Laser cladding process for irregularly shaped parts

Abstract

A method and apparatus for laser cladding of irregularly shaped parts are disclosed. The method involves acquiring the three-dimensional structural information and a standard three-dimensional model of the irregularly shaped part, registering the three-dimensional structural information with the standard three-dimensional model, calculating the geometric deviation between the actual geometric shape data and the standard geometric shape data, and identifying the part to be repaired based on a preset deviation threshold. Within the part to be repaired, curvature abrupt change points are identified by combining preset curvature statistical thresholds and normal vector angle thresholds. These curvature abrupt change points are topologically connected to form closed feature boundary loops, dividing the part to be repaired into multiple micro-planar units, including curvature abrupt change regions and flat regions. Repair material is pre-placed in the part to be repaired, and the laser cladding path trajectory parameters and laser energy parameters are adjusted based on the curvature of the micro-planar units, the normal vector, the thickness of the pre-placed repair material, and the geometric deviation value. This invention overcomes the limitations of traditional laser cladding in terms of adaptability, stability, and efficiency in repairing complex irregularly shaped parts.

Description

Technical Field

[0001] This invention relates to the fields of laser cladding processing and surface engineering technology, and in particular to a method and apparatus for laser cladding processing of irregularly shaped parts. Background Technology

[0002] Laser cladding repair technology, as an advanced surface engineering method, is widely used in the repair and performance enhancement of complex components in aerospace, energy and power, and high-end equipment industries. It is particularly suitable for irregularly shaped components with irregular geometric features, such as free-form surfaces, abrupt curvatures, and multi-regional composite structures. This technology uses a high-energy laser beam to melt pre-placed or synchronously delivered repair materials, forming a metallurgically bonded cladding layer on the component surface, achieving dimensional restoration and performance improvement.

[0003] However, traditional laser cladding repair methods still face the following key technical bottlenecks when dealing with complex, irregularly shaped parts:

[0004] 1. Insufficient adaptability to complex curved surfaces: Existing technologies mostly rely on fixed path planning and uniform process parameters, without fully considering the dynamic changes in macroscopic features such as the curvature and geometric deviation of irregular parts. This makes it difficult to balance the accuracy and uniformity of the cladding layer, especially in areas with abrupt changes in curvature where material accumulation or incomplete fusion defects are prone to occur.

[0005] 2. Lack of targeted parameter control: During the repair process, the setting of core parameters such as laser energy and material deposition is not based on the need for repair, resulting in material waste or overperformance. Moreover, the coordinated control of cladding temperature, laser cladding stress, and molten pool flow is insufficient, affecting the bonding strength and fatigue performance of the cladding layer.

[0006] 3. Difficulty in controlling quality stability: Clamping errors and uneven surfaces of complex irregular parts can easily lead to fluctuations in energy density during processing. Traditional open-loop control mode lacks real-time quality monitoring and feedback adjustment mechanisms, making it difficult to guarantee the consistency and reliability of batch repair.

[0007] Therefore, the existing technology has problems and needs further improvement and development. Summary of the Invention

[0008] (I) Purpose of the invention: In order to solve the problems existing in the prior art, the purpose of the present invention is to provide a laser cladding method and apparatus for irregularly shaped parts, which can provide a more accurate repair solution in the repair process of irregularly shaped parts.

[0009] (II) Technical Solution: To solve the above-mentioned technical problems, this technical solution provides a laser cladding processing method for irregularly shaped parts, which includes the following steps:

[0010] The three-dimensional structural information and standard three-dimensional model of the irregular part are obtained. The three-dimensional structural information includes the actual geometric shape data of the irregular part's surface, and the standard three-dimensional model includes the standard geometric shape data of the irregular part. The geometric shape data includes the normal vector and curvature of the irregular part's surface.

[0011] The three-dimensional structural information is registered with the standard three-dimensional model, the geometric deviation between the actual geometric topography data and the standard geometric topography data is calculated, and the part to be repaired is identified according to the preset deviation threshold.

[0012] Within the portion to be repaired, curvature abrupt change points are identified by combining preset curvature statistical thresholds and normal vector angle thresholds; topological connections are made to the curvature abrupt change points to form closed feature boundary loops; based on the feature boundary loops and curvature, the portion to be repaired is divided into multiple microplane units, each of which includes curvature abrupt change regions and flat regions;

[0013] Repair material is pre-placed in the part to be repaired. The parameters of laser cladding are adjusted according to the curvature, normal vector, thickness of the pre-placed repair material, and geometric deviation value of the micro-planar unit. The parameters include path trajectory parameters and laser energy parameters.

[0014] The laser cladding process for irregularly shaped parts, wherein the part to be repaired is a region whose geometric deviation value exceeds a preset deviation threshold, wherein the preset deviation threshold is 0.1mm~0.5mm.

[0015] The laser cladding process for irregularly shaped parts, wherein the region type of the micro-plane unit is determined by the priority order of the curvature value H, geometric deviation value D, and the thickness T of the pre-set repair material of the micro-plane unit, with the priority order being curvature value H > geometric deviation value D > pre-set repair material thickness T, and the micro-plane unit of the part to be repaired is divided into the following three types of regions;

[0016] In curvature-dominant regions, curvature value H is prioritized: when curvature value H > 1 mm -1 The thickness of the pre-placed repair material is T = k × H × β, where: k is a process constant, ranging from 0.5 to 1.0, and β is a filling coefficient, ranging from 1.2 to 1.5; the laser cladding path trajectory parameters and laser energy parameters of the micro-planar unit in the curvature-dominant region are dominated by curvature.

[0017] In the region dominated by geometric deviation, when the curvature value H ≤ 1 mm -1 When the curvature value H ≤ 1mm, the geometric deviation value D is determined first. -1 When the geometric deviation value D≤0.3 mm, the thickness of the pre-set repair material is T=D×β, and the laser cladding path trajectory parameters and laser energy parameters of the micro-planar unit in the geometric deviation-dominant region are dominated by the geometric deviation value.

[0018] In the thickness-dominant region, when 0.5 < curvature value H ≤ 1 mm -1 When 0.3 < geometric deviation value D ≤ 0.5 mm, and T > 0.3 mm as calculated by the pre-set repair material thickness T = D × β, the laser cladding parameters are dominated by the pre-set repair material thickness T.

[0019] The laser cladding process for irregularly shaped parts, wherein the path trajectory parameters include scanning direction, path spacing and scanning speed, and the laser energy parameters include laser power and spot diameter.

[0020] The laser cladding process for irregularly shaped parts, wherein,

[0021] For the scanning path spacing of curvature-dominated micro-planar units, the scanning path spacing is positively correlated with curvature and the thickness of the pre-placed repair material, and negatively correlated with geometric deviation; the value range of the scanning path spacing is 0.1~0.3mm.

[0022] For the scanning path spacing of micro-planar units dominated by geometric deviation correction: with the scanning path spacing of 0.4~0.5 mm as the benchmark in the thickness-dominant region where 0.3 < the pre-set repair material thickness T ≤ 0.5 mm, the scanning path spacing is reduced by 10%~20%;

[0023] The laser cladding scanning path spacing in the microplanar unit dominated by the thickness of the pre-set repair material is 0.3~0.4mm when the thickness of the pre-set repair material T>0.5mm; and 0.4~0.5mm when 0.3<T≤0.5mm.

[0024] The laser cladding method for irregularly shaped parts, wherein, for the micro-planar unit in the curvature abrupt change region, a second micro-ultrasonic vibration module is used to apply high-frequency vibration while laser cladding is being performed.

[0025] The laser cladding method for irregularly shaped parts, wherein the curvature gradient of the micro-planar units on the surface of the irregularly shaped part is divided into units ≤0.5mm. -1 The low gradient region, 0.5–1 mm -1 In the medium gradient region, >1mm -1 High gradient region;

[0026] The high-frequency vibration frequency in the high-gradient region increases linearly with the curvature gradient, with the frequency increasing by 0.5 mm for every 0.5 mm increase in gradient. -1 The frequency was increased from 30kHz to 50kHz, while the amplitude was fixed at 5-10μm.

[0027] The high-frequency vibration in the middle gradient region maintains a vibration frequency of 30kHz, and the amplitude increases linearly from 10μm to 15μm as the gradient decreases.

[0028] The high-frequency vibration in the low gradient region has a vibration frequency of 20-25kHz and an amplitude of 15-20μm.

[0029] The laser cladding process for irregularly shaped parts includes a spring damping assembly with a stroke of ±10mm set along the normal direction of the cladding head. The distance between the cladding head and the surface of the irregularly shaped part is monitored in real time by a displacement sensor. When the distance fluctuates due to clamping error or surface unevenness, the spring damping assembly compensates in real time through elastic deformation.

[0030] A laser cladding apparatus for irregularly shaped parts, comprising:

[0031] A three-dimensional structural information acquisition unit is used to acquire the three-dimensional structural information and standard three-dimensional model of the irregular part. The three-dimensional structural information includes the actual geometric shape data of the surface of the irregular part, and the standard three-dimensional model includes the standard geometric shape data of the irregular part. The geometric shape data includes the normal vector and curvature of the surface of the irregular part.

[0032] The part to be repaired identification unit registers the three-dimensional structural information with the standard three-dimensional model, calculates the geometric deviation value between the actual geometric shape data and the standard geometric shape data, and identifies the part to be repaired according to the preset deviation threshold.

[0033] The microplane unit division unit identifies curvature abrupt change points within the part to be repaired by combining preset curvature statistical thresholds and normal vector angle thresholds; it forms a closed feature boundary loop by topologically connecting the curvature abrupt change points; and divides the part to be repaired into multiple microplane units based on the feature boundary loop and curvature. The microplane unit includes curvature abrupt change regions and flat regions.

[0034] The repair unit pre-places repair material in the part to be repaired. Based on the curvature, normal vector, thickness of the pre-placed repair material, and geometric deviation value of the micro-plane unit, it adjusts the laser cladding path trajectory parameters and laser energy parameters to perform laser cladding on the pre-placed repair material.

[0035] The laser cladding processing device for irregularly shaped parts, wherein the pre-set repair material includes solid materials and powder materials, and the solid materials include metal foil and wire.

[0036] (III) Beneficial Effects: The present invention provides a cladding method and apparatus for irregularly shaped parts. The area to be repaired is divided into multiple micro-planar units, each further divided into curvature-dominated, geometric deviation-dominated, and thickness-dominated regions. By combining a dynamic matching rule of three parameters—curvature, geometric deviation, and pre-set repair material thickness—on-demand repair is achieved, improving the forming accuracy of complex curved surfaces. Secondly, a bounding box is constructed for multiple connected micro-planar units, dynamically matching the pre-set repair material thickness with the bounding box, improving material utilization and avoiding stress concentration caused by stepped thickness differences. Finally, the vibration is transmitted to the molten pool area of ​​the irregularly shaped part through a first micro-vibration module via a shelf. Acoustic impedance monitoring and high-frequency vibration are introduced for coordinated control. Vibration parameters are adjusted in real time through acoustic impedance curve fluctuations, improving molten pool fluidity and reducing porosity. Attached Figure Description

[0037] Figure 1 This is a flowchart illustrating the first preferred embodiment of the laser cladding process for irregularly shaped parts according to the present invention;

[0038] Figure 2 This is a flowchart illustrating a second preferred embodiment of the laser cladding process for irregularly shaped parts according to the present invention.

[0039] Figure 3 This is a flowchart illustrating the third preferred embodiment of the laser cladding process for irregularly shaped parts according to the present invention.

[0040] Figure 4 This is a schematic flowchart of the fourth preferred embodiment of the laser cladding process for irregularly shaped parts of the present invention;

[0041] Figure 5 This is a flowchart illustrating the fifth preferred embodiment of the laser cladding process for irregularly shaped parts according to the present invention.

[0042] Figure 6 This is a schematic flowchart of the sixth preferred embodiment of the laser cladding process for irregularly shaped parts of the present invention;

[0043] Figure 7 This is a schematic flowchart of the seventh preferred embodiment of the laser cladding process for irregularly shaped parts of the present invention;

[0044] Figure 8 This is a schematic diagram of the structure of the laser cladding processing device for irregularly shaped parts according to the present invention. Detailed Implementation

[0045] The present invention will be further described in detail below with reference to preferred embodiments. More details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention can obviously be implemented in many other ways different from those described herein. Those skilled in the art can make similar extensions and derivations based on actual application situations without departing from the spirit of the present invention. Therefore, the scope of protection of the present invention should not be limited by the content of this specific embodiment.

[0046] The accompanying drawings are schematic diagrams of embodiments of the present invention. It should be noted that these drawings are for illustrative purposes only and are not drawn to scale, and should not be construed as limiting the actual scope of protection of the present invention.

[0047] The first preferred embodiment of the laser cladding processing method for irregularly shaped parts provided by the present invention is as follows: Figure 1 As shown, it includes the following steps:

[0048] Step 101: Obtain the three-dimensional structural information and standard three-dimensional model of the irregular part. The three-dimensional structural information includes the actual geometric shape data of the surface of the irregular part, and the standard three-dimensional model has the standard geometric shape data of the irregular part. The geometric shape data includes the normal vector and curvature of the surface of the irregular part.

[0049] Step 102: Register the three-dimensional structural information with the standard three-dimensional model, calculate the geometric deviation value between the actual geometric shape data and the standard geometric shape data, and identify the part to be repaired according to the preset deviation threshold.

[0050] Step 103: Within the part to be repaired, identify curvature abrupt change points by combining preset curvature statistical thresholds and normal vector angle thresholds; form closed feature boundary loops by topologically connecting the curvature abrupt change points; and divide the part to be repaired into multiple microplane units based on the feature boundary loops and curvature, wherein the microplane units include multiple curvature abrupt change regions and multiple flat regions.

[0051] Step 104: Pre-place repair material in the part to be repaired, and adjust the laser cladding path trajectory parameters and laser energy parameters according to the curvature, normal vector, thickness of the pre-placed repair material and geometric deviation value of the micro-plane unit.

[0052] The irregularly shaped parts described in this invention can be metal parts such as bent pipes, curved pipe arrays, aero-engine blades, and irregularly shaped cavities in molds. These irregularly shaped parts include irregular geometric features such as concave and convex surfaces, stepped surfaces, grooves, and holes. Some or part of these irregular geometric features have a high curvature gradient. The irregularly shaped parts can be composite components formed by splicing together regions of different curvatures, and the location of defects on the surface of the irregularly shaped parts is uncertain. This invention achieves high-quality cladding repair of complex defects on the surface of irregularly shaped parts, and is particularly suitable for scenarios where the cost of pre-installed repair materials is low and the forming accuracy requirements are high.

[0053] This invention preferably acquires 3D point cloud data of an annotated model of an irregularly shaped part using laser scanning. After denoising and registration, the acquired 3D point cloud data is used to construct a triangular mesh model with topological relationships. A standard 3D model of the irregularly shaped part is then calculated based on this triangular mesh model, and this standard 3D model contains the standard geometric shape data of the irregularly shaped part. Similarly, 3D point cloud data of an irregularly shaped part with defects can be acquired using laser scanning, and a triangular mesh model with topological relationships can be constructed. The 3D structural information of the defective irregularly shaped part is then calculated based on this triangular mesh model, and this 3D structural information includes the actual geometric shape data of the irregularly shaped part's surface. The actual geometric shape data and the standard geometric shape data are collectively referred to as geometric shape data. The geometric shape data includes curvature and normal vectors. The curvature includes Gaussian curvature representing the type of curvature and average curvature representing the degree of curvature. The average curvature value H is an inherent geometric property of a single point on the surface, defined as the arithmetic mean of the two principal curvatures (k1, k2) at that point. The principal curvatures are the maximum and minimum curvatures in two mutually perpendicular directions at a point on a surface. For example, the principal curvatures at any point on a sphere are K = k1 = k2 = 1 / k2. R The principal curvatures at any point in the plane are k1=k2=0. The average curvature is used to describe the overall degree of curvature at that point.

[0054] The Gaussian curvature K = k1 × k2 is used to describe the direction of curvature, such as a convex surface, a concave surface, or a saddle surface. If the Gaussian curvature K > 0 and the absolute value of the average curvature H is large, it indicates that the surface has abrupt curvature changes, and the surface is a convex peak or a concave valley.

[0055] When the Gaussian curvature K≈0 and the average curvature H≈0, the plane represents a flat region, such as a plane or an approximately cylindrical surface.

[0056] A second preferred embodiment of the laser cladding method for irregularly shaped parts provided by the present invention is as follows: Figure 2 As shown, the three-dimensional structural information is registered with the standard three-dimensional model, the geometric deviation value between the actual geometric shape data and the standard geometric shape data is calculated, and the part to be repaired is identified according to the preset deviation threshold; the preset deviation threshold is preferably 0.1mm~0.5mm.

[0057] Within the portion to be repaired, curvature abrupt change points are identified by combining preset curvature statistical thresholds and normal vector angle thresholds; the curvature abrupt change points are topologically connected to form closed feature boundary loops; based on the feature boundary loops and curvature, the portion to be repaired is divided into multiple microplane units.

[0058] Traditional layered slicing processes struggle to adapt to complex, irregularly shaped surfaces, such as concave and convex surfaces, stepped surfaces, grooves, and holes, where abrupt curvature changes can lead to heat concentration and workpiece deformation during laser cladding. This invention calculates the feature boundary rings of the irregularly shaped geometric features to be repaired. This allows for the division of the irregular surface into multiple microplanar units, taking into account differences in surface curvature, and decomposing the complex surface into multiple microplanar units of varying sizes based on these differences in curvature.

[0059] First, the curvature statistical threshold of the portion of the irregular part's surface to be repaired is calculated. The curvature of all vertices of the triangular mesh model of the portion to be repaired on the irregular part's surface is calculated, including Gaussian curvature and average curvature. The mean curvature is obtained through global statistics. and standard deviation Set the curvature statistics threshold as The k is an empirical coefficient, such as in 2-3. When the curvature value H at a certain point > When the time is reached, it is marked as a candidate curvature inflection point.

[0060] Threshold for the angle between the normal vectors of candidate curvature abrupt change points Verification, the threshold angle of the normal vector Between 15° and 30°. If =15°, then when the angle θ between a point and the normal vector of its neighboring points is greater than 15°, the point is determined to be a curvature abrupt change point; if θ < 15°, it is considered a smooth surface transition. The angle θ between a candidate curvature abrupt change point and the normal vectors of its 3 to 5 consecutive neighboring points can be calculated; if θ > 15°, then the point is considered a curvature abrupt change point. If so, the candidate curvature abrupt change point is confirmed as a curvature abrupt change point.

[0061] The present invention forms a closed feature boundary loop by topologically connecting the curvature abrupt change points. The closed feature boundary loop refers to the polygonal contour line formed by topologically connecting the curvature abrupt change points, which directly corresponds to the boundary of the uniform curvature feature area on the surface of the irregular part.

[0062] This invention divides microplanar units based on feature boundary rings, specifically including the following steps:

[0063] Using a feature boundary ring as a rigid cutting boundary, the area to be repaired is divided into multiple micro-planar units according to rules, ensuring that the boundaries of the micro-planar units fit the feature boundary ring. The feature boundary ring is the non-crossable boundary for the division of micro-planar units; the boundaries of all micro-planar units must be cut along the edge of the feature boundary ring to ensure that micro-planar units inside and outside the feature boundary ring are completely separated, and no micro-planar units cross the feature boundary ring.

[0064] The curvature abrupt change points on the feature boundary ring of this invention are points identified by the curvature threshold and the angle between the normal vector and the curvature. These points, such as corner vertices and groove edge points, are the basic geometric elements constituting the feature boundary ring. The curvature abrupt change points on the feature boundary ring are the boundary points of the micro-planar units, ensuring that the boundary points of the micro-planar units are completely aligned with the feature boundary ring.

[0065] If the feature boundary ring is a polygonal ring formed by connecting 100 curvature abrupt change points, then these 100 curvature abrupt change points are all boundary points of micro-plane elements. Each curvature abrupt change point will become the boundary point of at least one micro-plane element, so that the micro-plane elements are distributed along the boundary and the contour line of the feature boundary ring.

[0066] This invention calculates or records the normal vector of the micro-plane unit inside the characteristic boundary ring of the region to be repaired, the thickness of the pre-set repair material, and the geometric deviation value.

[0067] The thickness setting of the pre-set repair material in this invention is determined by the curvature and geometric deviation values. The specific rules are as follows: the region type of the micro-plane unit is determined by the priority order of the curvature value H, geometric deviation value D and the thickness T of the pre-set repair material. The priority order is curvature value H > geometric deviation value D > thickness T of the pre-set repair material. The micro-plane units of the part to be repaired are divided into the following three types of regions.

[0068] In curvature-dominant regions, curvature value H is prioritized: when curvature value H > 1 mm -1 The thickness of the pre-placed repair material is T = k × H × β, where k is a process constant, ranging from 0.5 to 1.0, and β is a filling coefficient, ranging from 1.2 to 1.5. The laser cladding path trajectory parameters and laser energy parameters in this region are dominated by curvature. Dramatic curvature abrupt changes with small deviations necessitate avoiding material accumulation. For microplanar units dominated by curvature, regardless of the thickness of the pre-placed repair material and / or the magnitude of the geometric deviation, the average curvature has the greatest impact on the forming accuracy of laser cladding. The laser cladding path trajectory parameters and laser energy parameters of microplanar units are dominated by curvature.

[0069] The thickness of the pre-placed repair material is determined by the region dominated by the geometric deviation value. In the region dominated by the geometric deviation, when the curvature value H ≤ 1 mm... -1 When the curvature value H ≤ 1 mm, the geometric deviation value D is prioritized. -1 When the geometric deviation value D≤0.3 mm, the thickness of the pre-set repair material is T=D×β, and the laser cladding path trajectory parameters and laser energy parameters of the micro-planar unit in the geometric deviation-dominant region are dominated by the geometric deviation value.

[0070] Large geometric deviations and gentle curvatures necessitate ensuring sufficient filling and easy coverage of the microplanar elements in the area to be repaired. The thickness setting of the pre-placed repair material is determined by the microplanar elements, which are dominated by geometric deviations. The laser cladding path and laser energy parameters of the microplanar elements are primarily driven by these geometric deviations.

[0071] In the thickness-dominant region, when 0.5 < curvature value H ≤ 1 mm -1 When 0.3 < geometric deviation value D ≤ 0.5 mm, and T calculated according to T=D×β > 0.3 mm, the laser cladding parameters are dominated by the pre-set repair material thickness.

[0072] Repair material is pre-placed in the microplanar unit of the area to be repaired. Based on the curvature, normal vector, thickness of the pre-placed repair material, and geometric deviation of the microplanar unit, the parameters of the laser cladding are adjusted. These parameters include path trajectory parameters and laser energy parameters. The adjusted laser cladding path trajectory parameters include scanning direction, path spacing, and scanning speed.

[0073] In the region of abrupt curvature change, the curvature of the microplanar units, such as edges and grooves, is >0.5mm. -1 The preferred scanning direction is unidirectional scanning along the radius of curvature. For example, the bottom of the groove is along the length of the groove, and the corners are along the straight line of extension, that is, the continuous extension direction of the corners from the vertex to the bottom edge. This avoids material accumulation in the concave part caused by transverse scanning. At the same time, the scanning direction is adapted to the normal vector: the angle between the scanning direction and the normal vector of the micro-plane unit is ≤30°.

[0074] Preferably, for microplanar units in flat areas, a bidirectional alternating zigzag scanning method is used, such as reciprocating along the X-axis, with the scanning direction making an angle of 45° with the normal vector of the microplanar unit, thereby reducing the number of direction changes and improving efficiency.

[0075] Preferably, in this invention, the laser cladding scanning path spacing for the curvature-dominant microplanar unit is positively correlated with curvature and the thickness of the pre-placed repair material, and negatively correlated with geometric deviation; the value range of the scanning path spacing is 0.1~0.3mm.

[0076] For the scanning path spacing of microplanar units dominated by geometric deviation values: with the scanning path spacing of 0.4~0.5 mm as the benchmark in the thickness-dominant region where 0.3 < the thickness of the pre-set repair material T ≤ 0.5 mm, the scanning path spacing is reduced by 10%~20%;

[0077] The laser cladding scanning path spacing in the microplanar unit dominated by the thickness of the pre-set repair material is 0.3~0.4mm when the thickness of the pre-set repair material T>0.5mm; and 0.4~0.5mm when 0.3<T≤0.5mm.

[0078] For curvature-dominated microplanar cell scanning speeds: the greater the average curvature, the slower the scanning speed, in order to distribute heat.

[0079] Mean curvature H > 1 mm -1 The scanning speed is 5~15mm / s, preferably 10mm / s;

[0080] Average curvature H ≤ 0.5 mm -1 The scanning speed is 20~50mm / s, preferably 30mm / s.

[0081] Preferably, in this invention, the scanning speed of the laser cladding scan is as follows for microplanar units where the thickness of the pre-set repair material is dominant: the greater the thickness of the pre-set repair material, the slower the scanning speed, to ensure the melting depth:

[0082] Pre-placed repair material > 0.5mm, scanning speed 5~20mm / s;

[0083] Pre-placed repair material ≤0.3mm, scanning speed 30~50mm / s.

[0084] For the scanning speed of laser cladding scanning, the micro-planar unit with geometric deviation value correction is as follows: when the geometric deviation value is >0.3mm, the scanning speed is reduced by 15%~25%. For example, if the original scanning speed is 30mm / s, the corrected scanning speed is 22.5mm / s. The thermal input time is increased to ensure that the deviation area is filled.

[0085] The laser energy parameters described in this invention include laser power and spot diameter, and the laser energy parameters are adjusted as follows:

[0086] Based on the pre-set repair material thickness, geometric deviation value, and curvature characteristics of the microplanar unit, ensure that the energy density matches the laser cladding requirements of the microplanar unit. The optimal laser power for laser cladding of the microplanar unit is positively correlated with the pre-set repair material thickness and geometric deviation value, and negatively correlated with curvature.

[0087] When the micro-planar unit is dominated by the thickness of the pre-set repair material: the greater the thickness of the pre-set repair material, the higher the laser power, to ensure that the pre-set repair material melts through.

[0088] The pre-applied repair material thickness is 0.1~0.3mm, and the laser power is 500~1500W.

[0089] The pre-placed repair material is 0.5~1mm thick, and the laser power is 1500~3000W.

[0090] When the micro-plane unit is dominated by the geometric deviation value: the larger the geometric deviation value, the higher the laser power. By increasing the laser energy, it is ensured that the melted pre-placed repair material can fully fill the space of the geometric deviation value area, offsetting the insufficient actual filling amount caused by factors such as shrinkage and uneven distribution of the pre-placed repair material, and finally making the repaired surface consistent with the standard model.

[0091] The geometric deviation is between 0.1 and 0.3 mm, and the laser power is between 800 and 1500 W.

[0092] The geometric deviation value is >0.5mm, and the laser power is between 2000 and 3000W.

[0093] When the microfacet unit is dominated by curvature: when the average curvature > 1 mm -1 At the same time, the power is reduced by 10% to 15%. For example, if the original laser power is 1500W, it is reduced to 1300W to avoid heat concentration in the corner areas, which may cause deformation.

[0094] The preferred spot diameter for laser cladding of microplanar units is negatively correlated with curvature and positively correlated with the size of the flat area.

[0095] For microplanar elements in curvature-dominant regions, the curvature value H of the microplanar element is greater than 1 mm. -1 For sharp, angular areas, the laser spot diameter ranges from 0.4 to 0.6 mm, adapting to angular areas with varying degrees of sharpness.

[0096] For microplane elements in regions dominated by geometric deviations, the curvature value H of the microplane element is ≤1mm. -1 For flat areas with a geometric deviation value D ≤ 0.3 mm, the laser spot diameter ranges from 2 to 5 mm. A large spot is used to cover the flat area to improve efficiency. By increasing the spot coverage area, the number of scanning paths is reduced, processing time is shortened, and equipment energy consumption and mechanical wear are decreased, ultimately increasing the cladding area per unit time.

[0097] For microplanar elements in thickness-dominated regions, the curvature value H ≤ 1 mm for the microplanar element is 0.5 < curvature value H ≤ 1 mm. -1 It is used for rounded corner transition areas, with a laser spot diameter range of 0.7~0.9 mm, adaptable to rounded corner transition areas with different curvatures.

[0098] This invention discloses a laser cladding method for irregularly shaped parts. After dividing the part to be repaired into micro-planar units, a micro-planar unit database is established. The database includes parameters such as the unit's serial number, curvature, and normal vector. The curvature includes the average Gaussian curvature and average principal curvature of the planar unit. This invention adjusts the laser cladding path parameters and material deposition parameters based on the curvature and normal vector of the micro-planar units. By adjusting the uniformity and forming accuracy of the cladding layer, this invention achieves precise matching between the micro-planar units and the laser cladding parameters, balancing the forming accuracy and processing efficiency of complex surfaces.

[0099] A third preferred embodiment of the laser cladding process for irregularly shaped parts according to the present invention, such as... Figure 3 As shown, an irregularly shaped part is placed on a shelf, and a first miniature acoustic impedance piezoelectric sensor is positioned between the shelf and the part. One side of the miniature acoustic impedance piezoelectric sensor is rigidly connected to the shelf, and the other side contacts the surface of the part, ensuring acoustic transmission. The first miniature acoustic impedance piezoelectric sensor acts on the entire irregularly shaped part for stress release in the molten pool. Preferably, the invention also integrates a first miniature ultrasonic vibration module into the bottom of the workpiece shelf via an elastic damping pad, rigidly connected to the shelf. The preferred frequency of the first miniature ultrasonic vibration module is 20-50 kHz, and the amplitude is 5-20 μm. The invention transmits vibration through the shelf to the molten pool area of ​​the irregularly shaped part via the first miniature vibration module. In this embodiment of the invention, the miniature acoustic impedance piezoelectric sensor receives changes in the acoustic impedance of the molten pool, and the vibration portion of the first miniature ultrasonic vibration module counteracts the tensile stress generated by the cooling and shrinkage of the cladding layer, reducing the risk of crack formation.

[0100] The miniature acoustic impedance piezoelectric sensor described in this invention converts the received acoustic impedance signal into an electrical signal to obtain an acoustic impedance curve. If the acoustic impedance value remains higher than an impedance threshold, such as impedance threshold Z > 10... 6 The result of kg / (m²·s) indicates that the molten pool in the part to be repaired is not fluid enough, and the vibration frequency of the first micro ultrasonic vibration module needs to be increased, such as from 20 kHz to 30 kHz.

[0101] If the fluctuation range of the acoustic impedance curve is greater than 10%, it indicates that the stress distribution in the molten pool is uneven, and the amplitude of the first micro ultrasonic vibration module needs to be increased, such as from 5μm to 15μm.

[0102] When the acoustic impedance value stabilizes at 8×10 5 -10 6 When the vibration parameters are determined to be optimal (kg / (m²·s)) and the acoustic impedance curve fluctuation is ≤5%, the adjustment should be stopped.

[0103] Changes in molten pool fluidity and stress distribution directly lead to changes in acoustic impedance. The miniature acoustic impedance piezoelectric sensor described in this invention senses changes in molten pool fluidity and stress distribution by measuring the acoustic impedance signal. It also generates periodic pressure fluctuations in the molten pool through the vibration of the first miniature ultrasonic vibration module, promoting bubble merging and floating, reducing porosity, releasing stress, refining grains, and homogenizing the microstructure. The vibration energy interferes with the molten pool solidification process, inhibits columnar crystal growth, forms equiaxed crystal structure, and increases regional hardness.

[0104] A fourth preferred embodiment of the laser cladding method for irregularly shaped parts according to the present invention, as follows: Figure 4 As shown, a second micro-ultrasonic vibration module is installed at the end effector of a 6-DOF robot cladding head. The vibration direction of the second micro-ultrasonic vibration module is along the normal direction of the micro-planar unit surface. The second micro-ultrasonic vibration module acts locally on the cladding head, only affecting the micro-planar units in the curvature abrupt change region. The vibration is transmitted to the molten pool through the cladding head, improving the fluidity of the molten pool in the curvature abrupt change region, promoting the flow of molten metal, and eliminating bubbles and shrinkage cavities at the corners. This preferred embodiment achieves precise matching of vibration parameters with the curvature abrupt change region, avoiding over-vibration or under-vibration caused by one-size-fits-all vibration; moreover, vibration is activated only in the curvature abrupt change region and turned off in flat regions, reducing the impact on overall processing efficiency; finally, high-frequency, low-amplitude vibration, such as a vibration frequency of 40kHz and an amplitude of 8μm, promotes the spread of the molten pool along the corner surface, solving the problem of corner accumulation in traditional cladding.

[0105] The second micro ultrasonic vibration module of this invention vibrates along the normal direction of the tube bank surface, with a frequency of 20-50 kHz and an amplitude of 5-20 μm, and is used to repair boiler tube banks. The surface area of ​​the boiler tube bank to be repaired includes three typical structures:

[0106] High gradient region: curvature gradient > 1mm -1 For example, bends in pipes, elbows, and the bottom of U-shaped bends;

[0107] Medium gradient region: 0.5mm -1 <curvature gradient ≤ 1mm -1 For example, transition sections and variable diameter sections;

[0108] Low gradient region: curvature gradient ≤ 0.5mm -1 For example, straight pipe sections and support ring areas.

[0109] In the curvature gradient > 1mm -1 In the high gradient region, the vibration frequency of the second micro-ultrasonic vibration module increases linearly with the curvature gradient; for every 0.5 mm increase in curvature gradient... -1 The vibration frequency increased from 30kHz to 50kHz, while the amplitude remained constant at 5-10μm. When the gradient exceeded 1.5mm... -1 At that time, the frequency remained at 50kHz.

[0110] For example, for a 90° bend with a curvature gradient of 1.2mm -1 :

[0111] Gradient value = 1.2mm -1 Located at 1mm -1 <gradient ≤ 1.5mm -1 The vibration frequency range is 30kHz + (1.2mm). -1 -1mm -1 ) / 0.5mm -1 × (50kHz - 30kHz) = 38kHz; Amplitude = 6μm.

[0112] In the 0.5mm -1 <curvature gradient ≤ 1mm -1 In the middle gradient region, the vibration frequency is fixed at 30kHz, and the amplitude increases linearly from 10μm to 15μm as the gradient decreases. For every 0.1mm decrease in gradient... -1 The amplitude increased by 1 μm.

[0113] For example, for a curvature gradient of 0.7 mm -1 Transition section between straight pipe and elbow:

[0114] Gradient value = 0.7mm -1 Amplitude = 10μm + (1mm) -1 -0.7mm -1 ) / 0.5mm -1 × (15μm - 10μm) = 13μm; Vibration frequency = 30kHz.

[0115] When the curvature gradient is ≤0.5mm -1 In the low gradient region, the vibration frequency is 20-25kHz and the amplitude is 15-20μm. The smaller the gradient, the larger the amplitude.

[0116] For example, a curvature gradient of 0.2 mm -1 The straight pipe section has a vibration frequency of 25kHz. The straight pipe section has a large area, and the high frequency improves efficiency. The amplitude is 20μm, the curvature gradient is minimal, and the large amplitude ensures the fluidity of the molten pool.

[0117] The fourth preferred embodiment of the present invention targets the high-gradient bends, medium-gradient transition sections, and low-gradient straight sections of the tube bank. By setting vibration parameters in different zones: high-gradient zone uses high frequency and low amplitude, medium-gradient zone uses medium frequency with variable amplitude, and low-gradient zone uses low frequency and high amplitude, the cladding layer after tube bank repair achieves a bonding strength of ≥300MPa and a surface roughness Ra≤6.3μm, meeting the long-term service requirements of boiler tube banks.

[0118] A fifth preferred embodiment of the laser cladding processing method for irregularly shaped parts according to the present invention, as follows: Figure 5 As shown, the areas to be repaired on the surface of boiler tube banks contain three typical types of defects and structures:

[0119] For multiple microfacet units in regions of abrupt curvature change: extract curvature > 1 mm -1 The vertices, such as the vertices at the bottom of elbows and U-bends, are used to generate a connected graph through topological connectivity analysis. The number of vertices is 800 to 1200, and the side length is set to 0.2 mm to ensure that the outline of the bend is covered.

[0120] For multiple micro-plane elements in the region of geometric deviation value: extract vertices with geometric deviation value D≤0.3 mm, such as vertices of corrosion depressions and welding pits, generate an independent connected graph with 500~800 vertices and set the side length to 0.3 mm to cover the defect boundary.

[0121] For multiple microplane elements in the thickness-dominant region: located between the curvature abrupt change region and the geometric deviation value region, such as the connection section between an elbow and a straight pipe, the vertex curvature is 0.5~1mm. -1 With a geometric deviation of 0.2~0.3mm, a transitional connectivity graph is generated.

[0122] Generate a minimum bounding box (AABB) for each sub-region's connected graph. Calculate the dimensions of the bounding box along the X-axis, Y-axis, and Z-axis (pipeline height direction) using coordinate analysis tools: length, width, and height.

[0123] 1. Set bounding boxes for regions with abrupt changes in curvature, such as the connected graph of a 90° bend:

[0124] Vertex coordinate range: X coordinate is 100~160mm, Y coordinate is -30~30mm, Z coordinate is 50~80mm. Bounding box dimensions: length 60mm, X-axis, width 60mm, Y-axis, height 30mm, Z-axis, minimum Z-axis dimension is 30mm.

[0125] Pre-installed repair material thickness = minimum size of the enclosure box × (1 / 10~1 / 5).

[0126] Preferably, for a 90° elbow: minimum size = 30mm, thickness = 30mm × 1 / 10 = 3.0mm, to match the stress requirements of the bend and avoid material accumulation.

[0127] 2. Set the bounding box for the geometric deviation value area, and preset the repair material thickness = geometric deviation value × (1.2~1.5).

[0128] For example, a diagram showing the connectivity of corrosion depressions in a straight pipe section:

[0129] Vertex coordinate range: X coordinate 300~350mm, Y coordinate -30~30mm, Z coordinate 50~50mm, geometric deviation value = 0.5mm, which is the depth of the depression;

[0130] Corrosion pit: deviation value = 0.5mm, pre-placed repair material thickness = 0.5mm × 1.5 = 0.75mm, preferably 1.5 times, to compensate for the 8% melting shrinkage rate of low carbon steel.

[0131] For example, a diagram showing the connection of welding pits at the support ring:

[0132] Vertex coordinate range: X coordinate 400~420mm, Y coordinate -30~30mm, Z coordinate 50~50mm, geometric deviation value = 0.4mm, which is the pit depth.

[0133] Welding pit: deviation value = 0.4mm, pre-placed repair material thickness = 0.4mm × 1.2 = 0.48mm, preferably 1.2 times, to avoid local material being too thick and causing thermal cracking.

[0134] The present invention pre-determines the thickness of the repair material based on the minimum size ratio of the bounding box for the curvature abrupt change region and the deviation value multiple for the geometric deviation value region.

[0135] 3. Setting the thickness of the pre-placed repair material in the thickness-dominant area.

[0136] Between two adjacent pre-placed material areas of different thicknesses, a transition area with a horizontal width of 4mm is set. The thickness of the pre-placed material in this area decreases or increases uniformly from the thickness value of one side area.

[0137] The thickness of the pre-installed material gradually decreases from 3.0 mm at the 90° bend to 0.75 mm at the corrosion pit of the straight pipe section, a reduction of 0.56 mm per millimeter.

[0138] The purpose of this invention is to avoid stress concentration caused by abrupt changes in the thickness of the cladding layer through a smooth thickness transition, so as to achieve a smooth connection by uniformly decreasing the thickness of the pre-placed material.

[0139] This preferred embodiment targets typical repair areas such as pipe elbows dominated by curvature abrupt changes and corrosion depressions dominated by geometric deviations. It utilizes a segmented bounding box to dynamically match the pre-set repair material thickness: for curvature abrupt changes, the thickness is set to 1 / 10 to 1 / 5 of the minimum bounding box size; for geometric deviation areas, the thickness is set to 1.2 to 1.5 times the deviation value. A linear gradient transition is achieved in the transition zone, ultimately resulting in a cladding layer bonding strength ≥300MPa and no surface stress concentration. In this invention, multiple micro-planar units on the surface of irregularly shaped parts are divided into sub-regions and bounding boxes are generated. The thickness is dynamically matched to the curvature or geometric deviation values ​​within the bounding boxes, solving the material waste and stress problems caused by traditional uniform thickness methods.

[0140] A sixth preferred embodiment of the laser cladding processing method for irregularly shaped parts of the present invention, as follows: Figure 6 As shown, the morphology of the pre-placed repair material is matched with the characteristics of the connected regions: the curvature abrupt change points are divided into independent connected regions, such as edges and grooves, and continuous connected regions, such as large-area depressions, by using a topological connection algorithm.

[0141] For an area < 100 mm² and a curvature > 1 mm -1 Independent connected areas: solid materials, such as metal foil or wire, with a thickness of 0.05–0.2 mm, are used and pre-fixed by laser spot welding;

[0142] For areas ≥ 100 mm² and curvature ≤ 0.5 mm -1 The continuous connected region: uses a powder layer with a loose density of 1.2 to 1.8 g / cm³, and the thickness is controlled by scraping it with a scraper;

[0143] This invention automatically switches between solid and powder material forms through an end effector library, ensuring compatibility between connected regions and material forms. The invention adapts material forms based on the continuity of connected regions: solid materials are used in small, independent areas to prevent powder slippage, while powder is used in large, continuous areas to improve efficiency, resulting in a material utilization rate increase of ≥30%.

[0144] The seventh preferred embodiment of the laser cladding method for irregularly shaped parts of the present invention is as follows: Figure 7 As shown, a spring damping assembly with a stroke of ±10mm is set along the normal direction of the cladding head. The distance between the cladding head and the surface of the irregular part is monitored in real time by a displacement sensor. When the distance fluctuates due to clamping error or surface unevenness, the spring damping assembly compensates in real time through elastic deformation to ensure that the distance fluctuation between the cladding head and the surface of the irregular part is ≤±0.1mm.

[0145] Preferably, the spring and damper are coaxially mounted to avoid radial force during compensation, which could cause the cladding head to shift. This invention achieves distance fluctuation compensation through spring elastic deformation and damping vibration reduction, ensuring that the working focal length of the cladding head remains stable within the target value of ±0.1mm.

[0146] After the workpiece is clamped, that is, the irregularly shaped part is fixed on the shelf, the flatness deviation of the irregularly shaped part—the degree of deviation of the actual plane from the ideal plane, and the ±5mm tilt caused by thin-wall deformation—directly affects the processing accuracy, product performance, and assembly reliability of laser cladding. Therefore, this invention uses a spring damping component for real-time compensation technology to control the flatness deviation and ensure the quality of the blade.

[0147] The sensor detects an increase in distance Δd=5mm, the spring is compressed by 5mm, the lens barrel moves down, and the distance returns to the target value; the damper provides resistance proportional to the spring deformation speed, suppressing the bouncing during the compression process, and the vibration amplitude is reduced from ±0.3mm when there is no damping to ±0.05mm.

[0148] The workpiece surface has wavy undulations, such as casting pits with a depth of 2mm, and the scanning speed is 30mm / s;

[0149] The sensor detected a sudden decrease in distance Δd=2mm, indicating that the spring was stretched by 2mm, the lens barrel moved upward, and the distance quickly recovered.

[0150] The seventh preferred embodiment of this invention addresses the issue of fluctuations in the distance between the cladding head and the workpiece caused by clamping errors of ±0.1mm and changes in surface normal, which affect coating uniformity. This invention overcomes the limitations of traditional rigid machining platforms by utilizing spring elastic deformation and damping vibration reduction, extending the adaptability range of irregularly shaped parts to complex structures such as hollow and asymmetrical parts.

[0151] The laser cladding processing apparatus for irregularly shaped parts provided by this invention, such as... Figure 8 As shown, it includes:

[0152] A three-dimensional structural information acquisition unit is used to acquire the three-dimensional structural information and standard three-dimensional model of the irregular part. The three-dimensional structural information includes the actual geometric shape data of the surface of the irregular part, and the standard three-dimensional model includes the standard geometric shape data of the irregular part. The geometric shape data includes the normal vector and curvature of the surface of the irregular part.

[0153] The part to be repaired identification unit registers the three-dimensional structural information with the standard three-dimensional model, calculates the geometric deviation value between the actual geometric shape data and the standard geometric shape data, and identifies the part to be repaired according to the preset deviation threshold.

[0154] The microplane unit division unit identifies curvature abrupt change points within the part to be repaired by combining preset curvature statistical thresholds and normal vector angle thresholds; it forms a closed feature boundary loop by topologically connecting the curvature abrupt change points; and divides the part to be repaired into multiple microplane units based on the feature boundary loop and curvature. The microplane unit includes curvature abrupt change regions and flat regions.

[0155] The repair unit pre-places repair material in the part to be repaired. Based on the curvature, normal vector, thickness of the pre-placed repair material, and geometric deviation value of the micro-plane unit, it adjusts the laser cladding path trajectory parameters and laser energy parameters to perform laser cladding on the pre-placed repair material.

[0156] The pre-installed repair materials include solid materials and powder materials, and the solid materials include: metal foil and wire.

[0157] This invention provides a cladding method and apparatus for irregularly shaped parts. By dividing the area to be repaired into multiple micro-planar units, each micro-planar unit is further divided into curvature-dominated, geometric deviation-dominated, and thickness-dominated regions. A dynamic matching rule is established using three parameters: curvature, geometric deviation, and pre-set repair material thickness. This enables on-demand repair and improves the forming accuracy of complex curved surfaces. Secondly, a bounding box is constructed for multiple connected micro-planar units, dynamically matching the pre-set repair material thickness with the bounding box. This improves material utilization and avoids stress concentration caused by stepped thickness differences, increasing material utilization by ≥30%. Thirdly, a first micro-vibration module transmits vibration to the molten pool area of ​​the irregularly shaped part via a shelf. Acoustic impedance monitoring and high-frequency vibration are coordinated for control. Vibration parameters are adjusted in real-time based on acoustic impedance curve fluctuations, improving molten pool fluidity by 25% and reducing porosity from 3% in traditional processes to below 0.5%. This invention breaks through the limitations of adaptability, stability, and efficiency of traditional laser cladding in the repair of complex irregular parts. It achieves a repair accuracy of ±0.05mm, increases material utilization by 30%, and achieves a bonding strength of ≥300MPa, demonstrating significant technological innovation and engineering application value.

[0158] The above description illustrates preferred embodiments of the present invention and helps those skilled in the art to more fully understand the technical solution of the present invention. However, these embodiments are merely illustrative and should not be construed as limiting the specific implementation of the present invention to these embodiments. For those skilled in the art, several simple deductions and modifications can be made without departing from the inventive concept, and all such modifications should be considered within the protection scope of the present invention.

Claims

1. A laser cladding method for irregularly shaped parts, characterized in that, Includes the following steps: The three-dimensional structural information and standard three-dimensional model of the irregular part are obtained. The three-dimensional structural information includes the actual geometric shape data of the irregular part's surface, and the standard three-dimensional model includes the standard geometric shape data of the irregular part. The geometric shape data includes the normal vector and curvature of the irregular part's surface. The three-dimensional structural information is registered with the standard three-dimensional model, the geometric deviation between the actual geometric topography data and the standard geometric topography data is calculated, and the part to be repaired is identified according to the preset deviation threshold. Within the portion to be repaired, curvature abrupt change points are identified by combining preset curvature statistical thresholds and normal vector angle thresholds; topological connections are made to the curvature abrupt change points to form closed feature boundary loops; based on the feature boundary loops and curvature, the portion to be repaired is divided into multiple microplane units. Repair material is pre-placed in the part to be repaired. The parameters of laser cladding are adjusted according to the curvature, normal vector, thickness of the pre-placed repair material and geometric deviation value of the micro-plane unit. The parameters include path trajectory parameters and laser energy parameters. The region type of the microplane element is determined by the priority order of the curvature value H, geometric deviation value D, and the pre-set repair material thickness T of the microplane element. The priority order is curvature value H > geometric deviation value D > pre-set repair material thickness T. The microplane elements of the part to be repaired are divided into the following three types of regions. In curvature-dominant regions, curvature value H is prioritized: when curvature value H > 1 mm -1 The thickness of the pre-placed repair material is T = k × H × β, where: k is a process constant, ranging from 0.5 to 1.0, and β is a filling coefficient, ranging from 1.2 to 1.5; the laser cladding path trajectory parameters and laser energy parameters of the micro-planar unit in the curvature-dominant region are dominated by curvature. In the region dominated by geometric deviation, when the curvature value H ≤ 1 mm -1 When the curvature value H ≤ 1 mm, the geometric deviation value D is prioritized. -1 When the geometric deviation value D≤0.3 mm, the thickness of the pre-set repair material is T=D×β, and the laser cladding path trajectory parameters and laser energy parameters of the micro-planar unit in the geometric deviation-dominant region are dominated by the geometric deviation value. In the thickness-dominant region, when 0.5 < curvature value H ≤ 1 mm -1 When 0.3 < geometric deviation value D ≤ 0.5 mm, and T > 0.3 mm as calculated by the pre-set repair material thickness T = D × β, the laser cladding parameters are dominated by the pre-set repair material thickness T.

2. The laser cladding method for irregularly shaped parts according to claim 1, characterized in that, The part to be repaired is the area where the geometric deviation value exceeds a preset deviation threshold, which is 0.1mm to 0.5mm.

3. The laser cladding method for irregularly shaped parts according to claim 1, characterized in that, The path trajectory parameters include scanning direction, path spacing, and scanning speed, and the laser energy parameters include laser power and spot diameter.

4. The laser cladding method for irregularly shaped parts according to claim 3, characterized in that, For the scanning path spacing of curvature-dominated micro-planar units, the scanning path spacing is positively correlated with curvature and the thickness of the pre-placed repair material, and negatively correlated with geometric deviation; the value range of the scanning path spacing is 0.1~0.3mm. For the scanning path spacing of microplanar units dominated by geometric deviation correction: in the thickness-dominant region, with the scanning path spacing of 0.3 < preset repair material thickness T ≤ 0.5 mm as the benchmark, the scanning path spacing is reduced by 10% to 20%; The laser cladding scanning path spacing in the microplanar unit dominated by the thickness of the pre-set repair material is 0.3~0.4mm when the thickness of the pre-set repair material T>0.5mm; and 0.4~0.5mm when 0.3<T≤0.5mm.

5. The laser cladding method for irregularly shaped parts according to claim 1, characterized in that, For the micro-planar unit in the curvature abrupt change region, high-frequency vibration is applied using a second micro-ultrasonic vibration module while laser cladding is being performed.

6. The laser cladding method for irregularly shaped parts according to claim 5, characterized in that, The curvature gradient of the microplanar units on the surface of the irregular part is divided into units ≤0.5mm. -1 The low gradient region, 0.5–1 mm -1 In the medium gradient region, >1mm -1 High gradient region; The high-frequency vibration frequency in the high-gradient region increases linearly with the curvature gradient, with the frequency increasing by 0.5 mm for every 0.5 mm increase in gradient. -1 The frequency was increased from 30kHz to 50kHz, while the amplitude was fixed at 5-10μm. The high-frequency vibration in the middle gradient region maintains a vibration frequency of 30kHz, and the amplitude increases linearly from 10μm to 15μm as the gradient decreases. The high-frequency vibration in the low gradient region has a vibration frequency of 20-25kHz and an amplitude of 15-20μm.

7. The laser cladding method for irregularly shaped parts according to claim 1, characterized in that, A spring damping assembly with a stroke of ±10mm is set along the normal direction of the cladding head. The distance between the cladding head and the surface of the irregular part is monitored in real time by a displacement sensor. When the distance fluctuates due to clamping error or surface unevenness, the spring damping assembly compensates in real time through elastic deformation.

8. A laser cladding processing apparatus for irregularly shaped parts, characterized in that, include: A three-dimensional structural information acquisition unit is used to acquire the three-dimensional structural information and standard three-dimensional model of the irregular part. The three-dimensional structural information has the actual geometric shape data of the surface of the irregular part, and the standard three-dimensional model has the standard geometric shape data of the irregular part. Geometric topography data includes the normal vector and curvature of the irregularly shaped part's surface; The part to be repaired identification unit registers the three-dimensional structural information with the standard three-dimensional model, calculates the geometric deviation value between the actual geometric shape data and the standard geometric shape data, and identifies the part to be repaired according to the preset deviation threshold. The microplane unit partitioning unit identifies curvature abrupt change points within the part to be repaired by combining preset curvature statistical thresholds and normal vector angle thresholds; it then performs topological connections on the curvature abrupt change points to form closed feature boundary loops, and divides the part to be repaired into multiple microplane units based on the feature boundary loops and curvature. The repair unit pre-places repair material in the part to be repaired. Based on the curvature, normal vector, thickness of the pre-placed repair material, and geometric deviation value of the micro-plane unit, the laser cladding path trajectory parameters and laser energy parameters are adjusted to perform laser cladding on the pre-placed repair material. The region type of the microplane element is determined by the priority order of the curvature value H, geometric deviation value D, and the pre-set repair material thickness T of the microplane element. The priority order is curvature value H > geometric deviation value D > pre-set repair material thickness T. The microplane elements of the part to be repaired are divided into the following three types of regions. In curvature-dominant regions, curvature value H is prioritized: when curvature value H > 1 mm -1 The thickness of the pre-placed repair material is T = k × H × β, where: k is a process constant, ranging from 0.5 to 1.0, and β is a filling coefficient, ranging from 1.2 to 1.5; the laser cladding path trajectory parameters and laser energy parameters of the micro-planar unit in the curvature-dominant region are dominated by curvature. In the region dominated by geometric deviation, when the curvature value H ≤ 1 mm -1 When the curvature value H ≤ 1 mm, the geometric deviation value D is prioritized. -1 When the geometric deviation value D≤0.3 mm, the thickness of the pre-set repair material is T=D×β, and the laser cladding path trajectory parameters and laser energy parameters of the micro-planar unit in the geometric deviation-dominant region are dominated by the geometric deviation value. In the thickness-dominant region, when 0.5 < curvature value H ≤ 1 mm -1 When 0.3 < geometric deviation value D ≤ 0.5 mm, and T > 0.3 mm as calculated by the pre-set repair material thickness T = D × β, the laser cladding parameters are dominated by the pre-set repair material thickness T.

9. The laser cladding apparatus for irregularly shaped parts according to claim 8, characterized in that, The pre-installed repair materials include solid materials and powder materials, and the solid materials include metal foil and wire.

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