Powder material regeneration preparation system and method for laser additive repair of external field damaged equipment

Abstract

The invention relates to the field of metal powder preparation, in particular to a powder regeneration preparation system and method for laser additive repair of external field damaged equipment. Comprising an atomization unit, the atomization unit comprises an outer atomization tank, an inner atomization tank and a collaborative atomization mechanism, a multi-material smelting chamber is arranged at the top of the outer atomization tank, an aluminum alloy atomization cavity is formed in the inner atomization tank, a titanium alloy atomization cavity is formed between the outer atomization tank and the inner atomization tank, and the collaborative atomization mechanism comprises an aerial fog assembly and a centrifugal assembly. A flow dividing valve structure is arranged at the top of the inner atomization tank, when the vertical pipe communicates with the aluminum alloy atomization cavity, an inner flow channel is formed, and when the vertical pipe communicates with the titanium alloy atomization cavity, an outer flow channel is formed. According to the invention, on-site regeneration of aluminum and titanium alloy wastes is realized through modular integration and gradient smelting, an inner flow channel and an outer flow channel are accurately switched through a diverter valve structure in the powder preparation process, and centrifugal atomization and gas atomization processes are matched, so that high-purity and high-efficiency preparation of powder is ensured.

Description

Technical Field

[0001] The present invention relates to the field of metal powder preparation, and in particular to a powder material regeneration preparation system and method for laser additive repair of damaged equipment in the field. Background Art

[0002] Currently, field equipment repair primarily relies on traditional welding reinforcement, machining replacement, and offline additive manufacturing technologies. Powder production primarily relies on single-use gas atomization or centrifugal atomization, using stationary industrial-grade powder-making equipment to produce standardized metal powders. Powder materials rely on pre-stocked commercial aluminum and titanium alloy powders, which must be transported to the field via a supply chain. Existing mobile repair equipment often utilizes vehicle-mounted additive manufacturing units, and the powder production process remains separate from the repair equipment, relying on a pre-stocked powder material library.

[0003] The currently disclosed Chinese patent authorization announcement number CN114603149B is a centrifugal preparation device for alloy powder processing. It uses a rotating atomization component to centrifugally throw out the molten metal in layers and cool it with water. The drive system makes the atomization turntable and the push plate rotate at different speeds to achieve effective separation and uniform cooling of the powder. At the same time, the water flow is controlled by the pusher bar and spoiler to prevent powder adhesion and ensure powder quality.

[0004] The currently disclosed Chinese patent authorization announcement number CN119457098B is a continuous metal powder manufacturing device and method. Through a high-pressure nozzle with adjustable angle and height, the impact angle and position of water vapor on the molten metal are precisely controlled to achieve uniform atomization of different metals. At the same time, the self-cleaning function of the rotating nozzle is used to remove residual powder on the inner wall of the tank, avoid mixing, ensure the purity and uniformity of powder particle size, and improve manufacturing efficiency and product quality.

[0005] According to the above two patents, both rely on a single atomization technology, pure centrifugal atomization or pure gas atomization, and have adaptability limitations when processing multiple types of metals. Although high-pressure gas atomization can produce high-sphericity powders, it consumes significant energy for high-melting-point materials such as titanium alloys. Traditional centrifugal atomization is sensitive to melt viscosity and surface tension. When used for aluminum alloys, it may face a powder yield of less than 60%, making it difficult to balance high efficiency, energy saving and multi-material compatibility. More importantly, there is a lack of in-situ detection of waste composition and dynamic control of process parameters, making it impossible to adapt to the regeneration needs of heterogeneous materials such as mixed aluminum and titanium alloy fragments in the field, which seriously restricts the repair quality and equipment reuse reliability.

[0006] Therefore, there is a need for a powder material regeneration and preparation system that integrates centrifugal and atomization multi-modes for laser additive repair of damaged equipment in the field, so as to adapt to heterogeneous waste materials such as titanium and aluminum, break through the limitations of single atomization, and integrate the in-situ detection of waste composition and dynamic control of process parameters to achieve intelligent, efficient and precise regeneration from field waste parts to high-quality powder materials, ensuring the quality of repair and rapid reuse of equipment. Summary of the Invention

[0007] In response to the problems existing in the existing technology, a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field is provided. Through modular integration and gradient melting, on-site regeneration of aluminum and titanium alloy waste can be achieved. During the powder making process, the internal flow channel and the external flow channel can be accurately switched through the diverter valve structure, and the centrifugal atomization and gas atomization processes are matched to ensure high-purity and high-efficiency preparation of powder.

[0008] In order to solve the problems of the prior art, the present invention provides a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field, including a modular container integrated unit, wherein the modular container integrated unit is provided with a waste cleaning unit, a metal sorting unit, a metal crushing unit, a conveying unit, an atomization unit and a screening unit, wherein the atomization unit includes an outer atomization tank and an inner atomization tank coaxially arranged therein and a cooperative atomization mechanism, a multi-material melting chamber is provided on the top of the outer atomization tank and has a vertical pipe interconnected with the outer atomization tank, an aluminum alloy atomization chamber is inside the inner atomization tank, and a gas flow is formed between the outer atomization tank and the inner atomization tank. A titanium alloy atomization chamber is formed, a titanium alloy powder outlet is provided at the bottom of the outer atomization tank, an aluminum alloy powder outlet is provided at the bottom of the inner atomization tank, a cooperative atomization mechanism includes an aerosol component arranged on the upper half of the outer atomization tank and a centrifugal component arranged inside the inner atomization tank, and a diverter valve structure is provided on the top of the inner atomization tank for cooperating with the cooperative atomization mechanism to respectively atomize corresponding melts. When the diverter valve structure connects the vertical pipe and the aluminum alloy atomization chamber, an inner flow channel for the aluminum alloy melt to pass through is formed between the two. When the diverter valve structure connects the vertical pipe and the titanium alloy atomization chamber, an outer flow channel for the titanium alloy melt to pass through is formed between the two.

[0009] Preferably, the diverter valve structure includes a movable tube coaxially arranged below the vertical tube. The movable tube can move relative to the vertical tube along its axial direction at the top of the inner atomization tank. A pipe opening for the movable tube to pass through is opened at the top of the inner atomization tank. The inner diameter of the movable tube is larger than the outer diameter of the vertical tube.

[0010] Preferably, a lifting drive for driving the movable tube to move is provided on the top of the inner atomization tank, and the aerosol assembly is arranged between the vertical tube and the movable tube. When the movable tube moves upward and docks with the vertical tube, the inner flow channel is formed, and when the movable tube moves downward and out of the range of action of the aerosol assembly, the outer flow channel is formed.

[0011] Preferably, the inner upper half of the inner atomizing tank is provided with a sleeve which is sleeved on the movable tube, the upper end of the sleeve is fixedly connected to the inner atomizing tank, and the lower end extends vertically downward toward the centrifugal assembly, and the centrifugal assembly includes a bin body connected to the sleeve for the aluminum alloy melt to pass directly therethrough.

[0012] Preferably, an intermediate shaft is coaxially and fixedly provided in the sleeve, and a cone head is provided at the upper end of the intermediate shaft extending to the top of the inner atomization tank. The movable tube has an upper flow channel equal to the diameter of the cone head and a lower flow channel larger than the diameter of the cone head. When the movable tube moves downward so that the cone head is inserted into the upper flow channel, the inner flow channel is in a closed state.

[0013] Preferably, the top of the inner atomization tank is a right conical structure, the bottom of the outer atomization tank and the bottom of the inner atomization tank are both inverted conical structures, and the upper end of the movable tube has a conical surface that matches the surface of the cone head. When the inner flow channel is closed, the movable tube and the cone head together form a guide slope for the titanium alloy powder to slide smoothly.

[0014] Preferably, the sleeve is provided with an upper support plate for fixedly connecting the lower end of the intermediate shaft and the top of the warehouse body, and the inner lower half of the inner atomizing tank is provided with a lower support plate for fixedly connecting the bottom of the warehouse body, and both the upper support plate and the lower support plate have open grooves.

[0015] Preferably, the bin body is composed of an upper bin and a lower bin, a centrifugal gap is left between the upper bin and the lower bin, and the centrifugal assembly further includes an atomizing centrifugal disk rotatably arranged on the lower bin and coaxial with the sleeve, and the atomizing centrifugal disk is a disc-type centrifugal disk.

[0016] Preferably, the aerosol assembly includes a plurality of atomizing nozzles evenly distributed along the circumference of the outer atomizing tank, and the spray directions of all the atomizing nozzles converge at the central area of ​​the titanium alloy atomizing cavity.

[0017] The present invention also provides a powder material regeneration preparation method for laser additive repair of damaged equipment in the field, comprising the following steps: S1. Cleaning, sorting, and crushing the waste to separate the aluminum alloy and titanium alloy; S2, smelting aluminum alloy, and introducing the smelted aluminum alloy melt into an inner atomizing tank and performing centrifugal atomization through a centrifugal assembly to form aluminum alloy powder; S3, melting the titanium alloy, and introducing the melted titanium alloy into an external atomizing tank for atomization through an aerosol assembly to form a titanium alloy powder; S4. Screening the aluminum alloy powder and titanium alloy powder separately and packaging them.

[0018] Compared with the prior art, the present invention has the following advantages: 1. This invention utilizes modular containerized integrated units to efficiently prepare and recycle metal powder for field equipment repair. The waste is cleaned, sorted, and crushed to ensure raw material purity. Arc heating combined with a gradient melting process is used to first melt a low-melting-point aluminum alloy, followed by a higher-melting-point titanium alloy.

[0019] During this process, the movable tube raises and lowers to switch between the inner and outer flow channels, achieving centrifugal atomization of aluminum alloys and gas atomization of titanium alloys, respectively. This matches the physical properties of the different materials and improves powder sphericity and particle size uniformity. Combined with a screening unit and a return pipe, unqualified powder can be returned for remelting, improving material utilization. This system quickly and stably regenerates high-quality aluminum and titanium alloy powders that meet additive manufacturing requirements, effectively supporting emergency equipment repair needs in field environments.

[0020] 2. The present invention controls the movement of the movable tube relative to the vertical tube through a lifting driver to achieve switching between the inner flow channel and the outer flow channel, thereby ensuring directional diversion of the aluminum alloy melt and the titanium alloy melt.

[0021] As the movable tube moves, it cooperates with the cone on the intermediate shaft to open and close the internal flow channel. When it moves down to the closed position, the cone inserts into the upper flow channel, forming a seal and effectively blocking the inflow of the titanium alloy melt, preventing cross-contamination. This ensures the physical isolation and on-demand flow of the two molten metals, guaranteeing the safety, continuity, and accuracy of the multi-material atomization process, and improving powder purity and system automation.

[0022] 3. The present invention forms a continuous guide slope by cooperating the conical surface at the upper end of the movable tube with the cone head of the intermediate shaft, combined with the positive and inverted conical structures at the top and bottom of the inner atomizing tank and the outer atomizing tank, effectively guiding the powder or unsolidified droplets generated during the atomization process of the titanium alloy to slide smoothly, preventing accumulation or blockage in the top area, and ensuring unobstructed discharge.

[0023] During the preparation of aluminum alloy powder, the open grooves on the upper and lower support plates not only provide stable support for the silo body, but also allow the aluminum alloy melt to flow into the silo body through the open grooves of the upper support plate, and the atomized aluminum alloy powder can be discharged smoothly through the open grooves of the lower support plate, taking into account both structural strength and material flow requirements, and improving the reliability of system operation and discharge efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the three-dimensional structure of a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to the present invention.

[0025] Figure 2 It is a partial three-dimensional structural cross-sectional view of a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to the present invention.

[0026] Figure 3 It is a planar cross-sectional view of a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to the present invention.

[0027] Figure 4 It is a plan view of a closed inner flow channel of a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to the present invention.

[0028] Figure 5 It is a schematic diagram of the three-dimensional structure of a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field, with the inner flow channel closed.

[0029] Figure 6 It is a plan view of an open inner flow channel of a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to the present invention.

[0030] Figure 7 It is a schematic diagram of the three-dimensional structure of the powder material regeneration and preparation system for laser additive repair of damaged equipment in the field, with the inner flow channel opened.

[0031] Figure 8 It is a partial three-dimensional structural cross-sectional view of a centrifugal component of a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to the present invention.

[0032] Figure 9 The present invention Figure 8 A magnified schematic diagram of .

[0033] The numbers in the figure are: 1, outer atomizing tank; 11, titanium alloy atomizing chamber; 12, titanium alloy powder outlet; 2, inner atomizing tank; 21, aluminum alloy atomizing chamber; 22, aluminum alloy powder outlet; 23, support rod; 3, multi-material melting chamber; 31, vertical pipe; 32, electrode rod; 4, aerosol assembly; 41, atomizing nozzle; 5, centrifugal assembly; 51, warehouse; 511, upper warehouse; 512, lower warehouse; 5121, water outlet ; 513, centrifugal gap; 5131, pressure ring; 5132, hydraulic chamber; 52, atomizing centrifugal disk; 6, diverter valve structure; 61, internal flow channel; 62, external flow channel; 63, movable tube; 631, sleeve; 6311, upper support plate; 6312, lower support plate; 632, intermediate shaft; 6321, cone head; 64, lifting drive; 641, fixed electromagnet; 642, movable electromagnet. DETAILED DESCRIPTION

[0034] In order to further understand the features, technical means, specific objectives and functions achieved by the present invention, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0035] See also Figure 1-Figure 7As shown, a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field includes a modular container integrated unit, wherein the modular container integrated unit is provided with a waste cleaning unit, a metal sorting unit, a metal crushing unit, a conveying unit, an atomization unit and a screening unit, wherein the atomization unit includes an outer atomization tank 1 and an inner atomization tank 2 coaxially arranged therein and a cooperative atomization mechanism, a multi-material melting chamber 3 is provided on the top of the outer atomization tank 1 and has a vertical pipe 31 interconnected with the outer atomization tank 1, an aluminum alloy atomization chamber 21 is provided inside the inner atomization tank 2, a titanium alloy atomization chamber 11 is formed between the outer atomization tank 1 and the inner atomization tank 2, and the outer atomization tank 1 is provided with a titanium alloy powder outlet 12 at the bottom, and an aluminum alloy powder outlet 22 is provided at the bottom of the inner atomizing tank 2. The cooperative atomizing mechanism includes an aerosol assembly 4 arranged on the upper half of the outer atomizing tank 1 and a centrifugal assembly 5 arranged inside the inner atomizing tank 2. The top of the inner atomizing tank 2 is provided with a diverter valve structure 6 that cooperates with the cooperative atomizing mechanism to respectively atomize the corresponding melts. When the diverter valve structure 6 connects the vertical pipe 31 and the aluminum alloy atomizing chamber 21, an internal flow channel 61 for the aluminum alloy melt to pass through is formed between the two. When the diverter valve structure 6 connects the vertical pipe 31 and the titanium alloy atomizing chamber 11, an external flow channel 62 for the titanium alloy melt to pass through is formed between the two.

[0036] A return pipe is provided between the screening unit and the atomization unit. If the powder is qualified, it is packaged. If the powder is unqualified, it is returned to the atomization unit through the return pipe for washing, melting and atomization powder making.

[0037] The multi-material smelting chamber 3 has two cavities, each of which is provided with an electrode rod 32 extending therein for smelting the metal by arc heating. Each cavity has a discharge port connected to a vertical pipe.

[0038] Support rods 23 fixedly connected to the outer atomizing tank 1 are provided around the inner atomizing tank 2 .

[0039] When laser additive repair is required for damaged equipment in the field, the recovered waste is first sent to the waste cleaning unit in the modular container integration unit for flushing to remove oil, dust and other impurities attached to the surface, ensuring the purity of the subsequent processing process.

[0040] The cleaned waste is sequentially sent to the metal sorting unit through the conveying unit. The cleaned waste enters the metal sorting unit through the conveying unit. First, the waste is quickly tested for components using high-precision X-ray fluorescence spectroscopy to identify the material categories of aluminum alloy and titanium alloy. Laser-induced breakdown spectroscopy is then used to further confirm the elemental composition of the material for accurate classification. Based on the analysis results, waste materials of different materials are diverted to corresponding collection modules through an intelligent pneumatic sorting system to complete the efficient and automated separation of aluminum alloy and titanium alloy, providing pure and reliable raw material guarantees for subsequent laser additive manufacturing. After sorting, the waste enters the metal crushing unit to forcefully crush the metal blocks into small particles or fragments of uniform size that are easy to smelt, thereby improving smelting efficiency and heat conduction uniformity.

[0041] After being conveyed to the atomization unit, the crushed aluminum and titanium alloy particles first enter the multi-material melting chamber 3 located at the top of the outer atomization tank 1. Electrode rods 32 in each chamber are energized to generate a high-temperature arc, using arc heating to perform gradient melting of different types of scrap metal. The titanium and aluminum alloys are melted in their respective chambers to prevent contamination.

[0042] When metal smelting begins, the crushed aluminum alloy scrap and titanium alloy scrap are fed into corresponding cavities of multi-material melting chamber 3. Because aluminum alloy has a relatively low melting point, approximately 600°C to 700°C, the aluminum alloy scrap is heated under an inert atmosphere by controlling the electrode rods 32 to input appropriate heating power, gradually increasing its temperature and completely melting it, forming a uniform aluminum alloy melt.

[0043] When preparing aluminum alloy powder, the diverter valve structure 6 connects the vertical pipe 31 below the multi-material smelting chamber 3 with the inner atomizing tank 2, forming an internal flow channel 61 from top to bottom, allowing the aluminum alloy melt to flow smoothly into the aluminum alloy atomizing cavity 21 of the inner atomizing tank 2. At this time, the centrifugal assembly 5 arranged inside the inner atomizing tank 2 is activated to throw out the inflowing aluminum alloy melt, forming fine droplets under the action of centrifugal force. Due to the low viscosity and good fluidity of the aluminum alloy melt, it is very easy to evenly disperse into fine particles with high sphericity and narrow particle size distribution under the action of high-speed rotation, thereby achieving efficient and high-quality centrifugal atomization powder production.

[0044] After the aluminum alloy powder is prepared, the heating power of the electrode rod 32 is increased to enhance the arc energy output, so that the temperature in the melting chamber continues to rise until it reaches the melting point of the titanium alloy, about 1668°C, thereby heating and melting the titanium alloy.

[0045] When it is necessary to prepare titanium alloy powder, diverter valve structure 6 switches to another operating state, and vertical pipe 31 is communicated with the annular space between outer atomizing tank 1 and inner atomizing tank 2, that is, titanium alloy atomizing chamber 11, to form an outflow channel 62, so that high-temperature titanium alloy melt flows into this cavity. Because titanium alloy chemical property is extremely active at high temperature, it is easy to react with most refractory materials and its high melting point characteristic is not suitable for centrifugal atomization mode, so it is more suitable to adopt aerosol process. Now, aerosol assembly 4 starts, and high-pressure inert gas is sprayed into titanium alloy atomizing chamber 11 in the form of high-speed jet, impacts titanium alloy melt, and is broken into droplets. Rapid cooling and solidification form titanium alloy powder with smooth surface, low oxygen content, excellent sphericity.

[0046] Under the precise control of the coordinated atomization mechanism, the centrifugal assembly 5 and the aerosol assembly 4 can operate alternately according to actual needs, achieving the diversion of aluminum alloy and titanium alloy powders. The generated powders are discharged from the aluminum alloy powder outlet 22 at the bottom of the inner atomization tank 2 and the titanium alloy powder outlet 12 at the bottom of the outer atomization tank 1, respectively, and enter the screening unit for particle size classification.

[0047] The screening unit precisely selects the powder. Qualified powder that meets the requirements of the laser additive manufacturing process is collected and packaged for subsequent on-site repair work. Powder that does not meet the particle size requirements is returned to the atomization unit through a return pipe connecting the screening unit and the atomization unit, where it participates in the melting and atomization process again. This ensures the effective recycling of resources and improves overall work efficiency and material utilization.

[0048] See also Figure 2-Figure 7 As shown, the diverter valve structure 6 includes a movable tube 63 coaxially arranged below the vertical tube 31. The movable tube 63 can move along its axial direction relative to the vertical tube 31 at the top of the inner atomizing tank 2. A pipe opening for the movable tube 63 to pass through is provided at the top of the inner atomizing tank 2. The inner diameter of the movable tube 63 is larger than the outer diameter of the vertical tube 31.

[0049] When powder preparation is required, the movable tube 63 in the diverter valve structure 6 moves upward along the axial direction relative to the vertical tube 31, so as to be sleeved on the outside of the vertical tube 31, so that the internal flow channel 61 is opened to allow the aluminum alloy melt to enter the inner atomization tank 2 for centrifugal atomization treatment.

[0050] As the movable tube 63 moves downward, it gradually moves away from the vertical tube 31. This opens the outflow channel 62, allowing the titanium alloy melt to flow out. The aerosol assembly 4 then atomizes the falling titanium alloy melt. By controlling the up and down movement of the movable tube 63, directional diversion of different metal melts and switching of atomization modes are achieved.

[0051] See also Figure 2-Figure 7As shown, a lifting driver 64 is provided on the top of the inner atomization tank 2 for driving the movable tube 63 to move. The aerosol assembly 4 is arranged between the vertical tube 31 and the movable tube 63. When the movable tube 63 moves upward and docks with the vertical tube 31, the inner flow channel 61 is formed. When the movable tube 63 moves downward and leaves the range of action of the aerosol assembly 4, the outer flow channel 62 is formed.

[0052] The lifting actuator 64 comprises a fixed electromagnet 641 and a movable electromagnet 642, both of which are ring structures. The fixed electromagnet 641 is sleeved on the movable tube 63 and fixedly connected to the inner atomizing tank 2, while the movable electromagnet 642 is fixedly sleeved on the movable tube 63 and located above the fixed electromagnet 641.

[0053] When the fixed electromagnet 641 and the movable electromagnet 642 are energized and repel each other, the movable tube 63 gradually moves upward and docks with the vertical tube 31, so that the inner flow channel 61 is opened and the outer flow channel 62 is closed.

[0054] When the fixed electromagnet 641 and the movable electromagnet 642 are energized and attract each other, the movable tube 63 gradually moves downward due to its own gravity and magnetic attraction, so that the inner flow channel 61 is closed and the outer flow channel 62 is opened.

[0055] By controlling the energizing polarity of the fixed electromagnet 641 and the movable electromagnet 642 , repulsion or attraction is achieved, thereby precisely regulating the lifting and lowering movement of the movable tube 63 and completing the switching between the inner flow channel 61 and the outer flow channel 62 .

[0056] See also Figure 2-Figure 7 As shown, the inner upper half of the inner atomizing tank 2 is provided with a sleeve 631 which is sleeved on the movable tube 63. The upper end of the sleeve 631 is fixedly connected to the inner atomizing tank 2, and the lower end extends vertically downward toward the centrifugal assembly 5. The centrifugal assembly 5 includes a storage body 51 which is connected to the sleeve 631 for the aluminum alloy melt to pass directly therethrough.

[0057] When the movable tube 63 moves upward and docks with the vertical tube 31 to form the internal flow channel 61, the molten aluminum alloy melt flows from the vertical tube 31 through the inside of the movable tube 63 into the sleeve 631 connected to it. Under the action of gravity, the aluminum alloy melt flows downward along the inner wall of the sleeve 631 and directly enters the interior of the warehouse body 51, providing a stable melt supply for the centrifugal atomization process.

[0058] The sleeve 631 serves as a flow-guiding structure to ensure that the melt is transmitted continuously and without stagnation from the movable tube 63 to the chamber 51 of the centrifugal assembly 5, thereby ensuring the continuity and specificity of the atomization process.

[0059] See also Figure 2-Figure 7As shown, an intermediate shaft 632 is coaxially and fixedly provided in the sleeve 631, and a cone head 6321 is provided at the upper end of the intermediate shaft 632, which extends to the top of the inner atomizing tank 2. The movable tube 63 has an upper flow channel with the same diameter as the cone head 6321 and a lower flow channel with a diameter larger than the cone head 6321. When the movable tube 63 moves downward so that the cone head 6321 is inserted into the upper flow channel, the inner flow channel 61 is in a closed state.

[0060] The upper flow channel and the lower flow channel together form a stepped flow channel that decreases step by step from bottom to top.

[0061] When the movable tube 63 moves downward under the action of the lifting driver 64 to the position that closes the internal flow channel 61, the cone head 6321 at the upper end of the intermediate shaft 632 coaxially fixed in the sleeve 631 is inserted into the upper flow channel of the movable tube 63. Since the diameter of the cone head 6321 is equal to the inner diameter of the upper flow channel, the two form a tight fit, thereby blocking the flow path of the movable tube 63 and completely closing the internal flow channel 61. This effectively prevents the titanium alloy melt from entering the inner atomizing tank 2 and reliably shuts off the internal flow channel 61.

[0062] Because the flow channel structure of the movable tube 63 is a stepped flow channel that gradually decreases from bottom to top, the cone head 6321 can only be inserted into the upper flow channel to achieve a seal, while the lower flow channel provides the necessary space for the movable tube 63 to move upward. After the upper end of the movable tube 63 is docked with the vertical tube 31, the seal between the cone head 6321 and the movable tube 63 is released, forming an inner flow channel 61 to guide the aluminum alloy melt into the inner atomizing tank 2.

[0063] See also Figure 2-Figure 7 As shown, the top of the inner atomization tank 2 is a right conical structure, the bottom of the outer atomization tank 1 and the bottom of the inner atomization tank 2 are both inverted conical structures, and the upper end of the movable tube 63 has a conical surface that matches the surface of the cone head 6321. When the inner flow channel 61 is closed, the movable tube 63 and the cone head 6321 together form a guide slope for the titanium alloy powder to slide smoothly.

[0064] When the movable tube 63 moves downward to the lower limit position, the conical surface at its upper end and the outer surface of the cone head 6321 at the top of the intermediate shaft 632 form a continuous inclined surface. This inclined surface is consistent with the inclined surface of the forward conical structure at the top of the inner atomizing tank 2, and at the same time forms a continuous slope transition with the inverted conical structures at the bottom of the outer atomizing tank 1 and the bottom of the inner atomizing tank 2.

[0065] The formed guide slope can guide the titanium alloy powder or incompletely atomized droplets generated during the titanium alloy atomization process to slide smoothly down the slope, effectively avoiding powder accumulation or blockage in the top area, and ensuring that the powder is smoothly guided to the titanium alloy powder outlet 12 at the bottom of the outer atomization tank 1, thereby achieving efficient discharge and anti-retention.

[0066] See also Figure 2-Figure 8 As shown, an upper support plate 6311 is provided on the sleeve 631 for fixedly connecting the lower end of the intermediate shaft 632 and the top of the warehouse body 51, and a lower support plate 6312 is provided on the inner lower half of the inner atomizing tank 2 for fixedly connecting the bottom of the warehouse body 51. Both the upper support plate 6311 and the lower support plate 6312 have open grooves.

[0067] The opening grooves of the upper support plate 6311 and the lower support plate 6312 allow aluminum alloy melt and aluminum alloy powder to pass through, ensuring that the aluminum alloy melt can enter the warehouse body 51 after passing through the opening groove of the upper support plate 6311, and the aluminum alloy powder can slide toward the aluminum alloy powder outlet 22 through the opening groove of the lower support plate 6312 after being discharged from the warehouse body 51.

[0068] See also Figure 2 、 Figure 3 and Figure 6-Figure 9 As shown, the bin body 51 is composed of an upper bin 511 and a lower bin 512, and a centrifugal gap 513 is left between the upper bin 511 and the lower bin 512. The centrifugal assembly 5 also includes an atomizing centrifugal disk 52 rotatably arranged on the lower bin 512 and coaxial with the sleeve 631. The atomizing centrifugal disk 52 is a disc-type centrifugal disk.

[0069] The lower chamber 512 is provided with a pressure ring 5131 that is coaxial with the atomizing centrifugal disc 52. The pressure ring 5131 can move along its axial direction. A hydraulic chamber 5132 is formed between the lower chamber 512 and the pressure ring 5131. A water outlet 5121 that communicates with the hydraulic chamber 5132 is provided at the bottom of the lower chamber 512. When the pressure ring 5131 moves upward under the hydraulic thrust until it fits with the upper chamber 511, the centrifugal gap 513 is in a closed state. Conversely, the centrifugal gap 513 is in an open state.

[0070] When the aluminum alloy melt enters the silo 51, hydraulic medium is injected into the hydraulic chamber 5132 between the lower silo 512 and the pressure ring 5131 through the water inlet 5121 at the bottom of the lower silo 512. Under the action of hydraulic thrust, the pressure ring 5131 moves upward along the axis until it is in close contact with the lower surface of the upper silo 511. At this point, the centrifugal gap 513 between the upper and lower silos 511, 512 is completely closed, and the aluminum alloy melt is trapped in the silo 51 for centrifugal treatment. In this state, the disc-shaped centrifugal disc rotates at high speed, while the aluminum alloy melt accumulates in the silo 51, and the internal pressure gradually increases as the liquid level rises.

[0071] When the internal pressure of the silo 51 reaches a specified value, the pressure in the hydraulic chamber 5132 is released, and the pressure ring 5131 moves downward under its own gravity, reopening the centrifugal gap 513. The aluminum alloy melt is forcefully thrown out along the outer edge of the atomizing centrifugal disk 52 under the centrifugal force, forming uniform and fine droplets, which are rapidly cooled and solidified in an inert atmosphere, thereby realizing an efficient, stable, and size-controllable centrifugal atomization powder making process.

[0072] See also Figure 2-Figure 4 As shown, the aerosol assembly 4 includes a plurality of atomizing nozzles 41 evenly distributed along the circumference of the outer atomizing tank 1 , and the spray directions of all the atomizing nozzles 41 converge at the central area of ​​the titanium alloy atomizing chamber 11 .

[0073] When the titanium alloy melt needs to be atomized, several atomizing nozzles 41 arranged around the circumference of the outer atomizing tank 1 are activated simultaneously. The atomizing nozzles 41 are evenly distributed along the circumference of the outer atomizing tank 1 to ensure symmetry and uniformity of the airflow. The spray directions of all atomizing nozzles 41 converge toward the center of the titanium alloy atomizing chamber 11, forming a concentrated and intersecting high-pressure inert gas jet field.

[0074] When the titanium alloy melt flows into the titanium alloy atomization chamber 11 from the annular gap between the vertical tube 31 and the movable tube 63 and falls to the central area, the high-speed jet of inert gas simultaneously impacts the melt stream from multiple circumferential directions, fully breaking it into fine droplets, and then rapidly dispersed, cooled and solidified under the drive of the airflow, thereby realizing the preparation of efficient and high-sphericity titanium alloy powder.

[0075] A powder material regeneration preparation method for laser additive repair of damaged equipment in the field, applied to the above-mentioned powder material regeneration preparation system for laser additive repair of damaged equipment in the field, comprises the following steps: S1. Cleaning, sorting, and crushing the waste to separate the aluminum alloy and titanium alloy; S2, smelting aluminum alloy, and introducing the smelted aluminum alloy melt into the inner atomizing tank 2 and centrifugally atomizing it through the centrifugal assembly 5 to form aluminum alloy powder; S3, melting the titanium alloy, and introducing the melted titanium alloy into the outer atomizing tank 1 for atomization through the aerosol assembly 4 to form titanium alloy powder; S4. Screening the aluminum alloy powder and titanium alloy powder separately and packaging them.

[0076] This invention integrates modular container units to achieve on-site regeneration and efficient utilization of aluminum alloy and titanium alloy powders in an outdoor environment. Cleaning, sorting, and crushing ensure the purity of the raw materials. A gradient smelting process is then used to melt the low-melting-point aluminum alloy and high-melting-point titanium alloy in separate cavities at different times.

[0077] Subsequently, during the powder making process, the diverter valve structure 6 moves up and down through the electromagnetically driven movable tube 63, switching the inner flow channel 61 and the outer flow channel 62, guiding the aluminum alloy melt into the centrifugal atomization chamber and the titanium alloy melt into the gas atomization chamber, respectively, to achieve material diversion and process matching. The sealing structure of the cone head 6321 and the stepped flow channel ensures that the inner flow channel 61 is opened and closed reliably to prevent cross contamination. Combined with screening and return pipes, unqualified powder can be recycled and remade to improve material utilization. High-purity, high-efficiency, and automated preparation of multi-material powders is achieved, meeting the dual needs of field emergency repair for rapid material response and process stability.

[0078] The above embodiments merely represent one or more embodiments of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of protection of the present invention. It should be noted that a person of ordinary skill in the art may make various modifications and improvements without departing from the spirit of the present invention, and such modifications and improvements fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be subject to the appended claims.

Claims

1. A powder material regeneration and preparation system for laser additive repair of damaged equipment in the field, comprising a modular container integrated unit equipped with a waste cleaning unit, a metal sorting unit, a metal crushing unit, a conveying unit, an atomization unit, and a screening unit; It is characterized by: The atomization unit includes an outer atomization tank, an inner atomization tank coaxially arranged therein, and a coordinated atomization mechanism. A multi-material smelting chamber is provided on the top of the outer atomization tank and has a vertical pipe interconnected with the outer atomization tank. The interior of the inner atomization tank is an aluminum alloy atomization chamber, and a titanium alloy atomization chamber is formed between the outer atomization tank and the inner atomization tank; The bottom of the outer atomizing tank is provided with a titanium alloy powder outlet; An aluminum alloy powder outlet is provided at the bottom of the inner atomizing tank; The coordinated atomization mechanism includes an aerosol assembly arranged on the upper half of the outer atomization tank and a centrifugal assembly arranged inside the inner atomization tank; The top of the inner atomizing tank is provided with a diverter valve structure that cooperates with the cooperative atomizing mechanism to atomize the corresponding melts separately; When the diverter valve structure connects the vertical pipe and the aluminum alloy atomization chamber, an internal flow channel for the aluminum alloy melt to flow in is formed between the two; When the diverter valve structure connects the vertical pipe and the titanium alloy atomization chamber, an outflow channel for the titanium alloy melt to flow in is formed between the two.

2. The powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to claim 1 is characterized in that: The diverter valve structure includes a movable tube coaxially arranged below the vertical tube. The movable tube can move relative to the vertical tube along its axial direction at the top of the inner atomization tank. A pipe opening for the movable tube to pass through is opened at the top of the inner atomization tank. The inner diameter of the movable tube is larger than the outer diameter of the vertical tube.

3. The powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to claim 2 is characterized in that: A lifting drive is provided on the top of the inner atomization tank to drive the movable tube to move. The aerosol assembly is arranged between the vertical tube and the movable tube. When the movable tube moves upward and docks with the vertical tube, the inner flow channel is formed. When the movable tube moves downward and leaves the range of action of the aerosol assembly, the outer flow channel is formed.

4. The powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to claim 2 is characterized in that: The upper inner half of the inner atomizing tank is provided with a sleeve sleeved on the movable tube. The upper end of the sleeve is fixedly connected to the inner atomizing tank, and the lower end extends vertically downward toward the centrifugal assembly. The centrifugal assembly includes a warehouse body connected to the sleeve for aluminum alloy melt to pass directly therethrough.

5. The powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to claim 4 is characterized in that: An intermediate shaft is coaxially and fixedly provided in the sleeve, and a cone head is provided at the upper end of the intermediate shaft extending to the top of the inner atomizer tank. The movable tube has an upper flow channel with the same diameter as the cone head and a lower flow channel with a larger diameter than the cone head. When the movable tube moves downward so that the cone head is inserted into the upper flow channel, the inner flow channel is in a closed state.

6. The powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to claim 5 is characterized in that: The top of the inner atomization tank is a right cone structure, the bottom of the outer atomization tank and the bottom of the inner atomization tank are both inverted cone structures, and the upper end of the movable tube has a conical surface that matches the surface of the cone head. When the inner flow channel is closed, the movable tube and the cone head together form a guide slope for the titanium alloy powder to slide smoothly.

7. The powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to claim 5 is characterized in that: The sleeve is provided with an upper supporting plate for fixing the lower end of the intermediate shaft and the top of the warehouse body, and the inner lower half of the inner atomizing tank is provided with a lower supporting plate for fixing the bottom of the warehouse body. Both the upper supporting plate and the lower supporting plate have open grooves.

8. The powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to claim 4 is characterized in that: The bin body is composed of an upper bin and a lower bin, with a centrifugal gap between the upper and lower bins. The centrifugal assembly also includes an atomizing centrifugal disk rotatably arranged on the lower bin and coaxial with the sleeve. The atomizing centrifugal disk is a disc-type centrifugal disk.

9. The powder material regeneration and preparation system for laser additive repair of damaged equipment in the field according to claim 1 is characterized in that: The aerosol assembly comprises a plurality of atomizing nozzles evenly distributed along the circumference of the outer atomizing tank, and the spray directions of all the atomizing nozzles converge at the central area of ​​the titanium alloy atomizing cavity.

10. A powder material regeneration and preparation method for laser additive repair of damaged equipment in the field, applied to a powder material regeneration and preparation system for laser additive repair of damaged equipment in the field as claimed in any one of claims 1 to 9, characterized in that: The following steps are involved: S1. Cleaning, sorting, and crushing the waste to separate the aluminum alloy and titanium alloy; S2, smelting aluminum alloy, and introducing the smelted aluminum alloy melt into an inner atomizing tank and performing centrifugal atomization through a centrifugal assembly to form aluminum alloy powder; S3, melting the titanium alloy, and introducing the melted titanium alloy into an external atomizing tank for atomization through an aerosol assembly to form a titanium alloy powder; S4. Screening the aluminum alloy powder and titanium alloy powder separately and packaging them.

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