Compound machining system and machining method based on double-ring light spot

Abstract

The application provides a kind of based on double-ring light spot composite processing system and processing method, belong to laser processing technical field.The system includes first optical path component, including first light source, first collimating mirror, first annular light beam generation module and first hollow mirror;Second optical path component, including second light source, second collimating mirror, second annular light beam generation module and second mirror;Shaping optical path component, including negative roof prism, positive roof prism, second hollow mirror, and hollow focusing mirror, negative roof prism, positive roof prism are set to the side of first hollow mirror away from second optical path component;Wire feeding pipe, along vertical direction arrangement and be provided with the through hole on second hollow mirror and hollow focusing mirror;Powder feeding nozzle, along the radial direction of wire feeding pipe is set to wire feeding pipe end outside.The technical problem that metal wire material, powder and laser coupling caused by structural defects in prior art laser processing cladding system is poor can be solved.

Description

Technical Field

[0001] This invention relates to the field of laser processing technology, and in particular to a composite processing system and method based on a double-ring spot. Background Technology

[0002] Laser additive manufacturing and welding technology, as an important development direction in advanced manufacturing, has shown broad application prospects in high-end equipment manufacturing such as aerospace, rail transportation, and mold repair. With the continuous improvement of the manufacturing industry's requirements for component forming efficiency and metallurgical quality, processing technologies using a single energy source or a single filler method are no longer sufficient to meet the comprehensive performance requirements under complex working conditions. Especially in composite processing scenarios involving wire deposition and powder metallurgy, there is a need for both high wire deposition efficiency to improve forming speed and excellent microstructure properties obtained through powder metallurgy. This places higher demands on the synergistic relationship between energy distribution and filler methods in the laser welding process.

[0003] Currently, in laser cladding processes, to achieve composite deposition of wire and powder, independent wire and powder feeding mechanisms are typically used. These mechanisms push the metal wire into the molten pool formed by the interaction between the laser and the workpiece at a set angle and speed, supplemented by a bypass powder feeding method. The wire feeding mechanism, powder nozzle, and laser processing head are spatially relatively independent, requiring a precise motion control system to coordinate the relative motion trajectories between the laser head, wire feed nozzle, powder nozzle, and workpiece in real time, thereby completing the cladding deposition along the preset path. While this spatially separated arrangement can achieve composite deposition of wire and powder to a certain extent, its structure is relatively complex and requires high precision in the motion control system.

[0004] Existing single-spot or non-coaxial wire / powder feeding technologies still have significant limitations in practical applications, making it difficult to achieve precise coaxial coupling of laser energy, wire, and powder. Traditional wire-powder composite processes often employ off-axis powder feeding or single-ring spot energy distribution modes, resulting in uneven mixing of powder and molten pool. This easily leads to insufficient energy supply in the core area of ​​the molten pool while the edges overheat, causing process defects such as spatter, collapse, and excessively large heat-affected zones. These problems severely restrict the geometric accuracy and mechanical properties of the formed parts, becoming a key bottleneck hindering the further promotion and application of wire-powder composite laser processing technology. Summary of the Invention

[0005] This invention provides a composite processing system and method based on a dual-ring laser spot, which can solve the technical problem of poor coupling between metal wire, powder, and laser caused by structural defects in existing laser cladding systems. The technical solution is as follows: In a first aspect, embodiments of the present invention provide a composite processing system based on a dual-ring light spot, comprising: The first optical path assembly includes a first light source, a first collimating lens, a first annular beam generating module, and a first hollow reflector arranged sequentially at intervals along the vertical direction. The second optical path assembly is arranged horizontally at intervals on one side of the first optical path assembly, and includes a second light source, a second collimating lens, a second annular beam generating module, and a second reflecting mirror arranged vertically at intervals. The shaping optical path assembly includes a negative roof prism, a positive roof prism, and a second hollow reflector arranged at intervals along the horizontal direction, and a hollow focusing lens disposed below the second hollow reflector in the vertical direction. The negative roof prism and the positive roof prism are arranged at intervals on the side of the first hollow reflector away from the second optical path assembly. A wire feeding tube is arranged vertically and passes through a through hole in the second hollow reflector and the hollow focusing lens; The powder feeding nozzle is arranged radially along the outer side of the end of the wire feeding tube.

[0006] Optionally, the ridge lines of the negative ridge prism and the positive ridge prism are parallel to each other.

[0007] Optionally, the focal lengths of the first collimating lens and the second collimating lens may be the same or different.

[0008] Optionally, the first annular beam generating module includes a first negative cone lens and a first positive cone lens arranged coaxially at intervals along the beam direction emitted by the first light source and with their cone surfaces facing each other; the second annular beam generating module includes a second negative cone lens and a second positive cone lens arranged coaxially at intervals along the beam direction emitted by the second light source and with their cone surfaces facing each other.

[0009] Optionally, it also includes an adjustment frame having precision guide rails arranged in a vertical direction, wherein the first negative cone lens and the first positive cone lens, as well as the second negative cone lens and the second positive cone lens, can be slidably mounted on the corresponding precision guide rails.

[0010] Optionally, multiple powder feeding nozzles are provided and are arranged at equal angular intervals around the circumference of the wire feeding tube.

[0011] Optionally, the wire feeding tube is equipped with a variety of types, and the inner diameters of the various wire feeding tubes are different.

[0012] Optionally, it also includes a control system, which is communicatively connected to the first light source, the second light source, the wire feeding tube, and the powder feeding nozzle, for adjusting the beam power emitted by the first light source and the second light source, the wire feeding speed of the wire feeding tube, and the powder feeding rate of the powder feeding nozzle.

[0013] Optionally, the negative ridge prism and the positive ridge prism are detachably mounted in the composite processing system based on the double-ring light spot.

[0014] Secondly, embodiments of the present invention provide a processing method based on the composite processing system based on a dual-ring spot described in the first aspect, comprising: The light beam emitted by the first light source is shaped into a ring beam by the first collimating mirror and the first ring beam generating module. After being reflected by the first hollow reflector and passing through the negative roof prism and the positive roof prism, it is divided into multiple beams that are symmetrically distributed in space. After being reflected by the second hollow reflector, it is focused by the hollow focusing mirror to form an outer arc light spot around the end of the wire feeding tube. The beam emitted by the second light source is shaped into a ring beam by the second collimating mirror and the second ring beam generating module. After being reflected by the second reflecting mirror and passing through the through hole on the first hollow reflecting mirror, the negative roof prism and the positive roof prism, it is divided into multiple beams that are symmetrically distributed in space. After being reflected by the second hollow reflecting mirror, it is focused by the hollow focusing mirror to form an inner arc spot located between the end of the wire feeding tube and the outer arc spot. The wire is fed into the center of the inner arc-shaped spot using the wire feeding tube to achieve rapid through melting; the metal powder is spread onto the outer arc-shaped spot using the powder feeding nozzle to uniformly preheat the metal powder and melt it steadily at the edge of the molten pool.

[0015] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following: The composite processing system based on a double-ring spot provided in this invention generates two independently adjustable ring beams through a first optical path component and a second optical path component, respectively. These beams are then split and combined by a double-roof prism in the shaping optical path component, and focused by a second hollow reflector and a hollow focusing mirror, forming a double-ring arc spot structure with an inner and outer ring on the focal plane. The inner ring spot precisely acts on the central welding wire to achieve efficient penetration melting, while the outer ring spot uniformly acts on the circumferential powder to achieve stable melting. This effectively solves the technical problem of precise coaxial coupling of laser energy, wire, and powder in existing technologies, and overcomes the technical difficulty of conflicting wire and powder melting requirements in traditional single-spot processes, resulting in increased density and reduced porosity of the formed parts. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of a composite processing system based on a dual-ring light spot provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the working state of a composite processing system based on a double-ring light spot provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of the negative roof prism and the positive roof prism provided in the embodiments of the present invention; Figure 4 This is a schematic diagram of the structure of the first annular beam generation module provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of the second annular beam generation module provided in an embodiment of the present invention; Figure 6 This is a control structure block diagram of the control system provided in the embodiments of the present invention; Figure 7 This is a flowchart of the processing method provided in the embodiments of the present invention.

[0018] In the picture: 1-First optical path assembly; 11-First light source; 12-First collimating lens; 13-First annular beam generating module; 131-First negative cone lens; 132-First positive cone lens; 14-First hollow reflector; 2-Second optical path assembly; 21-Second light source; 22-Second collimating lens; 23-Second annular beam generating module; 231-Second negative cone lens; 232-Second positive cone lens; 24-Second reflecting mirror; 3-Shaping optical path assembly; 31-Negative roof prism; 32-Positive roof prism; 33-Second hollow reflector; 34-Hollow focusing lens; 4-Wire feeding tube; 5-Powder feeding nozzle; 6-Adjusting frame; 61-Precision guide rail; 7-Control system. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0020] Figure 1 This is a schematic diagram of a composite processing system based on a dual-ring light spot provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the working state of a composite processing system based on a double-ring light spot provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of the negative roof prism and the positive roof prism provided in the embodiments of the present invention; Figure 4 This is a schematic diagram of the structure of the first annular beam generation module provided in an embodiment of the present invention; Figure 5This is a schematic diagram of the structure of the second annular beam generation module provided in an embodiment of the present invention; Figure 6 This is a block diagram of the control structure of the control system provided in an embodiment of the present invention. Figures 1 to 6 As shown, this embodiment of the invention provides a composite processing system based on a dual-ring light spot, including a first optical path component 1, a second optical path component 2, a shaping optical path component 3, a wire feeding tube 4, and a powder feeding nozzle 5.

[0021] The first optical path assembly 1 includes a first light source 11, a first collimating lens 12, a first annular beam generating module 13, and a first hollow reflector 14, arranged sequentially along the vertical direction. The first light source 11 is located at the top of the first optical path assembly 1 and is used to emit a first laser beam. The first light source 11 can be a ring-core fiber laser or a laser whose beam is obtained through optical path conversion, and its power can be adjusted according to actual process requirements. The laser beam emitted by the first light source 11 propagates downwards along the vertical direction, first being shaped into a parallel beam by the first collimating lens 12, and then entering the first annular beam generating module 13, where it is shaped into a hollow annular beam. The shaped annular beam continues to propagate downwards along the vertical direction and reaches the first hollow reflector 14. The first hollow reflector 14 has a through hole at its center, and its reflecting surface is set at a 45° angle to the horizontal direction, used to reflect the first annular beam propagating in the vertical direction to the horizontal direction. Since the first hollow reflector 14 has a through hole at its center, it can allow the second beam to pass through the through hole while reflecting the first annular beam, thereby achieving the spatial merging of the two beams.

[0022] The second optical path assembly 2 is horizontally spaced on one side of the first optical path assembly 1, and includes a second light source 21, a second collimating mirror 22, a second annular beam generating module 23, and a second reflector 24 arranged vertically at intervals. The second light source 21 is located at the top of the second optical path assembly 2 and is used to emit a second laser beam. The laser beam emitted by the second light source 21 propagates downwards vertically, is shaped into a parallel beam by the second collimating mirror 22, and then enters the second annular beam generating module 23, where it is shaped into a hollow annular beam. The shaped second annular beam continues to propagate downwards to the second reflector 24, whose reflective surface is also set at a 45° angle to the horizontal direction, reflecting the vertically propagating second annular beam to the horizontal direction, so that the second annular beam propagates towards the first hollow reflector 14. Because the first hollow reflector 14 has a through-hole at its center, and the diameter of the second annular beam is smaller than that of the first annular beam, the second annular beam can pass through the central through-hole of the first hollow reflector 14 and propagate coaxially with the first annular beam reflected by the first hollow reflector 14 in the horizontal direction. Through this optical path structure where the beams are generated separately by two light sources and combined by the hollow reflectors, the two annular beams form a coaxial nested relationship with different diameters in the horizontal direction, with the first annular beam located on the outer side and the second annular beam located on the inner side, thus laying the foundation for the subsequent formation of inner and outer double-ring light spots on the focal plane.

[0023] The shaping optical path assembly 3 includes a negative roof prism 31, a positive roof prism 32, and a second hollow reflector 33 arranged horizontally at intervals, and a hollow focusing mirror 34 disposed vertically below the second hollow reflector 33. The negative roof prism 31 and the positive roof prism 32 are spaced apart on the side of the first hollow reflector 14 away from the second optical path assembly 2. In the beam propagation direction, the two coaxial annular beams, after being combined by the first hollow reflector 14, first enter the negative roof prism 31. The negative roof prism 31 has a roof surface behind its incident side, which is composed of two beam-splitting surfaces arranged at an obtuse angle and symmetrical with respect to the central ridge line. After the annular beams are incident on the negative roof prism 31, they are split by the beam-splitting surfaces along the ridge line into multiple beams symmetrically distributed in space. After being split by the negative roof prism 31, the multiple beams continue to propagate horizontally to the positive roof prism 32. The positive roof prism 32 combines and shapes the split beams so that they can form symmetrically distributed arc-shaped light spots on the focal plane during subsequent focusing.

[0024] The multiple beams of light, shaped by the negative roof prism 31 and the positive roof prism 32, reach the second hollow reflector 33. The second hollow reflector 33 also has a through-hole at its center, and its reflective surface reflects the horizontally propagating beam downwards. The beams reflected by the second hollow reflector 33 are focused by the hollow focusing lens 34, which also has a through-hole at its center. This results in a double-ringed arc-shaped light spot structure around the end of the wire feed tube 4 on the focal plane, consisting of an outer arc-shaped light spot and an inner arc-shaped light spot. The outer arc-shaped light spot is formed by focusing the first beam emitted from the first light source 11, while the inner arc-shaped light spot is formed by focusing the second beam emitted from the second light source 21. Since the second hollow reflector 33 and the hollow focusing mirror 34 are both provided with through holes in their centers, and there are gaps between multiple beams during beam transmission, they will not pass through the central area, thus providing unobstructed passage space for the wire feeding tube 4 and completely eliminating the risk of physical interference between the laser and the wire feeding tube 4 and the unmelted wire.

[0025] The wire feed tube 4 is arranged vertically and passes through the through holes in the second hollow reflector 33 and the hollow focusing lens 34. The outlet end of the wire feed tube 4 is precisely coaxial with the optical axis of the hollow focusing lens 34, allowing the metal welding wire to be fed through the wire feed tube 4 into the central region of the inner arc-shaped light spot at the focal plane. The welding wire is precisely fed along the optical axis to the inner arc-shaped light spot's action area. The energy of the inner arc-shaped light spot is highly concentrated, enabling rapid penetration of the central welding wire, ensuring full melting of the welding wire, and avoiding "incomplete penetration" defects.

[0026] The powder feeding nozzle 5 is radially positioned on the outer side of the end of the wire feeding tube 4. The powder feeding nozzle 5 is used to transport metal powder along the path of the outer arc-shaped spot to the edge area of ​​the molten pool. The energy distribution of the outer arc-shaped spot is uniform, which can match the powder spreading trajectory, so that the powder is uniformly preheated during flight and melts smoothly at the edge of the molten pool, greatly reducing the oxidation loss and splashing rate of the powder.

[0027] The composite processing system based on a double-ring spot provided in this invention generates two independently adjustable ring beams through the first optical path component 1 and the second optical path component 2. These beams are then split and combined by the double-roof prism in the shaping optical path component 3, and focused by the second hollow reflector 33 and the hollow focusing mirror 34, forming a double-ring arc spot structure with an inner and outer ring on the focal plane. The inner ring spot precisely acts on the central welding wire to achieve efficient penetration melting, while the outer ring spot uniformly acts on the circumferential powder to achieve stable melting. This effectively solves the technical problem of the difficulty in accurately coaxially coupling laser energy, wire, and powder in existing technologies. It also overcomes the technical challenge of conflicting wire and powder melting requirements in traditional single-spot processes, increasing the density of the formed part to over 99% and reducing porosity by an order of magnitude.

[0028] Furthermore, in this embodiment of the invention, the ridge lines of the negative ridge prism 31 and the positive ridge prism 32 are parallel to each other. Specifically, the negative ridge prism 31 has a ridge surface behind its incident side, which is composed of two beam-splitting surfaces arranged at an obtuse angle and symmetrical with respect to the central ridge line, and the ridge line extends vertically. The positive ridge prism 32 also has a ridge surface behind its incident side, and its ridge line extends in a direction parallel to the ridge line of the negative ridge prism 31, that is, it also extends vertically.

[0029] When two coaxial nested annular beams are incident on the negative roof prism 31, the negative roof prism 31 vertically splits each annular beam into two semi-annular beams. Specifically, the first annular beam is split into two outer semi-annular beams, and the second annular beam is split into two inner semi-annular beams. After being split by the negative roof prism 31, gaps are formed between the semi-annular beams. During reflection by the first hollow reflector 14 or direct horizontal propagation, these gaps ensure that the beams do not pass through the wire feed tube 4 in the central region, creating a stable gap avoidance effect. The split beams continue to propagate to the positive roof prism 32. Since the ridge line of the positive roof prism 32 is parallel to the ridge line of the negative roof prism 31, the positive roof prism 32 re-aligns and re-collimates the two semi-annular beams after being split by the negative roof prism 31. Finally, after reflection by the second hollow reflector 33, the laser beam is focused by the hollow focusing lens 34, forming a double semi-circular arc-shaped laser spot on the focal plane, i.e., two semi-circular arc-shaped beams. The two semi-circular arc-shaped beams are symmetrically distributed on both sides of the outlet end of the wire feeding tube 4 along the beam splitting direction defined by the ridge line, symmetrically heating the welding wire and powder.

[0030] By configuring the negative roof prism 31 and the positive roof prism 32 with their ridge lines parallel to each other, each annular beam is split into two semi-annular beams. After beam combining and focusing, these beams form two symmetrical semi-circular arc spots on the focal plane. This spot shape perfectly avoids the axial central region where the wire is fed through the wire feed tube 4. During transmission, the multiple beams remain within the gaps after beam splitting, ensuring that no beam passes through the wire feed tube 4 located in the center. This completely eliminates the risk of physical interference between the laser and the wire feed tube 4 and the unmelted wire. The two semi-circular arc spots symmetrically surround the end of the wire feed tube 4, delivering the metal wire and powder to the focal plane for efficient and uniform heating. This results in more complete and stable melting of the metal wire and powder, significantly reducing spatter and substantially improving weld formation quality and process consistency.

[0031] Exemplarily, in other possible implementations, the annular beam can also be split into more beams by changing the number of ridge surfaces and the ridge angle relationship of the negative ridge prism 31 and the positive ridge prism 32. For example, the ridge edges of the negative ridge prism 31 and the positive ridge prism 32 can be configured to be perpendicular to each other, and ridge surfaces can be provided on both the incident and exit sides of the ridge prisms, with the two ridge prisms arranged orthogonally. In this configuration, the annular beam is split into four beams after being split by the four beam-splitting surfaces on both sides of the negative ridge prism 31, and after being split by the four beam-splitting surfaces on both sides of the positive ridge prism 32, the four beams are re-collimated into four parallel beams. Finally, after being reflected by the second hollow reflector 33, the beams are focused by the hollow focusing lens 34 to form four arc-shaped light spots symmetrically distributed at 90° intervals in azimuth. Depending on the actual processing requirements, different ridge prism configurations and ridge angle relationships can be selected to obtain different numbers and distributions of arc-shaped light spots on the focal plane, and this invention does not limit this.

[0032] Furthermore, in this embodiment of the invention, the focal lengths of the first collimating lens 12 and the second collimating lens 22 are either the same or different.

[0033] When the focal lengths of the first collimating lens 12 and the second collimating lens 22 are the same, the two beams have the same beam diameter and divergence angle characteristics after passing through their respective collimating lenses. This is suitable for processing scenarios where the energy density and spot size consistency of the inner and outer ring spots are highly critical. When the focal lengths of the first collimating lens 12 and the second collimating lens 22 are different, the diameters of the two beams after collimation are different, resulting in differentiated size and energy density distributions of the inner and outer ring arc spots ultimately formed on the focal plane.

[0034] For example, the first collimating lens 12 can be configured with a larger focal length to obtain a first annular beam with a larger diameter, forming a larger outer arcuate spot on the focal plane to cover a larger powder spreading area; simultaneously, the second collimating lens 22 can be configured with a smaller focal length to obtain a second annular beam with a smaller diameter, forming a compact inner arcuate spot on the focal plane to concentrate energy and precisely melt the center welding wire. By flexibly configuring the focal lengths of the two collimating lenses, independent size control of the inner and outer annular spots can be achieved, meeting the differentiated energy requirements for wire deposition and powder metallurgy under different process parameters.

[0035] Furthermore, both the first collimating lens 12 and the second collimating lens 22 can be variable magnification beam expander collimating lenses. Variable magnification beam expander collimating lenses are typically composed of multiple lenses, and the output beam diameter and divergence angle can be changed by adjusting the lens spacing. By adjusting the beam expansion magnification, the annular beam can have the required diameter ratio before entering the hollow focusing lens 34. For example, the annular beam can be expanded to a larger size, allowing the split and combined beams to fully fill the outer ring region of the hollow focusing lens 34 to achieve optimal focusing quality. Simultaneously, changing the collimated beam diameter is equivalent to changing the final focal spot size; beam expansion can control the thickness of the arc-shaped spot to meet different molten pool size requirements, further improving the system's process flexibility.

[0036] Meanwhile, the power of the two light sources can be independently selected and matched according to process requirements. The power of the first light source 11 and the second light source 21 can be the same or different to achieve independent control of the energy density of the inner and outer ring light spots. For example, in the case where it is necessary to increase the amount of powder melting, the power of the first light source 11 can be increased to improve the energy density of the outer arc light spot; in the case where it is necessary to improve the penetration depth of the welding wire, the power of the second light source 21 can be increased to enhance the penetration ability of the inner arc light spot.

[0037] Furthermore, in this embodiment of the invention, the first annular beam generating module 13 includes a first negative conical lens 131 and a first positive conical lens 132 arranged coaxially at intervals along the beam direction emitted by the first light source 11 and having opposite conical surfaces. The second annular beam generating module 23 includes a second negative conical lens 231 and a second positive conical lens 232 arranged coaxially at intervals along the beam direction emitted by the second light source 21 and having opposite conical surfaces.

[0038] Specifically, in the first optical path assembly 1, the laser beam emitted by the first light source 11 is shaped into a parallel beam by the first collimating lens 12 and then enters the first annular beam generation module 13, which consists of a first negative conical lens 131 and a first positive conical lens 132. The first negative conical lens 131 diverges the incident parallel beam outward into a conical beam, and the first positive conical lens 132 then transforms the diverged conical beam into a hollow annular distribution, realizing the transfer of energy from the center of the beam to the edge ring, so that the light intensity is mainly concentrated in the annular region. After passing through this pair of conical lenses, the originally Gaussian distributed light spot is shaped into a hollow annular beam.

[0039] Similarly, in the second optical path assembly 2, the laser beam emitted by the second light source 21 is shaped into a parallel beam by the second collimating lens 22 and then enters the second annular beam generation module 23, which is composed of the second negative conical lens 231 and the second positive conical lens 232. The second negative conical lens 231 also diverges the incident parallel beam outward, and the second positive conical lens 232 then converts it into an annularly distributed beam.

[0040] By adjusting the axial distance between the first negative cone lens 131 and the first positive cone lens 132, the diameter and energy distribution of the first annular beam can be changed, thereby adjusting the size and power density of the outer arc-shaped light spot. Similarly, by adjusting the axial distance between the second negative cone lens 231 and the second positive cone lens 232, the parameters of the second annular beam can be adjusted independently, thereby controlling the characteristics of the inner arc-shaped light spot. The independent setting of the two sets of annular beam generation modules allows the parameters of the inner and outer annular light spots to be controlled separately, thereby achieving precise matching to the differentiated processing requirements of wire and powder.

[0041] Furthermore, in this embodiment of the invention, an adjustment frame 6 is also included. The adjustment frame 6 has a precision guide rail 61 arranged in a horizontal direction. The first negative cone lens 131 and the first positive cone lens 132, as well as the second negative cone lens 231 and the second positive cone lens 232, are all slidably mounted on the corresponding precision guide rail 61.

[0042] Specifically, the adjustment frame 6 is a modular installation structure, with corresponding adjustment frames 6 for the first annular beam generating module 13 and the second annular beam generating module 23. Each adjustment frame 6 is equipped with a precision guide rail 61 arranged vertically (i.e., in its respective beam propagation direction). The first negative cone lens 131 and the first positive cone lens 132 are slidably mounted on the precision guide rail 61 corresponding to the first annular beam generating module 13 via sliders. By manual fine-tuning or motor drive, the first negative cone lens 131 and the first positive cone lens 132 can be controlled to slide relative to each other along the precision guide rail 61, thereby continuously adjusting the axial distance between them. When the axial distance between the first negative cone lens 131 and the first positive cone lens 132 increases, the diameter of the first annular beam increases accordingly, and vice versa. This allows for continuous changes in the diameter and energy distribution of the initial annular beam within a certain range, thereby affecting the size and power density of the outer arc spot on the final focal plane. Similarly, the second negative cone lens 231 and the second positive cone lens 232 are slidably mounted on the precision guide rail 61 corresponding to the second annular beam generation module 23 via a slider, and the diameter parameters of the second annular beam can be adjusted independently, thereby controlling the characteristics of the inner arc spot.

[0043] By setting an adjustment frame 6 with a precision guide rail 61, the axial spacing of each conical lens in the two sets of annular beam generation modules can be adjusted independently and continuously, thereby adapting to welding wires of different diameters (such as Φ1.0mm, Φ1.2mm, Φ1.6mm, etc.) and different process requirements (such as welding, cladding, additive manufacturing), further improving the system's process flexibility and adaptability.

[0044] Furthermore, in this embodiment of the invention, multiple powder feeding nozzles 5 are provided and arranged at equal angular intervals around the circumference of the wire feeding tube 4. Specifically, the multiple powder feeding nozzles 5 are evenly arranged around the outer periphery of the end of the wire feeding tube 4, and the powder feeding nozzles 5 maintain equal angular intervals along the radial direction of the wire feeding tube 4. For example, three powder feeding nozzles 5 can be arranged at 120° intervals around the circumference, or four powder feeding nozzles 5 can be arranged at 90° intervals around the circumference; the specific number can be determined according to actual processing requirements. The powder discharge direction of the multiple powder feeding nozzles 5 is all towards the outer arc-shaped spot area on the focal plane, so that the metal powder is simultaneously transported to the edge of the molten pool from multiple directions along the path of the outer arc-shaped spot.

[0045] By circumferentially arranging multiple powder feeding nozzles 5, the metal powder can be evenly spread within the effective area of ​​the outer arc-shaped spot, avoiding uneven powder distribution and molten pool eccentricity caused by unilateral powder feeding, thereby improving powder utilization and the uniformity of the cladding layer composition. Simultaneously, the equiangular spacing of the multiple powder feeding nozzles 5 ensures consistent powder conveying performance in different processing directions, eliminating directional dependence in the processing and facilitating the forming of complex trajectories.

[0046] Furthermore, in this embodiment of the invention, the wire feeding tube 4 is equipped with multiple types, each with a different inner diameter. Specifically, for welding wires of different diameters, the system is configured with wire feeding tubes 4 of different inner diameters for interchangeable use according to processing requirements. For example, for a Φ1.0mm welding wire, a wire feeding tube 4 with an inner diameter slightly larger than 1.0mm is selected; for a Φ1.2mm welding wire, a wire feeding tube 4 with an inner diameter slightly larger than 1.2mm is selected; and for a Φ1.6mm welding wire, a wire feeding tube 4 with an inner diameter slightly larger than 1.6mm is selected. The inner diameter of each type of wire feeding tube 4 is precisely matched with the diameter of the corresponding welding wire, ensuring smooth feeding of the welding wire inside the wire feeding tube 4 while preventing the welding wire from shaking or shifting inside the wire feeding tube 4 due to excessive gaps. When replacing the wire feed tube 4, it is vertically inserted into the through-hole at the center of the second hollow reflector 33 and the hollow focusing mirror 34, ensuring that the outlet end of the wire feed tube 4 is precisely coaxial with the optical axis of the hollow focusing mirror 34. This guarantees that the metal welding wire always enters the core area of ​​the laser energy distribution without deviating from the optimal melting point, forming a uniform and stable molten pool. By equipping the system with wire feed tubes 4 of various inner diameters, the system can adapt to the processing needs of various specifications of welding wire, expanding the application range of the system.

[0047] Simultaneously, a modular wire feeding drive mechanism, such as a lifting module with grippers, can be set up to facilitate the replacement of the wire feeding tube 4. During the replacement and installation of the wire feeding tube 4, the top end of the wire feeding tube 4 is clamped by the grippers of the wire feeding drive mechanism, and then axially lowered so that the wire feeding tube 4 can accurately pass through the through holes of the second hollow reflector 33 and the hollow focusing lens 34 from the center, ensuring that the end is accurately positioned at the center of the focal plane where the arc-shaped light spot is located, thus improving assembly and processing accuracy.

[0048] Furthermore, in this embodiment of the invention, a control system 7 is also included. The control system 7 is communicatively connected to the first light source 11, the second light source 21, the wire feeding tube 4, and the powder feeding nozzle 5, and is used to regulate the beam power emitted by the first light source 11 and the second light source 21, the wire feeding speed of the wire feeding tube 4, and the powder feeding rate of the powder feeding nozzle 5.

[0049] Specifically, the control system 7 establishes communication connections with the first light source 11, the second light source 21, the wire feeding drive mechanism of the wire feeding tube 4, and the powder feeding drive mechanism of the powder feeding nozzle 5 via signal lines or wireless communication. The control system 7 can adjust the output power of the first light source 11 in real time, thereby controlling the energy density of the outer arc-shaped light spot to match the powder feeding rate, ensuring that the powder is fully preheated under the action of the outer arc-shaped light spot and melts smoothly at the edge of the molten pool. Simultaneously, the control system 7 can independently adjust the output power of the second light source 21, thereby controlling the energy density of the inner arc-shaped light spot to match the wire feeding speed, ensuring rapid penetration of the central welding wire. The control system 7 can also adjust the wire feeding speed of the wire feeding tube 4 and the powder feeding rate of the powder feeding nozzle 5 in real time. Through the coordinated control of multiple parameters such as laser power, wire feeding speed, and powder feeding rate, the optimal match between wire deposition efficiency and powder metallurgy performance is achieved.

[0050] For example, during gradient material manufacturing, the control system 7 can dynamically adjust the ratio of wire feeding speed and powder feeding rate during processing according to a preset gradient formula program, and simultaneously adjust the power of the first light source 11 and the second light source 21 accordingly, thereby achieving gradient design and precise control of the cladding layer composition. During dissimilar material welding, the control system 7 can optimize the energy parameters of the inner and outer ring light spots and the wire / powder feeding parameters based on the differences in the thermophysical properties of different materials, avoiding welding defects caused by improper energy distribution. Through the coordinated control function of the control system 7, the problem of insufficient composition control precision in traditional wire / powder composite processes is effectively solved, expanding the application scope of the system in dissimilar material welding and functionally graded parts manufacturing.

[0051] Furthermore, in this embodiment of the invention, the negative ridge prism 31 and the positive ridge prism 32 are detachably mounted in the composite processing system based on the double-ring light spot.

[0052] Specifically, the negative roof prism 31 and the positive roof prism 32 are fixed in the optical path of the shaping optical path assembly 3 via detachable mounting structures (such as snap-fit ​​connections, bolt connections, or magnetic connections). When it is necessary to change the number and distribution of the arc-shaped light spots on the focal plane, the existing negative roof prism 31 and positive roof prism 32 can be disassembled and replaced with roof prisms with different numbers of roof surfaces and ridge angles. For example, a pair of roof prisms with parallel roof ridge lines can be replaced with a pair of roof prisms with perpendicular roof ridge lines, so that the annular beam is divided into more symmetrical beams, thereby transforming the double semi-circular light spots on the focal plane into four arc-shaped light spots.

[0053] Furthermore, when the processing technology does not require the arc-shaped beam splitting effect (e.g., when only a complete annular beam is needed for wide-area cladding), the negative roof prism 31 and the positive roof prism 32 can be removed simultaneously. This allows the two annular beams to propagate directly horizontally to the second hollow reflector 33 and the hollow focusing lens 34 without beam splitting, ultimately forming complete inner and outer double annular beams on the focal plane. This achieves multi-condition adaptation of double semi-circular beams and annular beams. Through the detachable design of the negative roof prism 31 and the positive roof prism 32, the system can flexibly switch beam shapes according to different processing requirements. This further improves the system's adaptability and process flexibility while avoiding interference between the beam and the wire feeding mechanism.

[0054] Figure 7 This is a flowchart of the processing method provided in an embodiment of the present invention. For example... Figure 7 As shown, this embodiment of the invention also provides a processing method based on the aforementioned composite processing system based on a dual-ring spot, comprising the following steps: S1. The light beam emitted by the first light source 11 is shaped into a ring beam by the first collimating mirror 12 and the first ring beam generating module 13. After being reflected by the first hollow reflector 14 and passing through the negative roof prism 31 and the positive roof prism 32, it is divided into multiple beams that are symmetrically distributed in space. After being reflected by the second hollow reflector 33, it is focused by the hollow focusing mirror 34 to form an outer arc light spot around the end of the wire feeding tube 4.

[0055] The outer arc-shaped light spot has a uniform energy distribution and spreads over a large diameter range, precisely matching the spreading trajectory of the outer ring powder, providing uniform preheating and melting conditions for the metal powder. Since the outer arc-shaped light spot is formed by focusing the first ring beam with a large diameter, its coverage area can completely enclose the powder spreading area of ​​the powder feeding nozzle 5, ensuring that the powder is fully preheated before reaching the edge of the molten pool, reducing the oxidation and burn-off rate of the powder.

[0056] S2. The beam emitted by the second light source 21 is shaped into a ring beam by the second collimating mirror 22 and the second ring beam generating module 23. After being reflected by the second reflecting mirror 24 and passing through the through hole on the first hollow reflecting mirror 14, the negative roof prism 31 and the positive roof prism 32, it is divided into multiple beams that are symmetrically distributed in space. After being reflected by the second hollow reflecting mirror 33, it is focused by the hollow focusing mirror 34 to form an inner arc spot located between the end of the wire feeding tube 4 and the outer arc spot.

[0057] The energy of the inner arc-shaped light spot is highly concentrated and closely surrounds the outlet end of the wire feed tube 4, enabling efficient and uniform heating of the central welding wire. Since the inner arc-shaped light spot is formed by focusing a second ring beam with a smaller diameter, it has a high energy density and can quickly heat the welding wire to above the melting temperature, achieving rapid penetration of the welding wire.

[0058] It should be noted that steps one and two above can be performed simultaneously in the actual processing. That is, the first light source 11 and the second light source 21 emit light at the same time, and the two beams are transmitted, shaped and focused at the same time through their respective optical paths, forming an outer arc light spot and an inner arc light spot on the focal plane at the same time, so as to realize the synchronous effect of the inner and outer double ring light spots.

[0059] S3. Use wire feeding tube 4 to feed wire to the center of the inner arc spot to achieve rapid through melting; use powder feeding nozzle 5 to spread metal powder to the outer arc spot so that the metal powder is uniformly preheated and melts steadily at the edge of the molten pool.

[0060] Specifically, the wire is fed into the center of the inner arc-shaped laser beam using the wire feed tube 4. The welding wire is precisely delivered from the exit end of the wire feed tube 4 to the central region of the inner arc-shaped laser beam along the optical axis. The inner arc-shaped laser beam heats the welding wire symmetrically around it with high energy density, allowing the welding wire to melt rapidly and form a stable molten pool core. Because the inner arc-shaped laser beam perfectly avoids the axial central region of the wire feed tube 4, the laser beam will not pass through the central region where the wire feed tube 4 is located during transmission. This eliminates the risk of the laser being blocked by unmelted welding wire or the wire feed tube 4, significantly reducing spatter and improving the weld formation quality.

[0061] Simultaneously, metal powder is spread outwards via the powder feeding nozzle 5 using an outer arc-shaped light spot. Multiple powder feeding nozzles 5 simultaneously deliver metal powder from multiple circumferential directions of the wire feeding tube 4, ensuring the metal powder is evenly spread across the effective area of ​​the outer arc-shaped light spot. The uniform energy distribution of the outer arc-shaped light spot allows the metal powder to be uniformly preheated during its flight and melts smoothly upon reaching the edge of the molten pool, significantly reducing powder oxidation loss and spatter rate. The preheated powder fuses with the weld wire metal that penetrates the core area of ​​the molten pool, forming a composite cladding layer with good metallurgical bonding.

[0062] Throughout the entire processing, the control system 7 coordinates and regulates in real time the output power of the first light source 11 and the second light source 21, the wire feeding speed of the wire feeding tube 4, and the powder feeding rate of the powder feeding nozzle 5. Through the coordinated optimization of the above multiple parameters, the optimal match between efficient wire cladding and uniform powder metallurgy is achieved. Compared with the traditional single-spot process, the processing method of this invention effectively solves the problem of the contradiction between wire and powder melting requirements, significantly improving the density of the formed parts and greatly reducing the porosity. This processing method is applicable to various fields such as metal additive manufacturing, laser cladding, and dissimilar material welding, and can be used in high-end equipment manufacturing such as aerospace, rail transportation, and mold repair where there are high requirements for the forming efficiency and metallurgical quality of complex parts.

[0063] Unless otherwise defined, the technical or scientific terms used herein should be understood in their ordinary sense by one of ordinary skill in the art to which this invention pertains. The terms “first,” “second,” and similar terms used in this specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms “an” or “a” and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms “comprising” or “including” and similar terms mean that the elements or objects preceding “comprising” or “including” encompass the elements or objects listed following “comprising” or “including” and their equivalents, and do not exclude other elements or objects. The terms “connected” or “linked” and similar terms are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. The terms “upper,” “lower,” “left,” “right,” etc., are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0064] The above description is merely an optional embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A composite processing system based on a dual-ring light spot, characterized in that, include: The first optical path assembly (1) includes a first light source (11), a first collimating mirror (12), a first annular beam generating module (13), and a first hollow reflector (14) arranged sequentially at intervals along the vertical direction. The second optical path assembly (2) is arranged horizontally on one side of the first optical path assembly (1), including a second light source (21), a second collimating lens (22), a second annular beam generating module (23), and a second reflecting mirror (24) arranged vertically in sequence. The shaping optical path assembly (3) includes a negative ridge prism (31), a positive ridge prism (32), and a second hollow reflector (33) arranged at intervals along the horizontal direction, and a hollow focusing lens (34) arranged vertically below the second hollow reflector (33). The negative ridge prism (31) and the positive ridge prism (32) are arranged at intervals on the side of the first hollow reflector (14) away from the second optical path assembly (2). The wire feeding tube (4) is arranged vertically and passes through the through holes on the second hollow reflector (33) and the hollow focusing lens (34); The powder feeding nozzle (5) is arranged radially along the outer side of the end of the wire feeding tube (4).

2. The composite processing system based on a dual-ring light spot according to claim 1, characterized in that, The ridge lines of the negative ridge prism (31) and the positive ridge prism (32) are parallel to each other.

3. The composite processing system based on a dual-ring light spot according to claim 1, characterized in that, The focal lengths of the first collimating lens (12) and the second collimating lens (22) are either the same or different.

4. The composite processing system based on a dual-ring light spot according to claim 1, characterized in that, The first annular beam generating module (13) includes a first negative cone lens (131) and a first positive cone lens (132) arranged coaxially at intervals along the beam direction emitted by the first light source (11) and with their cone surfaces facing each other; the second annular beam generating module (23) includes a second negative cone lens (231) and a second positive cone lens (232) arranged coaxially at intervals along the beam direction emitted by the second light source (21) and with their cone surfaces facing each other.

5. The composite processing system based on a dual-ring light spot according to claim 4, characterized in that, It also includes an adjustment frame (6) having a precision guide rail (61) arranged in a vertical direction, wherein the first negative cone lens (131) and the first positive cone lens (132), as well as the second negative cone lens (231) and the second positive cone lens (232), can be slidably mounted on the corresponding precision guide rail (61).

6. The composite processing system based on a dual-ring light spot according to any one of claims 1 to 5, characterized in that, Multiple powder feeding nozzles (5) are provided and are arranged at equal angular intervals around the circumference of the wire feeding tube (4).

7. The composite processing system based on a dual-ring light spot according to any one of claims 1 to 5, characterized in that, The wire feeding tube (4) is equipped with a variety of types, and the inner diameter of the various wire feeding tubes (4) is different.

8. The composite processing system based on a dual-ring light spot according to any one of claims 1 to 5, characterized in that, It also includes a control system (7), which is communicatively connected to the first light source (11), the second light source (21), the wire feeding tube (4) and the powder feeding nozzle (5), and is used to control the beam power emitted by the first light source (11) and the second light source (21), the wire feeding speed of the wire feeding tube (4) and the powder feeding rate of the powder feeding nozzle (5).

9. The composite processing system based on a dual-ring spot according to any one of claims 1 to 5, characterized in that, The negative ridge prism (31) and the positive ridge prism (32) are detachably mounted in the composite processing system based on the double-ring spot.

10. A processing method based on the composite processing system based on a dual-ring spot as described in any one of claims 1 to 9, comprising: The beam emitted by the first light source (11) is shaped into a ring beam by the first collimating mirror (12) and the first ring beam generating module (13). After being reflected by the first hollow reflector (14) and passing through the negative roof prism (31) and the positive roof prism (32), it is divided into multiple beams that are symmetrically distributed in space. After being reflected by the second hollow reflector (33), it is focused by the hollow focusing mirror (34) to form an outer arc light spot around the end of the wire feeding tube (4). The beam emitted by the second light source (21) is shaped into a ring beam by the second collimating mirror (22) and the second ring beam generating module (23). After being reflected by the second reflector (24) and passing through the through hole on the first hollow reflector (14), the negative roof prism (31) and the positive roof prism (32), it is divided into multiple beams that are symmetrically distributed in space. After being reflected by the second hollow reflector (33), it is focused by the hollow focusing mirror (34) to form an inner arc spot located between the end of the wire feeding tube (4) and the outer arc spot. The wire is fed into the center of the inner arc spot using the wire feeding tube (4) to achieve rapid through melting; the metal powder is spread into the outer arc spot using the powder feeding nozzle (5) so that the metal powder is uniformly preheated and melted steadily at the edge of the molten pool.

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