3D printing process quality closed-loop control method and system for aviation equipment engine blade

Abstract

The invention provides a 3D printing process quality closed-loop control method and system for aviation equipment engine blades, and the method comprises the steps: adjusting a plurality of technological parameters of a 3D printer according to CAD of a to-be-printed blade, carrying out printing simulation, carrying out the technological parameter correction of the 3D printer according to a simulation result, obtaining a plurality of effective technological parameters, and carrying out the 3D printing process quality closed-loop control. The printing process of the 3D printer is constructed, a quality verification standard corresponding to each process node is generated, the corresponding quality verification standard is used for judging the multi-dimensional quality characteristics of a printed semi-finished product generated by the current printing node, a plurality of printing defects contained in the printed semi-finished product are determined, and a qualified semi-finished product of the current printing node is obtained through repairing. And after the 3D printer completes the printing process, comprehensive quality verification is conducted on a printed blade finished product, a printing report is generated and displayed, it is ensured that the quality of each printing node meets the aeronautical manufacturing standard, and the final finished product meets the aerospace use requirement.

Description

Technical Field

[0001] This invention relates to the field of 3D printing quality inspection technology, and in particular to a closed-loop quality control method and system for the 3D printing process of aircraft engine blades. Background Technology

[0002] Aero-engine blades are core components of aero-engines, operating in environments characterized by high temperature, high pressure, and high speed, demanding extremely high dimensional accuracy, mechanical properties, and structural integrity. 3D printing technologies (such as selective laser melting (SLM) and electron beam melting (EBM) have become one of the mainstream manufacturing methods for aero-engine blades due to their ability to achieve integrated molding of complex structures.

[0003] However, the 3D printing process for aero-engine blades faces many quality control challenges: First, the printing materials are mostly high-temperature alloys, titanium alloys and other difficult-to-process materials, which are extremely sensitive to process parameters such as laser power and scanning speed. Even slight fluctuations in these parameters may lead to defects such as cracks, pores and inclusions. Secondly, traditional quality control models primarily rely on "post-printing inspection," meaning defects are identified through non-destructive testing after printing. This approach lacks real-time intervention during the printing process, leading to product scrapping once defects occur. This not only increases manufacturing costs but also severely impacts production efficiency. Furthermore, existing process monitoring often focuses on a single dimension, failing to comprehensively cover the complex quality-influencing factors in blade printing. It also lacks a dynamic correlation mechanism between process parameters and quality status, hindering adaptive adjustments.

[0004] Therefore, there is an urgent need for a closed-loop quality control method that can monitor in real time, analyze accurately, adjust quickly, and optimize continuously to solve the quality control problem in the 3D printing process of aero-engine blades and improve product qualification rate and reliability. Summary of the Invention

[0005] This invention provides a closed-loop quality control method and system for the 3D printing process of aero-engine blades, which realizes real-time quality control and continuous optimization of the printing process, reduces the defect rate, and improves the 3D printing quality and production efficiency of aero-engine blades.

[0006] This invention provides a closed-loop quality control method for the 3D printing process of engine blades in aerospace equipment, comprising: Step 1: Adjust several process parameters of the 3D printer according to the CAD of the blade to be printed and perform printing simulation. Based on the simulation results, correct the process parameters of the 3D printer to obtain several effective process parameters. Step 2: Construct the current printing process of the 3D printer based on the CAD and the effective process parameters, generate the quality verification standard corresponding to each process node, and control the 3D printer to enter the printing state; Step 3: Obtain the multi-dimensional quality characteristics of the semi-finished product generated by the current printing node, and use the corresponding quality verification standard to judge the multi-dimensional quality characteristics to determine several printing defects of the semi-finished product. Step 4: Determine the printing repair process for generating the printed semi-finished product based on the judgment result, and integrate it into the current printing process to repair defects and obtain a qualified semi-finished product at the current printing node; Step 5: After the 3D printer completes the printing process, it performs a comprehensive quality check on the printed blade, generates a printing report, and displays it.

[0007] In one feasible embodiment, step 1 includes: Step 11: Draw the 3D blade structure of the blade to be printed according to the CAD drawing, identify the size of each 3D blade structure to obtain several first process parameters, and obtain several second process parameters according to the structural connection relationship between different 3D blade structures. Step 12: Use the first process parameters and the second process parameters to perform the first parameter adjustment of the 3D printer, perform the first printing simulation for each 3D blade structure to obtain the corresponding 3D simulation structure, and determine the parameters to be corrected of the 3D printer based on the structural differences between the 3D simulation structure and the corresponding 3D blade structure. Step 13: Generate a correction vector corresponding to the parameter to be corrected based on the structural differences, determine the correction range based on the vector magnitude of the correction vector, and determine the correction direction based on the vector direction of the correction vector. Iteratively adjust the parameter to be corrected in the corresponding correction direction within the corresponding correction range. Step 14: Obtain the iterative parameter set corresponding to each parameter to be corrected, select an iterative parameter from each iterative parameter set to construct a replacement parameter group, perform a second printing simulation using each replacement parameter group, select the replacement parameter with the highest accuracy based on the second simulation results, and obtain the effective process parameters of the 3D printer.

[0008] In one feasible embodiment, step 2 includes: Step 21: Divide the blade to be printed into several structures to be printed according to the CAD, and at the same time obtain several execution functions of the 3D printer. Combine the effective process parameters to determine the execution range corresponding to each execution function. Combine the execution functions according to the execution range to obtain the preliminary printing process of each structure to be printed. Step 22: Generate several printing conditions based on the outline of each of the structures to be printed, optimize the preliminary printing process using the printing conditions to obtain the complete printing process corresponding to each of the structures to be printed, and construct a connection printing process between different complete printing processes based on the structural relationship between the structures to be printed. Step 23: Construct the current printing process of the 3D printer based on the improved printing process and the connected printing process, and regard the end point of each improved printing process as a process node, and derive the improved printing result corresponding to the process node based on the improved printing process. Step 24: Generate the quality verification standard of the process node by performing semantic description based on the improved printing results, and determine the pre-preparation parameters of the 3D printer according to the current printing process. Adjust the 3D printer to the pre-preparation parameters and determine that the 3D printer enters the printing state.

[0009] In one feasible embodiment, step 3 includes: Step 31: After the 3D printer enters the printing state, collect the real-time printing data of the 3D printer, determine the current printing progress of the 3D printer at the current moment, and map the real-time printing data to each quality inspection dimension to obtain the inferred multidimensional quality characteristics of the printed semi-finished product. Step 32: Determine the printing completion time corresponding to the current printing node based on the current printing progress, and conduct on-site quality inspection of the printed semi-finished product using the corresponding quality verification standard at the printing completion time to obtain the on-site multi-dimensional quality characteristics of the printed semi-finished product; Step 33: When the on-site multidimensional quality characteristics meet the corresponding quality verification standards, and the inferred multidimensional quality characteristics are consistent with the on-site multidimensional quality characteristics, it is determined that the printed semi-finished product does not contain printing defects; otherwise, several printing defects of the printed semi-finished product are determined based on the inferred multidimensional quality characteristics and the on-site multidimensional quality characteristics.

[0010] In one implementable manner, step 33 includes: Step 331: When the on-site multidimensional quality characteristics are abnormal, determine the abnormal dimension of the on-site multidimensional quality characteristics according to the quality verification standard, identify several suspected printing defects in the printed semi-finished product that are consistent with the abnormal dimension, and perform a second on-site quality inspection on the suspected location corresponding to each of the suspected printing defects to determine several printing defects in the printed semi-finished product. Step 332: When the inferred multidimensional quality feature is abnormal, locate the data acquisition device of the 3D printer, determine several equipment fault items of the data acquisition device based on the feature difference between the inferred multidimensional quality feature and the on-site multidimensional quality feature, and optimize each of the equipment fault items respectively; Step 333: Synchronously adjust the real-time printing data according to the optimized data of the data acquisition device to generate corresponding updated inferred multidimensional quality features. If the updated inferred multidimensional features are inconsistent with the on-site multidimensional quality features, identify several suspected printing defects of the printed semi-finished product, and conduct secondary on-site quality inspections on the suspected locations corresponding to each suspected printing defect to determine several printing defects of the printed semi-finished product.

[0011] One feasible approach also includes: When the on-site multidimensional quality characteristics meet the corresponding quality verification standards, and the inferred multidimensional quality characteristics are consistent with the on-site multidimensional quality characteristics, it is determined that the printed semi-finished product does not contain printing defects. When the updated inferred multidimensional quality characteristics are consistent with the on-site multidimensional quality characteristics, it is determined that the printed semi-finished product does not contain printing defects.

[0012] In one feasible embodiment, step 4 includes: Step 41: Determine the defect dimension and defect location corresponding to each printing defect based on the judgment result, determine several repair processes for this repair based on the defect dimension and defect location, determine the execution location corresponding to each repair process based on the defect location, and generate a printing repair process; Step 42: Locate the process node in the current printing process, determine the integration position corresponding to the printing repair process, integrate the printing process into the integration position, update the current printing process, and perform defect repair on the printed semi-finished product to obtain a qualified semi-finished product of the current printing node.

[0013] In one feasible embodiment, step 5 includes: Step 51: Construct several overall verification standards for the blade to be printed based on the CAD, and input the quality verification standard corresponding to each process node into the overall verification standard for standard recombination to generate a comprehensive verification standard; Step 52: After the 3D printer completes the current printing process, it obtains the printed blade product. The quality of the printed blade product is verified using the comprehensive verification standard. The dimensional verification results of the printed blade product under each verification dimension are obtained, and a printing report of the printed blade product is generated and displayed.

[0014] This invention provides a quality closed-loop control system for the 3D printing process of engine blades in aerospace equipment, comprising: The parameter adjustment module is used to adjust several process parameters of the 3D printer according to the CAD of the blade to be printed and to perform printing simulation. Based on the simulation results, the process parameters of the 3D printer are corrected to obtain several effective process parameters. The quality inspection preparation module is used to construct the current printing process of the 3D printer based on the CAD and the effective process parameters, generate the quality verification standard corresponding to each process node, and control the 3D printer to enter the printing state. The defect identification module is used to obtain the multi-dimensional quality characteristics of the printed semi-finished product generated by the current printing node, and to judge the multi-dimensional quality characteristics using the corresponding quality verification standard to determine several printing defects of the printed semi-finished product. The defect repair module is used to determine the printing repair process for generating the printed semi-finished product based on the judgment result, and integrate it into the current printing process to repair defects and obtain a qualified semi-finished product at the current printing node. The comprehensive quality inspection module is used to perform comprehensive quality verification on the printed blades after the 3D printer completes the current printing process, generate a printing report, and display it.

[0015] In one implementable manner, the defect identification module includes: The real-time inference unit is used to collect the real-time printing data of the 3D printer after the 3D printer enters the printing state, determine the current printing progress of the 3D printer at the current moment, and map the real-time printing data to each quality inspection dimension to obtain the inferred multidimensional quality characteristics of the printed semi-finished product. The on-site quality inspection unit is used to determine the printing completion time corresponding to the current printing node based on the current printing progress, and to conduct on-site quality inspection of the printed semi-finished product using the corresponding quality verification standard at the printing completion time, so as to obtain the on-site multi-dimensional quality characteristics of the printed semi-finished product. The defect determination unit is used to determine that the printed semi-finished product does not contain printing defects when the on-site multidimensional quality characteristics meet the corresponding quality verification standard and the inferred multidimensional quality characteristics are consistent with the on-site multidimensional quality characteristics; otherwise, it determines several printing defects of the printed semi-finished product based on the inferred multidimensional quality characteristics and the on-site multidimensional quality characteristics.

[0016] The beneficial effects of the above technical solution are as follows: To provide reliable technical support for the efficient and high-quality manufacturing of aerospace engine blades and promote the large-scale application of 3D printing technology in the high-end manufacturing field of aerospace, the core process parameters of the 3D printer are first adjusted based on the CAD of the blade to be printed. Then, the parameter adaptability is predicted through printing simulation, and the effective process parameters are finally corrected to ensure that the effective process parameters meet both the forming requirements and the material properties, thereby improving the stability and consistency of the printing process from the source and laying the foundation for subsequent quality control. Then, the printing process is constructed based on the CAD and effective process parameters, and a dedicated quality verification standard is formulated for each node to control the printer to start printing. Quality control is moved to each printing node, rather than relying solely on finished product inspection, to ensure that defects can be identified in the early stages of formation and to avoid the expansion of defects due to the superposition of subsequent processes. Furthermore, multi-dimensional detection methods are used to obtain multi-dimensional quality characteristics of the printed semi-finished products. The system compares the printed blades with the corresponding node's verification standards in real time to accurately locate printing defects. It then develops specific repair procedures for each defect type and integrates these procedures into the current printing process in real time. This ensures immediate defect repair, allowing the blades to proceed to the next node only after obtaining qualified semi-finished products. This seamless integration of dynamic repair and printing processes guarantees the continuity of the printing process while addressing node defects in a targeted manner, significantly improving the finished product pass rate. After printing, the finished blades undergo comprehensive quality verification across all dimensions, generating and displaying a complete printing report. This ensures the finished products fully meet installation requirements, avoiding flight safety risks caused by substandard quality. Furthermore, the complete printing report enables full-process traceability from process parameters to finished product quality. When a blade's performance fails to meet standards, the report allows for backtracking to the parameter settings and defect repair records of the corresponding printing node, facilitating subsequent process optimization and meeting the aviation industry's quality audit requirements. This provides authoritative quality evidence for the blades' installation and use.

[0017] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings.

[0018] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0019] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the workflow of a closed-loop quality control method for 3D printing process of aircraft engine blades in an embodiment of the present invention. Figure 2 This is a schematic diagram of the composition of a quality closed-loop control system for the 3D printing process of aircraft engine blades in an embodiment of the present invention. Detailed Implementation

[0020] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0021] Example 1: This example provides a closed-loop quality control method for the 3D printing process of engine blades in aerospace equipment, such as... Figure 1 As shown, it includes: Step 1: Adjust several process parameters of the 3D printer according to the CAD of the blade to be printed and perform printing simulation. Based on the simulation results, correct the process parameters of the 3D printer to obtain several effective process parameters. Step 2: Construct the current printing process of the 3D printer based on the CAD and the effective process parameters, generate the quality verification standard corresponding to each process node, and control the 3D printer to enter the printing state; Step 3: Obtain the multi-dimensional quality characteristics of the semi-finished product generated by the current printing node, and use the corresponding quality verification standard to judge the multi-dimensional quality characteristics to determine several printing defects of the semi-finished product. Step 4: Determine the printing repair process for generating the printed semi-finished product based on the judgment result, and integrate it into the current printing process to repair defects and obtain a qualified semi-finished product at the current printing node; Step 5: After the 3D printer completes the printing process, it performs a comprehensive quality check on the printed blade, generates a printing report, and displays it.

[0022] In this example, the CAD file contains key information such as the complex curved surface, thin-walled structure, and high-temperature alloy material properties of the blade to be printed. In this example, the effective process parameters refer to the parameters presented by the 3D printer when performing this printing job, including: laser power, scanning speed, layer thickness, powder feed rate, protective gas flow rate, etc. In this example, a process node represents the node after completing an independent and separable sub-process. The verification standard of each process node is precisely aligned with the manufacturing specifications of aero-blades, avoiding subjectivity in quality judgment. In this example, multidimensional quality features represent the characteristics of the printed semi-finished product in different dimensions, including: dimensional accuracy, surface morphology, internal porosity, and fusion state. In this example, printing defects refer to non-conformities that appear on the printed semi-finished product; In this example, the printed report uses three display methods: a heat map of defect locations, a curve comparing dimensional deviations, and a table of performance test data.

[0023] The working principle and beneficial effects of the above technical solution are as follows: To provide reliable technical support for the efficient and high-quality manufacturing of aerospace engine blades and promote the large-scale application of 3D printing technology in the high-end manufacturing field of aerospace, the core process parameters of the 3D printer are first adjusted based on the CAD of the blade to be printed. Then, the parameter adaptability is predicted through printing simulation, and finally, effective process parameters are obtained by correction. This ensures that the effective process parameters meet both forming requirements and material properties, thereby improving the stability and consistency of the printing process from the source and laying the foundation for subsequent quality control. Then, the printing process is constructed based on the CAD and effective process parameters, and a dedicated quality verification standard is formulated for each node to control the printer to start printing. Quality control is moved to each printing node, rather than relying solely on finished product inspection, ensuring that defects can be identified in the early stages of formation and avoiding the expansion of defects due to the superposition of subsequent processes. Furthermore, multi-dimensional detection methods are used to obtain multi-dimensional quality characteristics of the printed semi-finished product. The system compares the printed blades with the corresponding node's verification standards in real time to accurately locate printing defects. It then develops specific repair procedures for each defect type and integrates these procedures into the current printing process in real time. This ensures immediate defect repair, allowing the blades to proceed to the next node only after obtaining qualified semi-finished products. This seamless integration of dynamic repair and printing processes guarantees the continuity of the printing process while addressing node defects in a targeted manner, significantly improving the finished product pass rate. After printing, the finished blades undergo comprehensive quality verification across all dimensions, generating and displaying a complete printing report. This ensures the finished products fully meet installation requirements, avoiding flight safety risks caused by substandard quality. Furthermore, the complete printing report enables full-process traceability from process parameters to finished product quality. When a blade's performance fails to meet standards, the report allows for backtracking to the parameter settings and defect repair records of the corresponding printing node, facilitating subsequent process optimization and meeting the aviation industry's quality audit requirements. This provides authoritative quality evidence for the blades' installation and use.

[0024] Example 2: Based on Example 1, the quality closed-loop control method for the 3D printing process of aircraft engine blades, step 1 includes: Step 11: Draw the 3D blade structure of the blade to be printed according to the CAD drawing, identify the size of each 3D blade structure to obtain several first process parameters, and obtain several second process parameters according to the structural connection relationship between different 3D blade structures. Step 12: Use the first process parameters and the second process parameters to perform the first parameter adjustment of the 3D printer, perform the first printing simulation for each 3D blade structure to obtain the corresponding 3D simulation structure, and determine the parameters to be corrected of the 3D printer based on the structural differences between the 3D simulation structure and the corresponding 3D blade structure. Step 13: Generate a correction vector corresponding to the parameter to be corrected based on the structural differences, determine the correction range based on the vector magnitude of the correction vector, and determine the correction direction based on the vector direction of the correction vector. Iteratively adjust the parameter to be corrected in the corresponding correction direction within the corresponding correction range. Step 14: Obtain the iterative parameter set corresponding to each parameter to be corrected, select an iterative parameter from each iterative parameter set to construct a replacement parameter group, perform a second printing simulation using each replacement parameter group, select the replacement parameter with the highest accuracy based on the second simulation results, and obtain the effective process parameters of the 3D printer.

[0025] In this example, the 3D blade structure represents the result of disassembling the structure of the blade to be printed and displaying each structure in 3D. In this example, the first process parameter represents the parameters constructed based on the size of the blade to be printed, and its function is to complete the independent printing work. The second process parameter represents the parameters constructed based on the connection relationship between different results, and its function is to connect the structures. In this example, the correction vector represents a vector pointing from the 3D simulated structure to the 3D blade structure, starting from the point where the structure differs. In this example, the structural differences represent the differences between the 3D simulated structure and the 3D blade structure; In this example, the iterative parameter set represents the set of all iterative parameters obtained after performing several iterations to adjust a parameter to be corrected; In this example, the substitution parameter group represents the dataset consisting of one iteration parameter selected from each iteration parameter set.

[0026] The working principle and beneficial effects of the above technical solution are as follows: To avoid fatal defects such as tenon breakage and dimensional deviations during printing, a 3D blade structure is first drawn based on the CAD drawing of the blade to be printed. On the one hand, the first process parameters are extracted by dimension recognition and directly matched with the geometric dimension requirements of each part of the blade to obtain the first process parameters, ensuring the basic forming accuracy of each part of the blade. On the other hand, the second process parameters are extracted by structural connection relationships to avoid forming defects caused by parameter mismatch with structure. Then, a 3D simulation structure is generated through the first printing simulation, and the differences in structure are located by comparing it with the original 3D blade structure to accurately lock the parameters to be corrected. Furthermore, a correction vector is generated based on the differences in structure, and the correction vector is used to model the corrected parameters. By defining the correction range and determining the correction direction through vector direction, parameter tuning can be completed while ensuring that the parameter adjustments are within a reasonable range. Finally, an iterative parameter set is generated for each parameter to be corrected, and multiple replacement parameter groups are constructed by combining the iterative parameters. Then, the forming accuracy of each parameter group is compared through a second printing simulation. Finally, the replacement parameter with the highest accuracy is selected as the effective process parameter. The simulation comparison of multiple parameter groups can accurately capture the synergistic effects between parameters and avoid new defects caused by adjusting a single parameter. In this way, it not only adapts to the structural characteristics of each part of the blade, but also has the synergistic optimization effect between parameters, which can minimize the risk of printing defects and provide a high-precision parameter benchmark for the quality control of subsequent printing processes.

[0027] Example 3: Based on Example 1, the quality closed-loop control method for the 3D printing process of aircraft engine blades, step 2 includes: Step 21: Divide the blade to be printed into several structures to be printed according to the CAD, and at the same time obtain several execution functions of the 3D printer. Combine the effective process parameters to determine the execution range corresponding to each execution function. Combine the execution functions according to the execution range to obtain the preliminary printing process of each structure to be printed. Step 22: Generate several printing conditions based on the outline of each of the structures to be printed, optimize the preliminary printing process using the printing conditions to obtain the complete printing process corresponding to each of the structures to be printed, and construct a connection printing process between different complete printing processes based on the structural relationship between the structures to be printed. Step 23: Construct the current printing process of the 3D printer based on the improved printing process and the connected printing process, and regard the end point of each improved printing process as a process node, and derive the improved printing result corresponding to the process node based on the improved printing process. Step 24: Generate the quality verification standard of the process node by performing semantic description based on the improved printing results, and determine the pre-preparation parameters of the 3D printer according to the current printing process. Adjust the 3D printer to the pre-preparation parameters and determine that the 3D printer enters the printing state.

[0028] In this example, the structure to be printed represents the structure that needs to be 3D printed, which is used to assemble the blade; In this example, the execution function represents the function that the 3D printer can perform; In this example, the execution scope refers to the scope of work and the product output scope of an execution function; In this example, the printing conditions represent the conditions that must be met to complete the structure to be printed; In this example, the pre-preparation parameters represent the preparation work that the 3D printer needs to do before printing, such as preheating before printing.

[0029] The working principle and beneficial effects of the above technical solution are as follows: To achieve precise printing, the blade to be printed is first divided into independent printable structures and effective process parameters based on CAD, and the adaptation range of each execution function is determined. Then, a preliminary printing process for each printable structure is generated to avoid functional mismatch. Next, exclusive printing conditions are generated for the contour characteristics of each printable structure, and the preliminary printing process is optimized accordingly. At the same time, a connected printing process is constructed based on the connection relationship of the printable structures to achieve seamless connection of each complete printing process, ensuring the continuous and stable printing process and uniform blade forming quality. Furthermore, the end point of each complete printing process is set as a process node, and the complete printing result of the node is derived based on the complete printing process. Finally, the complete printing result is converted into a quantifiable quality verification standard. At the same time, the printer pre-preparation parameters are determined based on this printing process, and the printer is adjusted to this state before printing is started, ensuring that the printer is in the optimal state when it starts, avoiding early defects caused by deviations in the start-up state, and greatly improving the stability of the printing start-up stage.

[0030] Example 4: Based on Example 1, the quality closed-loop control method for the 3D printing process of aircraft engine blades, step 3 includes: Step 31: After the 3D printer enters the printing state, collect the real-time printing data of the 3D printer, determine the current printing progress of the 3D printer at the current moment, and map the real-time printing data to each quality inspection dimension to obtain the inferred multidimensional quality characteristics of the printed semi-finished product. Step 32: Determine the printing completion time corresponding to the current printing node based on the current printing progress, and conduct on-site quality inspection of the printed semi-finished product using the corresponding quality verification standard at the printing completion time to obtain the on-site multi-dimensional quality characteristics of the printed semi-finished product; Step 33: When the on-site multidimensional quality characteristics meet the corresponding quality verification standards, and the inferred multidimensional quality characteristics are consistent with the on-site multidimensional quality characteristics, it is determined that the printed semi-finished product does not contain printing defects; otherwise, several printing defects of the printed semi-finished product are determined based on the inferred multidimensional quality characteristics and the on-site multidimensional quality characteristics.

[0031] In this example, the quality inspection dimensions include dimensional accuracy, surface roughness, internal fusion, and structural stability. The working principle and beneficial effects of the above technical solution are as follows: After the printer enters the printing state, real-time printing data is collected and combined with the current printing progress. The real-time data is mapped to the quality inspection dimension to generate the inferred multi-dimensional quality characteristics of the printed semi-finished product. Then, based on the current printing progress, the completion time of the current printing node is accurately locked. At this moment, professional testing equipment is used to conduct on-site quality inspection of the printed semi-finished product, and on-site multi-dimensional quality characteristics are obtained to ensure that the test data truly reflects the forming quality of the printing node. Finally, by comparing the inferred multi-dimensional quality characteristics and the on-site multi-dimensional quality characteristics, a dual judgment is made. If both meet the standards and the deviation is within the allowable range, it is determined that there is no defect. If either characteristic does not meet the standard (or the deviation between the two exceeds the threshold), the printing defect is accurately located, and the cause of the defect is deduced through the characteristic deviation, providing a clear direction for subsequent repair. This ensures that the quality of each printing node meets the aerospace manufacturing standards, laying a key foundation for the final product to be qualified.

[0032] Example 5: Based on Example 4, the quality closed-loop control method for the 3D printing process of aircraft engine blades, step 33 includes: Step 331: When the on-site multidimensional quality characteristics are abnormal, determine the abnormal dimension of the on-site multidimensional quality characteristics according to the quality verification standard, identify several suspected printing defects in the printed semi-finished product that are consistent with the abnormal dimension, and perform a second on-site quality inspection on the suspected location corresponding to each of the suspected printing defects to determine several printing defects in the printed semi-finished product. Step 332: When the inferred multidimensional quality feature is abnormal, locate the data acquisition device of the 3D printer, determine several equipment fault items of the data acquisition device based on the feature difference between the inferred multidimensional quality feature and the on-site multidimensional quality feature, and optimize each of the equipment fault items respectively; Step 333: Synchronously adjust the real-time printing data according to the optimized data of the data acquisition device to generate corresponding updated inferred multidimensional quality features. If the updated inferred multidimensional features are inconsistent with the on-site multidimensional quality features, identify several suspected printing defects of the printed semi-finished product, and conduct secondary on-site quality inspections on the suspected locations corresponding to each suspected printing defect to determine several printing defects of the printed semi-finished product.

[0033] In this example, the secondary on-site quality inspection refers to the process of re-inspecting suspected locations.

[0034] The working principle and beneficial effects of the above technical solution are as follows: To achieve refined identification of printing defects and in-depth localization of the root causes of problems, when multi-dimensional quality features are abnormal on-site, the abnormal dimensions are first identified according to the quality verification standards. Then, suspected defects matching the abnormal dimensions are located in the printed semi-finished product, and secondary on-site quality inspections are conducted on the suspected locations to accurately determine the actual printing defects, ensuring that defect identification is thorough and without misjudgment. When multi-dimensional quality feature anomalies are suspected, the data acquisition equipment of the 3D printer is checked. By comparing the difference between the suspected features and the on-site features, the equipment fault items are accurately located and timely optimization is performed to prevent the fault from affecting the subsequent printing process. To avoid distortion of inferred features due to data acquisition equipment failure, the process involves optimizing the data acquisition equipment, then using the optimized data to readjust the real-time printed data, generating updated inferred multidimensional features, and comparing them with the on-site features. If inconsistencies remain, suspected defects are identified again and a second quality inspection is conducted to ultimately determine the actual defect. This approach first identifies and optimizes the path encoder, then locates the defect through a second quality inspection. This solves the problem at the source of the equipment issue and accurately pinpoints the actual defect, providing clear guidance for subsequent localized melt repair. This ensures that the quality of each node on the blade meets aerospace manufacturing standards and further consolidates the reliability of the overall quality closed-loop control.

[0035] Example 6: Based on Example 5, the quality closed-loop control method for the 3D printing process of aircraft engine blades further includes: When the on-site multidimensional quality characteristics meet the corresponding quality verification standards, and the inferred multidimensional quality characteristics are consistent with the on-site multidimensional quality characteristics, it is determined that the printed semi-finished product does not contain printing defects. When the updated inferred multidimensional quality characteristics are consistent with the on-site multidimensional quality characteristics, it is determined that the printed semi-finished product does not contain printing defects.

[0036] The working principle and beneficial effects of the above technical solution are as follows: when there are no defects on the printed semi-finished product, it indicates that the printing work is proceeding smoothly and the next stage of printing work can begin.

[0037] Example 7: Based on Example 1, the quality closed-loop control method for the 3D printing process of aircraft engine blades, step 4 includes: Step 41: Determine the defect dimension and defect location corresponding to each printing defect based on the judgment result, determine several repair processes for this repair based on the defect dimension and defect location, determine the execution location corresponding to each repair process based on the defect location, and generate a printing repair process; Step 42: Locate the process node in the current printing process, determine the integration position corresponding to the printing repair process, integrate the printing process into the integration position, update the current printing process, and perform defect repair on the printed semi-finished product to obtain a qualified semi-finished product of the current printing node.

[0038] The working principle and beneficial effects of the above technical solution are as follows: First, based on the judgment results, the defect dimension and defect location of the printing defect are determined. Then, based on the dimensional characteristics, a dedicated repair process is matched, and the execution range of the repair process is locked according to the location coordinates to avoid invalid repairs during the repair process. Then, the current printing node is accurately located in this printing process, and the integration position of the repair process is determined according to the node progress. Subsequently, the printing repair process is seamlessly embedded into this position. The updated printing process does not require offline repair without stopping the machine. After the defect repair is completed at the current node, it enters the next process and finally obtains a qualified semi-finished product. After repair, it directly enters the next printing node, which solves the defect without interrupting the overall process and ultimately ensures that the quality of the finished blade meets the standards.

[0039] Example 8: Based on Example 1, the quality closed-loop control method for the 3D printing process of aircraft engine blades, step 5 includes: Step 51: Construct several overall verification standards for the blade to be printed based on the CAD, and input the quality verification standard corresponding to each process node into the overall verification standard for standard recombination to generate a comprehensive verification standard; Step 52: After the 3D printer completes the current printing process, it obtains the printed blade product. The quality of the printed blade product is verified using the comprehensive verification standard. The dimensional verification results of the printed blade product under each verification dimension are obtained, and a printing report of the printed blade product is generated and displayed.

[0040] The working principle and beneficial effects of the above technical solution are as follows: Based on the CAD of the blade to be printed, the overall verification standard of the blade to be printed is determined. Then, combined with the quality verification standard of each process node, a comprehensive verification standard covering all characteristics of the blade is generated. After the printer completes the entire printing process, the finished blade is tested by multiple devices in a collaborative manner and compared with the comprehensive verification standard to obtain the verification results of each dimension. This ensures that the quality of the finished product fully meets the installation safety standards. Finally, a printing quality inspection report of the finished product is generated, and the scanning path parameters of the corresponding printing node are traced back in the report, providing a clear direction for subsequent process optimization.

[0041] Example 9: This example provides a quality closed-loop control system for the 3D printing process of aircraft engine blades, such as... Figure 2 As shown, it includes: The parameter adjustment module is used to adjust several process parameters of the 3D printer according to the CAD of the blade to be printed and to perform printing simulation. Based on the simulation results, the process parameters of the 3D printer are corrected to obtain several effective process parameters. The quality inspection preparation module is used to construct the current printing process of the 3D printer based on the CAD and the effective process parameters, generate the quality verification standard corresponding to each process node, and control the 3D printer to enter the printing state. The defect identification module is used to obtain the multi-dimensional quality characteristics of the printed semi-finished product generated by the current printing node, and to judge the multi-dimensional quality characteristics using the corresponding quality verification standard to determine several printing defects of the printed semi-finished product. The defect repair module is used to determine the printing repair process for generating the printed semi-finished product based on the judgment result, and integrate it into the current printing process to repair defects and obtain a qualified semi-finished product at the current printing node. The comprehensive quality inspection module is used to perform comprehensive quality verification on the printed blades after the 3D printer completes the current printing process, generate a printing report, and display it.

[0042] In this example, the CAD file contains key information such as the complex curved surface, thin-walled structure, and high-temperature alloy material properties of the blade to be printed. In this example, the effective process parameters refer to the parameters presented by the 3D printer when performing this printing job, including: laser power, scanning speed, layer thickness, powder feed rate, protective gas flow rate, etc. In this example, a process node represents the node after completing an independent and separable sub-process. The verification standard of each process node is precisely aligned with the manufacturing specifications of aero-blades, avoiding subjectivity in quality judgment. In this example, multidimensional quality features represent the characteristics of the printed semi-finished product in different dimensions, including: dimensional accuracy, surface morphology, internal porosity, and fusion state. In this example, printing defects refer to non-conformities that appear on the printed semi-finished product; In this example, the printed report uses three display methods: a heat map of defect locations, a curve comparing dimensional deviations, and a table of performance test data.

[0043] The working principle and beneficial effects of the above technical solution are as follows: To provide reliable technical support for the efficient and high-quality manufacturing of aerospace engine blades and promote the large-scale application of 3D printing technology in the high-end manufacturing field of aerospace, the core process parameters of the 3D printer are first adjusted based on the CAD of the blade to be printed. Then, the parameter adaptability is predicted through printing simulation, and finally, effective process parameters are obtained by correction. This ensures that the effective process parameters meet both forming requirements and material properties, thereby improving the stability and consistency of the printing process from the source and laying the foundation for subsequent quality control. Then, the printing process is constructed based on the CAD and effective process parameters, and a dedicated quality verification standard is formulated for each node to control the printer to start printing. Quality control is moved to each printing node, rather than relying solely on finished product inspection, ensuring that defects can be identified in the early stages of formation and avoiding the expansion of defects due to the superposition of subsequent processes. Furthermore, multi-dimensional detection methods are used to obtain multi-dimensional quality characteristics of the printed semi-finished product. The system compares the printed blades with the corresponding node's verification standards in real time to accurately locate printing defects. It then develops specific repair procedures for each defect type and integrates these procedures into the current printing process in real time. This ensures immediate defect repair, allowing the blades to proceed to the next node only after obtaining qualified semi-finished products. This seamless integration of dynamic repair and printing processes guarantees the continuity of the printing process while addressing node defects in a targeted manner, significantly improving the finished product pass rate. After printing, the finished blades undergo comprehensive quality verification across all dimensions, generating and displaying a complete printing report. This ensures the finished products fully meet installation requirements, avoiding flight safety risks caused by substandard quality. Furthermore, the complete printing report enables full-process traceability from process parameters to finished product quality. When a blade's performance fails to meet standards, the report allows for backtracking to the parameter settings and defect repair records of the corresponding printing node, facilitating subsequent process optimization and meeting the aviation industry's quality audit requirements. This provides authoritative quality evidence for the blades' installation and use.

[0044] Example 10: Based on Example 9, the quality closed-loop control system for the 3D printing process of aerospace engine blades, wherein the defect identification module includes: The real-time inference unit is used to collect the real-time printing data of the 3D printer after the 3D printer enters the printing state, determine the current printing progress of the 3D printer at the current moment, and map the real-time printing data to each quality inspection dimension to obtain the inferred multidimensional quality characteristics of the printed semi-finished product. The on-site quality inspection unit is used to determine the printing completion time corresponding to the current printing node based on the current printing progress, and to conduct on-site quality inspection of the printed semi-finished product using the corresponding quality verification standard at the printing completion time, so as to obtain the on-site multi-dimensional quality characteristics of the printed semi-finished product. The defect determination unit is used to determine that the printed semi-finished product does not contain printing defects when the on-site multidimensional quality characteristics meet the corresponding quality verification standard and the inferred multidimensional quality characteristics are consistent with the on-site multidimensional quality characteristics; otherwise, it determines several printing defects of the printed semi-finished product based on the inferred multidimensional quality characteristics and the on-site multidimensional quality characteristics.

[0045] In this example, the quality inspection dimensions include dimensional accuracy, surface roughness, internal fusion, and structural stability. The working principle and beneficial effects of the above technical solution are as follows: After the printer enters the printing state, real-time printing data is collected and combined with the current printing progress. The real-time data is mapped to the quality inspection dimension to generate the inferred multi-dimensional quality characteristics of the printed semi-finished product. Then, based on the current printing progress, the completion time of the current printing node is accurately locked. At this moment, professional testing equipment is used to conduct on-site quality inspection of the printed semi-finished product, and on-site multi-dimensional quality characteristics are obtained to ensure that the test data truly reflects the forming quality of the printing node. Finally, by comparing the inferred multi-dimensional quality characteristics and the on-site multi-dimensional quality characteristics, a dual judgment is made. If both meet the standards and the deviation is within the allowable range, it is determined that there is no defect. If either characteristic does not meet the standard (or the deviation between the two exceeds the threshold), the printing defect is accurately located, and the cause of the defect is deduced through the characteristic deviation, providing a clear direction for subsequent repair. This ensures that the quality of each printing node meets the aerospace manufacturing standards, laying a key foundation for the final product to be qualified.

[0046] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A 3D printing process quality closed loop control method for aero equipment engine blade, characterized in that, The application relates to a method for quality control of 3D printing of a blade, comprising the following steps: Step 1: adjusting a plurality of process parameters of a 3D printer according to a CAD of a blade to be printed and performing a printing simulation, correcting the process parameters of the 3D printer according to a simulation result, and obtaining a plurality of effective process parameters; Step 2: constructing a printing flow of the 3D printer according to the CAD and the effective process parameters, generating a quality check standard corresponding to each flow node, and controlling the 3D printer to enter a printing state; Step 3: obtaining a multi-dimensional quality feature of a printing semi-finished product generated by a current printing node, judging the multi-dimensional quality feature by using the corresponding quality check standard, and determining a plurality of printing defects of the printing semi-finished product; Step 4: determining a printing repair flow for generating the printing semi-finished product according to a judgment result, and fusing the printing repair flow into the printing flow to repair the defects, so as to obtain a qualified semi-finished product of the current printing node; Step 5: when the 3D printer completes the printing flow, performing comprehensive quality check on a printed blade product to generate a printing report and displaying the printing report.

2. A 3D printing process quality closed loop control method for aero equipment engine blade as claimed in claim 1, wherein, The step 1 comprises the following steps: Step 11: drawing a 3D blade structure of the blade to be printed according to the CAD, identifying the size of each 3D blade structure to obtain a plurality of first process parameters, and obtaining a plurality of second process parameters according to a structural connection relationship between different 3D blade structures; Step 12: performing a first parameter adjustment on the 3D printer by using the first process parameters and the second process parameters, performing a first printing simulation on each 3D blade structure to obtain a corresponding 3D simulation structure, and determining to-be-corrected parameters of the 3D printer according to structural differences between the 3D simulation structure and the corresponding 3D blade structure; Step 13: generating a correction vector corresponding to the to-be-corrected parameters according to the structural differences, determining a correction range according to a vector module length of the correction vector, determining a correction direction according to a vector direction of the correction vector, and iteratively adjusting the to-be-corrected parameters in the corresponding correction range to the corresponding correction direction; Step 14: obtaining an iterative parameter set corresponding to each to-be-corrected parameter, selecting an iterative parameter in each iterative parameter set to construct a replacement parameter group, performing a second printing simulation by using each replacement parameter group, selecting a replacement parameter with the highest accuracy according to a second simulation result, and obtaining effective process parameters of the 3D printer.

3. A 3D printing process quality closed loop control method for aero equipment engine blade as claimed in claim 1, wherein, The step 2 comprises the following steps: Step 21: dividing the blade to be printed into a plurality of to-be-printed structures according to the CAD, obtaining a plurality of execution functions of the 3D printer, determining an execution range corresponding to each execution function in combination with the effective process parameters, combining the execution functions according to the execution range to obtain a preliminary printing flow of each to-be-printed structure; Step 22: generating a plurality of printing conditions according to the contour of each of the to-be-printed structures, optimizing the preliminary printing process by using the printing conditions to obtain a perfect printing process corresponding to each of the to-be-printed structures, and constructing a connection printing process between different perfect printing processes according to the structural relationship between the to-be-printed structures; Step 23: constructing the current printing process of the 3D printer according to the perfect printing process and the connection printing process, regarding the end point of each of the perfect printing processes as a process node, deriving a perfect printing result corresponding to the process node according to the perfect printing process; Step 24: generating a quality checking standard of the process node according to the semantic description of the perfect printing result, determining a pre-preparation parameter of the 3D printer according to the current printing process, and adjusting the 3D printer to the pre-preparation parameter to determine that the 3D printer enters a printing state.

4. A 3D printing process quality closed loop control method for aero equipment engine blade as claimed in claim 1, wherein, The step 3 comprises: Step 31: collecting real-time printing data of the 3D printer when the 3D printer enters the printing state, determining a current printing progress of the 3D printer at the current time, and mapping the real-time printing data into each quality inspection dimension to obtain a suspected multi-dimensional quality feature of the printing semi-finished product; Step 32: determining a printing completion time corresponding to the current printing node according to the current printing progress, and performing on-site quality inspection on the printing semi-finished product by using the corresponding quality checking standard at the printing completion time to obtain an on-site multi-dimensional quality feature of the printing semi-finished product; Step 33: when the on-site multi-dimensional quality feature meets the corresponding quality checking standard and the suspected multi-dimensional quality feature is consistent with the on-site multi-dimensional quality feature, determining that the printing semi-finished product does not contain a printing defect, otherwise, determining a plurality of printing defects of the printing semi-finished product according to the suspected multi-dimensional quality feature and the on-site multi-dimensional quality feature.

5. A 3D printing process quality closed loop control method for aero equipment engine blade as claimed in claim 4, wherein, The step 33 comprises: Step 331: when the on-site multi-dimensional quality feature is abnormal, determining an abnormal dimension of the on-site multi-dimensional quality feature according to the quality checking standard, identifying a plurality of suspected printing defects consistent with the abnormal dimension in the printing semi-finished product, and performing secondary on-site quality inspection on a suspected position corresponding to each of the suspected printing defects to determine a plurality of printing defects of the printing semi-finished product; Step 332: when the suspected multi-dimensional quality feature is abnormal, finding a data acquisition device of the 3D printer, determining a plurality of device fault items of the data acquisition device according to the feature difference between the suspected multi-dimensional quality feature and the on-site multi-dimensional quality feature, and optimizing each of the device fault items. Step 333: synchronously adjust the real-time printing data according to the optimization data of the data acquisition device, generate corresponding updated speculative multi-dimensional quality characteristics, and identify a plurality of suspected printing defects of the printing semi-finished product if the updated speculative multi-dimensional characteristics are inconsistent with the field multi-dimensional quality characteristics; and perform secondary field quality inspection on the suspected position corresponding to each suspected printing defect to determine a plurality of printing defects of the printing semi-finished product.

6. A 3D printing process quality closed loop control method for aero equipment engine blade as claimed in claim 5 wherein, Also comprising: When the field multi-dimensional quality characteristics meet the corresponding quality check standard, and the speculative multi-dimensional quality characteristics are consistent with the field multi-dimensional quality characteristics, it is determined that the printing semi-finished product does not contain printing defects. When the updated speculative multi-dimensional quality characteristics are consistent with the field multi-dimensional quality characteristics, it is determined that the printing semi-finished product does not contain printing defects.

7. A 3D printing process quality closed loop control method for aero equipment engine blade as claimed in claim 1, wherein, The step 4 comprises: Step 41: determining the defect dimension and defect position corresponding to each printing defect according to the judgment result, determining a plurality of repair processes for this repair according to the defect dimension and the defect position, determining the execution position corresponding to each repair process according to the defect position, and generating a printing repair process; Step 42: positioning the process node in the current printing process, determining the integration position of the printing repair process, integrating the printing process into the integration position to update the current printing process and perform defect repair on the printing semi-finished product to obtain a qualified semi-finished product of the current printing node.

8. A 3D printing process quality closed loop control method for aero equipment engine blade as claimed in claim 1, wherein, The step 5 comprises: Step 51: constructing a plurality of overall check standards for the to-be-printed blade according to the CAD, and inputting the quality check standard corresponding to each process node into the overall check standard for standard reorganization to generate a comprehensive check standard; Step 52: obtaining a printed blade product after the 3D printer completes the current printing process, performing quality check on the printed blade product by using the comprehensive check standard, obtaining the dimension check result corresponding to each check dimension of the printed blade product, generating a current printing report of the printed blade product, and displaying the current printing report.

9. A 3D printing process quality closed loop control system for aero equipment engine blades, characterized by, Comprise: A parameter adjustment module for adjusting a plurality of process parameters of a 3D printer according to a CAD of a to-be-printed blade and performing printing simulation, correcting the process parameters of the 3D printer according to the simulation result, and obtaining a plurality of effective process parameters; A quality inspection preparation module for constructing a current printing process of the 3D printer according to the CAD and the effective process parameters, generating a quality check standard corresponding to each process node, and controlling the 3D printer to enter a printing state; A defect identification module for obtaining multi-dimensional quality characteristics of a printing semi-finished product generated by a current printing node, determining a plurality of printing defects of the printing semi-finished product by using the corresponding quality check standard to determine the multi-dimensional quality characteristics; A defect repair module for determining and generating a printing repair process of the printing semi-finished product according to the judgment result, and integrating the printing repair process into the current printing process for defect repair to obtain a qualified semi-finished product of the current printing node. The comprehensive quality inspection module is configured to perform comprehensive quality inspection on the printed blade product after the 3D printer completes the current printing process, generate a printing report of the current printing process, and display the printing report.

10. A 3D printing process quality closed loop control system for aero equipment engine blade as claimed in claim 9 wherein, The defect identification module comprises: The real-time prediction unit is configured to collect real-time printing data of the 3D printer when the 3D printer enters a printing state, determine a current printing progress of the 3D printer at a current time, and map the real-time printing data to each quality inspection dimension to obtain a predicted multi-dimensional quality feature of the printed semi-finished product. The on-site quality inspection unit is configured to determine a printing completion time corresponding to the current printing node according to the current printing progress, and perform on-site quality inspection on the printed semi-finished product at the printing completion time by using the corresponding quality inspection standard to obtain an on-site multi-dimensional quality feature of the printed semi-finished product. The defect determination unit is configured to determine that the printed semi-finished product does not contain a printing defect when the on-site multi-dimensional quality feature meets the corresponding quality inspection standard and the predicted multi-dimensional quality feature is consistent with the on-site multi-dimensional quality feature, and otherwise, determine a plurality of printing defects of the printed semi-finished product according to the predicted multi-dimensional quality feature and the on-site multi-dimensional quality feature.

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