Large-size special-shaped defect material adding method and device based on reverse reconstruction

Abstract

The invention provides a large-size special-shaped defect material adding method and device based on reverse reconstruction, and the method comprises the steps that a preset special-shaped defect of a large-size metal component and a bottoming material for the special-shaped defect are determined, bottoming is conducted on the special-shaped defect based on the bottoming material for the special-shaped defect, a filling material for the special-shaped defect is determined, and the filling material is used for filling the special-shaped defect. Performing layer-by-layer surfacing on the bottomed special-shaped defect by adopting a layered slicing manner on the basis of the filling material to obtain a corresponding surfacing layer until the height of the surfacing layer is flat with the surface of the large-size metal component, determining the number of capping layers for capping repair on the special-shaped defect, performing layer-by-layer surfacing on the special-shaped defect on the basis of the number of capping layers to obtain the large-size metal component. And the surface of the special-shaped defect is fully higher than the surface target height of the large-size metal component. The method does not depend on manual repair any more, automation of large-size special-shaped defects is achieved, and the efficiency and effect of defect repair are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electric arc additive technology, in particular to a large-size special-shaped defect additive method and device based on reverse reconstruction. BACKGROUND

[0002] Large-size metal components will produce defects due to many factors during the manufacturing process, irregular defects such as spalling pits will be produced during the service operation process, and special-shaped defects will also be produced during the regenerative repair cleaning process. The existing forming technology has certain limitations when facing such large-size metal components. In order to meet the manufacturing needs of large-size and integrated structural parts, the low-cost and high-efficiency wire and arc additive manufacturing technology (WAAM) based on surfacing technology has gradually attracted attention.

[0003] At present, when facing large-size special-shaped defects, the wire and arc additive manufacturing technology is often combined with reverse reconstruction engineering to complete the repair engineering through reverse reduction of the defect model and arc additive manufacturing.

[0004] However, due to the uncertainty of the size, shape and repair scheme of the large-size special-shaped defect, the existing wire and arc additive manufacturing technology is mainly semi-automatic repair, which leads to general efficiency and effect of defect repair. SUMMARY

[0005] Therefore, the purpose of the present application is to provide a large-size special-shaped defect additive method and device based on reverse reconstruction, which realizes the repair of special-shaped defects by bottoming, filling material and surface repair of special-shaped defects of large-size metal components, no longer depends on manual repair, realizes the automation of large-size special-shaped defects, and improves the efficiency and effect of defect repair.

[0006] In a first aspect, the embodiments of the present application provide a large-size special-shaped defect additive method based on reverse reconstruction, which comprises: determining a special-shaped defect of a preset large-size metal component and a bottoming material for the special-shaped defect, and bottoming the special-shaped defect based on the bottoming material of the special-shaped defect; determining a filling material for the special-shaped defect, and performing layer-by-layer surfacing on the bottomed special-shaped defect based on the filling material, to obtain a corresponding surfacing layer, until the height of the surfacing layer is flat with the surface of the large-size metal component; determining the number of surface layers for surface repair of the special-shaped defect, and performing layer-by-layer surfacing on the special-shaped defect based on the number of surface layers, until the surface of the special-shaped defect is full and higher than the target height of the surface of the large-size metal component.

[0007] In a possible implementation, the bottoming of the irregular defect comprises: For the irregular defect, a spheroid-like surface corresponding to the irregular defect is determined, and a long axis and a short axis corresponding to the spheroid-like surface of the irregular defect are determined; the long axis is a straight line with the longest distance of the outermost edge of the irregular defect, and the short axis is a straight line in the maximum depth direction of the irregular defect; Based on the comparison result of the long axis and the short axis of the irregular defect, a corresponding bottoming mode is determined, and bottoming is performed along the surface of the irregular defect based on the bottoming mode.

[0008] In a possible implementation, based on the comparison result of the long axis and the short axis of the irregular defect, the corresponding bottoming mode is determined, and the bottoming is performed along the surface of the irregular defect based on the bottoming mode, which comprises: When the ratio of the long axis and the short axis of the irregular defect is greater than or equal to a first value and the direction of the short axis is perpendicular to the vertex of the bottom surface of the irregular defect, it is determined that the bottoming mode of the irregular defect is a curved surface vertical bottoming mode; Based on the curved surface vertical bottoming mode, a corresponding first overlay path is obtained, and the irregular defect is bottomed based on the first overlay path.

[0009] In a possible implementation, the bottoming of the irregular defect based on the first overlay path comprises: Starting from one end of the irregular defect, a zigzag path is walked in the vertical direction of the curved surface of the irregular defect to bottom the irregular defect; The long straight line direction of the zigzag path is perpendicular to the long-short axis plane formed by the long axis and the short axis, the short straight line direction of the zigzag path is consistent with the direction trend of the long axis, and the zigzag path fluctuates along the edge of the irregular defect; the zigzag path and the irregular defect are not in the same plane. In a possible implementation, based on the comparison result of the long axis and the short axis of the irregular defect, the corresponding bottoming mode is determined, and the bottoming of the irregular defect is performed based on the bottoming mode, which comprises: When the ratio of the long axis and the short axis of the irregular defect is greater than a second value and less than the first value, it is determined that the bottoming mode of the irregular defect is a plane vertical bottoming mode; Based on the plane vertical bottoming mode, a corresponding second overlay path is obtained, and the irregular defect is bottomed based on the second overlay path.

[0010] In a possible implementation, the bottoming of the irregular defect based on the second overlay path comprises: The surface of the ellipsoidal surface of the irregular defect is subjected to layering; wherein, the slope of each part inside the pit of the irregular defect after layering is different; the irregular defect after layering includes multiple planes; For the layered irregular defects, an offset path is adopted. Starting from the bottom of the irregular defect, the offset path of each layer is determined until the outermost contour of the irregular defect, so as to finally generate the elliptic curve overlay welding path of the irregular defect.

[0011] In one possible implementation, the method of layer-by-layer welding of irregular defects after the initial slicing includes: A reverse scan image of the irregular defect is obtained. The surface base portion of the irregular defect is removed from the reverse scan image to obtain the remaining space region of the irregular defect in the reverse scan image. The remaining space region of the irregular defect is then sliced ​​into layers to determine the corresponding filling path. The irregular defect after slicing includes multiple slice planes. The irregular defect is filled based on the filling path.

[0012] Secondly, embodiments of this application also provide an additive manufacturing apparatus for large-size irregular defects based on reverse reconstruction, the apparatus comprising: The base layer module is used to determine the pre-defined irregular defects of large-sized metal components and the base layer material for the irregular defects, and to apply the base layer material to the irregular defects. The filling module is used to determine the filling material for the irregular defect, and to perform layer-by-layer welding on the irregular defect after the base layer is applied using a layered slicing method based on the filling material to obtain the corresponding weld overlay layer until the height of the weld overlay layer is flat with the surface of the large-size metal component. The cover module is used to determine the number of cover layers for covering and repairing the irregular defect, and to perform layer-by-layer welding on the irregular defect based on the number of cover layers until the surface of the irregular defect is full and higher than the target surface height of the large-size metal component.

[0013] In one possible implementation, the base layer module is specifically used for: For the aforementioned irregular defect, an ellipsoidal surface corresponding to the irregular defect is determined, and the major axis and minor axis are determined based on the ellipsoidal surface of the irregular defect; wherein, the major axis is the straight line with the longest distance at the outermost edge of the irregular defect, and the minor axis is the straight line of the irregular defect in the direction of maximum depth; Based on the comparison of the major and minor axes of the irregular defect, a corresponding priming method is determined, and priming is performed along the surface of the irregular defect based on the priming method.

[0014] In one possible implementation, the base layer module is specifically used for: When the ratio of the major axis to the minor axis of the irregular defect is greater than or equal to a first value and the direction of the minor axis is perpendicular to the bottom vertex of the irregular defect, the bottoming method of the irregular defect is determined to be the curved surface vertical bottoming method. The first welding path is obtained based on the curved surface vertical underlay method, and the irregular defect is underlaid based on the first welding path.

[0015] In one possible implementation, the base layer module is specifically used for: Starting from one end of the irregular defect, walk along a zigzag path in the direction perpendicular to the curved surface of the irregular defect to lay the base of the irregular defect; Wherein, the long straight line direction of the "J"-shaped path is perpendicular to the long and short axis plane, which is the plane formed by the long axis and the short axis; the short straight line direction of the "J"-shaped path is consistent with the direction trend of the long axis and fluctuates along the edge of the irregular defect; the "J"-shaped path and the irregular defect are not on the same plane.

[0016] In one possible implementation, the base layer module is specifically used for: When the ratio of the major axis to the minor axis of the irregular defect is greater than the second value and less than the first value, the base treatment method of the irregular defect is determined to be the planar vertical base treatment method. The corresponding second welding path is obtained based on the planar vertical under-base method, and the irregular defect is under-based based on the second welding path.

[0017] In one possible implementation, the base layer module is specifically used for: The surface of the ellipsoidal surface of the irregular defect is subjected to layering; wherein, the slope of each part inside the pit of the irregular defect after layering is different; the irregular defect after layering includes multiple planes; For the layered irregular defects, an offset path is adopted. Starting from the bottom of the irregular defect, the offset path of each layer is determined until the outermost contour of the irregular defect, so as to finally generate the elliptic curve overlay welding path of the irregular defect.

[0018] In one possible implementation, the filling module is specifically used for: A reverse scan image of the irregular defect is obtained. The surface base portion of the irregular defect is removed from the reverse scan image to obtain the remaining space region of the irregular defect in the reverse scan image. The remaining space region of the irregular defect is then sliced ​​into layers to determine the corresponding filling path. The irregular defect after slicing includes multiple slice planes. The irregular defect is filled based on the filling path.

[0019] Thirdly, embodiments of this application provide an electronic device, including: a processor, a storage medium, and a bus. The storage medium stores machine-readable instructions executable by the processor. When the electronic device is running, the processor communicates with the storage medium via the bus, and the processor executes the machine-readable instructions to perform the steps of the additive manufacturing method for large-size irregular defects based on reverse reconstruction as described in any of the first aspects.

[0020] Fourthly, embodiments of this application provide a computer-readable storage medium storing a computer program, which, when executed by a processor, performs the steps of the additive manufacturing method for large-size irregular defects based on reverse reconstruction as described in any of the first aspects.

[0021] This application provides an additive manufacturing method and apparatus for large-size irregular defects based on reverse reconstruction. The method involves identifying a pre-defined irregular defect in a large-size metal component and a base material for the defect. The base material is used to apply a base coat to the defect. A filler material is then determined. Based on the filler material, the base-coated irregular defect is layered and welded layer by layer until the height of the welded layer is flush with the surface of the large-size metal component. The number of cover layers for repairing the defect is determined. Based on the number of cover layers, the irregular defect is welded layer by layer until its surface is full and exceeds the target height of the large-size metal component. This application achieves the repair of irregular defects in large-size metal components through base coat, filler material, and cover coat repair, eliminating reliance on manual repair, automating the repair of large-size irregular defects, and improving the efficiency and effectiveness of defect repair.

[0022] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a flowchart of an additive manufacturing method for large-size irregular defects based on reverse reconstruction, according to an embodiment of this application. Figure 2This is a schematic diagram of irregular defects in large-sized metal components; Figure 3 This is a schematic diagram of an irregular defect that requires expansion of its outer edge; Figure 4 This is a schematic diagram of the first weld path; Figure 5 This is a schematic diagram of the second welding path; Figure 6 This is a diagram illustrating the path filling; Figure 7 It is a schematic diagram of the path for priming, filling, and covering, and the actual repair result; Figure 8 This is a schematic diagram of the structure of an additive manufacturing device for large-size irregular defects based on reverse reconstruction, according to an embodiment of this application. Figure 9 This is a schematic diagram of the structure of an electronic device provided according to an embodiment of this application. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. It should be understood that the accompanying drawings in this application are for illustrative and descriptive purposes only and are not intended to limit the scope of protection of this application. Furthermore, it should be understood that the schematic drawings are not drawn to scale. The flowcharts used in this application illustrate operations implemented according to some embodiments of this application. It should be understood that the operations in the flowcharts may not be implemented in sequence, and steps without logical contextual relationships may be reversed or implemented simultaneously. In addition, those skilled in the art, guided by the content of this application, may add one or more other operations to the flowcharts, or remove one or more operations from the flowcharts.

[0026] Furthermore, the described embodiments are merely some, not all, of the embodiments of this application. The components of the embodiments of this application described and illustrated herein can typically be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0027] It should be noted that the term "comprising" will be used in the embodiments of this application to indicate the presence of the features declared thereafter, but does not exclude the addition of other features.

[0028] Considering that large-sized metal components are prone to defects during manufacturing due to various factors, and that irregular defects such as spalling pits may occur during service operation, as well as irregular shapes may arise during regenerative repair and cleaning, existing forming technologies exhibit certain limitations when dealing with such large-sized metal components. To meet the manufacturing needs of large-scale, integrated structural components, low-cost, high-efficiency wire and arc additive manufacturing (WAAM) technology, developed based on welding overlay technology, is gradually attracting attention.

[0029] Currently, when dealing with large-sized irregular defects, the repair process is often achieved by combining wire arc additive manufacturing technology and reverse engineering. The defect model is then reverse-engineered and the repair is completed using arc additive manufacturing.

[0030] However, due to the uncertainty of the size, shape, and repair scheme of large-sized irregular defects, the existing wire arc additive manufacturing technology is mainly a semi-manual repair, resulting in the general efficiency and effect of defect repair.

[0031] To address this issue, this application provides an additive manufacturing method and apparatus for large-size irregular defects based on reverse reconstruction. By performing base layering, filling material, and cover repair on irregular defects of large-size metal components, the method achieves the repair of irregular defects without relying on manual repair, realizes the automation of large-size irregular defects, and improves the efficiency and effectiveness of defect repair.

[0032] Figure 1 This is a flowchart of an additive manufacturing method for large-size irregular defects based on reverse reconstruction, according to an embodiment of this application. Figure 1 As shown, the additive manufacturing method for large-size irregular defects based on reverse reconstruction in this application embodiment may specifically include: S101. Determine the pre-defined irregular defects of large-size metal components and the base material for the irregular defects, and apply the base material to the irregular defects.

[0033] S102. Determine the filling material for irregular defects. Based on the filling material, use a layered slicing method to weld the irregular defects layer by layer after the base layer is applied to obtain the corresponding weld overlay layer until the height of the weld overlay layer is flat with the surface of the large-size metal component.

[0034] S103. Determine the number of cover layers for repairing irregular defects, and perform layer-by-layer welding on the irregular defects based on the number of cover layers until the surface of the irregular defects is full and higher than the target height of the surface of the large-size metal component.

[0035] In the above-mentioned additive manufacturing method for large-size irregular defects based on reverse reconstruction, the irregular defects of large-size metal components are repaired by applying a base layer, filling material, and covering the surface. This eliminates the need for manual repair, automates the repair of large-size irregular defects, and improves the efficiency and effectiveness of defect repair.

[0036] The exemplary steps described above in the embodiments of this application are illustrated below with specific examples: S101, determine the pre-defined irregular defects of large-size metal components and the base material for the irregular defects, and apply the base material to the irregular defects.

[0037] In this embodiment, the large-size metal component can be a large-size casting or forging, or other shaped metal component. The base material is a first target type of stainless steel or low-alloy high-strength steel, such as the ZM or ZD series stainless steel or low-alloy high-strength steel belonging to the applicant. The base material for the irregular defects of the large-size metal component is determined, and the irregular defects are treated according to the base material for subsequent processing. For example, as... Figure 2 The image shows an irregular defect in a large-sized metal component.

[0038] It should be noted that during the base coat, the cladding can be applied to irregularly shaped defects with a target thickness and number of layers. For example, a thin layer (e.g., 5-8 mm) can be applied along the surface of the irregularly shaped defect.

[0039] As one possible implementation, for irregular defects, an ellipsoidal surface corresponding to the irregular defect is determined, and the major and minor axes are determined based on the ellipsoidal surface of the irregular defect; based on the comparison results of the major and minor axes of the irregular defect, the corresponding sizing method is determined, and sizing is performed along the surface of the irregular defect based on the sizing method.

[0040] Wherein, the major axis is the straight line with the longest distance at the outermost edge of the irregular defect, and the minor axis is the straight line with the irregular defect in the direction of maximum depth. The length of the major axis is half of the total distance along the major axis direction. The comparison result is the ratio of the major axis to the minor axis of the irregular defect. The sizing methods include at least curved surface vertical sizing and planar offset sizing. In addition, the long straight line here specifically refers to the straight line with the longest straight distance in the zigzag path; the short straight line here specifically refers to the straight line with the shortest straight distance in the zigzag path; the curved path width is the center distance between two adjacent paths; the curved path simplification precision is the point simplification of the generated curved surface sizing path, and the larger the value, the higher the simplification precision.

[0041] It should be noted that irregular defects in large-sized components can often be considered as ellipsoidal surfaces. For subsequent additive manufacturing repair of these defects, the ratio of the major axis to the minor axis must be greater than 1 / 2, with the minor axis perpendicular to the bottom of the defect, typically representing the defect depth. For example, ...Figure 3 As shown, if the ratio of the major axis to the minor axis of the defect is not greater than 1 / 2, the anisotropic defect is relatively steep. In this case, simple manual processing is required to widen the outer edge of the defect. This is because the deeper the defect, the smaller the bevel angle, and the more difficult it is for the welding torch to reach in for welding. This necessitates manual shielded metal arc welding. For example, when repairing linear defects—cracks—it is necessary to first remove the base material exceeding the crack depth, and then create a certain bevel angle for easier operation. In half of these cases, a bevel angle greater than 40 degrees is required for repair to be feasible. If the bevel angle is too small, the operation becomes inconvenient, the process is prone to defects, and problems are easily encountered.

[0042] Optionally, based on the comparison results of the major and minor axes of the irregular defect, the corresponding priming method is determined. When priming along the surface of the irregular defect based on the priming method, it is mainly divided into the following two cases: a. When the ratio of the major axis to the minor axis of the irregular defect is greater than or equal to the first value and the direction of the minor axis is perpendicular to the bottom vertex of the irregular defect, the base treatment method of the irregular defect is determined to be the curved surface vertical base treatment method; the corresponding first welding path is obtained based on the curved surface vertical base treatment method, and the irregular defect is treated based on the first welding path.

[0043] Among them, the bottom vertex is the point with the largest defect depth, and the curved surface vertical bottoming method represents the welding torch being in an ellipsoidal curved surface that is always perpendicular to the irregular defect; the first value can be 1, and this application uses this as an example for description, but it does not constitute a limitation on the first value.

[0044] Specifically, when the ratio of the major axis to the minor axis of the ellipsoidal surface of the irregular defect is ≥1, and the direction of the minor axis is perpendicular to the vertex of the bottom surface, it indicates that the irregular defect is relatively gentle and has a small curvature. In this case, a perpendicular bottom-welding method is used, meaning the welding torch is always perpendicular to the ellipsoidal surface, and its first weld path is as follows: Figure 4 As shown.

[0045] It should be noted that when performing root pass on irregularly shaped defects based on the first weld path, starting from one end of the defect, the weld travels along a zigzag path perpendicular to the curved surface of the defect to perform root pass. The longer straight line of the zigzag path is perpendicular to the major and minor axis planes, which are the planes formed by the major and minor axes. The shorter straight lines of the zigzag path follow the same trend as the major axis, meaning the overall direction of the shorter straight lines of the zigzag path is the direction of the major axis, and it fluctuates along the edge of the defect. During the root pass, the welding torch is always in a position perpendicular to the curved surface of the defect to ensure proper formation (e.g., dimensions, weld quality, spatter, arc stability, etc.). The zigzag path and the defect are not on the same plane, which makes it highly adaptable to different defects. For example, as... Figure 4 As shown.

[0046] b. When the ratio of the major axis to the minor axis of the irregular defect is greater than the second value and less than the first value, the base treatment method for the irregular defect is determined to be the planar vertical base treatment method; the corresponding second welding path is obtained based on the planar vertical base treatment method, and the irregular defect is treated based on the second welding path.

[0047] The second value can be 1 / 2. This application uses this as an example for description, but it does not constitute a limitation on the second value.

[0048] Specifically, when the ratio of the major axis to the minor axis of the ellipsoidal surface of the irregular defect is 1 / 2 < major axis / minor axis < 1, it indicates that the irregular defect is relatively steep and has a large curvature. In this case, a planar offset underlay is used, and its second weld path is as follows: Figure 5 As shown in the figure, the upper part is a simplified schematic diagram of the simulated base path, and the lower part is a schematic diagram of the actual weld overlay path.

[0049] It should be noted that when performing the base layering on the irregularly shaped defect based on the second welding path, the surface of the ellipsoidal surface of the irregularly shaped defect is processed into layers. For the layered irregularly shaped defect, an offset path is used, determining the offset path for each layer starting from the bottom of the defect, up to the outermost contour of the defect, to ultimately generate the ellipsoidal curve welding path for the irregularly shaped defect. For example, as... Figure 5 As shown.

[0050] In this design, the slope of the pit inside the layered irregular defect varies at different locations. The layered irregular defect includes multiple planes (i.e., multiple planes). The offset path corresponding to each plane is the intersection line between the height plane of that layer and the curved surface of the irregular defect. The height plane of that layer is the width of the slice path from the previous plane. The width of the offset path is the distance between that layer (that plane) and the next plane. For example, the (n+1)th offset path corresponding to the (n+1)th layer is the intersection line between the height plane of that layer and the curved surface of the irregular defect. The height plane is the width or height of the slice path from the previous n-th plane.

[0051] Specifically, the curved surface of the irregular defect is processed in layers. Since the slopes of different parts inside the pit vary after layering, to avoid blank areas (the flatter the curve, the higher the probability of blank areas), an offset path is used. That is, starting from the bottom of the defect, the (n+1)th path (the path of the (n+1)th plane) is the intersection line of the height plane of this layer (the (n+1)th plane) with the width (height difference) of the slice path of the previous n-th plane and the curved surface of the defect, until the outermost contour of the defect. This ultimately forms a quasi-elliptical curve welding path that gradually increases in height, indicating that the base layer is complete. Furthermore, the width of the (n+1)th offset path is the distance between the nth and n+1th planes. Therefore, this second welding path can effectively handle irregular defects with relatively large curvature.

[0052] S102, determine the filling material for the irregular defect, and based on the filling material, use a layered slicing method to build up the irregular defect layer by layer to obtain the corresponding weld overlay layer until the height of the weld overlay layer is flat with the surface of the large-size metal component.

[0053] In this embodiment, the filler material is a low-alloy high-strength material of the second target type, such as the ZD series low-alloy high-strength material. The filler material meets the size and performance requirements for filling irregular defects. The filler material has target strength, target toughness and target fatigue resistance, that is, high strength, high toughness and high fatigue resistance. According to the filler material for irregular defects, the irregular defects after the base layer in step S101 are welded layer by layer to obtain the corresponding weld layer until the height of the weld layer is flat with the surface of the large-size metal component, that is, the original surface before the large-size metal component defects are generated, so as to carry out subsequent processing.

[0054] It should be noted that if the height of the weld overlay is flat with the surface of the large-sized metal component, it means that the difference between the final height of the weld overlay and the height of the surface of the large-sized metal component is within the preset error range, and at this time it is considered that the two are flat.

[0055] In some implementations, when performing layer-by-layer welding on irregularly shaped defects after the initial slicing, a reverse scan image of the defect is acquired. The surface slicing portion of the defect is removed from the reverse scan image, resulting in the remaining space region of the defect. This remaining space region is then sliced ​​layer by layer to determine the corresponding filling path. The defect is then filled based on the filling path. The irregularly shaped defect after layer-by-layer slicing comprises multiple slice planes. For example, the filling path might be as follows: Figure 6 As shown.

[0056] Optionally, when filling irregular defects based on the filling path, starting from one end of the long axis in the slice plane of the irregular defect, the path travels in a zigzag pattern on the slice plane. The zigzag path is on the same plane as the irregular defect; the long and short straight line directions of the first layer correspond to and are consistent with the long and short straight line directions of the previous layer.

[0057] Specifically, after receiving the reverse-scanned image of the irregular defect, the surface base portion of the irregular defect is removed from the reverse-scanned image or model. The remaining space is then sliced ​​into layers. The additive path for layer n begins along the long axis at one end and travels in a zigzag pattern on the slicing plane. The longer straight line of the zigzag pattern is perpendicular to both the major and minor axes, while the shorter straight lines generally align with the major axis, undulating along the defect edge. This path remains on the same plane, and the directions of the longer and shorter straight lines in layer n+1 are consistent with those in layer n. This path ensures dimensional requirements are met and minimizes deviations.

[0058] S103, determine the number of cover layers for repairing irregular defects, and perform layer-by-layer welding on the irregular defects based on the number of cover layers until the surface of the irregular defects is full and higher than the target height of the surface of the large-size metal component.

[0059] In this embodiment, the number of cover layers refers to the number of layers used to cover the irregular defect, for example, 1-2 layers. The target height refers to the height by which the surface of the irregular defect is higher than the surface of the large-size metal component, for example, 1-3 mm. The irregular defect is welded layer by layer according to the determined number of cover layers for covering and repairing the irregular defect until the surface of the irregular defect is full and higher than the target height of the surface of the large-size metal component.

[0060] The additive manufacturing method for large-size irregular defects based on reverse reconstruction provided in this application determines the pre-defined irregular defects of a large-size metal component and a base material for the defects. The method applies a base layer to the irregular defects based on the base material, determines a filler material for the defects, and then performs layer-by-layer welding on the base-applied irregular defects using a layered slicing method based on the filler material to obtain corresponding weld layers until the height of the weld layers is flush with the surface of the large-size metal component. The method then determines the number of cover layers for repairing the irregular defects and performs layer-by-layer welding on the irregular defects based on the number of cover layers until the surface of the irregular defects is full and exceeds the target height of the large-size metal component surface. This additive manufacturing method for large-size irregular defects based on reverse reconstruction achieves the repair of irregular defects by applying a base layer, filling material, and cover layer to the large-size metal component, eliminating reliance on manual repair, automating the repair of large-size irregular defects, and improving the efficiency and effectiveness of defect repair.

[0061] It should be noted that the process involves obtaining preset multi-dimensional additive manufacturing parameters; additive manufacturing is then performed based on these parameters, which is the aforementioned root pass, fill pass, and cap pass. In short, these multi-dimensional additive manufacturing parameters are used in the above additive manufacturing process. Of course, the specific parameters need to be adjusted according to various paths. These multi-dimensional additive manufacturing parameters include at least the following: 1.6mm diameter welding wire, welding current 300-320A, welding voltage 25.7-27.5V, arc length correction 3-5%, wire feed speed 5.6-6.2m / min, welding speed mm / s, interpass temperature 100-200℃, shielding gas CO2, and shielding gas flow rate 15L / min.

[0062] In addition, for the zigzag path, determine the corresponding additive manufacturing parameters. Specifically, for the zigzag path portion, the additive manufacturing parameters need to be adjusted. For example, the welding speed for long straight lines should be controlled at 4~6 mm / s, the welding speed for short straight lines should be in the range of 10~14 mm / s, the width of curved paths should be in the range of 6~8 mm, and the path simplification accuracy should be 1~3, in order to control the forming process.

[0063] For example, Table 1 below shows the major additive manufacturing parameters for each of the above-mentioned repair processes: priming, filling, and capping. Table 1. Major parameters for additive manufacturing of underlay, filler, and cover.

[0064] Correspondingly, such as Figure 7 The image shows a schematic diagram of the repair process, including the base coat, filling, and cover coat, along with corresponding photos of the actual repair results. It can be seen that the weld bead is uniform and the weld thickness is uniform.

[0065] Therefore, compared with other filling methods, this application can effectively improve the degree of automation, effectively adapt to large-sized irregular defects, and achieve better molding.

[0066] It should be noted that the additive manufacturing method for large-size irregular defects based on reverse reconstruction in this application is a method for additive manufacturing of large-size metal components with irregular defects, and also a method for repairing large-size metal components with irregular defects.

[0067] Figure 8 This is a schematic diagram of the structure of an additive manufacturing device for large-size irregular defects based on reverse reconstruction, according to an embodiment of this application; as shown below. Figure 8 As shown, the additive manufacturing device 800 for large-size irregular defects based on reverse reconstruction according to an embodiment of this application may specifically include: The base layer module 801 is used to determine the pre-set irregular defects of large-sized metal components and the base layer material for the irregular defects, and to perform base layering on the irregular defects based on the base layer material.

[0068] The filling module 802 is used to determine the filling material for the irregular defect. Based on the filling material, the irregular defect after the base layer is applied is welded layer by layer to obtain the corresponding weld overlay layer until the height of the weld overlay layer is flat with the surface of the large-size metal component.

[0069] The cover module 803 is used to determine the number of cover layers for covering and repairing irregular defects. Based on the number of cover layers, the irregular defects are welded layer by layer until the surface of the irregular defects is full and higher than the target height of the surface of the large-size metal component.

[0070] In one possible implementation, the base-layout module is specifically used for: For irregular defects, the corresponding ellipsoidal surface is determined, and the major axis and minor axis are determined based on the ellipsoidal surface of the irregular defect; where the major axis is the straight line with the longest distance at the outermost edge of the irregular defect, and the minor axis is the straight line of the irregular defect in the direction of maximum depth. Based on the comparison of the major and minor axes of the irregular defect, the corresponding priming method is determined, and priming is performed along the surface of the irregular defect based on the priming method.

[0071] In one possible implementation, the base-layout module is specifically used for: When the ratio of the major axis to the minor axis of the irregular defect is greater than or equal to the first value and the direction of the minor axis is perpendicular to the bottom vertex of the irregular defect, the base treatment method of the irregular defect is determined to be the curved surface vertical base treatment method. The first weld path is obtained based on the curved surface vertical base method, and the irregular defect is based based on the first weld path.

[0072] In one possible implementation, the base-layout module is specifically used for: Starting from one end of the irregular defect, walk along a zigzag path in the direction perpendicular to the curved surface of the irregular defect to lay the base of the irregular defect; Among them, the long straight line of the zigzag path is perpendicular to the long and short axis plane, which is the plane formed by the long and short axes; the short straight line of the zigzag path is consistent with the direction of the long axis and fluctuates along the edge of the irregular defect; the zigzag path and the irregular defect are not on the same plane.

[0073] In one possible implementation, the base-layout module is specifically used for: When the ratio of the major axis to the minor axis of the irregular defect is greater than the second value and less than the first value, the base treatment method for the irregular defect is determined to be the planar vertical base treatment method. The corresponding second welding path is obtained based on the planar vertical under-base method, and the irregular defect is under-based based on the second welding path.

[0074] In one possible implementation, the base-layout module is specifically used for: The surface of the ellipsoidal surface of the irregular defect is processed into layers; the slope of the pit inside the irregular defect is different in different parts after layering; the irregular defect after layering includes multiple planes. For the layered irregular defects, an offset path is used to determine the offset path of each layer starting from the bottom of the irregular defect, until the outermost contour of the irregular defect, so as to finally generate an elliptic curve welding path for the irregular defect.

[0075] In one possible implementation, the filling module is specifically used for: A reverse scan image of the irregular defect is obtained. The surface base portion of the irregular defect is removed from the reverse scan image to obtain the remaining spatial region of the irregular defect in the reverse scan image. The remaining spatial region of the irregular defect is then sliced ​​into layers to determine the corresponding filling path. The irregular defect after layer slicing includes multiple slice planes. Fill irregular defects based on the filling path.

[0076] The additive manufacturing apparatus for large-size irregular defects based on reverse reconstruction provided in this application determines the pre-defined irregular defects of a large-size metal component and a base material for the defects. Based on the base material, the apparatus applies a base coat to the irregular defects. A filler material is then determined for the irregular defects. Based on the filler material, the irregular defects are layered and welded layer by layer using a layered slicing method to obtain corresponding weld layers until the height of the weld layers is flush with the surface of the large-size metal component. The number of cover layers for repairing the irregular defects is determined, and the irregular defects are then welded layer by layer based on the number of cover layers until the surface of the irregular defects is full and exceeds the target height of the large-size metal component. This additive manufacturing apparatus for large-size irregular defects based on reverse reconstruction achieves the repair of irregular defects by applying a base coat, filling material, and covering the defects in large-size metal components. It eliminates reliance on manual repair, automates the repair of large-size irregular defects, and improves the efficiency and effectiveness of defect repair.

[0077] like Figure 9 As shown in the embodiment of this application, an electronic device 900 includes a processor 901, a memory 902, and a bus. The memory 902 stores machine-readable instructions executable by the processor 901. When the electronic device is running, the processor 901 communicates with the memory 902 via the bus. The processor 901 executes the machine-readable instructions to perform the steps of the additive manufacturing method for large-size irregular defects based on reverse reconstruction as described above.

[0078] Specifically, the memory 902 and processor 901 mentioned above can be general-purpose memory and processor, without any specific limitations. When the processor 901 runs the computer program stored in the memory 902, it can execute the above-mentioned additive manufacturing method for large-size irregular defects based on reverse reconstruction.

[0079] Corresponding to the above-described additive manufacturing method for large-size irregular defects based on reverse reconstruction, this application embodiment also provides a computer-readable storage medium storing a computer program, which, when executed by a processor, performs the steps of the above-described additive manufacturing method for large-size irregular defects based on reverse reconstruction.

[0080] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems and devices described above can be referred to the corresponding processes in the method embodiments, and will not be repeated here. In the several embodiments provided in this application, it should be understood that the disclosed systems, devices, and methods can be implemented in other ways. The device embodiments described above are merely illustrative. For example, the division of modules is only a logical functional division, and in actual implementation, there may be other division methods. Furthermore, multiple modules or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the displayed or discussed mutual coupling or direct coupling or communication connection can be through some communication interfaces; the indirect coupling or communication connection of devices or modules can be electrical, mechanical, or other forms.

[0081] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0082] In addition, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0083] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a processor-executable, non-volatile, computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the deployment methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, ROM, RAM, magnetic disks, or optical disks.

[0084] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An additive manufacturing method for large-size irregular defects based on reverse reconstruction, characterized in that, The method includes: Identify the pre-defined irregular defects of large-sized metal components and the base material for the irregular defects, and apply a base layer to the irregular defects based on the base material. A filling material is determined for the irregular defect. Based on the filling material, the irregular defect after the base layer is applied is welded layer by layer to obtain the corresponding weld overlay layer until the height of the weld overlay layer is flat with the surface of the large-size metal component. The number of cover layers to repair the irregular defect is determined, and the irregular defect is welded layer by layer based on the number of cover layers until the surface of the irregular defect is full and higher than the target surface height of the large-size metal component.

2. The method according to claim 1, characterized in that, The process of applying a base coat to the irregular defect includes: For the aforementioned irregular defect, an ellipsoidal surface corresponding to the irregular defect is determined, and the major axis and minor axis are determined based on the ellipsoidal surface of the irregular defect; wherein, the major axis is the straight line with the longest distance at the outermost edge of the irregular defect, and the minor axis is the straight line of the irregular defect in the direction of maximum depth; Based on the comparison of the major and minor axes of the irregular defect, a corresponding priming method is determined, and priming is performed along the surface of the irregular defect based on the priming method.

3. The method according to claim 2, characterized in that, Based on the comparison results of the major and minor axes of the irregular defect, a corresponding priming method is determined, and priming is performed along the surface of the irregular defect based on the priming method, including: When the ratio of the major axis to the minor axis of the irregular defect is greater than or equal to a first value and the direction of the minor axis is perpendicular to the bottom vertex of the irregular defect, the bottoming method of the irregular defect is determined to be the curved surface vertical bottoming method. The first welding path is obtained based on the curved surface vertical underlay method, and the irregular defect is underlaid based on the first welding path.

4. The method according to claim 3, characterized in that, The step of applying a base coat to the irregular defect based on the first weld overlay path includes: Starting from one end of the irregular defect, walk along a zigzag path in the direction perpendicular to the curved surface of the irregular defect to lay the base of the irregular defect; Wherein, the long straight line direction of the "J"-shaped path is perpendicular to the long and short axis plane, which is the plane formed by the long axis and the short axis; the short straight line direction of the "J"-shaped path is consistent with the direction trend of the long axis and fluctuates along the edge of the irregular defect; the "J"-shaped path and the irregular defect are not on the same plane.

5. The method according to claim 4, characterized in that, Based on the comparison results of the major and minor axes of the irregular defect, a corresponding priming method is determined, and the irregular defect is primed according to the priming method, including: When the ratio of the major axis to the minor axis of the irregular defect is greater than the second value and less than the first value, the base treatment method of the irregular defect is determined to be the planar vertical base treatment method. The corresponding second welding path is obtained based on the planar vertical under-base method, and the irregular defect is under-based based on the second welding path.

6. The method according to claim 5, characterized in that, The step of applying a base coat to the irregular defect based on the second welding path includes: The surface of the ellipsoidal surface of the irregular defect is subjected to layering; wherein, the slope of each part inside the pit of the irregular defect after layering is different; the irregular defect after layering includes multiple planes; For the layered irregular defects, an offset path is adopted. Starting from the bottom of the irregular defect, the offset path of each layer is determined until the outermost contour of the irregular defect, so as to finally generate the elliptic curve overlay welding path of the irregular defect.

7. The method according to claim 6, characterized in that, The method of layering and slicing to weld irregular defects after the base layer includes: A reverse scan image of the irregular defect is obtained. The surface base portion of the irregular defect is removed from the reverse scan image to obtain the remaining space region of the irregular defect in the reverse scan image. The remaining space region of the irregular defect is then sliced ​​into layers to determine the corresponding filling path. The irregular defect after slicing includes multiple slice planes. The irregular defect is filled based on the filling path.

8. An additive manufacturing device for large-size irregular defects based on reverse reconstruction, characterized in that, The device includes: The base layer module is used to determine the pre-defined irregular defects of large-sized metal components and the base layer material for the irregular defects, and to apply the base layer material to the irregular defects. The filling module is used to determine the filling material for the irregular defect, and to perform layer-by-layer welding on the irregular defect after the base layer is applied using a layered slicing method based on the filling material to obtain the corresponding weld overlay layer until the height of the weld overlay layer is flat with the surface of the large-size metal component. The cover module is used to determine the number of cover layers for covering and repairing the irregular defect, and to perform layer-by-layer welding on the irregular defect based on the number of cover layers until the surface of the irregular defect is full and higher than the target surface height of the large-size metal component.

9. An electronic device, characterized in that, include: The device includes a processor, a memory, and a bus. The memory stores machine-readable instructions executable by the processor. When the electronic device is running, the processor communicates with the memory via the bus. When the machine-readable instructions are executed by the processor, they perform the steps of the additive manufacturing method for large-size irregular defects based on reverse reconstruction as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a computer program that, when executed by a processor, performs the steps of the additive manufacturing method for large-size irregular defects based on reverse reconstruction as described in any one of claims 1 to 7.

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