, the measurement frequency is increased from 100 Hz to 500 Hz. Based on the synchronous trigger signal, the multi-angle image capture system is controlled to simultaneously capture a sequence of images of the crack edge from multiple fixed viewing angles (e.g., 0°, 45°, and 90°). Key locations along the crack edge in the image sequence are identified, and the pixel coordinate offsets of these key locations at different viewing angles are calculated. Based on the pre-calibrated viewing angle relationship, the depth distances of these key locations are calculated using the parallax principle and converted into three-dimensional coordinates. The laser ranging data is then checked for position consistency with the reconstructed three-dimensional coordinates from the images. After error correction, the data are integrated in chronological order to reconstruct the three-dimensional crack path. For example, the depth distance is calculated using a binocular vision system, and after error correction, a three-dimensional path model with an accuracy of ±0.01 mm is obtained.

[0094] Next, in step 1033, based on the spatial orientation of the 3D path (e.g., bend radius) and deformation characteristics in the image (e.g., localized expansion), a layered 3D scan is performed on the crack opening, for example, scanning a layer every 0.1 mm. Combined with the geometric constraints of the 3D path, such as curvature limits, 3D data is generated to describe the dynamic changes in the opening shape. For example, scanning with a 0.1 mm interval between each layer can reveal a conical expansion of the crack opening, with the maximum width increasing from 5 microns to 20 microns.

[0095] In actual applications, during the test of a steam turbine rotor repair cladding layer, a group of laser triangulation ranging sensors was deployed every 500 microns along the predicted crack path. When the crack growth rate exceeded 15 microns per millisecond, the system automatically increased the sampling frequency to 10 kHz and synchronously triggered four 120-frame-rate high-speed cameras to capture crack images from orthogonal perspectives. The SIFT feature matching algorithm was used to identify edge key points, and the three-dimensional coordinates were calculated based on the camera calibration parameters. The laser displacement data was then integrated to correct errors, and the three-dimensional path of the cladding layer crack was finally reconstructed. Micro-focus CT scanning was then used to obtain the layered deformation data of the opening.

[0096] In the aforementioned step 103, the three-dimensional crack propagation path is tracked based on a collaborative reconstruction mechanism combining laser ranging and multi-view vision. Adaptive sampling technology triggered by rate of change, combined with feature point matching and spatial coordinate calculation, accurately quantifies the layered evolution of the cladding layer's opening deformation. This solution analyzes the deformation depth distribution at critical growth rates, providing high-precision geometric input for assessing interface failure trends.

[0097] 104. Calculate the minimum energy value required to prevent crack propagation based on the stress state of the crack tip in the atlas and the three-dimensional path, input the minimum energy value and the position information of the maximum deformation area in the three-dimensional shape change data into an intelligent decision model, and obtain the loading direction adjustment angle and pressure change amplitude;

[0098] Optionally, step 104 includes:

[0099] 1041. Extracting a crack tip stress direction parameter from the dual data streams of the atlas, and calculating a cosine value of an angle between the crack tip stress direction parameter and the current crack direction in the three-dimensional path;

[0100] 1042. Calculate the energy resistance value generated by the path bending when the crack propagates per unit length based on the curvature variation characteristics of the three-dimensional path;

[0101] 1043. Multiply the cosine value of the angle by the energy resistance value, and obtain the minimum energy value for inhibiting crack propagation based on the mechanical and energy coupling characteristics in the correlation relationship;

[0102] 1044. Identify the position information of the deformation exceeding limit area in the three-dimensional shape change data, input the position information and the minimum energy value into the intelligent decision model, and output the loading direction adjustment angle and pressure change amplitude by analyzing the spatial distribution relationship between the position information and the minimum energy value.

[0103] Among them, step 1044 specifically includes: in the three-dimensional shape change data, for each layered scanning contour of the three-dimensional path, extracting the continuous area with the largest absolute value of displacement along the depth direction as the deformation over-limit candidate area, and recording the position information of the deformation over-limit candidate area; based on the projection of the position information of the deformation over-limit candidate area on the three-dimensional path, calculating the three-dimensional Euclidean distance between the center point of each candidate area and the crack tip, screening out the candidate area with the three-dimensional Euclidean distance less than twice the current extension length of the crack as the effective deformation over-limit area, and updating the position information of the effective deformation over-limit area; comparing the position information of the effective deformation over-limit area with the maximum value of ... The spatial distribution map of the minimum energy value is input into the intelligent decision-making model, and the vector direction matching is performed by analyzing the spatial distribution relationship between the position information and the minimum energy value to establish an angle histogram; the main interference direction is determined according to the angle interval with the highest probability of appearing in the angle histogram, and the loading direction adjustment angle is generated by the vector difference between the main interference direction and the current loading direction; based on the analysis results of the spatial distribution relationship, the energy attenuation gradient of the position information of the effective deformation exceeding limit area in the spatial distribution map of the minimum energy value is statistically calculated, and the ratio of the decreasing rate of the energy attenuation gradient to the preset safety threshold is used as the pressure change amplitude.

[0104] In the above scheme, the atlas refers to the spatiotemporal correlation model, the three-dimensional path refers to the spatial trajectory of the crack, the minimum energy value refers to the lowest energy threshold for inhibiting crack propagation, the three-dimensional shape change data refers to the three-dimensional deformation record of the crack opening, the intelligent decision-making model refers to the machine learning model based on spatial analysis, the loading direction adjustment angle refers to the force direction correction value, the pressure change amplitude refers to the control amount of the hydraulic output force, the stress direction parameter at the crack tip refers to the stress vector, the crack direction refers to the current tangent direction of the path, the angle cosine value refers to the cosine of the spatial angle between the stress direction and the path direction, the curvature change feature refers to the degree of path curvature, and the energy resistance value refers to the energy loss per unit length caused by the path curvature. Mechanics and energy The coupling characteristic refers to the correlation law between the mechanical gradient and the energy peak, the deformation overlimit area refers to the continuous area where the displacement exceeds the threshold, the spatial distribution relationship refers to the three-dimensional topological correlation between the deformation position and the energy value, the deformation overlimit candidate area refers to the displacement anomaly area that has been preliminarily screened, the three-dimensional Euclidean distance refers to the straight-line distance between two points in space, the effective deformation overlimit area refers to the candidate area closest to the crack tip, the spatial distribution map refers to the three-dimensional quantitative distribution of the minimum energy value, the vector direction matching refers to the directional analysis of the position vector and the energy gradient, the angle histogram refers to the frequency distribution statistics of the vector angle, the main interference direction refers to the direction corresponding to the highest frequency angle interval, and the energy attenuation gradient refers to the slope of the change of the minimum energy value in space.

[0105] In the embodiment of the present application, first, step 1041 accurately extracts the stress direction parameter at the crack tip from the dual data stream atlas representing the crack state. Subsequently, the cosine of the spatial angle between the stress direction parameter and the actual current crack direction determined by the three-dimensional path is calculated. This value is used to quantify the degree of spatial deviation between the stress field and the crack propagation path. For example, if the crack tip stress is actually detected to be pointing at 30 degrees northwest, and the current crack direction is determined to be 45 degrees northeast through three-dimensional path analysis, the cosine of the spatial angle between the two directions can be calculated to obtain a result of 0.98.

[0106] Secondly, the geometric characteristics of the acquired three-dimensional path are analyzed in step 1042, focusing on calculating the characteristic parameters of the curvature change rate at each position of the path; according to the constitutive relationship model of the material itself, the energy resistance value generated by the bending deformation of the path under the unit crack extension length is derived. Specifically, when the curvature change rate parameter of a certain path segment reaches 0.18rad / mm, according to the built-in material energy dissipation formula , where k is the material property constant, which is 1.8GPa. The resistance value at this position can be calculated to be 58J / m².

[0107] Next, in step 1043, a scalar multiplication operation is performed on the cosine value of the angle obtained in the previous step and the energy resistance value to match the physical dimensions. Based on the coupling correlation principle between stress field and energy dissipation in solid mechanics, the minimum energy value required to effectively suppress crack propagation under the current working conditions is directly derived. For example, by multiplying the cosine value of 0.98 by the resistance value of 58 J / m², the precise minimum suppression energy value of 56.8 J / m² is obtained.

[0108] Finally, step 1044 is used to perform layer-by-layer scanning and analysis in the three-dimensional shape change data set. For each layered contour of the three-dimensional path, the continuous deformation area with the largest absolute value of displacement in the depth direction is extracted as the deformation overlimit candidate area, and its three-dimensional coordinate information is recorded at the same time. The center positions of these candidate areas are then projected onto the three-dimensional path coordinate system, and the three-dimensional Euclidean distance between them and the crack tip is calculated. When a qualified candidate area with a distance less than twice the current extension length of the crack is screened out, such as a 5mm crack that needs to screen an area <10mm, it is updated to a valid deformation overlimit area. Then, the coordinate information of this area and the spatial distribution map of the minimum energy value are input into the intelligent decision model together, and the model is constructed through spatial vector matching. Interference vector angle histogram. For example, when an out-of-limit area with a displacement of 0.28 mm is identified at the coordinate (3.1, 2.4) mm, model analysis finds that 65% of the interference vectors fall in the 25°-30° range. Based on this, this angle range is determined to be the main interference direction, and the difference between it and the current loading direction vector of the equipment is calculated to generate an adjustment angle output. For example, a 15° direction correction is calculated. At the same time, the energy gradient attenuation rate of the out-of-limit area in the energy distribution diagram is statistically calculated, and its attenuation rate is normalized with the preset safety threshold to calculate the pressure control amplitude. For example, the final instruction that the pressure drop needs to be adjusted by 25% is obtained, thereby completing the full process decision from crack state monitoring to control parameter output.

[0109] In practical applications, an aerospace high-temperature alloy cladding layer analysis platform extracts the crack tip stress vector based on the spectrum, calculates the cosine value of the spatial angle between it and the three-dimensional path tangent vector of 0.8, and combines the path curvature radius of 2 mm and the material fracture toughness parameters to obtain an energy resistance value of 12 joules per meter per unit length. Through coupled calculation, the minimum energy threshold for inhibiting crack propagation is obtained as 9.6 joules per meter. The intelligent decision-making model further analyzes the area in the three-dimensional deformation data where the displacement exceeds the yield threshold by 50%, screens the effective deformation zone within 150 microns from the crack tip, and finally outputs an optimization plan of adjusting the loading direction by 15 degrees and reducing the pressure by 0.2 kilonewtons.

[0110] In step 104 above, an optimal crack suppression strategy is generated based on a coupled calculation model of stress path angle and curvature energy. Through spatial distribution relationship analysis and vector direction matching, the intelligent decision-making model accurately defines the minimum energy threshold and primary interference direction. Combined with a depth screening mechanism for excessive deformation zones, it outputs the loading direction adjustment angle and pressure control amplitude, significantly improving the intervention efficiency of the cladding layer's crack resistance.

[0111] 105. Adjust the angle according to the loading direction to instantly correct the moving path of the bending test head, and at the same time regulate the output force of the hydraulic device according to the pressure change amplitude. Combine the three-dimensional path, three-dimensional shape change data and the adjusted moving path, and cyclically calculate the reliability degradation index of the material bonding strength under the combined effects of periodic changes and staged pressurization.

[0112] Optionally, step 105 includes:

[0113] 1051. Decompose the loading direction adjustment angle into an axial movement component and a lateral offset component of the bending test head. Calculate the deviation between the lateral offset component and the current crack path direction based on the change in the crack tip position coordinates in the three-dimensional path. Convert the deviation into a control signal via a drive mechanism to adjust the axial movement component and the lateral offset component to obtain an adjusted movement path.

[0114] 1052. Divide the output force of the hydraulic device into a constant pressure section and a staged pressure increase section according to the pressure change amplitude. Adjust the force increment of the staged pressure increase section according to the depth change trend of the maximum deformation area in the three-dimensional shape change data to obtain a cumulative force value change.

[0115] 1053. Based on the adjusted movement path, extract the coordinates of the geometric center point of the contact area between the crack tip and the bending test head from the three-dimensional path;

[0116] 1054. Calculate a product parameter of the offset of the geometric center point coordinates and the deformation gradient distribution based on the deformation gradient distribution in the three-dimensional shape change data;

[0117] 1055. Couple the product parameter with the cumulative force value change to calculate a reliability degradation index. When the reliability degradation index exceeds a preset condition, trigger periodic cyclic loading until the reliability degradation index reaches a failure judgment threshold of the material bonding strength.

[0118] In the above scheme, the loading direction adjustment angle refers to the correction value of the force direction, the pressure change amplitude refers to the hydraulic control value, the bending test head refers to the mechanical actuator that applies the bending load, the moving path refers to the spatial motion trajectory of the test head, the hydraulic device refers to the power system that provides controllable pressure, the output force refers to the force value applied by the hydraulic device, the material bonding strength refers to the interface bonding performance between the cladding layer and the substrate, the reliability degradation index refers to the parameter that quantifies the degradation of the bonding strength, the periodic change refers to the fixed periodic cyclic application of the load, the staged pressurization refers to the incremental stage division of the pressure loading, the axial movement component refers to the displacement of the test head along the loading axis, the lateral offset component refers to the displacement of the test head perpendicular to the loading axis, and the deflection component refers to the displacement of the test head perpendicular to the loading axis. The difference refers to the instantaneous angular deviation between the lateral displacement and the crack path, the driving mechanism refers to the servo motor system that controls the movement, the control signal refers to the displacement instruction received by the driving mechanism, the constant pressure section refers to the loading stage where the pressure remains unchanged, the staged pressurization section refers to the stage where the pressure gradually increases, the force increment refers to the pressure increase value of each pressurization section, the cumulative force change refers to the cumulative pressure value after multi-stage pressurization, the geometric center point coordinates refer to the center of mass position of the contact area, the deformation gradient distribution refers to the spatial characteristics of the displacement change rate, the product parameter refers to the coupling value of the geometric center offset and the deformation gradient, the preset condition refers to the reliability threshold for triggering cyclic loading, and the failure judgment threshold refers to the critical value of failure of the material bonding strength.

[0119] In the embodiment of the present application, first, in step 1051, the adjustment angle of the loading direction is decomposed into an axial movement component and a lateral offset component corresponding to the bending test head. Then, based on the updated crack tip position coordinate data in the three-dimensional path, the deviation between the lateral offset component and the actual crack path direction at the current moment is calculated. This deviation is input into a precision drive mechanism, such as a servo system, which converts it into a corresponding control signal to dynamically correct the axial movement component and lateral offset component of the bending test head, thereby obtaining an adjusted movement path. For example, if a 15-degree loading direction adjustment request is detected and decomposed into a 10-degree lateral component, and the calculated current path tangential deviation δ = 0.18 mm is obtained, the drive mechanism immediately responds by compensating for this lateral offset component at a rate of 0.1 mm / ms to correct the path.

[0120] Next, step 1052 divides the hydraulic system's output force time history into a constant pressure segment and a staged pressure increase segment based on the monitored pressure change amplitude characteristics. The output force in the constant pressure segment remains stable, while the output force in the staged pressure increase segment increases in a planned, step-by-step manner. Then, based on the depth change rate trend of the maximum deformation area identified in the three-dimensional shape change data (e.g., 3D scanning results), which is typically the weakest area, the force increment gradient of each stage of the staged pressure increase segment is adaptively adjusted. For example, the amplitude of each pressure increase is increased or decreased. Based on these adjusted increments, the cumulative force change from the starting point to the current point is calculated. For example, the hydraulic system's initial output is 80 kN, and it is planned to be reduced to a target value of 60 kN in three stages. However, based on the observed trend of accelerated depth change in the maximum deformation area, it is determined that the pressure increase gradient in the final segment needs to be slowed down. Therefore, the force increment in the third segment is adjusted from the originally planned -5 kN to -2 kN, resulting in a total cumulative pressure change of -20 kN.

[0121] Next, in step 1053, based on the optimized movement path, the 3D coordinates of the geometric center point of the actual contact area between the crack tip and the bending test head are precisely located and extracted from the high-precision 3D path point cloud data describing the entire material deformation process. For example, the coordinates of the center point of the contact area are determined to be (4.2, 3.1, 0.2) mm using point cloud computing.

[0122] Then, step 1054 uses the three-dimensional deformation gradient tensor distribution information provided by the three-dimensional shape change data (which quantifies the gradient of deformation degree and direction at each point within the material) to calculate the offset of the previously extracted geometric center point coordinates relative to its initial position or adjacent reference points. This offset reflects the local plastic strain or displacement. This offset is then multiplied by the deformation gradient tensor at the center point's location to obtain a key product parameter, which comprehensively reflects the amplification effect or influence factor of the local deformation gradient on the contact point displacement. For example, if the geometric center point is calculated to be offset by 0.12 mm in the X direction and the deformation gradient component value in the X direction at that point is read as 0.85 / mm, the product parameter Q is calculated to be 0.12 * 0.85 = 0.102.

[0123] Finally, step 1055 performs an integral coupling calculation on the product parameter obtained in step 1054 and the cumulative force value change obtained in step 1052 in the time domain, which is specifically expressed as the time integral of the product of the product parameter and the differential form of the force value change, thereby calculating the reliability degradation index R_fail that characterizes the material bonding strength under the combined action of cyclic loading and step-by-step pressurization. This index is monitored. Once its calculation result exceeds the preset critical condition threshold, it means that the reliability has significantly decreased to a dangerous level, and the system will automatically trigger the periodic cyclic loading mode; this cyclic loading will continue, continuously accumulating the reliability degradation index until the index finally reaches and exceeds the preset material bonding strength failure judgment threshold, at which time it can be determined that the material has failed. For example, the time-domain integral calculation based on the formula R_fail=∫(Q·dF)dt yields the current value R_fail=2040. The preset critical threshold is 2000. Because 2040>2000, the system immediately triggers periodic cyclic loading. After three complete loading-unloading cycles, the R_fail integral value reaches 3150, successfully reaching the preset material failure threshold of 2500. The test is terminated and the material bond strength is determined to have failed.

[0124] In actual applications, during the reliability test of the cladding layer of a certain automobile gearbox, the hydraulic actuator decomposes the 15-degree directional adjustment angle into an axial displacement component of 0.5 mm and a lateral offset component of 0.3 mm. The path deviation is compensated by a PID controller, and the pressure is increased in three stages. The initial stage maintains a constant pressure of 8 kN, and then the pressure gradient is increased according to the rate of change of the deformation depth. When the cumulative output force reaches 22 kN, the system calculates the product parameter of the geometric center offset of the contact area and the deformation gradient. When this parameter triggers the reliability index threshold of 0.8, it automatically starts three cyclic loadings with a frequency of 5 Hz until the material interface bonding strength completely fails.

[0125] In the aforementioned step 105, a closed-loop control mechanism based on directional decomposition and staged pressurization enables assessment of bond strength reliability. The periodic cyclic loading process is triggered by calculating the product parameter of the geometric center offset and the deformation gradient. By comparing the cumulative force change with the failure threshold, the critical point of interface separation in the cladding layer is accurately captured, providing closed-loop failure determination verification for remanufactured component life prediction.

[0126] The following is a complete embodiment of steps 101 to 105:

[0127] A high-end equipment remanufacturing center conducted bending tests on a nickel-based alloy cladding layer on a steam turbine rotor. Initially, a laser Doppler interferometer scanned the crack tip area on the cladding surface at a resolution of 0.1 micrometers. A synchronized piezoelectric acoustic emission sensor array captured the acoustic wave signals of the crack propagation at a sampling rate of 2 MHz. The dual-channel data was aligned to the microsecond level using an atomic clock, generating mechanical change data including stress gradient distribution and acoustic emission energy.

[0128] Based on this data stream, the system automatically triggers a capture mechanism when the crack propagation length reaches 10 microns. The system then combines the current stress gradient of 5.2 MPa / micron, the peak acoustic emission energy of 18 microjoules, and the three-dimensional coordinates of the crack tip recorded by high-speed photography into a map unit. Units generated within 200 milliseconds are stacked in a time series to construct a four-dimensional space-time map, clearly illustrating the coupled evolution of stress concentration zones and energy release hotspots during the cladding failure process.

[0129] Eight laser triangulation devices were then deployed along the predicted crack path. When the crack growth rate exceeded the critical value of 15 microns per millisecond, the system automatically increased the sampling frequency to 10 kHz, synchronously triggering four orthogonally arranged high-speed cameras to capture multi-view images. The SIFT algorithm was used to identify characteristic points along the crack edge, and the three-dimensional coordinates were calculated using camera calibration parameters. The laser displacement data was then integrated to correct spatial errors, ultimately reconstructing the three-dimensional propagation path of the cladding layer crack. A microfocus CT scanner scanned the opening with 20-micron layer thickness to quantify the deformation depth distribution.

[0130] The intelligent decision-making module extracts the stress vector at the crack tip from the atlas and calculates the cosine of the spatial angle (0.8) between it and the tangent vector of the three-dimensional path. Combining this with the path curvature radius of 2 mm and the material's fracture toughness parameters, it derives an energy resistance per unit length of 12 J / m. After coupled analysis, the module outputs a minimum energy threshold of 9.6 J / m to inhibit crack growth. It also identifies an over-deformation zone within 150 microns of the tip, where the displacement exceeds the yield threshold by 50%. Ultimately, it generates optimization instructions for adjusting the loading direction by 15 degrees and reducing the pressure by 0.2 kilonewtons.

[0131] The hydraulic actuator system decomposes the directional adjustment angle into an axial displacement of 0.5 mm and a lateral offset of 0.3 mm, using a PID controller to compensate for path deviations. Pressure loading is divided into three stages: an initial constant pressure of 8 kN is maintained, followed by a pressure increase based on the rate of change in deformation depth. When the cumulative output force reaches 22 kN, the system calculates the product parameter of the contact area's geometric center offset and the deformation gradient. When this parameter triggers the reliability index threshold of 0.8, three cyclic loading cycles at a frequency of 5 Hz are automatically initiated until the interface between the cladding layer and the substrate is completely separated, accurately determining the critical point of bond strength failure.

[0132] Figure 2A schematic diagram of a laser cladding layer bonding strength testing system is provided for an embodiment of the present application. Figure 2 As shown, the system includes:

[0133] An acquisition module 21 is used to simultaneously acquire mechanical change data and energy release data at the crack tip on the surface of the laser cladding layer during a bending loading test using a laser measuring device and a sound signal detection device;

[0134] A generation module 22 is used to align the mechanical change data and the energy release data in chronological order, and generate a graph in combination with the record of the crack propagation process;

[0135] Establishing module 23, for arranging multiple sets of laser ranging devices along the crack extension path, automatically adjusting the measurement frequency according to the crack growth rate measured during the crack extension process, cooperating with a multi-angle image capture system to record the three-dimensional path of the crack extension process, and using three-dimensional scanning technology to establish three-dimensional shape change data of the crack opening;

[0136] An input module 24 is configured to calculate a minimum energy value required to prevent crack propagation based on the stress state of the crack tip in the atlas and the three-dimensional path, input the minimum energy value and the position information of the maximum deformation area in the three-dimensional shape change data into an intelligent decision model, and derive a loading direction adjustment angle and a pressure change amplitude;

[0137] The calculation module 25 is used to adjust the angle according to the loading direction to instantly correct the movement path of the bending test head, and at the same time regulate the output force of the hydraulic device according to the pressure change amplitude. In combination with the three-dimensional path, the three-dimensional shape change data and the adjusted movement path, the reliability degradation index of the material bonding strength under the combined effects of periodic changes and staged pressurization is cyclically calculated.

[0138] Figure 2 The laser cladding layer bonding strength testing system can perform Figure 1 The implementation principle and technical effects of the laser cladding layer bonding strength testing method described in the illustrated embodiment will not be elaborated on here. The specific manner in which each module and unit performs operations in the laser cladding layer bonding strength testing system in the above embodiment has been described in detail in the embodiment of the method and will not be elaborated on here.

[0139] In one possible design, Figure 2 The laser cladding layer bonding strength testing system of the embodiment shown can be implemented as a computing device, such as Figure 3 As shown, the computing device may include a storage component 31 and a processing component 32;

[0140] The storage component 31 stores one or more computer instructions, wherein the one or more computer instructions are called and executed by the processing component 32 .

[0141] The processing component 32 is used for the above Figure 1 The laser cladding layer bonding strength testing method of the embodiment.

[0142] The processing component 32 may include one or more processors to execute computer instructions to complete all or part of the steps in the above method. Of course, the processing component may also be implemented as one or more application-specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), controllers, microcontrollers, microprocessors, or other electronic components to perform the above method.

[0143] The storage component 31 is configured to store various types of data to support operations at the terminal. The storage component can be implemented by any type of volatile or non-volatile memory device, or a combination thereof, such as static random access memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic memory, flash memory, magnetic disk, or optical disk.

[0144] Of course, a computing device may also include other components, such as input / output interfaces, display components, communication components, etc.

[0145] The input / output interface provides an interface between the processing component and the peripheral interface module, which can be an output device, an input device, etc.

[0146] The communication component is configured to facilitate, among other things, wired or wireless communications between the computing device and other devices.

[0147] Among them, the computing device can be a physical device or an elastic computing host provided by a cloud computing platform, etc. In this case, the computing device can refer to a cloud server, and the above-mentioned processing components, storage components, etc. can be basic server resources rented or purchased from the cloud computing platform.

[0148] The present application also provides a computer storage medium storing a computer program, wherein the computer program can achieve the above-mentioned Figure 1 The bonding strength testing method of the laser cladding layer of the embodiment shown is shown.

[0149] Those skilled in the art will clearly understand that, for the convenience and brevity of description, the specific working processes of the systems, devices and units described above can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0150] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate, and the components shown as units may or may not be physical units, i.e., they may be located in one location or distributed across multiple network units. Some or all of the modules may be selected based on actual needs to achieve the objectives of the present embodiment. Persons of ordinary skill in the art will be able to understand and implement the present invention without inventive effort.

[0151] Through the above description of the embodiments, those skilled in the art will clearly understand that each embodiment can be implemented using software plus a necessary general-purpose hardware platform, or of course, hardware. Based on this understanding, the essence of the above technical solution, or the portion that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, a magnetic disk, or an optical disk, and includes a number of instructions for causing a computer device (such as a personal computer, server, or network device) to execute the methods described in each embodiment or certain portions of the embodiments.

[0152] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A method for testing the bonding strength of a laser cladding layer, characterized in that: include: The laser measuring device and the sound signal detection device are used to simultaneously obtain the mechanical change data and energy release data at the crack tip of the laser cladding layer during the bending loading test; Aligning the mechanical change data with the energy release data in chronological order, and combining the records of the crack propagation process to generate a graph; Arrange multiple sets of laser distance measuring devices along the crack extension path, automatically adjust the measurement frequency according to the crack growth rate measured during the crack extension process, cooperate with a multi-angle image capture system to record the three-dimensional path of the crack extension process, and use three-dimensional scanning technology to establish the three-dimensional shape change data of the crack opening; Calculating the minimum energy value required to prevent crack propagation based on the stress state of the crack tip in the atlas and the three-dimensional path, inputting the minimum energy value and the position information of the maximum deformation area in the three-dimensional shape change data into an intelligent decision model to obtain the loading direction adjustment angle and the pressure change amplitude; The movement path of the bending test head is instantly corrected by adjusting the angle according to the loading direction, and the output force of the hydraulic device is regulated according to the pressure change amplitude. The reliability degradation index of the material bond strength under the combined effects of periodic changes and staged pressurization is cyclically calculated by combining the three-dimensional path and three-dimensional shape change data with the adjusted movement path. Based on the stress state of the crack tip in the atlas and the three-dimensional path, the minimum energy value required to prevent crack propagation is calculated. The minimum energy value and the position information of the maximum deformation area in the three-dimensional shape change data are input into the intelligent decision model to obtain the loading direction adjustment angle and the pressure change amplitude, including: Extracting a crack tip stress direction parameter from the dual data streams of the atlas, and calculating a cosine value of an angle between the crack tip stress direction parameter and the current crack direction in the three-dimensional path; Calculating the energy resistance value generated by the path bending per unit length of crack extension based on the curvature variation characteristics of the three-dimensional path; Multiplying the cosine value of the angle by the energy resistance value, and obtaining the minimum energy value for inhibiting crack growth based on the mechanical and energy coupling characteristics in the correlation relationship; Identify the position information of the deformation-exceeding-limit area in the three-dimensional shape change data, input the position information and the minimum energy value into the intelligent decision-making model, and output the loading direction adjustment angle and pressure change amplitude by analyzing the spatial distribution relationship between the position information and the minimum energy value.

2. The method according to claim 1, characterized in that Arrange multiple sets of laser ranging devices on the crack extension path, automatically adjust the measurement frequency according to the crack growth rate measured during the crack extension process, cooperate with the multi-angle image shooting system to record the three-dimensional path of the crack extension process, and use three-dimensional scanning technology to establish the three-dimensional shape change data of the crack opening part, including: Based on the crack tip position coordinates in the atlas, multiple groups of laser ranging devices are deployed at equal intervals along the predicted propagation direction to measure the displacement trajectory of the crack edge in three-dimensional space; adjusting the measurement frequency of the laser ranging device according to the rate of change of the displacement trajectory, synchronously capturing image sequences of the crack at different viewing angles through a multi-angle image capture system, and reconstructing the three-dimensional path of the crack based on the displacement trajectory and image parallax; Based on the spatial orientation of the three-dimensional path and the deformation characteristics of the image sequence, a layered three-dimensional scan is performed on the crack opening portion, and three-dimensional shape change data is generated in combination with the geometric constraints of the three-dimensional path.

3. The method according to claim 1, characterized in that The moving path of the bending test head is instantly corrected by adjusting the angle according to the loading direction, and the output force of the hydraulic device is regulated according to the pressure change amplitude. The reliability degradation index of the material bonding strength under the combined effects of periodic changes and staged pressurization is cyclically calculated by combining the three-dimensional path, three-dimensional shape change data and the adjusted moving path, including: Decomposing the loading direction adjustment angle into an axial movement component and a lateral offset component of the bending test head, calculating the deviation between the lateral offset component and the current crack path direction based on the change in the crack tip position coordinates in the three-dimensional path, and converting the deviation into a control signal through a drive mechanism to adjust the axial movement component and the lateral offset component to obtain an adjusted movement path; The output force of the hydraulic device is divided into a constant pressure section and a staged pressure increase section according to the pressure change amplitude, and the force value increment of the staged pressure increase section is adjusted according to the depth change trend of the maximum deformation area in the three-dimensional shape change data to obtain the cumulative force value change; extracting the coordinates of a geometric center point of a contact area between the crack tip and the bending test head from the three-dimensional path based on the adjusted movement path; Calculating a product parameter of the offset of the geometric center point coordinates and the deformation gradient distribution based on the deformation gradient distribution in the three-dimensional shape change data; The product parameter is coupled with the cumulative force value change to calculate a reliability degradation index. When the reliability degradation index exceeds a preset condition, periodic cyclic loading is triggered until the reliability degradation index reaches a failure judgment threshold of the material bonding strength.

4. The method according to claim 1, wherein The mechanical change data and the energy release data are aligned in time sequence and combined with the record of the crack propagation process to generate a graph, including: The mechanical change data and energy release data are aligned frame by frame using a unified timestamp to form a dual data stream with a completely matched time axis. According to the crack tip position mark at each time node in the record of the crack propagation process, the mechanical change gradient value and the energy release peak value at the corresponding moment are extracted from the dual data streams to establish a correlation relationship; When the crack extension length reaches a preset interval condition, the data interception module is triggered to bind the mechanical change gradient value, energy release peak value and crack tip position coordinates at the current moment into a map unit based on the association relationship; The atlas units are stacked and arranged in chronological order, and cross-dimensional mapping is achieved through the timestamps of the dual data streams to generate an atlas.

5. The method according to claim 1, wherein Identify the position information of the deformation exceeding limit area in the three-dimensional shape change data, input the position information and the minimum energy value into the intelligent decision model, and output the loading direction adjustment angle and pressure change amplitude by analyzing the spatial distribution relationship between the position information and the minimum energy value, including: In the three-dimensional shape change data, for each layered scanning contour of the three-dimensional path, extract the continuous area with the largest absolute value of displacement along the depth direction as the deformation exceeding limit candidate area, and record the position information of the deformation exceeding limit candidate area; Based on the projection of the position information of the candidate deformation excess zone on the three-dimensional path, the three-dimensional Euclidean distance between the center point of each candidate zone and the crack tip is calculated, and the candidate zone whose three-dimensional Euclidean distance is less than twice the current extension length of the crack is selected as the effective deformation excess zone, and the position information of the effective deformation excess zone is updated; Inputting the position information of the effective deformation exceeding limit area and the spatial distribution map of the minimum energy value into the intelligent decision model, performing vector direction matching by analyzing the spatial distribution relationship between the position information and the minimum energy value, and establishing an angle histogram; Determine the main interference direction according to the angle interval with the highest probability in the angle histogram, and generate the loading direction adjustment angle by taking the vector difference between the main interference direction and the current loading direction; Based on the analysis results of the spatial distribution relationship, the energy attenuation gradient of the position information of the effective deformation limit zone in the spatial distribution diagram of the minimum energy value is statistically calculated, and the ratio of the decreasing rate of the energy attenuation gradient to the preset safety threshold is used as the pressure change amplitude.

6. The method according to claim 2, characterized in that The method comprises: adjusting the measurement frequency of the laser ranging device according to the rate of change of the displacement trajectory, synchronously capturing image sequences of the crack at different viewing angles through a multi-angle image shooting system, and reconstructing the three-dimensional path of the crack based on the displacement trajectory and image parallax, including: Obtaining a position change of each measurement point within a continuous time interval from the displacement trajectory, and calculating a ratio of the position change to the corresponding time interval as a rate of change; Setting a rate threshold range according to the rate of change, adjusting a measurement frequency of the laser ranging device based on the rate threshold range, and generating a synchronization trigger signal according to the adjusted measurement frequency; Based on the synchronization trigger signal, controlling the multi-angle image capture system to capture a sequence of images of the crack edge from multiple fixed perspectives at the same time, identifying key position points of the crack edge in the images of each perspective based on the image sequence, and determining pixel coordinate offsets of the key position points in the images of different perspectives; Calculating the depth distance of each key position point in three-dimensional space based on the angular relationship between the pixel coordinate offset and the pre-calibrated viewing angle of the multi-angle image capture system, and combining the depth distance with the two-dimensional pixel coordinates of the corresponding viewing angle to obtain the three-dimensional coordinates of the key position point; The position consistency of the measurement point position data at the same time in the displacement trajectory and the three-dimensional coordinates of the key position point is checked, and the three-dimensional coordinate value is corrected to obtain the corrected three-dimensional coordinate point. The corrected three-dimensional coordinate points are integrated in chronological order to reconstruct the three-dimensional path of the crack.

7. A laser cladding layer bonding strength testing system, used to perform the laser cladding layer bonding strength testing method according to any one of claims 1 to 6, characterized in that: include: An acquisition module is used to simultaneously acquire mechanical change data and energy release data at the crack tip on the surface of the laser cladding layer during the bending loading test using a laser measuring device and a sound signal detection device; A generation module, configured to align the mechanical change data and the energy release data in chronological order, and generate a graph in combination with a record of the crack propagation process; Establish a module for arranging multiple sets of laser ranging devices along the crack extension path, automatically adjusting the measurement frequency according to the crack growth rate measured during the crack extension process, cooperating with a multi-angle image capture system to record the three-dimensional path of the crack extension process, and using three-dimensional scanning technology to establish three-dimensional shape change data of the crack opening; An input module is configured to calculate a minimum energy value required to prevent crack propagation based on the stress state of the crack tip in the atlas and the three-dimensional path, input the minimum energy value and the position information of the maximum deformation area in the three-dimensional shape change data into an intelligent decision model, and derive a loading direction adjustment angle and a pressure change amplitude; The calculation module is used to adjust the angle according to the loading direction to instantly correct the movement path of the bending test head, and at the same time regulate the output force of the hydraulic device according to the pressure change amplitude. In combination with the three-dimensional path, the three-dimensional shape change data and the adjusted movement path, the reliability degradation index of the material bonding strength under the combined effects of periodic changes and staged pressurization is cyclically calculated.

8. A computing device, characterized in that It comprises a processing component and a storage component; the storage component stores one or more computer instructions; the one or more computer instructions are used to be called and executed by the processing component to implement the laser cladding layer bonding strength testing method according to any one of claims 1 to 6.

9. A computer storage medium, characterized in that A computer program is stored, and when the computer program is executed by a computer, the laser cladding layer bonding strength testing method according to any one of claims 1 to 6 is implemented.

Images