Manufacturing method of wallboard load-bearing structure

Abstract

The invention discloses a manufacturing method of a wall plate force bearing structure. The manufacturing method comprises the steps that a three-dimensional model of the force bearing structure is analyzed; determining an interface between the plate body of the bottom plate of the load-bearing structure and the boss; processing parameters and a three-dimensional model of the plate body are determined; determining machining parameters and a three-dimensional model of the boss; machining the plate body according to the determined machining parameters and the three-dimensional model of the plate body; according to the determined machining parameters and the three-dimensional model of the boss, the boss is machined on the plate body through an LED; carrying out stress annealing treatment on the processed bottom plate; the plate body and the boss are subjected to semi-finish machining; quality detection is conducted on the surface and the interior of the boss; processing grid ribs of the bearing structure and preparing before welding; the grid ribs are welded and fixed to the positions of the bosses; and the obtained force bearing structure is subjected to destressing and finish machining treatment. The technical problems that in the prior art, a technological boss is high in machining cost, long in period and the like are solved.

Description

Technical Field

[0001] The present application belongs to the field of aerospace processing technology, and specifically relates to a method for manufacturing a load-bearing structure of an optical wall panel for aerospace use. Background Art

[0002] The load-bearing structural products of large optical wall panels in aerospace are mostly regular square structures, and the conventional manufacturing methods of the load-bearing structures are mostly machining and welding. Welding is mainly used to connect the base plate and the grid ribs of the load-bearing structure. In order to meet the processing needs of welding the grid ribs to the base plate, structures such as process bosses need to be machined on the base plate first. To ensure the structural strength of the process bosses, the existing technology requires selecting plates that are thicker than conventional plates, and then removing a large area of ​​material from the plates to highlight the above-mentioned process bosses. This processing method has problems such as high processing costs, long cycles, and poor quality and accuracy assurance, which in turn affects the low-cost, large-scale production process of the entire large-scale frame load-bearing structure. Summary of the Invention

[0003] The present application aims to solve one of the technical problems in the related art at least to a certain extent.

[0004] In order to solve the above technical problems, the present application provides a method for manufacturing a wall panel load-bearing structure. This manufacturing method facilitates the processing of the load-bearing structure while ensuring structural strength, reduces the overall processing cost, shortens the overall processing cycle, and ensures the overall processing quality.

[0005] The manufacturing method of the wall panel load-bearing structure of the present application includes:

[0006] S1: Analyze the three-dimensional model of the load-bearing structure;

[0007] S2: Determine the interface between the bottom plate and the boss of the load-bearing structure;

[0008] S3: Determine the processing parameters and three-dimensional model of the plate;

[0009] S4: Determine the processing parameters and three-dimensional model of the boss;

[0010] S5: machining the plate body according to the determined processing parameters and three-dimensional model of the plate body;

[0011] S6: machining the boss on the plate by LDED according to the determined machining parameters and three-dimensional model of the boss;

[0012] S7: performing stress annealing treatment on the processed bottom plate;

[0013] S8: performing semi-finishing processing on the plate body and the boss;

[0014] S9: Performing quality inspection on the surface and interior of the boss;

[0015] S10: Process the grid reinforcement of the load-bearing structure and prepare for welding;

[0016] S11: Welding and fixing the mesh ribs to the bosses;

[0017] S12: performing stress relief and fine processing on the obtained load-bearing structure.

[0018] In some technical solutions, determining the processing parameters of the plate body includes determining the final forming size and the blank size of the plate body, and in step S5, processing the plate body according to the blank size of the plate body;

[0019] Determining the processing parameters of the boss includes determining the final forming size and the blank size of the boss, and in step S6, processing the boss according to the blank size of the boss.

[0020] In some technical solutions, the blank size of the plate body includes a thickness size of the plate body, and determining the thickness size includes the following steps:

[0021] A1: Simulate the process of machining the boss on the plate by LDED;

[0022] A2: Determine the thickness dimension based on the simulation results.

[0023] In some technical solutions, in step S4, determining the processing parameters of the boss includes the following steps:

[0024] B1: exporting the three-dimensional model of the boss;

[0025] B2: Design the molding process parameters of the 3D model in slicing software that can be recognized by LDED. The molding process parameters include: path planning parameters and the residence time of two adjacent deposition layers.

[0026] In some technical solutions, in step S5, the flatness of the processed plate is no greater than 5 μm;

[0027] And / or, in step S6, before machining the boss, the surface of the plate is cleaned and descaled.

[0028] In some technical solutions, the LDED has a formable size corresponding to the format size of the board body, the formable size is larger than the format size of the board body, and the distance between the edge of the formable size and the corresponding edge of the format size is 150 mm to 300 mm;

[0029] The blank size of the plate body includes the formable size, and the final forming size of the plate body includes the format size. In step S12, the plate body is processed and reduced from the formable size to the format size.

[0030] In some technical solutions, in step S6, machining the boss on the plate by LDED includes the following steps:

[0031] C1: Drying the additive material used in LDED, wherein the additive material is metal powder or metal wire, the particle size of the metal powder is 75 μm to 250 μm, and the diameter of the metal wire is 0.8 mm to 1.4 mm. The drying temperature is 80° C. to 120° C. and the drying time is 6 h to 12 h.

[0032] C2: The manufacturing additive material is transported to the convergence point of the laser spot through a carrier for layer-by-layer melting and sintering, and the molten pool width during the LDED processing is 6mm to 10mm, the laser power is 2000W to 7000W, the moving speed of the spot is 600mm / min to 1100mm / min, the feeding rate of the manufacturing additive material is 1000g / h to 1500g / h, the overlap rate is 25% to 50%, and the oxygen content of the atmosphere during the forming process is controlled below 100ppm.

[0033] In some technical solutions, in step S7, the stress annealing treatment is a vacuum stress relief annealing treatment, and the annealing temperature is 650° C. to 830° C., and the holding time is 4 hours to 6 hours.

[0034] In some technical solutions, in step S9, the quality detection is performed by fluorescence and X-ray quality detection;

[0035] And / or, in step S10, the pre-welding preparation includes pickling the surface of the boss and the surface of the mesh rib;

[0036] And / or, in step S11, the grid ribs are fixedly welded with welding parameters as follows: laser power of 6.5 kW to 15 kW, welding speed of 1.6 mm / s to 3.0 mm / s, and defocus ΔF of -3 mm to -12 mm.

[0037] In some technical solutions, in step S11, after the mesh ribs are welded and fixed to the bosses, the quality of the weld seams between the mesh ribs and the bosses is inspected;

[0038] And / or, the plate body and the grid ribs are formed by casting or forging;

[0039] And / or, the boss and the grid rib are in the shape of a rectangle, a square, a circle or an ellipse.

[0040] It can be seen from the above technical solution that the wall panel load-bearing structure manufacturing method of the present application facilitates the processing of the load-bearing structure while ensuring structural strength, reduces the overall processing cost, shortens the overall processing cycle, and ensures the overall processing quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the technical solutions in the embodiments of the present application, a brief introduction will be given below to the drawings required for use in the description of the embodiments. 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.

[0042] Figure 1 Schematic diagram of the overall process of the manufacturing method in the embodiment of the present application.

[0043] Figure 2 This is a schematic diagram of the overall structure of the load-bearing structure in an embodiment of the present application.

[0044] Figure 3 It is an exploded schematic diagram of the load-bearing structure in an embodiment of the present application.

[0045] Figure 4 This is a schematic diagram of the load-bearing structure in an embodiment of the present application with the plate body having the remainder removed.

[0046] Figure 5 Schematic diagram of the metallographic interface between the plate and the boss in the embodiment of the present application.

[0047] Description of reference numerals:

[0048] 1-base plate; 11-plate body; 12-boss; 13-removed part; 2-grid ribs. DETAILED DESCRIPTION

[0049] In order to enable those skilled in the art to understand the present application more clearly, the technical solutions 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. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of this application.

[0050] In addition, this application may repeat reference numbers and / or reference letters in different examples. This repetition is for the purpose of simplicity and clarity and does not in itself indicate the relationship between the various embodiments and / or settings discussed. In addition, this application provides examples of various specific processes and materials, but those of ordinary skill in the art will recognize the application of other processes and / or the use of other materials.

[0051] The specific technical solutions of the present application are described in detail below with reference to the accompanying drawings, which are not necessarily drawn to scale. Similar or identical reference numerals may be used to designate the same or similar parts in different figures. The use of similar or identical reference numerals in different figures does not imply that all figures including similar or identical reference numerals constitute a single or identical embodiment. The accompanying drawings generally illustrate various embodiments discussed in this application by way of example and not limitation.

[0052] An embodiment of the method for manufacturing the wall panel load-bearing structure of the present application is described below.

[0053] like Figure 1 As shown, the manufacturing method of the wall panel load-bearing structure of the embodiment of the present application (hereinafter referred to as the manufacturing method) includes:

[0054] S1: Analyze the three-dimensional model of the load-bearing structure. For example, Figure 2 and Figure 3 As shown, the load-bearing structure in the present application may include a frame beam structure, which includes a base plate 1 and grid ribs 2, wherein the base plate 1 may be roughly a rectangular flat plate, and the grid ribs 2 may include a plurality of rib plates arranged perpendicularly to each other.

[0055] The three-dimensional model of the load-bearing structure can be a model created using three-dimensional software, etc. Analysis of the three-dimensional model can include analysis prior to the creation of the three-dimensional model. Specifically, analysis of the three-dimensional model can include analysis of the steps, methods, and specific processes involved in creating the three-dimensional model. Furthermore, analysis of the three-dimensional model can also include analysis of the already created three-dimensional model. Specifically, this analysis can include analysis of the model's dimensions, the positional relationships between different parts, and the interfaces between different components. It should be noted that analysis of the three-dimensional model can include analysis of the aforementioned base plate 1 and mesh reinforcement 2.

[0056] Analyzing the three-dimensional model can facilitate the modeling of the three-dimensional model and help operators understand the specific situation of the three-dimensional model, thereby providing a reference basis for subsequent operations.

[0057] S2: Determine the interface between the plate body 11 and the boss 12 of the bottom plate 1 of the load-bearing structure. Specifically, Figure 3As shown, the base plate 1 of the load-bearing structure may include a plate body 11 and a boss 12, wherein the plate body 11 may be a rectangular flat plate, and the boss 12 may be a mesh frame structure, that is, the boss 12 may include a plurality of transverse ribs extending in the front-to-back direction and a plurality of longitudinal ribs extending in the left-to-right direction, and the plurality of transverse ribs and the plurality of longitudinal ribs are arranged to intersect vertically.

[0058] Step S2 can be performed after the three-dimensional model has been completely established. That is, after the three-dimensional model is created, the interface between the plate 11 and the boss 12 can be analyzed and determined using corresponding software. The interface is the interface that separates the plate 11 and the boss 12. The separation of the plate 11 and the boss 12 can be achieved by determining the interface.

[0059] S3: Determine the processing parameters and 3D model of the plate 11. Specifically, once the interface is determined, the plate 11 can be isolated. The 3D model of the plate 11 allows analysis of the processing parameters of the plate 11. These parameters may include the final dimensions of the plate 11 and the initial rough size. The independence of the 3D model of the plate 11 facilitates mechanical processing of the plate 11.

[0060] S4: Determine the processing parameters and 3D model of the boss 12. Specifically, once the interface is determined, the entire 3D model of the boss 12 can be isolated. This 3D model can be used to analyze the processing parameters of the boss 12. These parameters may include the final dimensions of the boss 12 and the initial rough size. Since the 3D model of the boss 12 is also independent, it is also convenient to use this 3D model to process and shape the boss 12.

[0061] S5: Mechanically process the plate body 11 according to the determined processing parameters and three-dimensional model of the plate body 11. Specifically, the plate body 11 can be formed by casting, forging, etc., and the processing can be completed according to the determined processing parameters of the plate body 11.

[0062] S6: Based on the determined processing parameters and three-dimensional model of the boss 12, the boss 12 is machined on the plate 11 through LDED. Specifically, LDED is a laser directed energy deposition (LDED) technology. After the plate 11 is machined and formed, the boss 12 can be formed on the corresponding surface of the plate 11 through LDED.

[0063] S7: performing stress annealing on the processed bottom plate 1. For example, the stress annealing on the bottom plate 1 can be performed by vacuum stress relief annealing, thereby eliminating stress.

[0064] S8: Semi-finishing the plate 11 and boss 12. For example, after the stress annealing treatment, the plate 11 and the formed boss 12 can be fine-finished using specialized machinery. During processing, the final molding dimensions and blank dimensions of the plate 11 and boss 12 obtained above can be referenced, and the overall fine-finishing can be gradually completed using the difference between the final molding dimensions and the blank dimensions.

[0065] S9: Performing quality inspection on the surface and interior of the boss 12. Specifically, the surface and interior of the boss 12 can be inspected by fluorescence, X-ray, etc., so as to ensure the overall quality of the processed boss 12.

[0066] S10: Processing the load-bearing structure's mesh reinforcement 2 and preparing for welding. For example, the mesh reinforcement 2 can be formed by casting. In other embodiments, the mesh reinforcement 2 can also be formed by forging, machining, or other methods. During processing, the mesh reinforcement 2 can be processed based on the corresponding parameters and dimensions determined by analyzing the three-dimensional model.

[0067] Preparation before welding may include cleaning the welding surface between the mesh ribs 2 and the base plate 1, thereby avoiding the influence of impurities on welding and improving the overall processing quality.

[0068] S11: Welding the mesh ribs 2 to the bosses 12. For example, the mesh ribs 2 can be fixed to the bosses 12 by laser welding, thereby ensuring processing accuracy and structural strength of the connection.

[0069] S12: The resulting load-bearing structure is subjected to stress relief and finishing. For example, after the mesh ribs 2 are completely welded and fixed, the entire load-bearing structure can be stress-relieved by vacuum stress relief annealing or other methods. After the stress is removed, the load-bearing structure can be finished. During the finishing process, both the base plate 1 and the mesh ribs 2 can be processed. After the finishing process, the load-bearing structure required for the present application can be obtained.

[0070] In some embodiments, determining the processing parameters of the plate body 11 includes determining the final molding size and the blank size of the plate body 11. In step S5, the plate body 11 is machined according to the blank size of the plate body 11. The blank size can be used to obtain a preliminary plate body 11. In this way, after integration with the subsequent bosses 12 and mesh ribs 2, the margin reserved for the blank size can be removed to obtain a plate body 11 corresponding to the final molding size, thereby ensuring the final molding quality of the plate body 11.

[0071] In some embodiments, determining the processing parameters of the boss 12 includes determining the final molding size and the blank size of the boss 12. In step S6, the boss 12 is machined according to the blank size of the boss 12. Similar to the plate 11 described above, a preliminary boss 12 can be obtained based on the blank size. After the boss 12 is machined using the LDED technology, the remaining margin of the boss 12 can be removed to obtain a boss 12 corresponding to the final molding size, thereby ensuring the final molding quality of the boss 12.

[0072] In some embodiments, the blank size of the plate body 11 includes the thickness size of the plate body 11, and determining the thickness size includes the following steps:

[0073] A1: Simulate the process of machining boss 12 on plate 11 using LDED. For example, the thickness dimension mentioned above can specifically be the vertical dimension of plate 11. Because the load-bearing structure is used in aerospace, plate 11 should be as light and thin as possible. However, since LDED technology heats or even melts plate 11, making it difficult to machine if the plate 11 is too thin.

[0074] Therefore, before processing the plate body 11, the entire processing process of the boss 12 can be simulated by simulation software. In other embodiments, the processing process of the boss 12 can also be simulated by a physical model with a reduced scale.

[0075] A2: Determine the thickness based on simulation results. Specifically, the above simulation test can be used to obtain the optimal thickness of the plate 11, which is as light and thin as possible while fully meeting the processing requirements.

[0076] In some embodiments, in step S4, determining the processing parameters of the boss 12 includes the following steps:

[0077] B1: Export the three-dimensional model of the boss 12. For example, a three-dimensional model can be created on processing software such as UG, and then the three-dimensional model of the boss 12 can be exported in a format such as STL.

[0078] B2: Design the molding process parameters of the 3D model in slicing software that can be recognized by LDED. The molding process parameters include: path planning parameters and the residence time of two adjacent deposition layers.

[0079] Specifically, the recognizable slicing software can meet the needs of subsequent importation into the LDED system for processing. After the 3D model of the boss 12 is imported into the slicing software, part forming parameters, path planning, and dwell time between deposition layers can be designed for the 3D model of the boss 12. The part can then be sliced ​​and the corresponding program generated. These forming process parameters can guide the subsequent specific processing of the boss 12, ensuring the processing and use requirements of the boss 12.

[0080] In some embodiments, in step S5, the flatness of the processed plate 11 is no greater than 5 μm. For example, the flatness of the plate 11 can be 2 μm, 3 μm, 4 μm, 5 μm, etc. This avoids the situation where the overall processing quality is easily reduced due to poor flatness of the plate 11.

[0081] In some embodiments, in step S6, the surface of the plate 11 is cleaned and descaled before the boss 12 is processed. This can prevent contamination defects such as oil stains, scale, and cracks on the surface of the boss 12.

[0082] In some embodiments, the LDED has a formable size corresponding to the format size of the plate body 11. The formable size is larger than the format size of the plate body 11, and the distance between the edge of the formable size and the corresponding edge of the format size is 150 mm to 300 mm. The blank size of the plate body 11 includes the formable size, and the final formed size of the plate body 11 includes the format size. In step S12, the plate body 11 is processed and reduced from the formable size to the format size.

[0083] For example, Figure 4 As shown, the format size can be the above-mentioned final forming size of the plate body 11, which can be specifically Figure 4 The size of the upper or lower surface of the middle plate 11. The formable size can be the minimum size of the plate 11 that the LDED system can clamp or operate in actual use, which can be Figure 4 The dimensions of the upper or lower surface corresponding to the outer circumferentially removed portion 13 of the middle plate 11 are also part of the dimensional parameters of the blank size of the plate 11. The removed portion 13 can be a rectangular frame structure, located on the outer circumference of the plate 11 and closed along the circumference to form a circle.

[0084] As a result, the blank size of the plate body 11 can meet the processing requirements of the LDED system and also meet the need to fix the edge of the plate body 11 during the forming of the boss 12. Secondly, the above-mentioned removed portion 13 can be removed by cutting or other methods during the final finishing process. In this way, the portion (removed portion 13) scratched on the surface of the plate body 11 due to clamping and other effects can be removed, ensuring the overall forming quality of the plate body 11.

[0085] Alternatively, as Figure 4 As shown, the distance between the edge of the formable size and the corresponding edge of the format size can be regarded as the width dimension M of the removed portion 13. The width dimension M can be 150mm, 160mm, 170mm, 180mm, 190mm, 200mm, 210mm, 220mm, 230mm, 240mm, 250mm, 260mm, 270mm, 280mm, 290mm, 300mm, etc. Within this size range, the requirements for clamping and fixing are met while limiting the overall size specifications of the blank size of the plate body 11, thereby reducing overall consumables.

[0086] In some embodiments, in step S6, machining the boss 12 on the plate 11 by LDED includes the following steps:

[0087] C1: Drying the additive materials used in LDED, wherein the additive materials are metal powder or metal wire, the particle size of the metal powder is 75μm to 250μm, and the diameter of the metal wire is 0.8mm to 1.4mm. The drying temperature is 80℃ to 120℃, and the drying time is 6h to 12h.

[0088] C2: The additive manufacturing material is transported through a carrier to the convergence point of the laser spot for layer-by-layer melting and sintering. The molten pool width during the LDED processing is 6mm to 10mm, the laser power is 2000W to 7000W, the moving speed of the spot is 600mm / min to 1100mm / min, the feeding rate of the additive manufacturing material is 1000g / h to 1500g / h, the overlap rate is 25% to 50%, and the oxygen content of the atmosphere is controlled below 100ppm during the forming process.

[0089] Therefore, the processing and forming quality of the boss 12 is fully guaranteed.

[0090] In some embodiments, in step S7 , the stress annealing treatment is a vacuum stress relief annealing treatment, and the annealing temperature is 650° C. to 830° C., and the holding time is 4 hours to 6 hours.

[0091] In some embodiments, in step S9, the quality detection is performed by fluorescence and X-ray quality detection;

[0092] In some embodiments, in step S10, the pre-welding preparation includes pickling the surface of the boss 12 and the surface of the mesh rib 2, thereby ensuring the cleanliness of the surface of the boss 12 and the surface of the mesh rib 2, and further ensuring the overall welding quality.

[0093] In some embodiments, in step S11, the welding parameters for securing the mesh ribs 2 are: laser power of 6.5 kW to 15 kW, welding speed of 1.6 mm / s to 3.0 mm / s, and defocus distance ΔF of -3 mm to -12 mm. Within this parameter range, the welding quality of the mesh ribs 2 is fully guaranteed, thereby ensuring the stability of the connection between the mesh ribs 2 and the bosses 12.

[0094] In some embodiments, in step S11, after the mesh ribs 2 are welded to the bosses 12, the quality of the weld seams between the mesh ribs 2 and the bosses 12 is inspected. Specifically, the quality of the weld seams can be inspected by X-rays or the like to ensure the overall molding quality.

[0095] In some embodiments, the plate body 11 and the mesh ribs 2 can be formed by casting or forging, thereby ensuring the structural strength of the plate body 11 and the mesh ribs 2.

[0096] In some embodiments, the bosses 12 and mesh ribs 2 are rectangular, square, circular, or elliptical. That is, the base plate 1 can be shaped as needed, such as rectangular, square, circular, or elliptical. In this case, the bosses 12 of the base plate 1 can also be shaped to match the shape of the bosses. Since the mesh ribs 2 are welded to the bosses 12, the overall shape of the mesh ribs 2 can also be adapted to the shape of the bosses 12.

[0097] A specific example of the method for manufacturing the wall panel load-bearing structure of the present application is described below.

[0098] Figure 1 , which is a flow chart of a low-cost hybrid manufacturing method for a load-bearing structure of a large optical wall panel according to an embodiment of the present application, specifically includes the following steps:

[0099] (1) Analyze the three-dimensional model characteristics of the target frame-beam structure;

[0100] (2) Determine the interface between the base plate and the remanufactured part;

[0101] (3) Determine the base plate size and 3D model data;

[0102] (4) Determine the size and three-dimensional digital model of the remanufactured boss part;

[0103] (5) Machining according to the base plate size requirements;

[0104] (6) LDED forming is performed according to the size of the boss blank of the remanufacturing process;

[0105] (7) The bottom plate is subjected to overall stress relief annealing treatment by the remanufacturing process boss;

[0106] (8) Semi-finishing of the base plate and boss allowance in the remanufacturing process;

[0107] (9) Surface and internal quality inspection of the base plate and remanufacturing process boss;

[0108] (10) Preparation before welding of mesh reinforcement for casting bottom plate;

[0109] (11) Laser welding of the bottom plate grid ribs and the bottom plate with process bosses;

[0110] (12) After stress relief and fine processing of the grid-ribbed bottom plate, large optical wall panel load-bearing metal components that meet the requirements can be manufactured.

[0111] In the above steps, the large optical wall panel component structure is disassembled based on base plate remanufacturing and cast grid reinforcement welding. The large optical wall panel component structure is disassembled with high welding accessibility and high welding efficiency as the requirements. After the disassembly, the interface between the base plate and the remanufacturing area (boss) is designed for the large frame beam assembly.

[0112] The pre-processing of the model such as splitting and size design can be done on the 3D model processing software UG to perform size and margin design, export the parts in STL format, and use the slicing software that can be recognized by the LDED system to design the part forming parameters, path planning, and the residence time between deposition layers. The part can then be sliced ​​and the forming program generated.

[0113] Based on the interface between the plate and the remanufactured parts, the plate is manufactured by casting or forging, while the remanufactured parts are remanufactured using laser directed energy deposition. Slicing software that can be recognized by the LDED system is used to design part forming parameters, path planning, and the dwell time between deposition layers.

[0114] The interface design should ensure that the process boss that meets the size requirements is manufactured while designing the plate size to be as thin as possible. Therefore, before remanufacturing, it is necessary to simulate the directed energy deposition remanufacturing process to determine the optimal base plate thickness, and the thickness of the plate is generally greater than or equal to 15 mm.

[0115] In the above steps, the size of the plate and the three-dimensional model data are determined, including the final size of the base plate after processing (final forming size) and the blank size required for remanufacturing.

[0116] Determine the size and three-dimensional digital model of the remanufacturing boss part, including the final size of the process boss after processing (final molding size) and the blank size required for remanufacturing. At this time, it is necessary to confirm the allowance size of the process boss according to the remanufacturing process design, that is, under the premise of ensuring dimensional accuracy, apply the smallest allowance design possible.

[0117] Machining is carried out according to the plate size requirements, that is, machining is carried out according to the plate blank size to ensure that the flatness of the remanufactured surface is below 5μm. After machining, strict surface cleaning and descaling treatment are required, and testing is required to ensure that there are no pollution defects such as oil stains, oxide scales and cracks on the remanufactured surface.

[0118] The materials available for remanufacturing additive manufacturing are either metal powder or metal wire. The raw materials are transported to the convergence point of the laser spot using argon gas as a carrier for LDED forming. The recommended powder particle size range is 75 to 250 μm, and the recommended wire diameter is 1.2 mm.

[0119] Powder or wire materials need to be dried in a vacuum drying oven. The recommended drying temperature is 100°C and the drying time is 8 hours.

[0120] Remanufacturing and forming: When the oxygen content in the forming chamber drops below 100 PPM, a powder / wire feeding machine is used to gather the material to the front end of the cladding head. A high-energy laser is used to melt and sinter the powder / wire material layer by layer. The molten pool width is 10 mm, the laser power is 5000 W, the moving speed is 1100 mm / min, the feeding rate is 1200 g / h, the overlap rate is 50%, and the oxygen content of the atmosphere is strictly controlled below 100 ppm during the forming process.

[0121] According to the LDED forming based on the boss blank size of the remanufacturing process, the XOY format size of the base plate should be smaller than the formable size of the laser directed energy remanufacturing. Generally, a 150mm margin is added in the X / Y direction for base plate clamping, etc.

[0122] The boss components of the base plate remanufacturing process are subjected to stress relief annealing heat treatment. The purpose of the annealing heat treatment is to eliminate stress. The formed parts are placed in a vacuum annealing furnace at room temperature, with an annealing temperature of 750 (± 10) ° C and kept warm for 4 hours.

[0123] After the annealing of the base plate with the process boss is completed, the allowance of the base plate for remanufacturing the process boss is semi-finished.

[0124] Fluorescence and X-ray detection methods are used to detect interface defects between LDED-made mesh ribs and forged plates to ensure the strength of the welding process boss.

[0125] The pre-welding preparation for mesh reinforcement assembly of cast base plate mainly includes mesh reinforcement casting, precision machining and pickling before laser welding, which can be used in the welding process after base plate assembly.

[0126] Laser welding is used to weld the base plate with process bosses to the base plate with cast grid ribs. The main setting parameters are as follows: laser power is 2.5~7kW, welding speed is 1.6~3.0mm / s, and defocus amount ΔF is -3~-12mm.

[0127] Fluorescence and X-ray detection methods are used to detect the quality of laser welding welds.

[0128] Finally, the welds are subjected to stress relief and fine processing to manufacture large optical wall panel load-bearing metal components that meet the requirements.

[0129] According to the surface and internal quality inspection of the base plate plus the remanufacturing process boss, fluorescence and X-ray inspections are required before further vertical plate welding to ensure the defect quality of the control base plate and the remanufacturing process boss interface, process boss structure, etc.

[0130] Take the metallurgical situation of titanium alloy remanufacturing interface as an example. Figure 5 As shown, the connection between the base plate and the remanufacturing process boss is a complete metallurgical bond, the interface bonding has no crack defects, and the tensile performance test has been passed, and no fracture occurs in the base material.

[0131] According to the base plate size and model structure, the forged plate is regular, and the shape of the boss has the characteristics of rectangle, square, circle, ellipse, polygon, etc. according to the process requirements. At the same time, for other relatively complex bosses for welding connections, adaptive structure and process design can be carried out. The plate body is selected as a forged plate, and the boss for connection is remanufactured using laser directed energy deposition technology.

[0132] The manufacturing method of the wall panel load-bearing structure of the present application involves multiple processes and multi-process controls such as manufacturing structure disassembly, remanufacturing interface design, model and margin design, remanufacturing performance and deformation control. That is, the large frame structure is first disassembled, and the anti-deformation process boss is designed based on precision welding control. The plate body of the base plate is manufactured by a forging process and used as a base material. The process boss for welding is formed by laser directed energy deposition remanufacturing, thereby providing an efficient and low-cost technical solution for the manufacture of process bosses for welding connections, avoiding the problems of material waste, cycle waste and so on caused by large-scale mechanical processing.

[0133] In this application, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Moreover, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0134] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise" and "counterclockwise" indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0135] It should be noted that all directional indications in the embodiments of the present application are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0136] In this application, unless otherwise specified or limited, the terms "connection" and "fixation" should be understood in a broad sense. For example, "fixation" can mean fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. For those skilled in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0137] In addition, the terms "first," "second," and so on, used in this application are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, features specified as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "plurality" means two or more, unless otherwise specifically defined.

[0138] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification.

[0139] In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the fact that ordinary technicians in this field can implement them. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0140] Although the embodiments of the present application have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions, and variations may be made to the embodiments without departing from the principles and intent of the present application, and that the scope of the present application is defined by the claims and their equivalents.

Claims

1. A method for manufacturing a wall panel bearing structure, characterized in that: include: S1: Analyze the three-dimensional model of the load-bearing structure; S2: Determine the interface between the bottom plate and the boss of the load-bearing structure; S3: Determine the processing parameters and three-dimensional model of the plate; S4: Determine the processing parameters and three-dimensional model of the boss; S5: machining the plate body according to the determined processing parameters and three-dimensional model of the plate body; S6: machining the boss on the plate by LDED according to the determined machining parameters and three-dimensional model of the boss; S7: performing stress annealing treatment on the processed bottom plate; S8: performing semi-finishing processing on the plate body and the boss; S9: Performing quality inspection on the surface and interior of the boss; S10: Process the grid reinforcement of the load-bearing structure and prepare for welding; S11: Welding and fixing the mesh ribs to the bosses; S12: performing stress relief and fine processing on the obtained load-bearing structure.

2. The method for manufacturing a wall panel bearing structure according to claim 1, characterized in that: Determining the processing parameters of the plate body includes determining the final forming size and the blank size of the plate body, and in step S5, processing the plate body according to the blank size of the plate body; Determining the processing parameters of the boss includes determining the final forming size and the blank size of the boss, and in step S6, processing the boss according to the blank size of the boss.

3. The method for manufacturing a wall panel load-bearing structure according to claim 2, characterized in that: The blank size of the plate body includes the thickness size of the plate body, and determining the thickness size includes the following steps: A1: Simulate the process of machining the boss on the plate by LDED; A2: Determine the thickness dimension based on the simulation results.

4. The method for manufacturing a wall panel load-bearing structure according to claim 2, characterized in that: In step S4, determining the processing parameters of the boss includes the following steps: B1: exporting the three-dimensional model of the boss; B2: Design the molding process parameters of the 3D model in slicing software that can be recognized by LDED. The molding process parameters include: path planning parameters and the residence time of two adjacent deposition layers.

5. The method for manufacturing a wall panel bearing structure according to claim 2, characterized in that: In step S5, the flatness of the processed plate is no greater than 5 μm; And / or, in step S6, before machining the boss, the surface of the plate is cleaned and descaled.

6. The method for manufacturing a wall panel load-bearing structure according to claim 2, characterized in that: The LDED has a formable size corresponding to the format size of the plate body, the formable size is larger than the format size of the plate body, and the distance between the edge of the formable size and the corresponding edge of the format size is 150 mm to 300 mm; The blank size of the plate body includes the formable size, and the final forming size of the plate body includes the format size. In step S12, the plate body is processed and reduced from the formable size to the format size.

7. The method for manufacturing a wall panel load-bearing structure according to claim 1, characterized in that: In step S6, the boss is machined on the plate by LDED. The following steps are involved: C1: Drying the additive material used in LDED, wherein the additive material is metal powder or metal wire, the particle size of the metal powder is 75 μm to 250 μm, and the diameter of the metal wire is 0.8 mm to 1.4 mm. The drying temperature is 80° C. to 120° C. and the drying time is 6 h to 12 h. C2: The manufacturing additive material is transported to the convergence point of the laser spot through a carrier for layer-by-layer melting and sintering, and the molten pool width during the LDED processing is 6mm to 10mm, the laser power is 2000W to 7000W, the moving speed of the spot is 600mm / min to 1100mm / min, the feeding rate of the manufacturing additive material is 1000g / h to 1500g / h, the overlap rate is 25% to 50%, and the oxygen content of the atmosphere during the forming process is controlled below 100ppm.

8. The method for manufacturing a wall panel load-bearing structure according to claim 1, characterized in that: In step S7 , the stress annealing treatment is a vacuum stress relief annealing treatment, and the annealing temperature is 650° C. to 830° C., and the holding time is 4 hours to 6 hours.

9. The method for manufacturing a wall panel load-bearing structure according to claim 1, characterized in that: In step S9, the quality detection is performed by fluorescence and X-ray quality detection; And / or, in step S10, the pre-welding preparation includes pickling the surface of the boss and the surface of the mesh rib; And / or, in step S11, the grid ribs are fixedly welded with welding parameters as follows: laser power of 6.5 kW to 15 kW, welding speed of 1.6 mm / s to 3.0 mm / s, and defocus ΔF of -3 mm to -12 mm.

10. The method for manufacturing a wall panel load-bearing structure according to any one of claims 1 to 9, characterized in that: In step S11, after the mesh ribs are welded and fixed on the bosses, the quality of the weld seams between the mesh ribs and the bosses is inspected; And / or, the plate body and the grid ribs are formed by casting or forging; And / or, the boss and the grid rib are in the shape of a rectangle, a square, a circle or an ellipse.

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