Intelligent manufacturing method of bright arc surfacing high-chromium process thin plate

Abstract

The application relates to the technical field of surfacing processing, in particular to an intelligent manufacturing method of a bright-arc surfacing high-chromium process thin plate, which comprises the following steps: S1: base plate cleaning pretreatment, surface polishing, rust removal and oil stain removal treatment are carried out on a base plate matched with a thin wear-resistant plate, the base plate surface is polished to present a uniform metal luster, then the base plate surface is comprehensively wiped with anhydrous ethanol, and residual impurities and moisture are removed. The application can realize stable wear-resistant layer core alloy content through full-process collaborative optimization, improve product wear resistance and service life, inhibit plate deformation and cracking through full-cycle thermal-power control, improve forming quality and size precision, realize stable batch production of high-end thin wear-resistant plates through digital closed-loop control and the elimination of artificial dependence, guarantee batch consistency, realize stable batch production of high-end thin wear-resistant plates, meanwhile, the efficiency and quality are considered, the interface bonding force is enhanced, product full-process tracing is realized, production material and energy consumption are reduced, and the comprehensive advantages are outstanding.

Description

Technical Field

[0001] This application relates to the field of welding processing technology, and in particular to an intelligent manufacturing method for high-chromium thin plates using open arc welding. Background Technology

[0002] Thin wear-resistant plates are widely used in high-end working conditions such as mining, metallurgy, and building materials. Their wear resistance directly determines the service life and operational stability of equipment. The open arc welding high-chromium process is the core technology to improve its wear resistance. By fusing a high-chromium wear-resistant layer onto the surface of the substrate, the wear resistance and corrosion resistance of the plate can be significantly enhanced, meeting the stringent requirements of high-end scenarios for wear-resistant parts. In actual production, due to the thinness of the wear-resistant layer, the precision requirements of the welding process for thin wear-resistant plates are extremely high. If the process is not properly controlled, various quality problems are likely to occur, seriously affecting its application in high-end scenarios.

[0003] Currently, the industry generally uses open arc welding with high chromium to produce thin wear-resistant plates. This process uses a high-temperature electric arc to melt high-chromium welding material onto the surface of the substrate to form a wear-resistant layer. It has the advantages of high production efficiency, relatively low cost, and convenient operation, and is widely used in the mass production of various wear-resistant plates. However, for thin plates, the existing process has not optimized the welding parameters and operation procedures, and still follows the conventional welding approach for thick wear-resistant plates, without fully considering the characteristics of thin plates, such as thin substrate, fast heat conduction, and weak deformation resistance.

[0004] The existing open-arc welding high-chromium process has significant overall technical defects in the production of thin wear-resistant plates, which are particularly prominent in high-end applications. Due to unreasonable process parameter design, the chromium cladding is uneven during the welding process, and the substrate metal is prone to excessive dilution of the high-chromium wear-resistant layer. As a result, the chromium content of the wear-resistant layer after welding cannot be stably maintained at 30%, leading to insufficient wear resistance of the plate. This makes it unable to withstand the severe wear and tear of high-end applications such as mining material erosion and metallurgical equipment friction, thus shortening the service life of the equipment. At the same time, the unreasonable welding process will generate uneven thermal stress. Thin plates, due to their weak resistance to deformation, are prone to defects such as flat plate deformation and cracks. This not only leads to substandard product appearance and dimensional accuracy but also significantly increases the production defect rate and reduces production stability. It is impossible to achieve mass and stable production of high-end thin wear-resistant plates, becoming a long-term technical bottleneck restricting the development of the industry. Summary of the Invention

[0005] To improve production efficiency, this application provides an intelligent manufacturing method for thin plates using open arc welding with high chromium process.

[0006] This application provides a smart manufacturing method for thin plates using open-arc welding with a high-chromium process, comprising the following steps: S1: Substrate cleaning pretreatment: The substrate of the thin wear-resistant plate is polished, rust removed and oil removed. Polishing is carried out until the substrate surface has a uniform metallic luster. Then, anhydrous ethanol is used to wipe the substrate surface thoroughly to remove residual impurities and moisture, ensuring that the substrate surface cleanliness meets the requirements of welding bonding. S2: Substrate laser microtexturing process, which uses nanosecond laser equipment to etch a micron-level regular pit array on the substrate surface to be welded, replacing the traditional shot blasting process, increasing the bonding area between the substrate and the weld layer, providing high-density nucleation points for the molten pool, and suppressing the problem of thin-layer cladding flow. S3: Preset welding parameter template. Through the parameter preset system of the mother patent equipment, call the exclusive parameter template for high chromium welding of thin plates, set the welding wire diameter to 2.8~3.2mm, welding current to 300~320A, welding voltage to 30~32V, welding wire extension length to 20~25mm, and set the interlayer temperature threshold of welding to ≤150℃, and lock the welding reference parameters. S4: Dual-gun welding path simulation planning. Based on the substrate size and the design requirements of 4mm wear-resistant layer, a thermo-mechanical coupling simulation model is constructed to simulate the temperature field and stress field distribution during the welding process. The welding path and asymmetric jump welding sequence of the dual guns are planned. The arrangement scheme of 20mm weld bead for single gun and 40mm complete weld bead for dual gun combination is clarified, and the distance between the front and rear guns and the specifications of the thin plate are matched. S5: Low-temperature preheating of the substrate: Place the pre-treated substrate into the preheating equipment and preheat it at a low temperature of 80~100℃. Keep it warm until the overall temperature of the substrate is uniform, eliminate residual stress inside the substrate, and avoid cold cracks caused by excessive temperature difference during the welding process. S6: Flexible positioning and clamping of the substrate. The preheated substrate is fixed with a special flexible clamping fixture to avoid squeezing damage to the thin substrate caused by rigid clamping. At the same time, the welding benchmark and flatness are calibrated by laser calibration equipment to control the substrate positioning error within 0.1mm and ensure that the substrate surface level meets the accuracy requirements of dual gun synchronous welding. S7: Dynamic zone gradient preheating. An infrared heating array with independent temperature control is used to cover the entire substrate. During the welding process, the local area to be welded is preheated at a medium temperature of 300~350℃, while the surrounding areas that have been welded and are to be welded are kept at a low temperature of 150~200℃, forming a dynamic temperature gradient field that moves synchronously with the welding process. S8: Dual-gun synchronous open arc welding adopts a synchronous welding mode with two guns arranged in front and behind, strictly follows the preset welding parameters and planned path, controls the welding speed to 280mm / min, the single gun single pass weld width is 20mm, and the two guns are combined to form a 40mm complete weld bead, realizing the step-by-step conduction of welding heat; during the welding process, high-chromium main welding wire is fed in conjunction with auxiliary welding wire containing niobium, vanadium and rare earth elements, and the welding wire feeding speed is precisely controlled. A layered multi-pass welding method is adopted, and the interpass temperature is strictly controlled to ≤150℃ until the 4mm thick wear-resistant layer is completed. S9: Multi-source real-time monitoring of the molten pool. During the welding process, the visual sensor, miniature spectral probe and infrared thermal imaging module integrated in the welding gun, together with the weld defect recognition algorithm, monitor the weld formation status, the cladding of core elements such as chromium and carbon in the molten pool, the temperature field distribution of the weld in real time, and simultaneously monitor the real-time deformation of the plate, collecting full-dimensional data of the welding process. S10: Adaptive closed-loop control of welding parameters. Based on real-time monitoring data of the molten pool and weld bead, the system automatically completes closed-loop fine-tuning of welding parameters. In response to problems such as insufficient chromium content and uneven penetration, the system adjusts the welding current, wire feed speed and equipment travel speed in real time to accurately control the cladding state. In response to the deformation trend of the plate, the system simultaneously fine-tunes the distance between the two guns and the welding sequence to ensure uniform heat input across the entire plate surface. S11: Weld performance optimization during welding. After each single weld bead is completed, a pulsed atomized cooling medium is pulsedly sprayed through a pulsed atomized nozzle that moves synchronously with the welding gun according to the real-time temperature of the weld bead. This precisely controls the cooling rate of the weld bead and optimizes the microstructure of the wear-resistant layer. Then, an ultrasonic impact gun is used to fully cover the surface of the weld bead, which is still in a warm state, to convert the residual tensile stress inside the weld bead into compressive stress and inhibit crack initiation and plate deformation. S12: Post-weld slow cooling and stress homogenization treatment. After all the welding operations are completed, the plate and the clamping fixture are placed in the slow cooling furnace. The slow cooling rate is strictly controlled at 5~10℃ / min until the plate is cooled to room temperature with the furnace. Then the plate is transferred to the vibration aging station. The inherent resonant frequency of the plate is identified by the exciter frequency sweep and multidimensional resonant load is applied to homogenize the residual stress inside the plate. S13: Finished product quality inspection. A laser scanner is used to acquire the three-dimensional morphology of the board material, and a multi-point hydraulic leveling head is driven to complete adaptive leveling to ensure that the flatness of the board material is ≤0.3mm / m. Targeted welding treatment is carried out on unqualified products, and qualified products are integrated with the entire process and test data to generate a digital twin process file for archiving and traceability.

[0007] Optionally, the etching of a micron-scale regular pit array on the substrate surface to be soldered using a nanosecond laser device in step S2 includes: S2.1: Simulation and parameter preset of laser microtexturing scheme. Based on the material and size of the thin substrate and the requirements of the 4mm wear-resistant layer welding process, a simulation model of molten pool flow and interface combination is constructed to simulate the suppression effect of pit array on molten pool nucleation and cladding flow. The design parameters of the micron-level pit array are determined, including pit diameter of 30~80μm, depth of 10~30μm, array spacing of 100~200μm, and orderly arrangement of square grid. Simultaneously, the pre-planning of nanosecond laser processing path is completed. S2.2: Substrate positioning. The substrate that has completed the S1 cleaning pretreatment is transferred to the laser processing station and clamped and fixed using a vacuum adsorption flexible fixture adapted to the thin substrate to avoid warping and deformation of the substrate caused by rigid clamping. The reference calibration of the substrate surface to be welded is completed by the laser coaxial vision positioning system, and the substrate level deviation is adjusted to ≤0.05mm and the positioning error is ≤0.02mm to ensure that the etching position is accurately matched with the subsequent weld overlay. S2.3: Nanosecond laser equipment debugging. Select a nanosecond fiber laser with a pulse width of 10~100ns to complete laser optical path calibration and focusing debugging to ensure that the laser focus is accurately placed on the substrate surface to be soldered; preset laser processing reference parameters, including average laser power of 10~30W, repetition frequency of 20~100kHz, and scanning speed of 500~2000mm / s; and perform trial etching verification on a test board of the same material to calibrate the parameters until the pit size and morphology meet the design requirements, avoiding problems such as overheating and insufficient etching; S2.4: Partitioned skip laser etching process. According to the preset array parameters and processing path, the substrate surface to be soldered is divided into multiple processing units of equal area. The etching process is carried out by asymmetric skip scanning method. After completing the etching of a single set of pits in a processing unit, the process jumps to the processing unit in the diagonal area to continue the operation. This avoids local heat concentration and substrate thermal deformation caused by continuous processing. The etching status is monitored in real time through a vision system throughout the process to ensure that the pit array completely covers the substrate surface to be soldered. S2.5: Post-processing of textured surface. After laser etching, the substrate surface is thoroughly blew with clean and dry compressed air to remove molten spatter and dust generated during etching. Then, the substrate is placed in an anhydrous ethanol ultrasonic cleaning tank and ultrasonically cleaned for 5-10 minutes to thoroughly remove residual micro-molten slag and surface oxide layer inside the pits. After cleaning, the substrate is dried with low-temperature hot air to avoid secondary contamination of the substrate surface throughout the process.

[0008] Optional, also includes: S2.6: Texture quality inspection. A laser confocal microscope is used to sample and inspect the etched surface of the substrate to check the diameter, depth, array spacing and morphological uniformity of the pits, ensuring that the deviation between the measured parameters and the design values ​​is ≤10%. A high-precision flatness meter is used to check the overall flatness of the substrate to ensure that the substrate deformation is ≤0.1mm / m. A metallographic microscope is used to check for surface microcracks and overheating defects. Qualified products are transferred to the next process, and unqualified products are reworked.

[0009] Optionally, a thermo-mechanical coupling simulation model is constructed in S4. The core of this model is to achieve coupling between the heat conduction control equation and the elastoplastic stress-strain control equation.

[0010] Optionally, the algorithm formula for the heat conduction control equation is as follows: The heat conduction governing equation is used to describe the temperature field distribution during the welding process: , In the formula: The mixed density of substrate and solder overlay (kg / m³) 3 ), calculated based on the weighted average of the substrate and high-chromium welding wire material ratios; The isobaric specific heat capacity of the material (J / (kg·K)) is dynamically determined as it changes with temperature. Temperature (K); Time (s); The thermal conductivity of the material (W / (m·K)) is dynamically adjusted in conjunction with the temperature gradient. For the Laplace operator; For the internal heat source intensity of welding (W / m) 3 The corresponding dual-gun arc heat input is calculated using the following formula: ( For the arc thermal efficiency, a value of 0.75~0.85 is used; Welding voltage (V); Welding current (A); The volume of the weld pool (m) 3 )).

[0011] 6. The intelligent manufacturing method for high-chromium thin plates using open-arc welding according to claim 5, characterized in that: the algorithm formula for the elastic-plastic stress-strain control equation is as follows: Elastic-plastic stress-strain governing equations are used to describe the stress field and deformation distribution during the welding process: , In the formula: For stress tensor (Pa); The stress tensor subscript represents the spatial coordinate direction; Volume force (N / m) 3The main considerations are gravity and thermal stress loads. For displacement components (m); These are the subscripts for the displacement components, corresponding to the three spatial directions: x, y, and z.

[0012] 7. The intelligent manufacturing method for high-chromium thin plates using open-arc welding according to claim 6, characterized in that: it further includes a thermo-mechanical coupling correlation equation to achieve bidirectional coupling between the temperature field and the stress field, the specific algorithm formula of which is as follows: , In the formula: This is the total strain tensor; For the elastic strain tensor, according to Hooke's law calculate( It represents the elastic modulus (Pa). Poisson's ratio, (for Kroneck symbol) The plastic strain tensor is solved using the von Mises yield criterion; The thermal strain tensor is calculated using the following formula: ( is the coefficient of thermal expansion (1 / K). The initial ambient temperature (K) is used.

[0013] Optionally, step S6, which involves calibrating the weld overlay reference and flatness using a laser calibration device, specifically includes the following steps: S6.1: Calibration System Integration and Coordinate System 1. After completing the flexible clamping and fixing of the substrate, the motion control system of the line laser 3D calibration equipment and the dual-gun bright arc welding equipment are integrated for communication and debugging to establish a unified machine tool processing coordinate system. Zero-point calibration, focal length calibration and measurement accuracy verification are performed on the laser calibration equipment to ensure that the single-point measurement accuracy of the equipment is ≤0.02mm. At the same time, the positioning reference holes of the flexible clamping fixture are matched to eliminate the system error caused by the installation of the fixture and establish a unified accuracy benchmark for subsequent calibration operations. S6.2: Substrate welding reference coordinate system calibration. Start the laser calibration equipment to perform a full-area contour scan on the clamped substrate, identify the two perpendicular process reference edges of the substrate and the contour of the surface to be welded, and establish a two-dimensional welding coordinate system of the substrate surface to be welded with the intersection of the two reference edges as the origin. Simultaneously calibrate the layout reference line of the dual-gun welding beads to ensure that the parallelism deviation between the welding bead layout reference and the substrate contour is ≤0.03mm. At the same time, collect the initial height data of the substrate surface to be welded, and calibrate the Z-axis height reference of the welding operation to provide a reference basis for the gun height control and penetration depth adjustment of the dual-gun welding gun. S6.3: Global flatness calibration and deviation compensation of substrate. Based on the three-dimensional point cloud data of the substrate surface to be welded collected by the laser calibration equipment, a global flatness distribution map of the substrate is generated. The height deviation of each region from the reference plane is calculated, and the out-of-tolerance regions of local warping and depression are identified. Through the multi-point fine-tuning support mechanism of the flexible clamping fixture, the out-of-tolerance regions are adaptively fine-tuned to eliminate the deformation and gap caused by the substrate clamping until the global flatness deviation of the substrate is ≤0.05mm / m. At the same time, the height deviation data of each region is converted into Z-axis compensation parameters for welding to ensure the consistency of gun height and heat input during the dual-gun welding process.

[0014] Optional, also includes: S6.4: Calibration accuracy verification and process flow judgment. After completing the benchmark calibration and flatness calibration, the laser calibration equipment performs a second full-area scan of the substrate for verification. The focus is on verifying three core indicators: the deviation of the origin of the welding coordinate system, the parallelism of the weld bead reference line, and the flatness of the entire substrate. This ensures that the overall positioning error of the substrate is ≤0.1mm, fully matching the accuracy requirements of dual-gun synchronous welding. After the verification is qualified, the substrate clamping state is locked, and the calibrated benchmark parameters and compensation data are uploaded to the welding equipment control system simultaneously to complete the process flow. For substrates that fail the verification, the clamping adjustment and calibration work is repeated until the accuracy meets the standard.

[0015] Optionally, S13 further includes using a spectrometer, an eddy current array detector, and non-destructive testing equipment to complete a comprehensive test of the chromium content, hardness distribution, and internal defects of the wear-resistant layer, ensuring that the chromium content of the wear-resistant layer is stably above 30% and the product defect rate is ≤2%.

[0016] In summary, this application includes the following beneficial technical effects: This technical solution, through the synergistic effect of multiple steps such as interface modification, precise matching of alloy composition, and real-time control of molten pool state, fundamentally inhibits the excessive dilution of the wear-resistant layer by the substrate, ensuring the stability of the core alloy element content of the wear-resistant layer. At the same time, it optimizes the microstructure of the wear-resistant layer, making the wear resistance performance uniform and consistent throughout the entire range, greatly improving the service capability of the product under harsh wear scenarios, extending the service life of supporting equipment, and solving the problems of insufficient wear resistance and short service life of existing products.

[0017] This technical solution effectively solves the defects of frequent deformation and cracking during the welding of thin plates in existing technologies, resulting in substandard dimensional accuracy of finished products. It significantly improves the forming quality and dimensional stability of products. Existing technologies mostly use post-weld straightening to deal with deformation problems, which cannot fundamentally solve the problem of uneven thermal stress generated during the welding process. This easily leads to plate deformation and wear-resistant layer cracking. At the same time, rigid clamping can easily cause damage to the substrate, and post-weld straightening may also cause secondary defects, making it impossible for the product to meet the dimensional accuracy requirements. This technical solution uses full-cycle thermo-mechanical synergistic control, from preheating, welding, welding treatment to post-weld stress homogenization, to precisely control the temperature gradient and stress distribution throughout the entire process. This effectively suppresses thermal stress concentration, avoids crack initiation and plate deformation, and eliminates clamping damage through flexible clamping and precise positioning. Combined with self-adaptive straightening of finished products, it ensures that the dimensional accuracy of finished products meets the standards, solving the problems of poor forming quality, high defect rate and insufficient dimensional accuracy of existing products.

[0018] This technical solution addresses the shortcomings of existing technologies, such as poor production stability and the inability to mass-produce high-end thin wear-resistant plates. It significantly improves production efficiency and stability, breaking through industry development bottlenecks. Existing technologies rely on manual experience for control, with fixed process parameters that cannot adapt to fluctuations in the welding process. This results in large deviations in performance and dimensions within the same batch of products, high defect rates, long changeover cycles, and an inability to achieve continuous mass production. This technical solution, through full-process digital closed-loop management, eliminates reliance on manual experience. In the early stages, simulation planning optimizes the process path, and during the process, the welding status is monitored in real time and parameters are adaptively adjusted to ensure that the production status of each product is within a controllable range. This significantly improves the consistency of products within the same batch, reduces the defect rate, and can quickly adapt to the production of different specifications, shortening the changeover cycle. It meets the needs of large-scale standardized production as well as small-batch customized needs, achieving stable mass production of high-end thin wear-resistant plates.

[0019] This technical solution, through the synergistic matching of various stages, achieves a synergistic advantage that cannot be realized by existing single-point technical improvements. It resolves several contradictions in existing technologies that are difficult to balance simultaneously. Firstly, it achieves simultaneous improvement in production efficiency and product quality, breaking the dilemma of having to reduce efficiency to control defects in existing technologies. While significantly improving welding efficiency, it ensures that product performance and forming quality do not decline, thus addressing the dual requirements of efficiency and quality. Secondly, it significantly improves the interfacial bonding strength between the substrate and the wear-resistant layer, solving the hidden problems of easy detachment and peeling of the wear-resistant layer in existing technologies. Through the synergistic effect of interface modification, cleaning treatment, and low dilution rate control, the interfacial bonding force is greatly enhanced, preventing the wear-resistant layer from peeling under working conditions. First, it improves the overall reliability of the product. Second, it enables full lifecycle traceability and continuous process optimization. It collects process and testing data throughout the entire process, establishes a complete process file for each product, and can quickly trace the root cause of quality problems. At the same time, the accumulated data analysis can provide support for process optimization and achieve continuous iteration and upgrading of the process. This is an advantage that existing experience-based production processes cannot achieve. Third, it significantly reduces material and energy losses in the production process. Through full-process quality control, it reduces the rework and scrap of unqualified products, reduces raw material losses, and optimizes preheating, heat treatment and other links to reduce energy consumption. It has significant cost advantages and energy-saving effects, and further improves the economics of production. Attached Figure Description

[0020] Figure 1 This is a flowchart of an embodiment of this application. Detailed Implementation

[0021] The following is in conjunction with the appendix Figure 1 This application will be described in further detail.

[0022] This application discloses an intelligent manufacturing method for thin plates using a high-chromium open-arc welding process. For example... Figure 1 As shown, it includes the following steps: S1: Substrate cleaning pretreatment: The substrate of the thin wear-resistant plate is polished, rust removed and oil removed. Polishing is carried out until the substrate surface has a uniform metallic luster. Then, anhydrous ethanol is used to wipe the substrate surface thoroughly to remove residual impurities and moisture, ensuring that the substrate surface cleanliness meets the requirements of welding bonding. This step thoroughly removes oxide layers, rust, oil stains, and other attached impurities from the substrate surface, eliminating interference from impurities in the subsequent cladding process and preventing welding defects such as porosity and slag inclusions from forming after impurities enter the molten pool. At the same time, it removes interface barriers for the metallurgical bonding between the substrate and the wear-resistant overlay, ensuring stable and qualified interface bonding strength. This reduces quality problems such as uneven cladding and poor bonding strength caused by insufficient substrate surface cleanliness from the source, providing a clean substrate that meets the metallurgical bonding requirements for subsequent full-process overlay welding operations.

[0023] S2: Substrate laser microtexturing process, which uses nanosecond laser equipment to etch a micron-level regular pit array on the substrate surface to be welded, replacing the traditional shot blasting process, increasing the bonding area between the substrate and the weld layer, providing high-density nucleation points for the molten pool, and suppressing the problem of thin-layer cladding flow. The process of etching a micron-scale regular pit array on the substrate surface to be soldered using a nanosecond laser in S2 includes: S2.1: Simulation and parameter preset of laser microtexturing scheme. Based on the material and size of the thin substrate and the requirements of the 4mm wear-resistant layer welding process, a simulation model of molten pool flow and interface combination is constructed to simulate the suppression effect of pit array on molten pool nucleation and cladding flow. The design parameters of the micron-level pit array are determined, including pit diameter of 30~80μm, depth of 10~30μm, array spacing of 100~200μm, and orderly arrangement of square grid. Simultaneously, the pre-planning of nanosecond laser processing path is completed. S2.2: Substrate positioning. The substrate that has completed the S1 cleaning pretreatment is transferred to the laser processing station and clamped and fixed using a vacuum adsorption flexible fixture adapted to the thin substrate to avoid warping and deformation of the substrate caused by rigid clamping. The reference calibration of the substrate surface to be welded is completed by the laser coaxial vision positioning system, and the substrate level deviation is adjusted to ≤0.05mm and the positioning error is ≤0.02mm to ensure that the etching position is accurately matched with the subsequent weld overlay. S2.3: Nanosecond laser equipment debugging. Select a nanosecond fiber laser with a pulse width of 10~100ns to complete laser optical path calibration and focusing debugging to ensure that the laser focus is accurately placed on the substrate surface to be soldered; preset laser processing reference parameters, including average laser power of 10~30W, repetition frequency of 20~100kHz, and scanning speed of 500~2000mm / s; and perform trial etching verification on a test board of the same material to calibrate the parameters until the pit size and morphology meet the design requirements, avoiding problems such as overheating and insufficient etching; S2.4: Partitioned skip laser etching process. According to the preset array parameters and processing path, the substrate surface to be soldered is divided into multiple processing units of equal area. The etching process is carried out by asymmetric skip scanning method. After completing the etching of a single set of pits in a processing unit, the process jumps to the processing unit in the diagonal area to continue the operation. This avoids local heat concentration and substrate thermal deformation caused by continuous processing. The etching status is monitored in real time through a vision system throughout the process to ensure that the pit array completely covers the substrate surface to be soldered. S2.5: Post-processing of textured surface. After laser etching, the substrate surface is thoroughly blew with clean and dry compressed air to remove molten spatter and dust generated during etching. Then, the substrate is placed in an anhydrous ethanol ultrasonic cleaning tank and ultrasonically cleaned for 5-10 minutes to thoroughly remove residual micro-molten slag and surface oxide layer inside the pits. After cleaning, it is dried with low-temperature hot air to avoid secondary contamination of the substrate surface throughout the process. S2.6: Texture quality inspection. A laser confocal microscope is used to sample and inspect the etched surface of the substrate to check the diameter, depth, array spacing, and morphological uniformity of the pits, ensuring that the deviation between the measured parameters and the design values ​​is ≤10%. A high-precision flatness meter is used to check the overall flatness of the substrate to ensure that the substrate deformation is ≤0.1mm / m. A metallographic microscope is used to check for surface microcracks and overheating defects. Qualified products are transferred to the next process, and unqualified products are reworked. This step utilizes nanosecond lasers for precise microtexturing, which, compared to traditional shot blasting, enables precise and controllable processing of the substrate surface morphology. This avoids problems such as uneven surface treatment, dust pollution, and impact deformation of thin substrates caused by traditional shot blasting. The regular micron-level pit array can significantly increase the actual bonding area between the substrate and the weld overlay, enhance the interfacial bonding strength, and prevent the wear-resistant layer from peeling or flaking during service. The pit array can provide high-density nucleation points for the solidification process of the molten pool, refine the solidification structure of the wear-resistant layer, and improve the uniformity of the wear-resistant layer performance. At the same time, through the interfacial constraint effect of the pits, it effectively suppresses the flow problem of thin-layer cladding during the weld overlay process of thin plates, and improves the regularity and uniformity of the weld bead formation.

[0024] S3: Preset welding parameter template. Through the parameter preset system of the mother patent equipment, call the exclusive parameter template for high chromium welding of thin plates, set the welding wire diameter to 2.8~3.2mm, welding current to 300~320A, welding voltage to 30~32V, welding wire extension length to 20~25mm, and set the interlayer temperature threshold of welding to ≤150℃, and lock the welding reference parameters. This step, tailored to the specific characteristics of thin substrates, sets and locks suitable welding reference parameters, replacing the conventional operation of using welding parameters for thick wear-resistant plates in existing technologies. It matches the characteristics of thin substrates, such as fast heat conduction and weak deformation resistance, from the source, avoiding core problems such as excessive heat input, uncontrolled penetration, and excessive dilution of the wear-resistant layer by the substrate metal due to parameter mismatch. The use of dedicated parameter templates eliminates the reliance on manual parameter adjustment experience, significantly reduces parameter fluctuations during batch production, improves the quality consistency of products in the same batch, shortens the parameter debugging cycle before production, reduces trial welding and error costs, and adapts to the needs of stable mass production.

[0025] S4: Dual-gun welding path simulation planning. Based on the substrate size and the design requirements of 4mm wear-resistant layer, a thermo-mechanical coupling simulation model is constructed to simulate the temperature field and stress field distribution during the welding process. The welding path and asymmetric jump welding sequence of the dual guns are planned. The arrangement scheme of 20mm weld bead for single gun and 40mm complete weld bead for dual gun combination is clarified, and the distance between the front and rear guns and the specifications of the thin plate are matched. In S4, a thermo-mechanical coupling simulation model is constructed. The core of this model is to achieve coupling between the heat conduction control equation and the elastoplastic stress-strain control equation. The algorithm formula for the heat conduction control equation is as follows: The heat conduction governing equation is used to describe the temperature field distribution during the welding process: , In the formula: The mixed density of substrate and solder overlay (kg / m³) 3 ), calculated based on the weighted average of the substrate and high-chromium welding wire material ratios; The isobaric specific heat capacity of the material (J / (kg·K)) is dynamically determined as it changes with temperature. Temperature (K); Time (s); The thermal conductivity of the material (W / (m·K)) is dynamically adjusted in conjunction with the temperature gradient. For the Laplace operator; For the internal heat source intensity of welding (W / m) 3 The corresponding dual-gun arc heat input is calculated using the following formula: ( For the arc thermal efficiency, a value of 0.75~0.85 is used; Welding voltage (V); Welding current (A); The volume of the weld pool (m) 3 )).

[0026] 6. The intelligent manufacturing method for high-chromium thin plates using open-arc welding according to claim 5, characterized in that: the algorithm formula for the elastic-plastic stress-strain control equation is as follows: Elastic-plastic stress-strain governing equations are used to describe the stress field and deformation distribution during the welding process: , In the formula: For stress tensor (Pa); The stress tensor subscript represents the spatial coordinate direction; Volume force (N / m) 3 The main considerations are gravity and thermal stress loads. For displacement components (m); These are the subscripts for the displacement components, corresponding to the three spatial directions: x, y, and z. It also includes thermo-mechanical coupling correlation equations to achieve bidirectional coupling between the temperature field and the stress field. The specific algorithm formula is as follows: , In the formula: This is the total strain tensor; For the elastic strain tensor, according to Hooke's law calculate( It represents the elastic modulus (Pa). Poisson's ratio, (for Kroneck symbol) The plastic strain tensor is solved using the von Mises yield criterion; The thermal strain tensor is calculated using the following formula: ( is the coefficient of thermal expansion (1 / K). (Initial ambient temperature (K)) This step uses thermo-mechanical coupling simulation to pre-simulate the temperature and stress field distribution throughout the welding process, which can predict and avoid risks such as thermal stress concentration and plate deformation that may occur during welding. It replaces the existing technology that relies on manual experience to plan the welding path, avoiding problems such as uneven heat input and uncontrollable deformation caused by unplanned welding. The planned asymmetric jump welding sequence can achieve uniform heat input distribution across the entire plate surface, significantly reducing local thermal stress peaks and effectively preventing welding deformation of thin substrates. The arrangement of dual-gun combined weld beads can match the operation mode of dual-gun synchronous welding, improving welding efficiency while ensuring the uniformity of weld bead overlap, avoiding problems such as uneven cladding and forming defects caused by poor overlap of single weld beads.

[0027] S5: Low-temperature preheating of the substrate: Place the pre-treated substrate into the preheating equipment and preheat it at a low temperature of 80~100℃. Keep it warm until the overall temperature of the substrate is uniform, eliminate residual stress inside the substrate, and avoid cold cracks caused by excessive temperature difference during the welding process. This step, through uniform low-temperature preheating, can eliminate residual stress inside the substrate in advance, while significantly reducing the temperature difference between the high-temperature molten pool and the room-temperature substrate during the welding process. This prevents cold cracks caused by rapid solidification of the molten pool due to contact with the cold substrate, and provides a stable temperature environment for uniform solidification of the molten pool and full melting of alloying elements. Using a low-temperature preheating range of 80~100℃ can avoid the thermal deformation problem of thin substrates caused by high-temperature preheating, adapt to the weak deformation resistance of thin substrates, and reduce energy consumption in the preheating process, thereby improving the economic efficiency of the production process.

[0028] S6: Flexible positioning and clamping of the substrate. The preheated substrate is fixed with a special flexible clamping fixture to avoid squeezing damage to the thin substrate caused by rigid clamping. At the same time, the welding benchmark and flatness are calibrated by laser calibration equipment to control the substrate positioning error within 0.1mm and ensure that the substrate surface level meets the accuracy requirements of dual gun synchronous welding. The S6 step of calibrating the welding reference and flatness using a laser calibration device specifically includes the following steps: S6.1: Calibration System Integration and Coordinate System 1. After completing the flexible clamping and fixing of the substrate, the motion control system of the line laser 3D calibration equipment and the dual-gun bright arc welding equipment are integrated for communication and debugging to establish a unified machine tool processing coordinate system. Zero-point calibration, focal length calibration and measurement accuracy verification are performed on the laser calibration equipment to ensure that the single-point measurement accuracy of the equipment is ≤0.02mm. At the same time, the positioning reference holes of the flexible clamping fixture are matched to eliminate the system error caused by the installation of the fixture and establish a unified accuracy benchmark for subsequent calibration operations. S6.2: Substrate welding reference coordinate system calibration. Start the laser calibration equipment to perform a full-area contour scan on the clamped substrate, identify the two perpendicular process reference edges of the substrate and the contour of the surface to be welded, and establish a two-dimensional welding coordinate system of the substrate surface to be welded with the intersection of the two reference edges as the origin. Simultaneously calibrate the layout reference line of the dual-gun welding beads to ensure that the parallelism deviation between the welding bead layout reference and the substrate contour is ≤0.03mm. At the same time, collect the initial height data of the substrate surface to be welded, and calibrate the Z-axis height reference of the welding operation to provide a reference basis for the gun height control and penetration depth adjustment of the dual-gun welding gun. S6.3: Global flatness calibration and deviation compensation of substrate. Based on the three-dimensional point cloud data of the substrate surface to be welded collected by the laser calibration equipment, a global flatness distribution map of the substrate is generated. The height deviation of each region from the reference plane is calculated, and the out-of-tolerance areas of local warping and depression are identified. Through the multi-point fine-tuning support mechanism of the flexible clamping fixture, the out-of-tolerance areas are adaptively fine-tuned to eliminate the deformation and gap caused by the substrate clamping until the global flatness deviation of the substrate is ≤0.05mm / m. At the same time, the height deviation data of each region is converted into Z-axis compensation parameters for welding to ensure the consistency of gun height and heat input during the dual-gun welding process. S6.4: Calibration accuracy verification and process flow judgment. After completing the benchmark calibration and flatness calibration, the laser calibration equipment performs a second full-area scan of the substrate for verification. The focus is on verifying three core indicators: the deviation of the origin of the welding coordinate system, the parallelism of the weld bead reference line, and the flatness of the entire substrate. This ensures that the overall positioning error of the substrate is ≤0.1mm, fully matching the accuracy requirements of dual-gun synchronous welding. After the verification is qualified, the substrate clamping state is locked, and the calibrated benchmark parameters and compensation data are synchronously uploaded to the welding equipment control system to complete the process flow. Substrates that fail the verification are re-clamped, adjusted, and calibrated until the accuracy meets the standard. This step uses a dedicated flexible clamping fixture to fix the substrate, which avoids the problems of compression deformation and surface damage caused by rigid clamping of thin substrates in existing technologies. While achieving stable fixation of the substrate, it also eliminates substrate deformation caused by the clamping process. The matching laser calibration equipment can achieve high-precision calibration of the welding benchmark and full-area flatness calibration of the substrate, controlling the substrate positioning error within a very small range. This ensures the consistency of the welding torch height during the dual-gun synchronous welding process, thereby ensuring uniform penetration and accurate weld bead arrangement. It avoids welding defects such as weld bead offset, poor overlap, and uneven cladding caused by positioning deviation and insufficient flatness, providing a stable and accurate foundation for dual-gun synchronous welding.

[0029] S7: Dynamic zone gradient preheating. An infrared heating array with independent temperature control is used to cover the entire substrate. During the welding process, the local area to be welded is preheated at a medium temperature of 300~350℃, while the surrounding areas that have been welded and are to be welded are kept at a low temperature of 150~200℃, forming a dynamic temperature gradient field that moves synchronously with the welding process. This step utilizes an independently temperature-controlled infrared heating array to create a dynamic temperature gradient field that moves synchronously with the welding position throughout the welding process. This replaces the fixed-temperature overall preheating method in existing technologies, enabling precise dynamic control of the temperature field during the welding process. Medium-temperature preheating of the welding front area further reduces the temperature difference between the molten pool and the substrate, preventing cold cracking and improving the fluidity of the molten pool to ensure uniform weld bead formation. Low-temperature insulation of the surrounding area strictly controls the interlayer temperature within a preset threshold, preventing excessive heat input accumulation and thermal stress concentration caused by excessively high interlayer temperatures. It also reduces the temperature gradient across the entire board, avoiding uneven thermal stress caused by excessive local temperature differences, effectively preventing welding deformation of thin substrates, and adapting to the unique characteristics of rapid heat conduction in thin substrates.

[0030] S8: Dual-gun synchronous open arc welding adopts a synchronous welding mode with two guns arranged in front and behind, strictly follows the preset welding parameters and planned path, controls the welding speed to 280mm / min, the single gun single pass weld width is 20mm, and the two guns are combined to form a 40mm complete weld bead, realizing the step-by-step conduction of welding heat; during the welding process, high-chromium main welding wire is fed in conjunction with auxiliary welding wire containing niobium, vanadium and rare earth elements, and the welding wire feeding speed is precisely controlled. A layered multi-pass welding method is adopted, and the interpass temperature is strictly controlled to ≤150℃ until the 4mm thick wear-resistant layer is completed. This step employs a synchronous welding mode with dual guns arranged front and rear, enabling stepwise heat transfer and significantly reducing localized heat input peaks caused by single-gun welding. This reduces the risk of thermal deformation of thin substrates. Simultaneously, the dual-gun combination forms a complete weld bead, greatly improving welding efficiency, ensuring uniform weld bead overlap, and avoiding forming defects caused by poor overlap in single weld beads. The high-chromium main welding wire, coupled with an auxiliary welding wire containing alloying elements, is fed synchronously, allowing for precise control of the wear-resistant layer's alloy system. This forms a dispersed high-hardness carbide reinforcing phase in the molten pool, enhancing the chromium cladding stability and effectively inhibiting excessive dilution of the high-chromium wear-resistant layer by the substrate metal, ensuring the core alloy element content of the wear-resistant layer remains stable and meets standards. The layered, multi-pass welding method, combined with strict interlayer temperature control, further reduces heat input accumulation during the welding process, avoids thermal stress concentration, prevents thin substrate deformation and wear-resistant layer crack initiation, and achieves uniform and stable cladding of the designed thickness wear-resistant layer.

[0031] S9: Multi-source real-time monitoring of the molten pool. During the welding process, the visual sensor, miniature spectral probe and infrared thermal imaging module integrated in the welding gun, together with the weld defect recognition algorithm, monitor the weld formation status, the cladding of core elements such as chromium and carbon in the molten pool, the temperature field distribution of the weld in real time, and simultaneously monitor the real-time deformation of the plate, collecting full-dimensional data of the welding process. This step utilizes multi-source integrated sensing devices to achieve real-time acquisition and monitoring of all-dimensional data throughout the entire welding process. This replaces the existing methods that rely on manual visual monitoring and post-weld inspection, eliminating dependence on human experience and enabling visualized and quantitative control of the welding process. Visual sensors can identify weld formation defects in real time, miniature spectral probes can quantitatively monitor the cladding of core alloying elements in the molten pool in real time, and infrared thermal imaging modules can monitor the temperature field distribution and interlayer temperature of the weld in real time. Simultaneously, they can monitor the deformation trend of the plate in real time. All data is collected and stored throughout the process, providing a precise and real-time data source for subsequent adaptive closed-loop parameter control. It can promptly identify abnormal states during the welding process, avoiding product scrap caused by discovering defects after welding and reducing quality losses in the production process.

[0032] S10: Adaptive closed-loop control of welding parameters. Based on real-time monitoring data of the molten pool and weld bead, the system automatically completes closed-loop fine-tuning of welding parameters. In response to problems such as insufficient chromium content and uneven penetration, the system adjusts the welding current, wire feed speed and equipment travel speed in real time to accurately control the cladding state. In response to the deformation trend of the plate, the system simultaneously fine-tunes the distance between the two guns and the welding sequence to ensure uniform heat input across the entire plate surface. This step, based on multi-source real-time monitoring of the molten pool, enables dynamic adaptive closed-loop fine-tuning of welding parameters, solving the core problem in existing technologies where fixed welding parameters cannot adapt to fluctuations in the welding process. Addressing issues of insufficient alloy element content and uneven penetration, it allows for real-time adjustment of welding current, wire feed speed, and equipment travel speed, precisely controlling the molten pool penetration and alloy element cladding ratio. This effectively suppresses excessive dilution of the substrate metal and ensures stable core alloy element content in the wear-resistant layer. Furthermore, it addresses the deformation trend of the plate material by simultaneously fine-tuning the dual-gun spacing and welding sequence, dynamically adjusting the heat input distribution across the entire plate surface to counteract deformation and ensure uniform heat input. This dynamic and precise control of the welding process significantly improves the quality consistency of each weld pass and each plate, reducing product defect rates.

[0033] S11: Weld performance optimization during welding. After each single weld bead is completed, a pulsed atomized cooling medium is pulsedly sprayed through a pulsed atomized nozzle that moves synchronously with the welding gun according to the real-time temperature of the weld bead. This precisely controls the cooling rate of the weld bead and optimizes the microstructure of the wear-resistant layer. Then, an ultrasonic impact gun is used to fully cover the surface of the weld bead, which is still in a warm state, to convert the residual tensile stress inside the weld bead into compressive stress and inhibit crack initiation and plate deformation. This step achieves simultaneous weld performance optimization and stress control during welding, completing the treatment at the critical stage of weld formation. It replaces the post-weld centralized treatment method in existing technologies, achieving simultaneous optimization of weld performance and stress state without adding extra production steps or reducing production efficiency. The pulsed aerosol nozzle can precisely control the cooling rate according to the real-time temperature of the weld, promoting the uniform precipitation of high-hardness carbides in the wear-resistant layer, optimizing the microstructure of the wear-resistant layer, and improving the hardness and wear resistance of the wear-resistant layer. The ultrasonic impact treatment under warm conditions can cause plastic deformation of the surface metal of the weld, converting the residual tensile stress inside the weld into compressive stress, fundamentally inhibiting the initiation and propagation of cracks during the weld cooling process, and at the same time offsetting the welding deformation trend of the plate. This solves the problems of crack initiation and stress concentration during weld cooling that cannot be solved by existing post-weld treatment technologies.

[0034] S12: Post-weld slow cooling and stress homogenization treatment. After all the welding operations are completed, the plate and the clamping fixture are placed in the slow cooling furnace. The slow cooling rate is strictly controlled at 5~10℃ / min until the plate is cooled to room temperature with the furnace. Then the plate is transferred to the vibration aging station. The inherent resonant frequency of the plate is identified by the exciter frequency sweep and multidimensional resonant load is applied to homogenize the residual stress inside the plate. This step combines slow cooling with vibration aging to achieve stress homogenization and deformation control of the welded sheet metal, solving the problems of uncontrollable cooling rate, uneven stress release, and sheet metal deformation and cracking caused by air cooling after welding in existing technologies. Slow cooling of the sheet metal along with the clamping fixture can maintain the positioning of the sheet metal during the slow cooling process, avoiding warping deformation of the sheet metal during stress release. Strictly controlled slow cooling rate can avoid temperature gradients and structural stress caused by excessively rapid cooling, further reducing the risk of crack initiation. Vibration aging treatment applies multidimensional resonant loads through a vibrator, which can fully release and homogenize the residual stress inside the sheet metal, greatly reducing the deformation risk of the sheet metal during subsequent processing and service, and improving the dimensional stability of the product. Compared with traditional high-temperature tempering treatment, vibration aging treatment has a shorter cycle, lower energy consumption, and will not cause secondary thermal deformation to thin substrates, combining economy and practicality.

[0035] S13: Finished product quality inspection. A laser scanner is used to acquire the three-dimensional morphology of the sheet material. A spectrometer, eddy current array detector and non-destructive testing equipment are used to complete the comprehensive inspection of the chromium content, hardness distribution and internal defects of the wear-resistant layer. This ensures that the chromium content of the wear-resistant layer is stably above 30% and the product defect rate is ≤2%. A multi-point hydraulic leveling head is driven to complete adaptive leveling to ensure the flatness of the sheet material is ≤0.3mm / m. Targeted welding treatment is carried out on unqualified products. Qualified products are integrated with the entire process and test data to generate a digital twin process file for archiving and traceability. This step achieves dimensional accuracy correction of the finished product, comprehensive quality inspection, and full-process data archiving, ensuring the quality and traceability of the products leaving the factory. A laser scanner captures the three-dimensional morphology of the sheet material, driving a multi-point hydraulic leveling head to complete adaptive leveling. This accurately corrects residual deformation of the sheet material, ensuring the flatness of the finished product meets design requirements, while avoiding secondary cracking of the wear-resistant layer caused by traditional force leveling. Targeted welding repair of defective products reduces product scrap and material waste. The digital twin process archive generated by integrating the entire process and inspection data enables quality traceability throughout the product lifecycle. When quality problems occur, the root cause can be quickly located. Simultaneously, the accumulated full production data provides quantitative support for subsequent process optimization, enabling continuous iterative upgrades of the production process and adapting to the stable mass production needs of high-end thin wear-resistant plates.

[0036] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A smart manufacturing method for thin plates using open-arc welding with high chromium content, characterized in that, Includes the following steps: S1: Substrate cleaning pretreatment: The substrate of the thin wear-resistant plate is polished, rust removed and oil removed. Polishing is carried out until the substrate surface has a uniform metallic luster. Then, anhydrous ethanol is used to wipe the substrate surface thoroughly to remove residual impurities and moisture, ensuring that the substrate surface cleanliness meets the requirements of welding bonding. S2: Substrate laser microtexturing process, which uses nanosecond laser equipment to etch a micron-level regular pit array on the substrate surface to be welded, replacing the traditional shot blasting process, increasing the bonding area between the substrate and the weld layer, providing high-density nucleation points for the molten pool, and suppressing the problem of thin-layer cladding flow. S3: Preset welding parameter template. Through the parameter preset system of the mother patent equipment, call the exclusive parameter template for high chromium welding of thin plates, set the welding wire diameter to 2.8~3.2mm, welding current to 300~320A, welding voltage to 30~32V, welding wire extension length to 20~25mm, and set the interlayer temperature threshold of welding to ≤150℃, and lock the welding reference parameters. S4: Dual-gun welding path simulation planning. Based on the substrate size and the design requirements of 4mm wear-resistant layer, a thermo-mechanical coupling simulation model is constructed to simulate the temperature field and stress field distribution during the welding process. The welding path and asymmetric jump welding sequence of the dual guns are planned. The arrangement scheme of 20mm weld bead for single gun and 40mm complete weld bead for dual gun combination is clarified, and the distance between the front and rear guns and the specifications of the thin plate are matched. S5: Low-temperature preheating of the substrate: Place the pre-treated substrate into the preheating equipment and preheat it at a low temperature of 80~100℃. Keep it warm until the overall temperature of the substrate is uniform, eliminate residual stress inside the substrate, and avoid cold cracks caused by excessive temperature difference during the welding process. S6: Flexible positioning and clamping of the substrate. The preheated substrate is fixed with a special flexible clamping fixture to avoid squeezing damage to the thin substrate caused by rigid clamping. At the same time, the welding benchmark and flatness are calibrated by laser calibration equipment to control the substrate positioning error within 0.1mm and ensure that the substrate surface level meets the accuracy requirements of dual gun synchronous welding. S7: Dynamic zone gradient preheating. An infrared heating array with independent temperature control is used to cover the entire substrate. During the welding process, the local area to be welded is preheated at a medium temperature of 300~350℃, while the surrounding areas that have been welded and are to be welded are kept at a low temperature of 150~200℃, forming a dynamic temperature gradient field that moves synchronously with the welding process. S8: Dual-gun synchronous open arc welding adopts a synchronous welding mode with two guns arranged in front and behind, strictly follows the preset welding parameters and planned path, controls the welding speed to 280mm / min, the single gun single pass weld width is 20mm, and the two guns are combined to form a 40mm complete weld bead, realizing the step-by-step conduction of welding heat; during the welding process, high-chromium main welding wire is fed in conjunction with auxiliary welding wire containing niobium, vanadium and rare earth elements, and the welding wire feeding speed is precisely controlled. A layered multi-pass welding method is adopted, and the interpass temperature is strictly controlled to ≤150℃ until the 4mm thick wear-resistant layer is completed. S9: Multi-source real-time monitoring of the molten pool. During the welding process, the visual sensor, miniature spectral probe and infrared thermal imaging module integrated in the welding gun, together with the weld defect recognition algorithm, monitor the weld formation status, the cladding of core elements such as chromium and carbon in the molten pool, the temperature field distribution of the weld in real time, and simultaneously monitor the real-time deformation of the plate, collecting full-dimensional data of the welding process. S10: Adaptive closed-loop control of welding parameters. Based on real-time monitoring data of the molten pool and weld bead, the system automatically completes closed-loop fine-tuning of welding parameters. In response to problems such as insufficient chromium content and uneven penetration, the system adjusts the welding current, wire feed speed and equipment travel speed in real time to precisely control the cladding state. In response to the deformation trend of the flat plate, the distance between the two guns and the welding sequence are adjusted simultaneously to ensure uniform heat input across the entire plate surface. S11: Weld performance optimization during welding. After each single weld bead is completed, a pulsed atomized cooling medium is pulsedly sprayed through a pulsed atomized nozzle that moves synchronously with the welding gun according to the real-time temperature of the weld bead. This precisely controls the cooling rate of the weld bead and optimizes the microstructure of the wear-resistant layer. Then, an ultrasonic impact gun is used to fully cover the surface of the weld bead, which is still in a warm state, to convert the residual tensile stress inside the weld bead into compressive stress and inhibit crack initiation and plate deformation. S12: Post-weld slow cooling and stress homogenization treatment. After all the welding operations are completed, the plate and the clamping fixture are placed in the slow cooling furnace. The slow cooling rate is strictly controlled at 5~10℃ / min until the plate is cooled to room temperature with the furnace. Then the plate is transferred to the vibration aging station. The inherent resonant frequency of the plate is identified by the exciter frequency sweep and multidimensional resonant load is applied to homogenize the residual stress inside the plate. S13: Finished product quality inspection. A laser scanner is used to acquire the three-dimensional morphology of the board material, and a multi-point hydraulic leveling head is driven to complete adaptive leveling to ensure that the flatness of the board material is ≤0.3mm / m. Targeted welding treatment is carried out on unqualified products, and qualified products are integrated with the entire process and test data to generate a digital twin process file for archiving and traceability.

2. The intelligent manufacturing method for a thin sheet using open-arc welding of high-chromium plates according to claim 1, characterized in that: The process of etching a micron-scale regular pit array on the substrate surface to be soldered using a nanosecond laser in S2 includes: S2.1: Simulation and parameter preset of laser microtexturing scheme. Based on the material and size of the thin substrate and the requirements of the 4mm wear-resistant layer welding process, a simulation model of molten pool flow and interface combination is constructed to simulate the suppression effect of pit array on molten pool nucleation and cladding flow. The design parameters of the micron-level pit array are determined, including pit diameter of 30~80μm, depth of 10~30μm, array spacing of 100~200μm, and orderly arrangement of square grid. Simultaneously, the pre-planning of nanosecond laser processing path is completed. S2.2: Substrate positioning. The substrate that has completed the S1 cleaning pretreatment is transferred to the laser processing station and clamped and fixed using a vacuum adsorption flexible fixture adapted to the thin substrate to avoid warping and deformation of the substrate caused by rigid clamping. The reference calibration of the substrate surface to be welded is completed by the laser coaxial vision positioning system, and the substrate level deviation is adjusted to ≤0.05mm and the positioning error is ≤0.02mm to ensure that the etching position is accurately matched with the subsequent weld overlay. S2.3: Nanosecond laser equipment debugging. Select a nanosecond fiber laser with a pulse width of 10~100ns to complete laser optical path calibration and focusing debugging to ensure that the laser focus is accurately placed on the substrate surface to be soldered; preset laser processing reference parameters, including average laser power of 10~30W, repetition frequency of 20~100kHz, and scanning speed of 500~2000mm / s; and perform trial etching verification on a test board of the same material to calibrate the parameters until the pit size and morphology meet the design requirements, avoiding problems such as overheating and insufficient etching; S2.4: Partitioned skip laser etching process. According to the preset array parameters and processing path, the substrate surface to be soldered is divided into multiple processing units of equal area. The etching process is carried out by asymmetric skip scanning method. After completing the etching of a single set of pits in a processing unit, the process jumps to the processing unit in the diagonal area to continue the operation. This avoids local heat concentration and substrate thermal deformation caused by continuous processing. The etching status is monitored in real time through a vision system throughout the process to ensure that the pit array completely covers the substrate surface to be soldered. S2.5: Post-processing of textured surface. After laser etching, the substrate surface is thoroughly blew with clean and dry compressed air to remove molten spatter and dust generated during etching. Then, the substrate is placed in an anhydrous ethanol ultrasonic cleaning tank and ultrasonically cleaned for 5-10 minutes to thoroughly remove residual micro-molten slag and surface oxide layer inside the pits. After cleaning, the substrate is dried with low-temperature hot air to avoid secondary contamination of the substrate surface throughout the process.

3. The intelligent manufacturing method for a thin sheet using open-arc welding of high-chromium plates according to claim 2, characterized in that: Also includes: S2.6: Texture quality inspection. A laser confocal microscope is used to sample and inspect the etched surface of the substrate to check the diameter, depth, array spacing and morphological uniformity of the pits, ensuring that the deviation between the measured parameters and the design values ​​is ≤10%. A high-precision flatness meter is used to check the overall flatness of the substrate to ensure that the substrate deformation is ≤0.1mm / m. A metallographic microscope is used to check for surface microcracks and overheating defects. Qualified products are transferred to the next process, and unqualified products are reworked.

4. The intelligent manufacturing method for a thin sheet using open-arc welding of high-chromium plates according to claim 3, characterized in that: The S4 section describes the construction of a thermo-mechanical coupling simulation model, the core of which uses the heat conduction control equation and the elastoplastic stress-strain control equation to achieve coupling.

5. The intelligent manufacturing method for a thin sheet using open-arc welding of high-chromium plates according to claim 4, characterized in that: The algorithm formula for the heat conduction control equation is as follows: The heat conduction governing equation is used to describe the temperature field distribution during the welding process: ， In the formula: The mixed density of substrate and solder overlay (kg / m³) 3 ), calculated based on the weighted average of the substrate and high-chromium welding wire material ratios; The isobaric specific heat capacity of the material (J / (kg·K)) is dynamically determined as it changes with temperature. Temperature (K); Time (s); The thermal conductivity of the material (W / (m·K)) is dynamically adjusted in conjunction with the temperature gradient. For the Laplace operator; For the internal heat source intensity of welding (W / m) 3 The corresponding dual-gun arc heat input is calculated using the following formula: ( For the arc thermal efficiency, a value of 0.75~0.85 is used; Welding voltage (V); Welding current (A); The volume of the weld pool (m) 3 )).

6. The intelligent manufacturing method for a thin sheet using open-arc welding of high-chromium plates according to claim 5, characterized in that: The algorithm formula for the elastoplastic stress-strain control equation is as follows: Elastic-plastic stress-strain governing equations are used to describe the stress field and deformation distribution during the welding process: ， In the formula: For stress tensor (Pa); The stress tensor subscript represents the spatial coordinate direction; Volume force (N / m) 3 The main considerations are gravity and thermal stress loads. For displacement components (m); These are the subscripts for the displacement components, corresponding to the three spatial directions: x, y, and z.

7. The intelligent manufacturing method for a thin sheet using open-arc welding of high-chromium plates according to claim 6, characterized in that: It also includes thermo-mechanical coupling correlation equations to achieve bidirectional coupling between the temperature field and the stress field. The specific algorithm formula is as follows: ， In the formula: This is the total strain tensor; For the elastic strain tensor, according to Hooke's law calculate( It represents the elastic modulus (Pa). Poisson's ratio, (for Kroneck symbol) The plastic strain tensor is solved using the von Mises yield criterion; The thermal strain tensor is calculated using the following formula: ( is the coefficient of thermal expansion (1 / K). The initial ambient temperature (K) is used.

8. The intelligent manufacturing method for a thin sheet using open-arc welding of high-chromium plates according to claim 7, characterized in that: The S6 step of calibrating the welding reference and flatness using a laser calibration device specifically includes the following steps: S6.1: Calibration System Integration and Coordinate System 1. After completing the flexible clamping and fixing of the substrate, the motion control system of the line laser 3D calibration equipment and the dual-gun bright arc welding equipment are integrated for communication and debugging to establish a unified machine tool processing coordinate system. Zero-point calibration, focal length calibration and measurement accuracy verification are performed on the laser calibration equipment to ensure that the single-point measurement accuracy of the equipment is ≤0.02mm. At the same time, the positioning reference holes of the flexible clamping fixture are matched to eliminate the system error caused by the installation of the fixture and establish a unified accuracy benchmark for subsequent calibration operations. S6.2: Substrate welding reference coordinate system calibration. Start the laser calibration equipment to perform a full-area contour scan on the clamped substrate, identify the two perpendicular process reference edges of the substrate and the contour of the surface to be welded, and establish a two-dimensional welding coordinate system of the substrate surface to be welded with the intersection of the two reference edges as the origin. Simultaneously calibrate the layout reference line of the dual-gun welding beads to ensure that the parallelism deviation between the welding bead layout reference and the substrate contour is ≤0.03mm. At the same time, collect the initial height data of the substrate surface to be welded, and calibrate the Z-axis height reference of the welding operation to provide a reference basis for the gun height control and penetration depth adjustment of the dual-gun welding gun. S6.3: Global flatness calibration and deviation compensation of substrate. Based on the three-dimensional point cloud data of the substrate surface to be welded collected by the laser calibration equipment, a global flatness distribution map of the substrate is generated. The height deviation of each region from the reference plane is calculated, and the out-of-tolerance regions of local warping and depression are identified. Through the multi-point fine-tuning support mechanism of the flexible clamping fixture, the out-of-tolerance regions are adaptively fine-tuned to eliminate the deformation and gap caused by the substrate clamping until the global flatness deviation of the substrate is ≤0.05mm / m. At the same time, the height deviation data of each region is converted into Z-axis compensation parameters for welding to ensure the consistency of gun height and heat input during the dual-gun welding process.

9. The intelligent manufacturing method for a thin sheet using open-arc welding of high-chromium plates according to claim 8, characterized in that: Also includes: S6.4: Calibration accuracy verification and process flow judgment. After completing the benchmark calibration and flatness calibration, the laser calibration equipment performs a second full-area scan of the substrate for verification. The focus is on verifying three core indicators: the deviation of the origin of the welding coordinate system, the parallelism of the weld bead reference line, and the flatness of the entire substrate. This ensures that the overall positioning error of the substrate is ≤0.1mm, fully matching the accuracy requirements of dual-gun synchronous welding. After the verification is qualified, the substrate clamping state is locked, and the calibrated benchmark parameters and compensation data are uploaded to the welding equipment control system simultaneously to complete the process flow. For substrates that fail the verification, the clamping adjustment and calibration work is repeated until the accuracy meets the standard.

10. The intelligent manufacturing method for a thin sheet using open-arc welding of high-chromium plates according to claim 9, characterized in that: S13 also includes using a spectrometer, eddy current array detector and non-destructive testing equipment to complete a comprehensive test of the chromium content, hardness distribution and internal defects of the wear-resistant layer, ensuring that the chromium content of the wear-resistant layer is stably above 30% and the product defect rate is ≤2%.

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