Laser processing method and device for defect repair of special-shaped component
Layered repair using laser processing equipment solves the problems of poor applicability, high cost, and large heat-affected zone in the repair of defects in irregularly shaped components. It enables efficient and low-cost repair of difficult-to-weld materials such as aluminum alloys, and is particularly suitable for post-weld porosity and overcut defects in precision machining of aluminum alloys.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-19
- Publication Date
- 2026-04-10
AI Technical Summary
In the existing technology, the defect repair methods for irregularly shaped components have problems such as poor applicability, high cost, long cycle and large heat-affected zone. In particular, traditional methods are difficult to effectively solve the problems of post-weld porosity and overcut defects in precision machining of difficult-to-weld materials such as aluminum alloys.
Defect repair is performed using a laser processing device, which includes components such as a laser head, a multi-directional linear module, and an electric push rod. The defect area is located through non-destructive testing, a layered repair strategy is planned, and coaxial powder feeding laser scanning is used for repair. Internal and external protective gases are used to prevent powder blockage and improve the cooling effect.
It achieves efficient and low-cost repair results, is suitable for complex-shaped workpieces, has low heat input, and high repair accuracy. It is especially suitable for efficient repair of difficult-to-weld materials such as aluminum alloys, avoiding blockage of powder guiding channels and thermal deformation.
Smart Images
Figure CN121826699A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of laser processing and repair technology, and in particular to a laser processing method and apparatus for repairing defects in irregularly shaped components. Background Technology
[0002] EBW (Extended Embedded Welding) processes have extremely high requirements for workpiece preparation. Aluminum alloys with poor weldability are prone to internal porosity during welding due to insufficient gas escape or metallurgical reactions. Furthermore, during post-weld finishing, stress release or positioning errors can lead to overcutting in certain areas (i.e., machining beyond tolerance, causing localized depressions in the part). Both types of defects severely affect the product's sealing performance, structural strength, and service life. Currently, the conventional repair method for such defects is the "cut-and-fit method": this involves completely removing the defective area through machining, then preparing a matching patch of the same material, and inserting it into the removed area using TIG welding or laser welding. While reliable, this method has significant drawbacks: 1. Poor applicability: For workpieces with complex curved surfaces, irregular structures or internal cavity features, mechanical patching operations are extremely difficult, making it hard to guarantee the shape matching of the patch and potentially further weakening the strength of the workpiece itself.
[0003] 2. High cost and long cycle: The patching process requires precise CNC programming and machining. The preparation, assembly, welding and post-weld processing of the patch are complicated, resulting in a long repair cycle and high cost.
[0004] 3. Large heat-affected zone: Traditional welding methods such as TIG welding have a large heat input, which may cause new thermal deformation or thermal damage to precision workpieces.
[0005] While laser cladding technology can be used for surface repair, conventional processes are mostly used for the preparation of wear-resistant and anti-corrosion coatings. When used directly for the repair of high-requirement structural defects, it still faces challenges in controlling the density of the repair area, the bonding strength with the substrate, and the internal quality (such as porosity). Summary of the Invention
[0006] This application provides a laser processing method and apparatus for repairing defects in irregularly shaped components, which solves the problems of poor applicability, high cost, long cycle, large heat-affected zone, and poor repair quality of the existing "tightening method". It has the advantages of low heat input, high repair accuracy, and wide applicability. It is particularly suitable for efficient and low-cost repair of porosity or overcut defects in vacuum electron beam welding of difficult-to-weld materials such as aluminum alloys.
[0007] This application provides a laser processing device for repairing defects in irregularly shaped components, including a processing table. A control panel is mounted on the surface of the processing table, and a laser processing mechanism is provided on the surface of the processing table. The laser processing mechanism includes a multi-directional linear module, an adjusting slide, and a laser head. The multi-directional linear module is mounted on the surface of the processing table, and an adjusting slide is mounted on the surface of the multi-directional linear module. The control panel controls the multi-directional linear module to move the adjusting slide back, forth, left, and right. A laser head is provided below the adjusting slide.
[0008] Preferably, the laser processing mechanism further includes an electric push rod, a receiving cylinder, a tilting motor, a turntable, a sliding frame, and a rotary motor. A sliding frame is slidably mounted on one side of the adjusting slide. An electric push rod is mounted on the surface of the adjusting slide. The input end of the electric push rod is electrically connected to the output end of the control panel. One end of the electric push rod is fixedly connected to the top of the sliding frame. A rotary motor is installed inside the sliding frame. The input end of the rotary motor is electrically connected to the output end of the control panel. A rotating shaft is fixed to the output end of the rotary motor via a coupling. A receiving cylinder is fixed to one end of the rotating shaft. A turntable is rotatably connected to one side of the receiving cylinder. The turntable is fixed to the laser head by screws. A tilting motor is installed inside the receiving cylinder. The input end of the tilting motor is electrically connected to the output end of the control panel. A rotating shaft is fixed to the output end of the tilting motor via a coupling. One end of the rotating shaft is fixedly connected to the center of the turntable.
[0009] Preferably, the laser head includes a laser generator, a laser section, and a connecting plate. The laser generator is fixed to one side of the turntable by screws. The input end of the laser generator is electrically connected to the output end of the control panel. The laser section is fixed to the bottom of the laser generator. The structure at the bottom of the laser section is an inverted cone shape. The connecting plate is fitted on the outer side of the laser section.
[0010] Preferably, the laser head further includes an inner gas guide shroud, a powder conveying section, an outer cover, and an outer gas guide channel. The inner gas guide shroud is fitted on the outer side of the bottom position of the laser section. The inner gas guide shroud is coaxial with the laser section. The top of the inner gas guide shroud is tightly fitted with the surface of the connecting plate. The outer cover is fitted on the outer side of the inner gas guide shroud. The outer cover is coaxial with the laser section. An outer gas guide channel is opened inside the outer cover. The outer gas guide channel is coaxial with the outer cover. A powder conveying section is provided between the outer cover and the inner gas guide shroud. The powder conveying section is coaxial with the laser section. The top of the powder conveying section is tightly fitted with the top of the inner gas guide shroud and the top of the outer cover. The top of the connecting plate, the inner gas guide shroud, the powder conveying section, and the top of the outer cover are sealed and connected by screws and nuts.
[0011] Preferably, the powder conveying unit includes a powder guiding cone, a powder guiding channel, a collar, a diffuser frame, and a mounting plate. The mounting plate is disposed between the inner gas guide hood and the outer cover. The bottom of the mounting plate is fitted with a collar, which is sleeved on the outside of the inner gas guide hood. A diffuser frame is fixed circumferentially on the surface of the collar. The bottom of the collar is fixed with a powder guiding cone. The powder guiding cone is coaxial with the outer cover, and a powder guiding channel is formed between the powder guiding cone and the outer cover. The powder guiding channel is coaxial with the laser unit.
[0012] Preferably, the laser head further includes an outer gas guide tube, a powder guide tube, and an inner gas guide tube. A powder guide tube is fixed circumferentially at the top of the outer cover, one end of which extends into the interior of the outer cover and is located outside the diffuser. An outer gas guide tube is installed circumferentially on the surface of the outer cover, one end of which extends into the interior of the outer gas guide channel. An inner gas guide tube is fixed circumferentially on the surface of the connecting plate, one end of which passes through the connecting plate and extends to the top of the inner side of the inner gas guide cover.
[0013] Preferably, the laser head is provided with an anti-blocking mechanism, which includes a striking ball, a support base, and a rotating rod. The support base is fixed circumferentially to the inner wall of the powder guide cone, and the rotating rod is rotatably connected to the top of the support base. One end of the rotating rod is fixed with a striking ball.
[0014] Preferably, the anti-blocking mechanism further includes an impeller and a port, the port being circumferentially opened on the inner wall of the inner air guide shroud, and the impeller being rotatably connected inside the port, the impeller cooperating with the striking ball.
[0015] Preferably, the laser head is provided with a cooling mechanism, which includes a water-cooling circulation section, an air guide ring, and a baffle plate. The water-cooling circulation section is installed inside the outer casing and surrounds the outside of the powder conveying section. The air guide ring is respectively fitted on the outside of the inner air guide shroud. The air guide ring is coaxial with the inner air guide shroud and has a hollow structure. The baffle plate is fixed inside the air guide ring by a bracket. The baffle plate is coaxial with the inner air guide shroud and the inner wall of the baffle plate is in close contact with the surface of the laser head.
[0016] A laser processing method for repairing defects in irregularly shaped components, in conjunction with the aforementioned laser processing device for repairing defects in irregularly shaped components, the method comprising: S1. Defect location and pretreatment: Use non-destructive testing or visual measurement to accurately locate the area and depth of the workpiece defect, and mechanically clean the defect area to form a clean area to be repaired. The edges of the repair area are machined with a gentle slope to avoid sharp corners. S2. Repair Parameter Planning: Select metal powders with the same composition or excellent compatibility according to the substrate material and dry them thoroughly. Based on the depth and area of the defect, plan a layered repair strategy: divide the entire repair depth into several layers, with each layer having a cladding thickness of 0.2-0.5mm. Set core process parameters such as laser power, spot diameter, scanning speed, powder feed rate, and protective gas flow rate. S3. Coaxial powder feeding laser repair: The processed workpiece to be repaired is installed at the designated position on the surface of the processing table. Then, the laser processing device is turned on and laser scanning and cladding is performed on the defect area of the workpiece through the laser head according to the planned path and parameters. The scanning path adopts parallel scanning or concentric circle scanning. The scanning direction between layers is rotated at a certain angle to refine the grains and reduce stress concentration. Layer by layer, the filling metal is piled up until it is slightly higher than the theoretical surface of the workpiece. S4. Post-weld treatment and finishing: After the repair is completed, the repaired area is visually inspected and non-destructively tested to ensure that there are no new defects such as cracks or lack of fusion. The repaired area is then machined to the final dimensions and geometric tolerances required by the product drawings using CNC milling or grinding.
[0017] One or more technical solutions provided in this application have at least the following technical effects or advantages: By setting up a laser processing mechanism, the processed workpiece to be repaired is installed at the designated position on the processing table surface. Then, the control panel is operated to start the laser processing device. According to the planned path and parameters, the laser head is controlled to move to the repair area of the workpiece. At this time, the laser head can be controlled to move forward, backward, left and right under the action of the multi-directional linear module, and the laser head can be controlled to move up and down under the action of the electric push rod. At the same time, the rotating motor can drive the housing cylinder to rotate, which drives the laser head to rotate horizontally. The rotating motor can drive the turntable to rotate, which drives the laser head to rotate. The laser head performs laser scanning and cladding in the defect area of the workpiece. This effectively solves the problems of poor applicability, high cost, long cycle, large heat-affected zone and poor repair quality of the existing "tightening method". It has the advantages of low heat input, high repair accuracy and wide applicability. It is especially suitable for efficient and low-cost repair of pores or overcut defects in vacuum electron beam welding of difficult-to-weld materials such as aluminum alloys. By configuring the laser head, during assembly, the powder conveying unit is inserted into the outer casing, forming a powder guiding channel at the bottom between the powder conveying unit and the outer casing. Then, the inner gas guide cover is inserted into the powder conveying unit, followed by the laser head. The connecting plate, inner gas guide cover, powder conveying unit, and outer casing are then secured with screws and nuts, completing the laser head installation. During use, high-purity argon or nitrogen gas is blown into the outer gas guide channel and inner gas guide cover through the outer and inner gas guide pipes respectively, creating a localized protective atmosphere. The inner protective gas prevents powder from rebounding and sticking to the outlet, causing blockage, while the outer protective gas prevents powder oxidation. Simultaneously, the laser emits... The laser beam generated by the device is emitted from the center of the laser section and focused on the surface of the workpiece to form a molten pool. Powder enters the outer side of the collar through the powder guide tube and the powder carrier gas, high-purity argon or nitrogen. At this time, the powder impacts the diffuser and then falls into the powder guide channel along the powder guide cone. It is then fed into the laser molten pool in a ring shape through the powder guide channel. The energy of the laser causes the powder to melt rapidly in the molten pool to form a cladding layer. Since the powder guide channel is coaxial with the laser section, coaxial powder feeding can make the powder flow and the laser beam converge precisely at one point, achieving consistent powder feeding in a 360-degree direction. This is particularly suitable for curved surface repair and realizes the function of easy assembly. At the same time, it makes the powder fall in a ring shape and improves the cladding effect of the laser processing device. By setting up an anti-blocking mechanism, when the internal protective gas is introduced into the inner side of the inner air guide hood, the protective gas drives the impeller to rotate, causing the impeller blades to push the striking ball. The striking ball rotates upward under the action of the rotating rod, causing the striking ball to strike the powder guide cone, shaking off the powder adhering to the surface of the powder guide cone. This avoids the channel blockage caused by too much powder adhering to the surface of the powder guide cone. When the blades on the impeller surface move away from the striking ball, the striking ball resets under the action of gravity, causing the rotating rod to fall onto the surface of the support base. This effectively solves the problem of dust blockage caused by the small space of the powder guide channel in the existing technology. By setting up a cooling mechanism, the incoming internal protective gas is deflected through the cooperation of the air guide ring and the baffle plate, so that the internal protective gas can contact the powder guide cone and cool the powder guide cone with air. Combined with the water cooling circulation unit, the internal and external cooling of the powder guide channel can be achieved, which improves the cooling effect of the powder guide channel when the laser processing device is in use. Attached Figure Description
[0018] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a schematic diagram of the front cross-sectional structure of the present invention; Figure 3 This is an enlarged schematic diagram of the laser processing mechanism of the present invention; Figure 4 This is a magnified schematic diagram of the laser head structure of the present invention; Figure 5 This is a top view enlarged cross-sectional schematic diagram of the powder conveying section of the present invention; Figure 6 This is a three-dimensional exploded magnified structural diagram of the laser head of the present invention; Figure 7 This is an enlarged exploded cross-sectional view of the laser head of the present invention; Figure 8 This is an enlarged structural schematic diagram of the inner air guide shroud and powder conveying section of the present invention.
[0019] In the diagram: 1. Processing table; 11. Control panel; 2. Laser processing mechanism; 21. Multi-directional linear module; 22. Adjustable slide; 23. Electric push rod; 24. Receiving cylinder; 25. Tilting motor; 26. Turntable; 27. Sliding frame; 28. Rotary motor; 3. Laser head; 31. Laser generator; 32. Laser unit; 33. Inner gas guide hood; 34. Powder conveying unit; 341. Powder guide cone; 342. Powder guide. 343. Channel; 344. Ring; 345. Diffusion frame; 346. Mounting plate; 35. Outer cover; 36. Connecting plate; 37. External air guide channel; 38. External air guide pipe; 39. Powder guide pipe; 310. Internal air guide pipe; 4. Anti-blocking mechanism; 41. Impeller; 42. Striking ball; 43. Port; 44. Support base; 45. Rotating rod; 5. Cooling mechanism; 51. Water cooling circulation section; 52. Air guide ring; 53. Baffle plate. Detailed Implementation
[0020] To facilitate understanding of the present invention, a more complete description of this application will be given below with reference to the accompanying drawings, which illustrate preferred embodiments of the invention. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to enable a more thorough and complete understanding of the disclosure of the present invention.
[0021] It should be noted that the terms "vertical," "horizontal," "up," "down," "left," "right," and similar expressions used in this article are for illustrative purposes only and do not represent the only possible implementation.
[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to limit the invention; the term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.
[0023] Example 1: As Figure 1 and Figure 2As shown, the laser processing device for repairing defects in irregularly shaped components of this application includes a processing table 1. A control panel 11 is mounted on the surface of the processing table 1. A lithium battery and a processor are embedded inside the control panel 11. The processor includes an amplifier tube, a protective resistor Rm, a filter, an A / D converter, and a microcontroller. The sensor and the protective resistor Rm are connected in parallel with the amplifier tube and then in series with the filter. The signal is converted by the A / D converter and sent to the microcontroller. The display screen receives the processing signal sent by the microcontroller. A laser processing mechanism 2 is mounted on the surface of the processing table 1. The laser processing mechanism 2 includes a multi-directional linear module 21, an adjusting slide 22, and a laser head 3. The multi-directional linear module 21 is mounted on the surface of the processing table 1. The adjusting slide 22 is mounted on the surface of the multi-directional linear module 21. The control panel 11 controls the multi-directional linear module 21 to move the adjusting slide 22 back and forth and left and right. The laser head 3 is located below the adjusting slide 22.
[0024] Furthermore, such as Figure 3 As shown, the laser processing mechanism 2 also includes an electric push rod 23, a receiving cylinder 24, a tilting motor 25, a turntable 26, a sliding frame 27, and a rotary motor 28. The sliding frame 27 is slidably mounted on one side of the adjusting slide 22. The electric push rod 23 is mounted on the surface of the adjusting slide 22. The input end of the electric push rod 23 is electrically connected to the output end of the control panel 11. One end of the electric push rod 23 is fixedly connected to the top of the sliding frame 27. The rotary motor 28 is installed inside the sliding frame 27. The input end of the rotary motor 28 is connected to the output end of the control panel 11. Electrically connected, the output end of the rotary motor 28 is fixed to a rotating shaft via a coupling, one end of the rotating shaft is fixed to a receiving cylinder 24, and a turntable 26 is rotatably connected to one side of the receiving cylinder 24. The turntable 26 is fixed to the laser head 3 by screws, which facilitates the disassembly and maintenance of the laser head 3. A flip motor 25 is installed inside the receiving cylinder 24. The input end of the flip motor 25 is electrically connected to the output end of the control panel 11. The output end of the flip motor 25 is fixed to a rotating shaft via a coupling, and one end of the rotating shaft is fixedly connected to the center position of the turntable 26.
[0025] The control panel 11 is used to control the coordinated operation of various components of the laser processing device; the multi-directional linear module 21 can be a TOYO series linear module; the electric push rod 23 can be a TA series model; the rotary motor 28 and the flip motor 25 can be JO series models; all of these are existing technologies and will not be described in detail here.
[0026] The laser processing apparatus for repairing defects in irregularly shaped components according to embodiments of this application operates as follows: S1. Defect Location and Pre-treatment: Use non-destructive testing (such as X-ray, penetrant testing) or visual measurement to accurately locate the area and depth of workpiece defects (pore groups or overcut depressions), and mechanically clean the defect area (such as using small diameter milling cutters, ball end mills or laser cleaning) to remove oxide scale, oil stains and other impurities until the metal luster is exposed, forming a clean area to be repaired. The edges of the repair area are machined with a gentle slope to avoid sharp corners; S2. Repair Parameter Planning: Select metal powders with the same composition or excellent compatibility (such as AlSi10Mg powder) based on the substrate material (e.g., 6061 aluminum alloy). The powder particle size range is 50-150μm, and the powder is thoroughly dried. Based on the depth and area of the defect, plan a layered repair strategy: divide the entire repair depth into several layers, with each layer having a cladding thickness of 0.2-0.5mm. Set core process parameters such as laser power, spot diameter, scanning speed, powder feed rate, and protective gas flow rate (for aluminum alloys, a low-power, high-speed process is recommended to reduce heat input). S3. Coaxial Powder Feeding Laser Repair: The processed workpiece to be repaired is installed at the designated position on the surface of the processing table 1. Then, the control panel 11 is operated to control the laser processing device to start. According to the planned path and parameters, the laser head 3 is controlled to move to the repair area of the workpiece. At this time, the laser head 3 can be controlled to move back and forth and left and right under the action of the multi-directional linear module 21, and the laser head 3 can be controlled to move up and down under the action of the electric push rod 23. At the same time, the rotary motor 28 can drive the housing cylinder 24 to rotate, which drives the laser head 3 to rotate horizontally. The flip motor 25 can drive the turntable 26 to rotate, which drives the laser head 3 to flip. The laser head 3 performs laser scanning cladding in the defect area of the workpiece. The scanning path adopts parallel scanning or concentric circle scanning. The scanning direction between layers is rotated by a certain angle (such as 90°) to refine the grains, reduce stress concentration, and build up layer by layer until the filler metal is slightly higher than the theoretical surface of the workpiece (leaving a finishing allowance of 0.2-0.5mm). S4. Post-weld treatment and finishing: After the repair is completed, the repaired area is visually inspected and non-destructively tested to ensure that there are no new defects such as cracks or lack of fusion. Finishing methods such as CNC milling or grinding are used to process the repaired area to the final dimensions and geometric tolerances required by the product drawings.
[0027] For example: Take the repair of a precision overcut defect (approximately Φ5mm × 0.8mm deep) on the inner curved surface of an aluminum alloy liquid cooling chassis as an example.
[0028] S1: Defect location and pretreatment: Use a coordinate measuring machine to accurately locate the overcut depression, use a Φ3mm ball end mill to gently clean the depression area, remove burrs and oxide layer, and machine a smooth transition bevel. S2: Repair parameter planning: Select dry AlSi12 powder (particle size 53-150μm), plan to repair in 3 layers, each layer with a target thickness of 0.3mm, set laser power to 1.2kW, scanning speed to 10mm / s, spot diameter to 2mm, powder feed rate to 8g / min, and protective gas (argon) flow rate to 15L / min.
[0029] S3: Coaxial powder feeding laser repair: Fix the chassis on the processing table 1, adjust the angle of the laser head 3 so that it is always perpendicular to the curved surface point to be repaired, start the system, first blow air for protection, and then scan and clad according to the preset concentric circle path, rotate 60° between layers, and the repaired surface is 0.3mm higher than the substrate.
[0030] S4: Post-weld treatment and finishing: After repair, X-ray inspection showed no defects. Finally, a precision engraving machine was used to perform micro-grinding on the repaired area to restore the surface contour and dimensional accuracy to within the tolerance range (±0.05mm). The repaired workpiece passed the inspection and was put into use.
[0031] The technical solutions in the above embodiments of this application have at least the following technical effects or advantages: they overcome the shortcomings of traditional clipping and patching methods in adapting to complex-shaped workpieces, and have the advantages of low heat input, high repair accuracy, and wide applicability. They are particularly suitable for efficient and low-cost repair of porosity or overcut defects in vacuum electron beam welding of difficult-to-weld materials such as aluminum alloys.
[0032] Example 2: The structure of the laser head 3 in Example 1 is generally more complex and the assembly is more complicated. Moreover, the powder tube used to transport the powder is generally set along the circumference of the laser axis, resulting in lower uniformity of the powder falling. The present application example is an optimization based on the above example.
[0033] like Figure 4 and Figure 6As shown, the laser head 3 includes a laser generator 31, a laser section 32, and a connecting plate 36. The laser generator 31 is fixed to one side of the turntable 26 by screws. The laser generator 31 can be an LMD series model. The input end of the laser generator 31 is electrically connected to the output end of the control panel 11. The laser section 32 is fixed to the bottom of the laser generator 31. The structure at the bottom of the laser section 32 is an inverted cone shape. The connecting plate 36 is fitted on the outer side of the laser section 32. The laser head 3 also includes an inner gas guide shroud 33, a powder conveying section 34, an outer cover 35, and an outer gas guide channel 37. The inner gas guide shroud 33 is fitted on the outer side of the bottom of the laser section 32. The inner gas guide shroud 33 is connected to the laser section 26. The laser head 32 is coaxial, and the top of the inner gas guide shroud 33 is tightly fitted to the surface of the connecting plate 36. An outer cover 35 is fitted on the outside of the inner gas guide shroud 33. The outer cover 35 is coaxial with the laser head 32. An outer gas guide channel 37 is opened inside the outer cover 35. The outer gas guide channel 37 is coaxial with the outer cover 35. A powder conveying part 34 is provided between the outer cover 35 and the inner gas guide shroud 33. The powder conveying part 34 is coaxial with the laser head 32. The top of the powder conveying part 34 is tightly fitted to the top of the inner gas guide shroud 33 and the top of the outer cover 35. The connecting plate 36, the inner gas guide shroud 33, the powder conveying part 34 and the top of the outer cover 35 are sealed and connected by screws and nuts, which facilitates the assembly of the laser head 3.
[0034] Furthermore, such as Figure 5 and Figure 7 As shown, the powder conveying unit 34 includes a powder guiding cone 341, a powder guiding channel 342, a collar 343, a diffuser frame 344, and a mounting plate 345. A mounting plate 345 is provided between the inner air guide hood 33 and the outer cover 35 for assembling the powder conveying unit 34. A collar 343 is fitted onto the bottom of the mounting plate 345, and the collar 343 is fitted onto the outside of the inner air guide hood 33. A diffuser frame 344 is fixed circumferentially to the surface of the collar 343. The diffuser frame 344 has a triangular structure. The powder guiding cone 341 is fixed to the bottom of the collar 343. The powder guiding cone 341 and the outer cover 345 are connected... The outer casing 35 is coaxial with the powder guide cone 341, forming a powder guide channel 342. The powder guide channel 342 is a conical channel and is coaxial with the laser unit 32. After the powder enters the outer casing 35 through the powder guide tube 39, it first contacts and disperses with the diffuser frame 344. Then, under the action of gravity, it falls along the powder guide cone 341 into the powder guide channel 342 and is discharged from the powder guide channel 342. Compared with the traditional method of setting four sets of powder tubes around the outside of the laser unit 32 for conveying powder, the powder falls in a ring structure and is dispersed more evenly.
[0035] Furthermore, such as Figure 6As shown, the laser head 3 also includes an outer air guide tube 38, a powder guide tube 39, and an inner air guide tube 310. The powder guide tube 39 is fixed circumferentially at the top of the outer cover 35. One end of the powder guide tube 39 extends into the interior of the outer cover 35, and the other end of the powder guide tube 39 is located outside the diffuser 344, so that the powder flow fed through the powder guide tube 39 can be blown onto the surface of the diffuser 344 and dispersed by the diffuser 344. The outer air guide tube 38 is installed circumferentially on the surface of the outer cover 35. One end of the outer air guide tube 38 extends into the interior of the outer air guide channel 37. The inner air guide tube 310 is fixed circumferentially on the surface of the connecting plate 36. One end of the inner air guide tube 310 passes through the connecting plate 36 and extends to the top of the inner side of the inner air guide cover 33. One end of the outer air guide tube 38, the powder guide tube 39, and the inner air guide tube 310 are all fixed with connectors for sealing the connection pipes, so as to facilitate the sealed connection with the protective gas delivery pipe and the powder flow pipe.
[0036] During assembly, the powder conveying unit 34 is inserted into the outer cover 35, forming a powder guiding channel 342 at the bottom between the powder conveying unit 34 and the outer cover 35. Then, the inner gas guide shroud 33 is inserted into the powder conveying unit 34, followed by the laser unit 32. The connecting plate 36, inner gas guide shroud 33, powder conveying unit 34, and outer cover 35 are then secured with screws and nuts, completing the laser head 3 installation. In use, high-purity argon or nitrogen is blown into the outer gas guide channel 37 and inner gas guide shroud 33 through the outer gas guide pipe 38 and inner gas guide pipe 310 respectively, forming a localized protective atmosphere. The inner protective gas prevents powder from rebounding and sticking to the outlet, causing blockage. The external protective gas prevents powder oxidation. At the same time, the laser beam generated by the laser generator 31 is emitted from the center of the laser section 32 and focused on the surface of the workpiece to form a molten pool. The powder enters the outer side of the collar 343 through the powder guide tube 39 and the powder carrier gas, high-purity argon or nitrogen. At this time, the powder impacts the diffuser 344 and then disperses along the powder guide cone 341 into the powder guide channel 342. It is then fed into the laser molten pool in a ring shape through the powder guide channel 342. The energy of the laser causes the powder to melt rapidly in the molten pool, forming a cladding layer. Since the powder guide channel 342 is coaxial with the laser section 32, coaxial powder feeding can make the powder flow and the laser beam converge precisely at one point, achieving consistent powder feeding in a 360-degree direction, which is particularly suitable for curved surface repair.
[0037] The technical solutions described in the embodiments of this application have at least the following technical effects or advantages: they facilitate assembly and allow the powder to fall uniformly in a ring shape, thereby improving the cladding effect of the laser processing device.
[0038] Example 3: In Example 2 above, the powder falls evenly through the powder guiding channel 342. However, due to the small space of the powder guiding channel 342, dust blockage is likely to occur. This application example is an optimization based on the above example.
[0039] like Figure 7 and Figure 8 As shown, the laser head 3 is internally equipped with an anti-clogging mechanism 4, which includes a striking ball 42, a support base 44, and a rotating rod 45. The support base 44 is circumferentially fixed to the inner wall of the powder guiding cone 341. The rotating rod 45 is rotatably connected to the top of the support base 44, and the striking ball 42 is fixed to one end of the rotating rod 45. Under normal conditions, the striking ball 42 and the rotating rod 45 are subjected to gravity, causing one side of the rotating rod 45 to contact the top of the support base 44, thus moving the striking ball 42 away from the powder guiding cone 341. The anti-clogging mechanism 4 also includes an impeller 41 and a port 43, which is circumferentially opened in the inner air guide shroud. An impeller 41 is rotatably connected to the inner wall of the inner air guide shroud 33. The impeller 41 and the striking ball 42 cooperate with each other. When the inner protective gas enters the inner air guide shroud 33, the airflow moves from top to bottom, pushing the impeller 41 to rotate. This causes the blades on the surface of the impeller 41 to push the striking ball 42 upward, causing the striking ball 42 to strike the powder guide cone 341. When the striking ball 42 strikes the powder guide cone 341, the tip of the blade of the impeller 41 contacts the outermost end of the striking ball 42. As the impeller 41 continues to rotate, it will separate from the striking ball 42, so that the movement trajectories of the impeller 41 and the striking ball 42 will not be mutually exclusive.
[0040] When in use, when the internal protective gas is introduced into the inner air guide shroud 33, the protective gas drives the impeller 41 to rotate, causing the blades of the impeller 41 to push the striking ball 42. Under the action of the rotating rod 45, the striking ball 42 rotates upward, causing the striking ball 42 to strike the powder guide cone 341, shaking off the powder adhering to the surface of the powder guide cone 341, thus preventing the channel from being blocked by too much powder adhering to the surface of the powder guide cone 341. When the blades on the surface of the impeller 41 move away from the striking ball 42, the striking ball 42 resets under the action of gravity, causing the rotating rod 45 to fall onto the surface of the support base 44.
[0041] The technical solutions in the above embodiments of this application have at least the following technical effects or advantages: when protective gas is introduced into the inner side of the inner gas guide shroud 33, the gas can drive the impeller 41 to rotate and drive the striking ball 42 to reciprocate, striking the powder guide cone 341, thereby avoiding the phenomenon of blockage of the powder guide channel 342 when the laser processing device is used.
[0042] Example 4: The laser head 3 in Example 2 above generates high temperature when working. Generally, the outside of the powder guiding channel 342 is cooled only by the water cooling circulation structure, and the cooling effect is poor. This application example is based on the above example with certain optimizations.
[0043] like Figure 7 and Figure 8As shown, the laser head 3 has a cooling mechanism 5 inside. The cooling mechanism 5 includes a water-cooling circulation section 51, an air guide ring 52, and a baffle 53. The water-cooling circulation section 51 is installed inside the outer casing 35 and surrounds the outside of the powder conveying section 34 to cool the outside of the powder conveying section 34. The air guide ring 52 is fixed to the outside of the inner air guide shroud 33. The air guide ring 52 is coaxial with the inner air guide shroud 33 and has a hollow structure. The baffle 53 is fixed inside the air guide ring 52 by a bracket. Coaxial with the inner air guide shroud 33, the inner wall of the baffle 53 is in close contact with the surface of the laser part 32. During assembly, the inner wall of the baffle 53 is in close contact with the surface of the laser part 32, blocking the airflow. At the same time, the baffle 53 divides the air guide ring 52 into two parts, so that the airflow enters the upper part of the air guide ring 52 laterally under the obstruction of the baffle 53, and blows along the baffle 53 to the surface of the powder guide cone 341, cooling the powder guide cone 341. Then the airflow enters the lower part of the air guide ring 52 and flows back to the inner side of the inner air guide shroud 33 along the air guide ring 52 and the baffle 53.
[0044] In use, the water cooling circulation unit 51 cools the outside of the powder guiding channel 342. At the same time, when the protective gas enters the inner air guiding cover 33, the protective gas enters the inner air guiding ring 52 along the inner air guiding cover 33. At this time, the baffle 53 blocks the protective gas, allowing the protective gas to enter the interior of the air guiding ring 52 and come into contact with the powder guiding cone 341, thus cooling the powder guiding cone 341. Then, the protective gas flows back to the inner air guiding cover 33 along the bottom of the air guiding ring 52.
[0045] The technical solutions in the above embodiments of this application have at least the following technical effects or advantages: the air guide ring 52 and the baffle 53 work together to deflect the incoming internal protective gas, so that the internal protective gas can contact the powder guide cone 341 and cool the powder guide cone 341 with air. With the help of the water cooling circulation unit 51, the internal and external cooling of the powder guide channel 342 can be achieved, which improves the cooling effect of the powder guide channel 342 when the laser processing device is in use.
[0046] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. For those skilled in the art, the present invention can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.
Claims
1. A laser processing device for repairing defects in irregularly shaped components, comprising a processing table (1), characterized in that: The processing table (1) is equipped with a control panel (11) and a laser processing mechanism (2) is provided on the surface of the processing table (1). The laser processing mechanism (2) includes a multi-directional linear module (21), an adjusting slide (22) and a laser head (3). The processing table (1) is equipped with a multi-directional linear module (21) and an adjusting slide (22) is provided on the surface of the multi-directional linear module (21). The control panel (11) controls the multi-directional linear module (21) to drive the adjusting slide (22) to move back, forth and left, right. The adjusting slide (22) is provided below the laser head (3).
2. The laser processing apparatus for repairing defects in irregularly shaped components according to claim 1, characterized in that: The laser processing mechanism (2) further includes an electric push rod (23), a receiving cylinder (24), a flip motor (25), a turntable (26), a sliding frame (27), and a rotary motor (28). The sliding frame (27) is slidably arranged on one side of the adjusting slide (22). The electric push rod (23) is mounted on the surface of the adjusting slide (22). The input end of the electric push rod (23) is electrically connected to the output end of the control panel (11). One end of the electric push rod (23) is fixedly connected to the top of the sliding frame (27). The rotary motor (28) is installed inside the sliding frame (27). The input end of the rotary motor (28) is connected to the control panel (11). The output end of the control panel (11) is electrically connected. The output end of the rotary motor (28) is fixed with a rotating shaft through a coupling. One end of the rotating shaft is fixed with a receiving cylinder (24). A turntable (26) is rotatably connected to one side of the receiving cylinder (24). The turntable (26) is fixed to the laser head (3) by screws. A flip motor (25) is installed inside the receiving cylinder (24). The input end of the flip motor (25) is electrically connected to the output end of the control panel (11). The output end of the flip motor (25) is fixed with a rotating shaft through a coupling. One end of the rotating shaft is fixedly connected to the center position of the turntable (26).
3. The laser processing apparatus for repairing defects in irregularly shaped components according to claim 1, characterized in that: The laser head (3) includes a laser generator (31), a laser section (32), and a connecting plate (36). The laser generator (31) is fixed to one side of the turntable (26) by screws. The input end of the laser generator (31) is electrically connected to the output end of the control panel (11). The laser section (32) is fixed to the bottom of the laser generator (31). The structure at the bottom of the laser section (32) is an inverted cone structure. The connecting plate (36) is fitted on the outer side of the laser section (32).
4. The laser processing apparatus for repairing defects in irregularly shaped components according to claim 3, characterized in that: The laser head (3) also includes an inner gas guide shroud (33), a powder conveying section (34), an outer cover (35), and an outer gas guide channel (37). The inner gas guide shroud (33) is fitted on the outer side of the bottom position of the laser section (32). The inner gas guide shroud (33) is coaxial with the laser section (32). The top of the inner gas guide shroud (33) is tightly fitted with the surface of the connecting plate (36). The outer cover (35) is fitted on the outer side of the inner gas guide shroud (33). The outer cover (35) is coaxial with the laser section (32). The inner gas guide shroud (35) has an inner gas guide channel (37). An external air guide channel (37) is provided, which is coaxial with the outer cover (35). A powder conveying part (34) is provided between the outer cover (35) and the inner air guide hood (33). The powder conveying part (34) is coaxial with the laser part (32). The top of the powder conveying part (34) is tightly fitted with the top of the inner air guide hood (33) and the outer cover (35), respectively. The top of the connecting plate (36), the inner air guide hood (33), the powder conveying part (34) and the outer cover (35) are sealed and connected by screws and nuts.
5. The laser processing apparatus for repairing defects in irregularly shaped components according to claim 4, characterized in that: The powder conveying unit (34) includes a powder guiding cone (341), a powder guiding channel (342), a collar (343), a diffuser frame (344), and a mounting plate (345). The mounting plate (345) is provided between the inner gas guide hood (33) and the outer cover (35). The bottom of the mounting plate (345) is fitted with a collar (343). The collar (343) is fitted on the outside of the inner gas guide hood (33). The diffuser frame (344) is fixed circumferentially on the surface of the collar (343). The bottom of the collar (343) is fixed with a powder guiding cone (341). The powder guiding cone (341) is coaxial with the outer cover (35). A powder guiding channel (342) is formed between the powder guiding cone (341) and the outer cover (35). The powder guiding channel (342) is coaxial with the laser unit (32).
6. The laser processing apparatus for repairing defects in irregularly shaped components according to claim 4, characterized in that: The laser head (3) also includes an outer air guide tube (38), a powder guide tube (39), and an inner air guide tube (310). The powder guide tube (39) is fixed circumferentially at the top position of the outer cover (35). One end of the powder guide tube (39) extends into the interior of the outer cover (35). One end of the powder guide tube (39) is located outside the diffuser frame (344). The outer air guide tube (38) is installed circumferentially on the surface of the outer cover (35). One end of the outer air guide tube (38) extends into the interior of the outer air guide channel (37). The inner air guide tube (310) is fixed circumferentially on the surface of the connecting plate (36). One end of the inner air guide tube (310) passes through the connecting plate (36) and extends to the top position inside the inner air guide cover (33).
7. The laser processing apparatus for repairing defects in irregularly shaped components according to claim 1, characterized in that: The laser head (3) is provided with an anti-blocking mechanism (4). The anti-blocking mechanism (4) includes a striking ball (42), a support base (44) and a rotating rod (45). The support base (44) is fixed circumferentially to the inner wall of the powder guide cone (341). The top of the support base (44) is rotatably connected to the rotating rod (45), and a striking ball (42) is fixed at one end of the rotating rod (45).
8. The laser processing apparatus for repairing defects in irregularly shaped components according to claim 7, characterized in that: The anti-blocking mechanism (4) also includes an impeller (41) and a port (43). The port (43) is circumferentially opened on the inner wall of the inner air guide shroud (33). The impeller (41) is rotatably connected inside the port (43). The impeller (41) cooperates with the striking ball (42).
9. The laser processing apparatus for repairing defects in irregularly shaped components according to claim 1, characterized in that: The laser head (3) is provided with a cooling mechanism (5). The cooling mechanism (5) includes a water cooling circulation section (51), an air guide ring (52), and a baffle (53). The water cooling circulation section (51) is installed inside the outer cover (35) and surrounds the outside of the powder conveying section (34). The air guide ring (52) is respectively fixed on the outside of the inner air guide cover (33). The air guide ring (52) is coaxial with the inner air guide cover (33). The air guide ring (52) is a hollow structure. The baffle (53) is fixed inside the air guide ring (52) by a bracket. The baffle (53) is coaxial with the inner air guide cover (33). The inner wall of the baffle (53) is in close contact with the surface of the laser section (32).
10. A laser processing method for repairing defects in irregularly shaped components, coupled with the laser processing apparatus for repairing defects in irregularly shaped components as described in claim 6, characterized in that, The method includes: S1. Defect location and pretreatment: Use non-destructive testing or visual measurement to accurately locate the area and depth of the workpiece defect, and mechanically clean the defect area to form a clean area to be repaired. The edges of the repair area are machined with a gentle slope to avoid sharp corners. S2. Repair Parameter Planning: Select metal powders with the same composition or excellent compatibility according to the substrate material and dry them thoroughly. Based on the depth and area of the defect, plan a layered repair strategy: divide the entire repair depth into several layers, with each layer having a cladding thickness of 0.2-0.5mm. Set core process parameters such as laser power, spot diameter, scanning speed, powder feed rate, and protective gas flow rate. S3. Coaxial powder feeding laser repair: The processed workpiece to be repaired is installed at the designated position on the surface of the processing table (1). Then, the laser processing device is turned on. According to the planned path and parameters, the laser head (3) performs laser scanning cladding in the defect area of the workpiece. The scanning path adopts parallel scanning or concentric circle scanning. The scanning direction between layers is rotated by a certain angle to refine the grains, reduce stress concentration, and build up layer by layer until the filling metal is slightly higher than the theoretical surface of the workpiece. S4. Post-weld treatment and finishing: After the repair is completed, the repaired area is visually inspected and non-destructively tested to ensure that there are no new defects such as cracks or lack of fusion. The repaired area is then machined to the final dimensions and geometric tolerances required by the product drawings using CNC milling or grinding.