Performance evaluation method and apparatus for directed energy deposition additive manufacturing of aerospace structures

Abstract

The application relates to a performance evaluation method and device for directional energy deposition additive manufacturing of an aviation structure, which comprises the following steps: constructing a structure performance analysis model according to a three-dimensional structure model of the aviation structure, analyzing and defining load conditions and boundary conditions under preset service working conditions, introducing manufacturing constraint conditions matched with a DED process into the structure performance analysis model, establishing a thermal-mechanical coupling simulation model to obtain a simulation result, extracting target structure features and constructing simulation samples corresponding to the target structure features, obtaining preset performance parameters of the simulation samples, comparing the simulation result with the preset performance parameters to establish model correction parameters, and correcting the thermal-mechanical coupling simulation model. Finally, the overall performance of the aviation structure is comprehensively evaluated based on the corrected simulation model and in combination with preset evaluation indexes, and performance judgment results and process adaptation evaluation results are generated. The application can realize overall evaluation of geometric precision, residual stress state and mechanical performance of the aviation structure.

Description

Technical Field

[0001] This application relates to the field of aerospace equipment performance evaluation technology, and more specifically to a performance evaluation method, apparatus and computer-readable storage medium for directional energy deposition additive manufacturing of aerospace structural components. Background Technology

[0002] With the increasing demand for lightweight, high-performance and rapid manufacturing in aerospace equipment, additive manufacturing technology has been widely used in the field of aerospace structural component manufacturing due to its advantages in complex structure forming, material utilization and design freedom. Among them, Directed Energy Deposition (DED) is one of the important technical routes of metal additive manufacturing. It can achieve high deposition efficiency, direct manufacturing of large-size components and local repair, and is particularly suitable for the preparation of large load-bearing structural components and functionally graded structural components in aerospace.

[0003] Currently, in aerospace structural applications, aerospace structural components typically need to withstand complex service conditions such as multiaxial composite loads, vibration loads, and thermal loads, which impose strict requirements on strength, stiffness, fatigue life, and dimensional stability. However, existing performance evaluation methods often rely on the production of a large number of physical prototypes and destructive testing, which is not only costly and time-consuming, but also makes it difficult to predict structural risks in the design phase. At the same time, since the process parameters, deposition path, and forming direction of directional energy deposition additive manufacturing have a significant impact on the microstructure and mechanical behavior, it is difficult to accurately reflect the true performance of complex structural components under actual manufacturing conditions by simply relying on the test results of standard specimens. Summary of the Invention

[0004] This application provides a performance evaluation method and electronic device for directional energy deposition additive manufacturing of aerospace structural components. Based on the structural design model, it integrates manufacturing constraints, thermo-mechanical coupling simulation, key structural feature extraction, simulated sample verification, and model calibration design to achieve a comprehensive evaluation of the geometric accuracy, residual stress state, and mechanical properties of aerospace structural components, thereby improving the reliability of performance prediction and reducing the trial production risk of aerospace structural components.

[0005] In a first aspect, this application provides a performance evaluation method for directionally coupled additive manufacturing of aerospace structural components, comprising: constructing a structural performance analysis model based on a three-dimensional structural model of the aerospace structural component, and performing load analysis and boundary condition definition on the structural performance analysis model under preset service conditions; introducing manufacturing constraints matching the characteristics of the directionally coupled additive manufacturing process into the structural performance analysis model and constructing a thermo-mechanical coupling simulation model using the finite element method to generate simulation results of the directionally coupled deposition of the aerospace structural component; extracting target structural features of the aerospace structural component based on the simulation results to construct a simulated sample matching the target structural features, thereby obtaining preset performance parameters of the simulated sample manufactured under the same process conditions as the aerospace structural component, and constructing model correction parameters based on the preset performance parameters and simulation results to correct the thermo-mechanical coupling simulation model; and evaluating the overall performance of the aerospace structural component based on the corrected thermo-mechanical coupling simulation model and combined with preset index data, generating and outputting performance judgment results and process adaptation evaluation results.

[0006] In one optional embodiment of the first aspect, the step of constructing a structural performance analysis model based on a three-dimensional structural model of the aerospace structural component and performing load analysis and boundary condition definition on the structural performance analysis model under preset service conditions includes: classifying and analyzing preset loads on the aerospace structural component in the actual service environment and modeling assembly constraint relationships to transform the preset boundary region of the aerospace structural component into finite element boundary conditions; using a load spectrum construction method to perform multi-condition combination analysis and superimposing calculations on different extreme conditions, fatigue-sensitive conditions, and control conditions to obtain the stress distribution, displacement response, and safety margin parameters of the aerospace structural component under various conditions, and extracting its maximum principal stress, equivalent stress, and dangerous section deformation as performance evaluation input parameters to construct a structural performance analysis model; wherein, the preset loads include one or more of constant static loads, periodic variable loads, impact loads, and thermal stress loads, and the preset boundary region includes connection interfaces, mounting flange surfaces, and positioning hole features.

[0007] In one alternative embodiment of the first aspect, the introduction of manufacturing constraints matching the characteristics of the directional energy deposition additive manufacturing process into the structural performance analysis model includes: setting a minimum feature size threshold, a droop angle threshold, and a minimum wall thickness limit based on the characteristics of the directional energy deposition additive manufacturing process, wherein the droop angle threshold is not lower than a preset critical angle; defining the deposition direction as the principal anisotropic direction of the material and introducing direction-dependent elastoplastic constitutive parameters into the structural performance analysis model; introducing an interlayer thermal cycling influence function characterizing the effect of different scanning strategies on the accumulation of residual stress, combined with the thermal input characteristics of the directional energy deposition additive manufacturing process; and identifying structural regions that deviate from the process constraints and performing structural correction or local rounding treatment on the structural regions.

[0008] In one alternative embodiment of the first aspect, the step of constructing a thermo-coupled simulation model using the finite element method to output simulation results of the aerospace structural component during the directional energy deposition process includes: dividing the three-dimensional structural model into a finite element mesh and defining a layer-by-layer activation element strategy identical to the directional energy deposition path; introducing a moving heat source model into the structural performance analysis model and using laser power, scanning speed, spot diameter, and interlayer dwell time as input parameters to solve the transient temperature field of the deposition process; establishing a coupling term between thermal expansion strain and phase transformation strain and calculating the thermal stress evolution and residual stress distribution during the deposition process using a time-stepping method; and outputting simulation results that include at least the temperature field distribution, residual stress evolution, and forming deformation behavior.

[0009] In one optional embodiment of the first aspect, the step of extracting the target structural features of the aerospace structural component based on the simulation results to construct a simulated specimen matching the target structural features includes: identifying hazardous areas in the aerospace structural component based on the simulation results and preset load distribution data, wherein the hazardous areas include at least high equivalent stress areas, high strain gradient areas, geometric abrupt change areas, and potential fatigue-sensitive areas; classifying the hazardous areas according to structural morphology to form a set of structural feature parameters including local wall thickness, radius of curvature, aperture size, transition fillet radius, and internal cavity size; screening the set of structural feature parameters according to the characteristics of directional energy deposition additive manufacturing process, and eliminating features that do not meet the minimum feature size, overhang angle threshold, and minimum wall thickness; constructing the retained features in the set of structural feature parameters into target structural features for independent testing, and maintaining the same geometric proportions and deposition direction parameters as the original structure for the target structural features; and generating directional energy deposition paths and process parameters based on the target structural features and manufacturing a simulated specimen matching the target structural features under the same process conditions.

[0010] In one alternative embodiment of the first aspect, the step of extracting the target structural features of the aerospace structural component based on the simulation results to construct a simulated specimen matching the target structural features further includes: manufacturing a simulated specimen of the target structural features of the aerospace structural component based on the simulation results under the same equipment, the same material batch, and the same process parameters used in directional energy deposition additive manufacturing of the aerospace structural component; wherein the deposition direction of the simulated specimen is the same as or arranged at a preset angle to the forming direction of the aerospace structural component; and after manufacturing, the simulated specimen undergoes the same post-processing and heat treatment as the aerospace structural component to maintain the same microstructure as the aerospace structural component.

[0011] In one alternative embodiment of the first aspect, obtaining the preset performance parameters of a simulated specimen manufactured under the same process conditions as the aerospace structural component includes: performing coordinate measuring machine (CMM) measurement or non-contact 3D scanning on the manufactured simulated specimen to obtain spatial coordinate point cloud data of the simulated specimen; superimposing and registering the spatial coordinate point cloud data with a 3D structural model, calculating dimensional deviations and form and position deviations, and setting independent tolerance thresholds for critical areas and relaxed tolerance thresholds for non-critical areas; and obtaining the preset performance parameters of the simulated specimen after tensile, compression, and torsion tests, and performing statistical analysis on the preset performance parameters to calculate their mean, standard deviation, and anisotropy ratio, thereby identifying deformation trends and local manufacturing defects.

[0012] In one optional embodiment of the first aspect, the step of constructing model correction parameters based on the preset performance parameters and simulation results to correct the thermo-coupling simulation model includes: comparing the preset performance parameters with the simulation results of the thermo-coupling simulation model, establishing a simulation prediction error function, and performing reverse correction on the material constitutive parameters, heat source model parameters, and boundary heat transfer coefficients based on the simulation prediction error function; constructing a mapping relationship between process parameters, residual stress, and structural deformation based on preset experimental data, and generating model correction coefficients based on the mapping relationship; and using the model correction coefficients to correct the thermo-coupling simulation model.

[0013] In one optional embodiment of the first aspect, the step of evaluating the overall performance of the aerospace structural component based on the modified thermo-mechanical coupling simulation model and combined with preset index data, and generating and outputting performance judgment results and process adaptation evaluation results, includes: establishing a comprehensive evaluation index that includes geometric accuracy index, material mechanical property index, residual stress index, and structural response index, and setting qualified threshold ranges for each index; using the modified thermo-mechanical coupling simulation model to generate modified simulation results of directional energy deposition for the aerospace structural component; generating a comprehensive performance score value based on the modified simulation results and the comprehensive evaluation index, and performing a preset division of the aerospace structural component based on the comprehensive performance score value to generate corresponding performance judgment results; as well as associating the performance judgment results with the directional energy deposition additive manufacturing process parameters to form process adaptation evaluation results; and outputting the performance judgment results and process adaptation evaluation results.

[0014] In a second aspect, this application provides an electronic device, comprising: a processor adapted to execute a computer program; and a computer-readable storage medium storing a computer program, wherein when executed by the processor, the computer program implements the method described in any one of the first aspects.

[0015] Thirdly, this application provides a computer-readable storage medium for storing a computer program that, when run on a computer, causes the computer to perform the method described in any one of the first aspects.

[0016] It should be understood that the above general characterization and the detailed characterization below are merely exemplary and do not limit this application. Attached Figure Description

[0017] The accompanying drawings, which are incorporated herein and form part of this specification, illustrate one or more embodiments of the present application and, together with the characterization, serve to explain the principles of the present application and to enable those skilled in the art to make and use the present application.

[0018] Figure 1 This is a schematic diagram based on an existing exemplary directional energy deposition additive manufacturing process.

[0019] Figure 2 This is a flowchart illustrating an exemplary performance evaluation method according to some embodiments of this application.

[0020] Figure 3 This is a flowchart illustrating an exemplary model building and parsing method according to some embodiments of this application.

[0021] Figure 4 This is a flowchart illustrating an exemplary method for introducing manufacturing constraints according to some embodiments of this application.

[0022] Figure 5 This is a flowchart illustrating an exemplary simulation result generation method according to some embodiments of this application.

[0023] Figure 6 This is a schematic flowchart of an exemplary simulated sample construction method according to some embodiments of this application.

[0024] Figure 7 This is a flowchart illustrating an exemplary method for obtaining performance parameters according to some embodiments of this application.

[0025] Figure 8 This is a schematic diagram of an exemplary tensile, compression, and torsion test according to some embodiments of this application; wherein (a) is a tensile process and a specimen after fracture, (b) is a compression process and a specimen after compression, and (c) is a torsion process and a specimen after torsion.

[0026] Figure 9 This is a flowchart illustrating an exemplary modified model method according to some embodiments of this application.

[0027] Figure 10 This is a Mises stress distribution diagram after an exemplary correction model according to some embodiments of this application.

[0028] Figure 11 This is a Mises stress distribution diagram of an exemplary simulated specimen according to some embodiments of this application.

[0029] Figure 12 This is an exemplary stress distribution diagram of an aerospace structural component according to some embodiments of this application.

[0030] Figure 13 This is a flowchart illustrating an exemplary performance evaluation and output method according to some embodiments of this application.

[0031] Figure 14 This is a schematic diagram of an existing exemplary lift height deviation defect; where (a) is interlayer non-fusion caused by excessive lift height and (b) is warping caused by insufficient lift height.

[0032] Figure 15 This is a schematic diagram of printing a single-wall wall under exemplary optimal light spot parameters according to some embodiments of this application.

[0033] Figure 16 This is a schematic diagram of an exemplary feature printing according to some embodiments of this application; wherein, (a) is an actual printed thin-walled feature, (b) is an actual printed corner feature, (c) is an actual printed first overhanging feature, and (d) is an actual printed second overhanging feature.

[0034] Figure 17 This is a schematic diagram of an exemplary 1 / 4 ring temperature distribution according to some embodiments of this application.

[0035] Figure 18 This is a schematic diagram of an exemplary one-cycle equivalent stress distribution according to some embodiments of this application.

[0036] Figure 19 This is a schematic diagram of the module connections of an exemplary aerospace structural component performance evaluation device according to some embodiments of this application.

[0037] Figure 20 This is a schematic diagram of the structure of an exemplary electronic device according to some embodiments of this application. Detailed Implementation

[0038] Exemplary embodiments will now be characterized more fully with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in various forms and should not be construed as limited to the examples set forth herein; rather, their characterization is intended to make this application more comprehensive and complete, and to fully convey the concept of the exemplary embodiments to those skilled in the art. The characterized features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following characterization to provide a deeper understanding of the embodiments of this application.

[0039] To facilitate understanding of the technical solutions provided in this application, the relevant terms are explained below.

[0040] It should be noted that the terminology used in the implementation section of this application is only for explaining the embodiments of this application and is not intended to limit this application.

[0041] For example, the term "and / or" in this article merely describes a relationship between related objects, indicating that three relationships can exist. For instance, A and / or B can represent: A alone, A and B simultaneously, and B alone. The term "at least one" merely describes a combination relationship between listed objects, indicating that one or more can exist. For instance, at least one of the following: A, B, C can represent the following combinations: A alone, B alone, C alone, A and B simultaneously, A and C simultaneously, B and C simultaneously, and A, B, and C simultaneously. The term "multiple" refers to two or more. The character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0042] For example, the term "correspondence" can indicate a direct or indirect correspondence between two things, or an association between them, or a relationship of instruction and being instructed, configuration and being configured, etc. The term "when..." can be interpreted as "if," "when," or "in response," etc. The terms "first," "second," etc., are used to distinguish different objects, not to indicate a specific order. The terms "including" and "having," and any variations thereof, are intended to cover non-exclusive inclusion.

[0043] Directed energy deposition (DED) technology, as an important branch of additive manufacturing, has achieved significant development in recent years. Figure 1 As shown, its core principle involves focusing a high-energy beam, such as a laser, electron beam, or electric arc, onto the surface of a substrate or workpiece to form a molten pool. Metal powder or wire is simultaneously fed into the molten pool through coaxial or lateral nozzles, rapidly melting and metallurgically bonding with the matrix. Through a layer-by-layer deposition process, a CNC system controls the coordinated movement of the energy beam and the feeding device, stacking materials layer by layer along a preset path to ultimately form a three-dimensional solid part. Its core characteristics are high precision, high deposition efficiency, and multi-material compatibility, making it suitable for the manufacturing of large components, the development of functionally graded materials, and the repair of high-performance parts. Compared to selective melting technologies, it has a higher deposition rate and larger manufacturing scale. However, its forming process involves complex heat input, molten pool dynamics, and rapid solidification behavior, which can easily introduce large temperature gradients and thermal cycling effects, leading to problems such as residual stress accumulation, component deformation, microstructure anisotropy, and local defects.

[0044] Currently, in aerospace structural applications, aerospace structural components typically need to withstand complex service conditions such as multiaxial composite loads, vibration loads, and thermal loads, which impose strict requirements on strength, stiffness, fatigue life, and dimensional stability. However, existing performance evaluation methods often rely on the production of a large number of physical prototypes and destructive testing, which is not only costly and time-consuming, but also makes it difficult to predict structural risks in the design phase. At the same time, since the process parameters, deposition path, and forming direction of directional energy deposition additive manufacturing have a significant impact on the microstructure and mechanical behavior, it is difficult to accurately reflect the true performance of complex structural components under actual manufacturing conditions by simply relying on the test results of standard specimens.

[0045] Figure 2 A flowchart illustrating an exemplary performance evaluation method 100 according to some embodiments of this application is shown.

[0046] Therefore, to solve the above-mentioned technical problems, some embodiments of this application provide a performance evaluation method 100 for directional energy deposition additive manufacturing of aerospace structural components, referencing... Figure 2As shown, the performance evaluation method 100 of this application includes at least the following steps 101 to 104.

[0047] 101: Construct a structural performance analysis model based on the three-dimensional structural model of the aerospace structural component, and perform load analysis and boundary condition definition on the structural performance analysis model under preset service conditions.

[0048] Specifically, in step 101, the three-dimensional structural model file of the aerospace structural component is imported into the finite element analysis software to generate a computable three-dimensional structural model. Then, the three-dimensional structural model is subjected to geometric processing, including removing non-load-bearing decorative features and process chamfer features, merging small-sized redundant surfaces, repairing topological gaps and geometrically discontinuous boundaries, and refining and preserving key stress concentration areas. Then, a finite element discretization strategy is set according to the material properties and thickness distribution characteristics of the aerospace structural component, and an adaptive mesh generation algorithm is used to generate a mesh. Finally, the mesh size is set according to the structural feature size ratio to form the initial structural finite element model of the aerospace structural component.

[0049] The finite element discretization strategy includes using shell elements to model the thin-walled plate shell structure, using solid elements to model the solid stiffeners and connecting blocks, using transition elements to couple the connecting areas, and setting mesh refinement areas for local high-stress zones; the mesh size of the key stress areas is at least 50% smaller than the overall average mesh size; the three-dimensional structural model can be derived from a solid design model or a three-dimensional scan reconstruction model.

[0050] Figure 3 The diagram illustrates a flowchart of an exemplary model building and parsing method according to some embodiments of this application.

[0051] refer to Figure 3 As shown. Specifically, in step 101, a structural performance analysis model is constructed based on the three-dimensional structural model of the aerospace structural component, and load analysis and boundary condition definition are performed on the structural performance analysis model under preset service conditions, including at least the following steps 101a to 101b.

[0052] 101a: After the initial structural finite element model is generated, the preset loads of the aerospace structural component in the actual service environment are classified and analyzed, and the preset boundary region of the aerospace structural component is transformed into finite element boundary conditions by modeling the assembly constraint relationship.

[0053] The preset loads include one or more of the following: constant static load, periodic variable load, impact load, and thermal stress load. Examples of constant static loads include self-weight and steady-state aerodynamic forces; periodic variable loads include aerodynamic loads or vibration loads; impact loads include takeoff and landing impacts and bird strike transient loads; and thermal stress loads include high-altitude temperature differences or temperature rise in the vicinity of the engine. The preset boundary regions include features such as connection interfaces, mounting flange surfaces, and positioning holes. In actual implementation, the amplitude and loading position of various loads can be obtained through flight envelope data or engineering design manuals, and then the loads are applied to the corresponding regions of the model in the form of concentrated forces, surface forces, or volume loads.

[0054] Specifically, after the pre-defined load classification and analysis, mathematical expression models for the corresponding loads are established according to different types of loads. The constant static load is applied directly through the static equilibrium equation, the periodic variable load is expressed as a time function through the load spectrum function, the impact load is input through the pulse function or transient acceleration, and the thermal stress load is calculated by coupling the temperature field distribution function and the thermal expansion coefficient of the material. This process can be constructed by the designer using existing mathematical models according to actual needs, thereby converting the different types of loads into finite element nodal loads.

[0055] Then, constraint modeling is performed on the assembly relationship of the aerospace structural component, transforming the actual assembly method into finite element boundary conditions. That is, based on the actual assembly method, the boundary condition type is defined (such as one or more of fixed constraints, displacement constraints, elastic support constraints, contact constraints, and multi-point coupling constraints). Then, the preset boundary region of the aerospace structural component is transformed into calculable finite element boundary conditions. For example, fixed constraints or elastic constraints are used to simulate bolted or riveted connections for connection interfaces, displacement constraints or elastic support boundaries are applied to mounting flange surfaces, and multi-point constraints or rigid connection elements are used to constrain positioning hole features. In actual implementation, boundary settings can be achieved by defining full constraints or restricting some degrees of freedom to ensure that the model is consistent with the actual assembly state.

[0056] 101b: A multi-condition combined analysis is performed using load spectrum construction and weight allocation methods. Different extreme conditions, fatigue-sensitive conditions and control conditions are superimposed for calculation to obtain the stress distribution, displacement response and safety margin parameters of aerospace structural components under various conditions. The maximum principal stress, equivalent stress and dangerous section deformation are extracted as input parameters for performance evaluation to construct a structural performance analysis model.

[0057] Specifically, after transforming the pre-defined boundary region of the aerospace structural component into finite element boundary conditions, a standard flight mission load spectrum is constructed. Then, based on the flight phase, extreme conditions, fatigue-sensitive conditions, and control conditions are defined. Weighting coefficients are then assigned to each condition (these coefficients can be set by the designer based on the load occurrence probability or design safety factor). Multi-condition combination calculations are performed using linear superposition or nonlinear coupling analysis methods to obtain nodal stress distribution, nodal displacement response, equivalent plastic strain, and safety margin parameters. From these parameters, the maximum principal stress, equivalent stress, critical section deformation, maximum displacement, and local buckling index are extracted. These extracted parameters are used as input parameters for performance evaluation to construct a structural performance analysis model. During the calculation process, one or more of the following are performed: static analysis, transient dynamic analysis, thermo-structural coupling analysis, and fatigue life analysis.

[0058] 102: Introduce manufacturing constraints that match the characteristics of the directional energy deposition additive manufacturing process into the structural performance analysis model and use the finite element method to construct a thermo-mechanical coupling simulation model to generate simulation results of directional energy deposition for aerospace structural components.

[0059] Figure 4 A flowchart illustrating an exemplary method for introducing manufacturing constraints according to some embodiments of this application is shown.

[0060] refer to Figure 4 As shown. Specifically, in step 102, manufacturing constraints matching the characteristics of the directional energy deposition additive manufacturing process are introduced into the structural performance analysis model, including at least the following steps 102a to 102d.

[0061] 102a: Based on the equipment and process parameters of directional energy deposition additive manufacturing, set manufacturing constraint parameters including minimum feature size threshold, overhang angle threshold and minimum wall thickness limit.

[0062] The minimum feature size threshold is determined based on the width of the molten pool in a single nozzle, the minimum wall thickness limit is determined based on the width of the single deposition and the overlap ratio, and the overhang angle threshold is set based on the critical angle of molten pool collapse. The minimum overhang angle for stable forming, such as 55° or 60°, can be obtained through overhang sample tests. Therefore, the overhang angle threshold is set to be no less than the critical angle. The manufacturing constraint parameters can be set by the designer with reference to the calibration test data of the directional energy deposition additive manufacturing equipment or the statistical results of historical manufactured samples.

[0063] 102b: The deposition direction is defined as the principal anisotropic direction of the material, and direction-dependent elastoplastic constitutive parameters are introduced into the structural performance analysis model.

[0064] In the finite element software, the elastic modulus is defined along the deposition direction and along the perpendicular deposition direction, and then the yield strength in different directions is defined respectively. In actual implementation, the direction mapping can be achieved by transforming between the material coordinate system and the global coordinate system, so that the element stiffness varies with the deposition direction. Anisotropy refers to the characteristic that the mechanical properties of a material exhibit differences in different directions. For additive manufacturing parts, due to the process characteristics of its layer-by-layer manufacturing, the microstructure often exhibits columnar crystals growing along the construction direction, which leads to its mechanical properties exhibiting obvious anisotropy.

[0065] 102c: Combining the thermal input characteristics of directional energy deposition additive manufacturing process, an interlayer thermal cycling influence function is introduced to characterize the effect of different scanning strategies on residual stress accumulation.

[0066] The thermal input characteristics include power input parameters, scanning speed, and spot diameter; the interlayer thermal cycle influence function includes at least the interlayer cooling time interval, peak temperature, temperature gradient, and remelting region ratio parameters.

[0067] 102d: Identify structural regions that deviate from process constraints and perform structural corrections or local rounding on these regions.

[0068] Based on the aforementioned manufacturing constraints, one or more of the following are identified: excessive overhang areas, residual stress exceeding limits, areas with excessive local deformation, and areas at risk of hot cracking. Then, one or more of the following treatments are applied to the identified structural areas: adding support structures, adjusting wall thickness, modifying deposition direction, optimizing scanning path, and performing local rounding.

[0069] Figure 5 A flowchart illustrating an exemplary simulation result generation method according to some embodiments of this application is shown.

[0070] refer to Figure 5 As shown. Specifically, in step 102, the process of constructing a thermo-mechanical coupling simulation model using the finite element method to generate simulation results of directional energy deposition for aerospace structural components includes at least the following steps 102e to 102h.

[0071] 102e: Divide the finite element mesh according to the three-dimensional structural model and define the same layer-by-layer activation element strategy as the directional energy deposition path.

[0072] The finite element mesh generation includes using solid thermal-structural coupled mesh elements for the deposition region, solid structural mesh elements for the substrate region, and appropriately thickening the mesh size for regions far from the deposition region. The layer-by-layer activation strategy includes dividing the model into layers according to a preset deposition path, dividing each deposition layer into multiple scan channels, and initially setting the corresponding layer elements to an inactive state. When the moving heat source moves to the corresponding path position, the corresponding mesh elements are activated to participate in the calculation. The layer-by-layer activation sequence is consistent with the actual directional energy deposition path, including the scanning direction, interlayer sequence, and partition construction sequence.

[0073] 102f: A moving heat source model is introduced into the structural performance analysis model, and the transient temperature field of the deposition process is solved by using laser power, scanning speed, spot diameter and interlayer dwell time as input parameters; the interlayer dwell time is used to simulate the cooling time interval between layers.

[0074] Specifically, this moving heat source model is used to simulate the spatial distribution and temporal variation characteristics of laser energy on the material surface during directional energy deposition. It can use an existing Gaussian distribution heat source function to represent the heat flux density of the laser on the material surface, which has a maximum value at the center of the laser spot and decays exponentially in the radial direction. The heat flux density is directly proportional to the laser power and energy absorption efficiency, and inversely proportional to the spot area. Furthermore, the heat flux density decays rapidly according to an exponential law as it moves further away from the center of the heat source. The energy absorption efficiency is the actual proportion of laser energy absorbed by the material. During the simulation, the heat source moves along a preset scanning path. Its motion law is that the position of the heat source center changes linearly with time under constant scanning speed conditions, the position of the heat source at any given moment is determined by the product of scanning speed and time, and when the scanning path is a segmented path, the direction of heat source movement is updated sequentially according to the path segments.

[0075] In step 102f, the process of temperature change within the material over time is also solved. This process is reflected as the rate of temperature change per unit volume of the material over time, which is equal to the temperature change caused by the thermal conductivity and diffusion capacity within the material, plus the heat input from the moving heat source. The temperature change over time is related to the material density and specific heat capacity, and is determined by the thermal conductivity of the material due to the thermal diffusion capacity in space. By performing time integration calculation on this process, the transient temperature field distribution at different time points during the deposition process can be obtained, such as the temperature distribution at each time step, the highest temperature region of the molten pool, and the cooling rate distribution.

[0076] 102g: A coupling term between thermal expansion strain and phase transformation strain was established, and the thermal stress evolution and residual stress distribution during the deposition process were calculated using a time-stepping method.

[0077] Specifically, after obtaining the transient temperature field of the deposition process, the temperature change is converted into the thermal expansion strain of the material. The physical meaning of this thermal expansion strain is the volume or length expansion of the material due to the increase in temperature. Its magnitude is proportional to the linear expansion coefficient of the material and proportional to the difference between the current temperature and the initial ambient temperature. Therefore, at any point, the higher the temperature and the greater the difference from the initial temperature, the greater the thermal expansion strain generated. Furthermore, when the material undergoes phase transformation strain during heating or cooling, an additional volume change will also be generated. The magnitude of this phase transformation strain is related to the phase transformation volume fraction of the material at the current temperature and the inherent phase transformation volume change constant of the material. Thus, the total thermal strain generated by the material during the deposition process is equal to the pure thermal expansion strain plus the volume change strain caused by the phase transformation. The superposition of these two terms generates a coupling term of thermal expansion strain and phase transformation strain.

[0078] Specifically, in the numerical calculation, the entire deposition process is divided into multiple time increments. Within each time increment, the following steps are performed sequentially: updating the heat source location, calculating the temperature field, calculating the thermal strain based on temperature changes, using the thermal strain as a load input, and solving for the stress field and displacement field at the current moment. The time step must not exceed the mesh cell size corresponding to the distance the heat source moves within that time. After all layers are deposited, the cooling stage simulation continues until the overall temperature of the structure returns to the ambient temperature. During this process, the stress gradually redistributes and forms residual stress, thereby obtaining the thermal stress evolution process, the spatial distribution of residual stress, and the cumulative plastic strain distribution.

[0079] 102h: Generate simulation results including at least temperature field distribution, residual stress evolution, and forming deformation behavior.

[0080] This generates temperature field distribution at different times, thermal stress evolution process, three-dimensional distribution of residual stress, structural deformation after forming, and stress-time curves at key sections.

[0081] 103: Extract the target structural features of the aerospace structural components based on the simulation results, construct a simulated specimen that matches the target structural features, and then obtain the preset performance parameters of the simulated specimen manufactured under the same process conditions as the aerospace structural components. Based on the preset performance parameters and simulation results, construct model correction parameters to correct the thermo-mechanical coupling simulation model.

[0082] Figure 6 A schematic flowchart of an exemplary simulated sample construction method according to some embodiments of this application is shown.

[0083] refer to Figure 6 As shown. Specifically, in step 103, the target structural features of the aerospace structural component are extracted based on the simulation results to construct a simulated specimen that matches the target structural features, including at least the following steps 103a to 103e.

[0084] 103a: Identify hazardous areas in aerospace structural components based on simulation results and preset load distribution data.

[0085] The identification of dangerous areas includes areas where the equivalent stress exceeds a preset threshold of the material's yield strength, areas where the equivalent plastic strain exceeds a preset strain limit, areas where the strain gradient is greater than a preset gradient threshold, areas with peak temperature gradients, and areas with concentrated residual stress. Specifically, the designers set preset danger thresholds according to actual needs. When any of the above areas exceeds the preset danger threshold, the area is determined to be a dangerous area. The dangerous area includes at least high equivalent stress areas, high strain gradient areas, geometric change areas, and potentially fatigue-sensitive areas.

[0086] 103b: Classify hazardous areas according to their structural morphology to form a set of structural characteristic parameters, including local wall thickness, radius of curvature, aperture size, transition fillet radius, and internal cavity size.

[0087] Specifically, after identifying the hazardous area, the hazardous area is geometrically decomposed to transform it into a set of quantifiable structural feature parameters, such as local wall thickness, radius of curvature, aperture size, transition fillet radius, internal cavity size, stiffener height and width, and interlayer deposition direction angle. This set of structural feature parameters can be obtained by parametric measurement of the three-dimensional structural model of the aerospace structural component.

[0088] 103c: Based on the characteristics of the directional energy deposition additive manufacturing process, the set of structural feature parameters is screened, and features that do not meet the minimum feature size, overhang angle threshold and minimum wall thickness are removed.

[0089] Specifically, the set of structural feature parameters is compared with the manufacturing constraints set in step 102. Features smaller than the minimum feature size threshold, features with overhang angles smaller than the critical overhang angle, and features with wall thicknesses lower than the minimum wall thickness limit are eliminated. For features close to the critical value, only features with a safety margin greater than or equal to the preset value are retained.

[0090] 103d: Construct the retained features from the set of structural feature parameters into target structural features for independent testing, and maintain the same geometric proportions and deposition direction parameters as the original structure for the target structural features.

[0091] Specifically, the construction principles for the target structural features of this independent test include maintaining the same geometric proportions as the original structure, maintaining the same deposition direction parameters, maintaining the same interlayer overlap ratio, and maintaining the same scanning path pattern. Furthermore, for multi-feature regions, a combined structure can be constructed.

[0092] For example, the extraction of the target structural features can be based on the service conditions of the aerospace structural components (such as vibration and impact loads), combined with simulation results (stress concentration areas) or historical test data, to determine the features prone to failure (such as thin walls, rounded transitions, and internal cavities). At the same time, considering the limitations of the directional energy deposition additive manufacturing process (such as overhang angle ≥ 55°, minimum feature size ≥ 0.5 mm), features that cannot be formed are eliminated. The extracted target structural features are then transformed into simplified simulation specimens that can be tested independently. This ensures that the simulation specimens meet the requirements of the directional energy deposition additive manufacturing process (such as adding support structures to avoid defects with overhang angles < 55°), so as to export the three-dimensional model (STP format) of the simulation specimen and the process path planning file.

[0093] 103e: Generate directional energy deposition paths and process parameters based on the target structural characteristics, and manufacture a simulated sample matching the target structural characteristics under the same process conditions.

[0094] Specifically, in step 103e, under the same equipment, material batch, and process parameters used in directional energy deposition additive manufacturing of aerospace structural components, a simulated sample of the target structural features of the aerospace structural component is manufactured based on the simulation results. The deposition direction of the simulated sample is the same as or at a preset angle to the forming direction of the aerospace structural component. After manufacturing, the simulated sample undergoes the same post-processing and heat treatment as the aerospace structural component to maintain the same microstructure. This post-processing and heat treatment includes stress-relieving annealing, aging treatment, and surface finishing.

[0095] For example, when manufacturing a simulated sample matching the target structural features, plasma cleaning / chemical solvent treatment is used to remove oil, oxide layer, and particulate impurities from the substrate surface, ensuring the metallurgical bonding quality between the cladding layer and the substrate. Then, a three-dimensional coordinate system of the substrate is established using laser scanning to compensate for thermal deformation errors (accuracy ±2μm), maintaining a substrate temperature gradient ≤5℃ / mm to ensure a clean and flat substrate meeting process requirements, with a positioning error <10μm. Next, within the forming chamber, argon purity ≥99.999%, oxygen content <10 ppm, and pressure gradient controlled within ±0.05 kPa are maintained. A multi-laser collaborative scanning strategy is employed, with the molten pool temperature controlled in real-time within ±15℃ of the material's melting point. The interlayer overlap rate is optimized to 30-50%. During sample forming, a high-speed camera (frame rate ≥1000fps) captures the droplet transition morphology, and a spectrometer dynamically monitors the plasma emission spectrum. Finally, a dual-energy CT system (resolution ≤5μm) is used to achieve three-dimensional reconstruction of internal defects in the cladding layer, identifying pores (diameter >50). μm), unfused (volume > 0.1 mm) 3Defects such as those mentioned above are eliminated; a gradient cooling process (cooling rate 5-20℃ / min) is adopted to eliminate ≥90% of the internal stress. After cold treatment, a coordinate measuring machine or a non-contact three-dimensional scanning device is used to complete the full-size inspection (measurement uncertainty U≤15 μm).

[0096] Figure 7 A flowchart illustrating an exemplary method for obtaining performance parameters according to some embodiments of this application is shown.

[0097] refer to Figure 7 As shown. Specifically, in step 103, the preset performance parameters of the simulated specimen manufactured under the same process conditions as the aerospace structural component are obtained, including at least the following steps 103f to 103h.

[0098] 103f: Perform coordinate measuring or non-contact 3D scanning on the manufactured simulated sample to obtain the spatial coordinate point cloud data of the simulated sample.

[0099] Specifically, the simulated sample that has been manufactured and undergone necessary post-processing is subjected to contact measurement using a coordinate measuring machine, or non-contact 3D scanning using a structured light scanner or laser scanner, in order to obtain spatial coordinate point cloud data of the simulated sample, including point coordinates, surface normal vectors and point density information. Isolated noise points are removed from the spatial coordinate point cloud data, points are added to the scanned occluded areas for reconstruction, and voxel filtering is used for uniform downsampling.

[0100] For example, when performing coordinate measuring machine (CMM) measurements, this application scans the simulated sample according to the GB / T 1182-2018 standard to generate spatial coordinate point cloud data. The corresponding technical requirements are shown in the table below: Table: Comparison Table of Geometric Inspection and Process Correlation Analysis

[0101]

[0102] 103g: The spatial coordinate point cloud data is overlaid and registered with the 3D structural model, the dimensional deviation and geometric deviation are calculated, and independent tolerance thresholds are set for key areas and relaxed tolerance thresholds are set for non-key areas.

[0103] Specifically, the processed spatial coordinate point cloud data is imported into relevant model comparison software and overlaid and registered with the original three-dimensional structural model of the aerospace structural component. During registration, preliminary alignment can be performed by feature point matching or manual selection of reference surfaces, and least squares fitting registration is performed using the iterative nearest point algorithm. After registration, the dimensional deviation and geometric deviation of each point cloud data point to the surface of the original three-dimensional structural model are calculated. Then, the dangerous area is defined as the critical area and an independent tolerance threshold is set, and a relaxed tolerance threshold is set for the non-critical area. Areas with deviations exceeding the corresponding tolerance thresholds are marked as geometrically unstable areas.

[0104] 103h: Obtain the preset performance parameters of the simulated specimen after tensile test, compression test and torsion test, and perform statistical analysis on the preset performance parameters to calculate their mean, standard deviation and anisotropy ratio, so as to identify deformation trend and local manufacturing defects.

[0105] To reflect the anisotropic characteristics of the material, test specimens were prepared along different deposition directions, such as along the deposition direction (0°), perpendicular to the deposition direction (90°), and inclined (45°). During the test, the specimens were loaded at a preset loading rate, and performance parameters such as stress-strain curves, yield point, ultimate strength, elongation at break, elastic modulus, and torsional stiffness were recorded in real time. Simulated specimens with different deposition directions were tested separately to obtain direction-related performance data. The anisotropy ratio can be obtained by dividing the performance parameters of the deposition direction by the performance parameters of the perpendicular or inclined directions. Thus, the obtained mean, standard deviation, and anisotropy ratio are used to identify the performance dispersion, anisotropy, local performance weakening trend, and deviation from the simulation prediction values ​​of the simulated specimens. When the performance in a certain direction is significantly lower than the simulation prediction value, it is determined that there is a potential manufacturing defect or microstructure inhomogeneity problem in that area. When identifying local manufacturing defects, fracture morphology analysis can be combined to identify whether there are porosity, lack of fusion, or microcracks.

[0106] Figure 8 A schematic diagram of an exemplary tensile, compressive, and torsional test according to some embodiments of this application is shown; wherein Figure 8 (a) shows the tensile process and the specimen after fracture. Figure 8 (b) shows the compression process and the sample after compression. Figure 8 (c) shows the torsion process and the sample after torsion.

[0107] refer to Figure 8 As shown. Tensile testing is the core method for evaluating the mechanical properties of metal additively manufactured parts under axial tensile loads. It can obtain key indicators such as elastic limit, elongation, elastic modulus, proportional limit, area reduction, tensile strength, and yield point / yield strength. High-temperature tensile testing can also obtain creep data, providing a basis for the reliability of high-temperature service.

[0108] For example, the tensile tests in this application were conducted using a servo-controlled electronic universal testing machine conforming to GB / T 228.1-2021 "Metallic materials, tensile testing—Part 1: Tests at room temperature". During the elastic modulus determination, the strain rate was 0.00025~0.0025 / s (corresponding to a displacement rate of 0.001~0.01 mm / min); during the yield strength determination, the strain rate was 0.0025 / s (corresponding to a displacement rate of 0.01 mm / min); during the uniform plastic deformation stage, the strain rate was ≤0.0083 / s (corresponding to a displacement rate ≤0.033 mm / min); and after the maximum force, the test rate was ≤0.05 / s (corresponding to a displacement rate ≤0.2 mm / min). Standards such as mm / min are followed. Due to the potential anisotropy of the simulated specimens, additional simulated specimens in the longitudinal, transverse, and thickness directions need to be prepared. The simulated specimens are then centered and clamped into the tensile testing machine. After setting parameters such as loading speed, a load is applied, and the load and gauge length elongation are recorded by sensors. Curves are plotted and performance indicators are calculated. The meanings of each indicator are clear: the elastic limit is the maximum stress in the elastic deformation stage; elongation (after fracture / total maximum force) and area reduction measure plasticity; the elastic modulus reflects the resistance to elastic deformation; the proportional limit is the critical stress in the linear stress-strain relationship; the tensile strength is the maximum bearing stress (corresponding to necking fracture); and the yield point / strength is the initiation stress of plastic deformation (for materials without obvious yielding phenomena, the stress corresponding to 0.2% plastic strain is taken). Furthermore, internal defects such as pores and lack of fusion in the parts will reduce strength and plasticity, and microstructural anisotropy (such as grain directional growth) will lead to performance differences in different directions. Therefore, during the test, it is necessary to record the sampling direction, location, and process parameters of the simulated specimens to provide support for process optimization and part design.

[0109] Compression testing is a crucial method for evaluating the resistance to axial compressive deformation and fracture of metal additive manufacturing parts. It clarifies the material's deformation patterns, yield characteristics, compressive strength, and fracture modes, and is particularly important for additive parts such as supporting structures and load-bearing components that are primarily subjected to compressive loads. The test principle involves applying a load perpendicular to the axial direction to the specimen using a compression testing machine, recording the load-deformation curve, and calculating indices such as compressive strength and yield strength. Plastic materials often exhibit large plastic deformation (without significant fracture), while brittle materials fracture with minimal deformation. Specimen preparation must adhere to the GB / T 7314-2005 standard, commonly using cylindrical specimens (diameter d = 10-20 mm, deviation ±0.05 mm; length L = (2.5-3.5) d, (5-8) d, or (1-2) d; e.g., L = 25 mm when d = 10 mm). Parallelism and perpendicularity of both end faces must be ensured, and the surface roughness Ra ≤ 0.8. μm, with the gauge length not less than d / 2 from the end face to ensure uniform load transfer; during the test, the specimen is first placed on the lower platen of the testing machine, and the upper platen is adjusted to lightly touch the specimen. The loading speed is set according to the material properties (slightly faster for ductile materials and slower for brittle materials). Data is recorded in real time during loading: ductile materials first undergo elastic deformation (load-deformation linear), then the curve plateau fluctuates after yielding, and finally is compressed into a disc shape (maximum stress is compressive strength); brittle materials do not have obvious plastic deformation, and the stress at fracture is compressive strength; and the internal pores, unfused defects or closure (small pores initially compact to increase strength) or expansion (large / multiple defects lead to strength reduction and premature fracture), and the anisotropy of the microstructure cause differences in performance in different directions. Therefore, it is necessary to prepare multi-directional simulated specimens according to the service direction, and at the same time record the sampling direction and process parameters to provide support for process optimization and part design.

[0110] Torsion testing is a core test for evaluating the torsional resistance of metallic materials and additively manufactured parts. It yields indicators such as torsional strength, shear modulus, torsion angle, yield torque, and fracture torque, clarifying the torsional deformation pattern and fracture characteristics. For parts subjected to torsional loads, such as drive shafts and bolts, it is crucial for verifying their mechanical properties. The test principle is as follows: a simulated specimen is clamped between the two grips of a torsion testing machine (ensuring the specimen's axis coincides with the machine shaft). Equal torques in opposite directions are applied at both ends of the gauge length, and the torque (M)-torsion angle (θ) curve is recorded. This is then converted into a shear stress-shear strain curve, and various performance indicators are calculated. Simulated specimen preparation must comply with GB / T 10128-2007 standard. Commonly used are cylindrical specimens with long gauge lengths (L=10d) and short gauge lengths (L=5d) (e.g., when d=10 mm, L is 100 mm and 50 mm respectively). The gauge length diameter must be uniform, the surface roughness must meet the standard, and the clamping ends must be sufficiently long and rigid to avoid slippage or stress concentration. GB / T 10128-2007 is a basic standard for room temperature torsion, which specifies the equipment accuracy (torque sensor ≥ 0.5 grade, torsion angle measurement ≥ 0.1°), loading speed (slightly faster for plastic materials, slower for brittle materials) and index calculation (such as torsional strength = maximum torque / torsional section modulus). The indexes obtained through this torsion test can support structural design (such as calculating the maximum load torque of the drive shaft), and can also analyze the relationship between test results and process parameters, optimize laser power, scanning speed, etc., and improve the torsional performance of the structure.

[0111] Figure 9 A flowchart illustrating an exemplary modified model method according to some embodiments of this application is shown.

[0112] refer to Figure 9 As shown. Specifically, in step 103, model correction parameters are constructed based on preset performance parameters and simulation results to correct the thermo-coupling simulation model, including at least the following steps 103i to 103k.

[0113] 103i: Compare the preset performance parameters with the simulation results of the thermo-mechanical coupling simulation model, establish the simulation prediction error function, and perform reverse correction on the material constitutive parameters, heat source model parameters, and boundary heat transfer coefficient based on the simulation prediction error function.

[0114] Specifically, the preset performance parameters of the simulated specimen are matched with the prediction results of the thermo-mechanical coupling simulation model before correction. Then, for each performance parameter, the difference between the measured value and the simulation prediction value is calculated, the absolute value of the difference is taken, the absolute value is divided by the corresponding measured value to obtain the relative error of the performance parameter, preset weights are set according to the degree of influence of different performance parameters on the overall performance of the structure, and each relative error is multiplied by the corresponding preset weight. The weighted error values ​​are summed to generate a comprehensive simulation prediction error function value. The preset weights are used to reflect the differences in the degree of influence of different indicators on the overall performance and can be set by the designer according to the purpose of the structure, the stress characteristics, and the safety level.

[0115] After generating the simulation prediction error function, when the simulation prediction error function exceeds the error threshold preset by the designer, the parameter update process is initiated. During the parameter update process, the material constitutive parameters (such as elastic modulus, yield strength, and hardening parameters), heat source model parameters (such as energy absorption efficiency and heat source range), and boundary heat transfer coefficient are corrected. The correction steps include selecting a set of parameters to be adjusted and slightly increasing or decreasing the values ​​of these parameters, re-executing the thermo-mechanical coupling simulation, recalculating the comprehensive error evaluation value, and judging whether the error has decreased. If the error decreases, the current parameter adjustment direction is retained; if the error increases, the parameters are adjusted in the opposite direction. These processes are repeated until the simulation prediction error function converges to the preset convergence threshold set by the designer, thereby obtaining the corrected material constitutive parameters, heat source model parameters, and boundary heat transfer coefficient.

[0116] 103j: Construct a mapping relationship between process parameters, residual stress and structural deformation based on preset experimental data, and generate model correction coefficients based on this mapping relationship to characterize the influence of process parameters on material properties and deformation behavior.

[0117] Specifically, after obtaining the corrected material constitutive parameters, heat source model parameters, and boundary heat transfer coefficients, multiple sets of different process conditions were selected for experimental verification. These multiple sets of different process conditions included laser power, scanning speed, powder feeding rate, layer thickness, overlap ratio, and deposition direction. Then, under each set of process conditions, samples were manufactured, corresponding residual stress values ​​were measured, forming deformation was measured, and material mechanical properties were determined. The experimental data under different combinations of process parameters were statistically analyzed to establish a quantitative relationship between structural response and process parameters. This quantitative relationship reflects the influence trend of single process parameter changes on residual stress or deformation, the coupling effect between multiple process parameters, the influence path of process parameter changes on temperature gradient and cooling rate, and the degree of influence of different deposition directions on material anisotropy. Thus, a regression analysis method was used to obtain the fitting coefficient used to characterize this quantitative relationship.

[0118] Then, the above fitting coefficients are sorted out to generate model correction coefficients, which are used to characterize the proportion of residual stress change, the proportion of structural deformation change, and the intensity of interaction between process parameters when process parameters change.

[0119] 103k: The model correction coefficient is used to correct the thermo-coupling simulation model.

[0120] Specifically, the generated model correction coefficients are embedded into the thermo-mechanical coupling simulation model. The process involves introducing model correction coefficients into the predicted residual stress and deformation values, and using these coefficients to proportionally compensate and adjust the predicted values ​​to obtain the corrected residual stress and deformation field results. Then, the corrected simulation results are compared with the experimental data. If the error is within the allowable range, the correction is considered effective. If the error exceeds the allowable range, the process returns to step 103i and repeats the parameter optimization process. When the corrected prediction results consistently meet the error requirements, the thermo-mechanical coupling simulation model is finally determined as the calibration model for predicting the performance of aerospace structural components.

[0121] For example, after model correction, a static simulation of the aerospace structural component is performed again to simulate the stress and displacement distribution under an upward load of 9 g (the most dangerous load), referring to... Figure 10 As shown, the maximum Mises stress recalculated after model correction is 252.9 MPa, an increase of 2.8% compared to the original 246 MPa, a relatively small change. The designed simulation specimen was imported, and a fixed constraint was applied to the bottom. A connector was used at the top to connect the entire surface to a single point, where a force of 884 N (the force generated by an aerospace structural component weighing approximately 10 kg under a gravitational acceleration of 9 g) was applied. The mesh element size was set to 0.1 mm (balancing computational speed and accuracy). Considering moderate gravity, a more accurate calculation precision was selected. Static calculations were run, and the results are referenced. Figure 11 As shown, the maximum Mises stress is 252.4 MPa, and it is concentrated around the central hole. To better understand the stress concentration area distribution, the stress concentration area is magnified for reference. Figure 12 As shown; comparing the stress levels of the actual aerospace structural component and the simulated sample, it was found that the maximum Mises stress of the actual aerospace structural component was 252.9 MPa, while the maximum Mises stress of the simulated sample was 252.4 MPa. The stress levels of the two are almost identical, and the stress distribution characteristics of the two are observed to be distributed around the bolts. Therefore, it can be concluded that the stress concentration area around the target structural features of the aerospace structural component can be fitted by the simulated sample.

[0122] 104: Based on the modified thermo-mechanical coupling simulation model and combined with preset index data, the overall performance of aerospace structural components is evaluated, and performance judgment results and process adaptation evaluation results are generated and output.

[0123] Figure 13 A flowchart illustrating an exemplary performance evaluation and output method according to some embodiments of this application is shown.

[0124] refer to Figure 13 As shown. Specifically, in step 104, the overall performance of the aerospace structural component is evaluated based on the modified thermo-mechanical coupling simulation model and in combination with preset index data, and performance judgment results and process adaptation evaluation results are generated and output, including at least the following steps 104a to 104d.

[0125] 104a: Establish a comprehensive evaluation index that includes geometric accuracy index, material mechanical property index, residual stress index and structural response index, and set qualified threshold ranges for each index.

[0126] The geometric accuracy indicators include maximum dimensional deviation, flatness deviation, key feature hole position deviation, and maximum warpage. The material mechanical property indicators include yield strength, tensile strength, elongation, and anisotropy ratio. The residual stress indicators include maximum residual tensile stress, residual stress gradient, and residual stress concentration factor. The structural response indicators include maximum equivalent stress, safety margin, maximum displacement response, and fatigue damage parameters. The qualified threshold range includes at least a lower threshold and an upper threshold, which are set by the designer according to design specifications, material standard data, and engineering safety factors.

[0127] 104b: Using the modified thermo-mechanical coupling simulation model, the modified simulation results of directional energy deposition for aerospace structural components are generated.

[0128] Specifically, the thermo-mechanical coupling simulation model calibrated in step 103 is called up to perform a complete simulation calculation on the aerospace structural component again, thereby generating corrected simulation results including the corrected temperature field, residual stress distribution, forming deformation amount and structural response parameters. Then, the corrected simulation results are substituted into the comprehensive evaluation index to obtain the values ​​of each individual index.

[0129] 104c: Based on the corrected simulation results and comprehensive evaluation indicators, a comprehensive performance score is generated, and the aerospace structural components are pre-divided according to the comprehensive performance score to generate corresponding performance judgment results. The performance judgment results are then correlated with the process parameter data of directional energy deposition additive manufacturing to form process adaptation evaluation results.

[0130] Specifically, based on the corrected simulation results and comprehensive evaluation indicators, a weighted summation method is used to generate a comprehensive performance score. The process involves calculating the standardized score for each evaluation indicator, assigning weights to each indicator according to their importance, multiplying the standardized score for each indicator by its corresponding weight, and summing the weighted results of all indicators to obtain the comprehensive performance score for the aerospace structural component. These weights are set by the designers according to actual needs. Furthermore, different indicators have different physical meanings, therefore standardization is required. For indicators where smaller values ​​are better (such as deformation or residual stress), the actual measured value is calculated as a ratio to its allowable upper limit. The score for this indicator is calculated by subtracting the actual value from the target value. When the actual value is close to the upper limit of the allowable range, the score is close to zero. When the actual value is much smaller than the upper limit of the allowable range, the score is close to 1. For indicators where a larger value is better (such as safety margin or fatigue life), the ratio of the actual measured value to its target value is calculated. This ratio is directly used as the score for this indicator. When the actual value reaches or exceeds the target value, the score is close to or reaches 1. When an indicator exceeds the qualified threshold range, the score for this indicator is directly recorded as zero, indicating that the indicator does not meet the design requirements. Among them, fatigue life refers to the number of cycles that a material undergoes from the start of loading to fatigue fracture under a specific alternating load. Fatigue life is affected by internal defects and surface quality.

[0131] After generating the comprehensive performance score, the aerospace structural components are classified into grades according to a preset score range. For example, when the comprehensive performance score is greater than or equal to the preset high-grade threshold, it is determined to meet the design requirements; when the comprehensive score is in the preset middle range, it is determined to be restricted to use; and when the comprehensive score is lower than the preset low-grade threshold, it is determined to be unqualified. The specific numerical ranges of the preset high-grade threshold, the preset middle range, and the preset low-grade threshold included in the preset score range are set by the designer according to the importance of the product.

[0132] Therefore, after determining the performance level, the category of the lowest-scoring indicator is identified. Through the mapping relationship between process parameters, residual stress, and structural deformation, sensitive parameters significantly affecting performance, process combinations leading to excessive residual stress, and deposition strategies causing uncontrolled deformation are identified. This results in a process fit evaluation, including recommended process parameter ranges, key parameters requiring optimization, unsuitable process combinations, risk levels, and process optimization suggestions. Specifically, for cases determined to require optimization or be unqualified, process optimization suggestions are generated, including one or more of the following: adjusting the laser power range, reducing the scanning speed, changing the scanning path direction, and adjusting the deposition sequence.

[0133] 104d: Output performance judgment results and process adaptation evaluation results.

[0134] Specifically, the final output includes the comprehensive performance score of the aerospace structural component, the performance level determination result, the specific indicators that do not meet the requirements, and the recommended range of process parameters or optimization directions. The output format includes one or more of the following: structured numerical values, graphical display of the scores of each indicator, and a list of process optimization suggestions. This is used to determine whether the aerospace structural component can be directly put into engineering application or whether further optimization of the directional energy deposition additive manufacturing process is required.

[0135] For example, taking the airborne radar bracket in the aerospace structural components of this application as an example, the structural performance of its original design can be evaluated. First, its frame working conditions are clarified as follows: Overall frame weight: maximum upward inertial acceleration of 9g, forward inertial acceleration of 2g, backward inertial acceleration of 6g, downward inertial acceleration of 3g, and left and right inertial acceleration of 4g.

[0136] The frame is made entirely of 316L stainless steel, and its mechanical properties are shown in the table below: Table: Mechanical Properties of 316L Stainless Steel

[0137]

[0138] For example, the finite element simulation in this application evaluates and improves the mechanical properties and lightweight design of aerospace structural components under complex working conditions through numerical simulation and algorithm optimization; the finite element method (FEM) is a numerical method based on variational principles.

[0139] In some examples of this application, the performance evaluation method 100 of this application is used to optimize process parameters. For example, 316L stainless steel is used as the material, with the core constraints being to meet the requirements of mechanical properties, dimensional accuracy, and forming quality. Under the premise of distinguishing the process differences between thin-walled features (2.2mm spot diameter) and non-thin-walled features (4mm spot diameter), the process parameters of single-pass samples are first tested and determined by Archimedes' displacement method. The highest density process parameters under single-pass conditions are: thin-walled, 1600W laser power, 800mm / s scanning speed, 5g / min powder feed rate, 2.2mm spot diameter, and 0.4mm lift height; non-thin-walled, 2000W laser power, 800mm / s scanning speed, 15g / min powder feed rate, 4mm spot diameter, and 0.5mm lift height. The density of both sets of parameters is ≥99.5%, which establishes an optimized baseline for subsequent feature processes and overall printing.

[0140] In directional energy deposition additive manufacturing (OED), the laser spot diameter is a fundamental parameter determining the forming accuracy and efficiency. It must directly match the structural features of the part. A small spot diameter of 2.2 mm is used for thin-walled features to ensure accuracy and low deformation, while a 4 mm spot diameter is used for non-thin-walled features to improve efficiency and density. Experiments showed that the highest density was achieved with a small spot diameter at a laser power of 1600 W, a scanning speed of 800 mm / s, and a powder feed rate of 5 g / min. The optimal density was achieved with a large spot diameter at a laser power of 2000 W, a scanning speed of 800 mm / s, and a powder feed rate of 15 g / min. Small spot experiments showed that when the laser power was 1600 W, the scanning speed was 800 mm / s, and the powder feed rate was 5 g / min, the melt channel width was stable at 2.4-2.6 mm, with good surface quality and dimensional accuracy. If the power was too high (2000 W), the melt pool would be too large, leading to deformation of the thin-walled structure; if the power was too low, the powder might not melt completely, resulting in discontinuous melt channels. Large spot experiments show that when the laser power is 2000W, the scanning speed is 800mm / s, and the powder feed rate is 15g / min, the density detection rate can reach over 99% within a reasonable range of 4.2-4.6mm for the pass width, 0.2-0.4mm for the melt depth, and 0.4-0.7mm for the melt height. If the powder feed rate is increased to 18g / min, the power needs to be further increased, but care should be taken to avoid molten pool splashing due to excessive energy, which could lead to surface pits.

[0141] Among these factors, laser power is the most important parameter affecting the temperature and depth of the molten pool. Too low a power will lead to poor fusion, while too high a power will cause defects such as overheating and porosity. First, two defect maps, one for overmelting and one for incomplete melting, were established through single-pass experiments. After multiple rounds of experiments, it was finally determined that for thin-walled features (2.2mm spot diameter), a laser power of 1600W combined with a scanning speed of 800mm / s and a powder feed rate of 5g / min can keep the energy density within a reasonable range, ensuring that the powder is fully melted, while preventing excessive heat input that could cause thin-wall deformation. For non-thin-walled features (4mm spot diameter), a laser power of 2000W combined with a scanning speed of 800mm / s and a powder feed rate of 15g / min can ensure that the interlayer fusion depth is sufficient, while controlling the energy input to avoid excessive energy input and problems such as molten pool splashing and surface pits, thereby obtaining a non-thin-walled structure with high density and good quality.

[0142] Scanning speed is a key parameter affecting deposition efficiency and forming quality in directional energy deposition additive manufacturing (DED). It directly determines the interaction time between the laser and the material. When the scanning speed is too high, the interaction time between the laser and the material is too short, and the powder cannot be fully melted, resulting in discontinuous melt channels, spheroidization, and even microcracks. When the scanning speed is too low, although the heat input is sufficient and the melt channel continuity is good, heat accumulation is severe, especially in thin-walled feature printing, which can easily lead to sidewall warping and deformation. After multiple rounds of gradient experiments, it was finally determined that for thin-walled features (2.2mm spot diameter), a scanning speed of 800mm / min combined with 1600W power and a powder feed rate of 5g / min, with heat input controlled at 0.8-1.2J / mm, avoids σ phase precipitation while maintaining the continuity and surface quality of thin-walled single-pass printing. For non-thin-walled features (4mm spot diameter), a scanning speed of 800mm / min combined with 2000W power and a powder feed rate of 15g / min yields a non-thin-walled multilayer structure with tight interlayer bonding and good quality.

[0143] Among them, the powder feed rate is the core parameter for controlling the material supply rate in the directional energy deposition additive manufacturing process. It needs to be precisely matched with the laser power and scanning speed to ensure that the powder is fully melted and achieves stable deposition. When the powder feed rate is too low, the material supply is insufficient, the melt channel height fluctuates greatly, and the interlayer bonding strength decreases. In particular, in non-thin-wall feature printing, incomplete fusion defects are easily generated. When the powder feed rate is too high, the amount of powder entering the molten pool exceeds the laser melting capacity, resulting in unmelted powder and spatter, leading to increased porosity and deterioration of surface quality. Through orthogonal experiments and multi-parameter synergistic optimization, it was finally determined that for thin-walled features (2.2mm spot diameter), a powder feed rate of 5g / min combined with 1600W power and 800mm / min scanning speed ensures a reasonable match between the melting height and the lifting height, resulting in a thin-walled structure with good surface quality and dimensional accuracy. For non-thin-walled features (4mm spot diameter), a powder feed rate of 15g / min combined with 2000W power and 800mm / min scanning speed can fully utilize the large molten pool capacity of non-thin-walled structures, improve material deposition efficiency, and obtain non-thin-walled multilayer structures with high density and fast deposition efficiency.

[0144] Among them, the lift height is a key parameter in directional energy deposition additive manufacturing (OED) that controls the interlayer bonding quality and surface smoothness, directly affecting the uniformity of the deposited layer and the overall performance of the part. (Refer to...) Figure 14 As shown in (a), when the elevation is too high, the interlayer bonding is insufficient, and incomplete fusion defects are easily generated; Reference Figure 14As shown in (b), when the lift is too small, excessive interlayer compression leads to increased residual stress and warping deformation. For thin-walled features (2.2 mm spot diameter), the lift height was fixed at 0.4 mm because thin-walled structures are sensitive to heat input and require a smaller lift height to ensure tight interlayer bonding and avoid deformation caused by heat accumulation. The 0.4 mm lift height ensured deposition uniformity and surface quality. For non-thin-walled features (4 mm spot diameter), the lift height was fixed at 0.5 mm because non-thin-walled structures require higher deposition efficiency and a larger melt pool capacity. The 0.5 mm lift height ensured interlayer bonding strength and deposition stability.

[0145] Therefore, taking the target tensile strength requirement of ≥470 MPa as an example, the possible optimal parameter combinations are as follows: The thin-walled characteristics led to the determination of optimal parameters: laser power 1600 W, scanning speed 800 mm / s, powder feed rate 5 g / min, spot diameter 2.2 mm, and lift height 0.4 mm, to meet tensile strength requirements and ensure density within a reasonable range. Figure 15 Sample number 3 is shown in the diagram.

[0146] The non-thin-walled characteristics were investigated, and the optimal parameters were finally obtained: laser power of 2000 W, scanning speed of 800 mm / s, powder feed rate of 15 g / min, spot diameter of 4 mm, and lift height of 0.6 mm, achieving high tensile strength and density. (Reference) Figure 15 Sample number 2 is shown in the diagram.

[0147] In some examples of this application, the performance evaluation method 100 of this application is used to optimize geometric characteristics. For example, the geometric characteristics of 316L stainless steel additive manufacturing parts are modified using a testing machine, such as thin walls, corners, overhangs and interruptions. Based on the above-mentioned process parameter optimization, this application solves the core problems such as heat accumulation, stress concentration and molten pool collapse through experimental verification and simulation analysis, and finally makes the surface of the characteristic sample visually free of collapse, warping or cracks.

[0148] In directional energy deposition additive manufacturing (OED), thin-walled features (such as sidewalls and precision interfaces, approximately 2 mm thick) are prone to warping due to concentrated heat input. The core issue lies in the low thermal conductivity of 316L stainless steel (15.9 W / (m·K)), leading to heat accumulation. The basic process parameters are: laser power 1600 W, scanning speed 800 mm / s, powder feed rate 5 g / min, and spot diameter 2.2 mm. However, actual forming experiments revealed that when the number of printed layers exceeded 5, the heat-affected zone (HAZ) significantly expanded, requiring dynamic parameter adjustments: first, the power was gradually reduced from 1600 W to 1200 W, and 2-3 layers were continuously printed, with the powder feed rate simultaneously fine-tuned to 3 g / min. Once the HAZ shrank to 2-3 mm, the original parameters were restored. This adjustment temporarily reduced heat input to prevent deformation while ensuring melt flow continuity and dimensional accuracy. Experimental results showed that the optimized thin-walled structure exhibited no warping or cracks, meeting assembly requirements. Figure 16 As shown in (a).

[0149] Among them, the forming problem of corner features is mainly due to the molten pool flow and material accumulation caused by the sudden change in scanning direction. When turning at a right angle, the laser energy is concentrated instantaneously, and the molten pool tends to converge towards the inside of the corner under the action of gravity and surface tension, forming local bulges or incomplete fusion. Based on multiple forming experiments, a path transition combined with parameter gradient adjustment scheme is proposed: First, the corner scanning path is changed from a right angle to an arc transition to avoid sudden energy changes; second, the parameters are adjusted in the 20 mm area before and after the corner: before entering the corner, the laser power is linearly reduced from the thin-wall base value of 1600 W to 1200 W, and the scanning speed is increased from 800 mm / s to 1000 mm / s to reduce pre-accumulated heat; in the core area of ​​the corner, the power is maintained at 1600 W, and the scanning speed is reduced to 600 mm / s to prolong the interaction time between the laser and the material and promote uniform spread of the molten pool; after the corner, the base parameters of 1600 W and 800 mm / s are gradually restored; at the same time, in order to compensate for the material loss caused by the molten pool flow, the powder feed rate is temporarily increased from 5 g / min to 7 g / min in the corner area. g / min, after the corner printing is completed, the original toner feed rate is restored. This solution can effectively avoid material accumulation at the corner and eliminate incomplete fusion defects, meeting the requirements of subsequent assembly for corner dimensions. (Reference) Figure 16 As shown in (b).

[0150] The key to forming the overhang feature (angle > 55°) lies in suppressing molten pool collapse. When the overhang angle is too large, it is necessary to control the molten pool flow by increasing power and reducing scanning speed. The overhang feature needs to be adjusted as follows: laser power is increased from 1600 W to 2000 W, and scanning speed is reduced from 800 mm / s to 600 mm / s. By increasing energy input, the existence time of the molten pool is extended to ensure that the powder is fully melted; the powder feed rate is finely adjusted from 5 g / min to 7 g / min to increase the material supply per unit time and avoid incomplete forming due to insufficient molten pool flow. At the same time, a component printing combined with a robotic arm connection assistance scheme is proposed: the overhang part is printed separately from the main structure, and the connection area is precisely positioned by the robotic arm. Local deposition is performed using adjusted parameters to achieve metallurgical bonding. This strategy achieves a density of over 99.5% in the overhang area, with no collapse phenomenon, and the surface flatness meets the interface mating requirements. Figure 16 As shown in (c).

[0151] Interruption features (such as pauses or resumes during printing) are prone to causing poor interlayer bonding and arcing defects. The core issue is the temperature gradient between the interrupted surface and the molten pool during cold starts. The following process strategy is adopted for interrupted features: Before restarting, the interrupted surface is scanned 2-3 times with a low laser power of 800 W to remove residual powder and reduce the temperature difference through low-energy preheating; during restarting, the laser power is linearly increased from 800 W to 1600 W (the increase process lasts 2-3 seconds) to avoid molten pool splashing caused by sudden power changes; the powder feeder is delayed by 0.5 seconds to allow a stable molten pool to form on the interrupted surface (uniform molten pool brightness, no local blackening) before supplying powder; the scanning path advances from 5 mm outside the interrupted surface towards the center to ensure stable fusion forms at the edge of the interrupted surface first. Experimental verification shows that the optimized interrupted area has good interlayer bonding, no arcing defects, and the interruption marks are invisible to the naked eye. The mechanical properties are consistent with those of the continuously printed area. Figure 16 As shown in (d), this scheme effectively solves the reliability problem of interrupted production by using preheating and parameter gradual change, providing technical support for the segmented manufacturing of large parts.

[0152] In some examples of this application, the performance evaluation method 100 of this application is used for path planning and scanning strategy optimization. Exemplary path planning is the core of the DED process. For aerospace structural components, a partitioned scanning strategy is adopted: thin-walled areas are scanned continuously in a single pass to limit concentrated heat input; reinforcing ribs are filled with concentric circles to improve efficiency; flange flanges are scanned linearly with a 70% overlap rate to ensure density; interlayer rotation of 66.7° disrupts the texture and reduces residual stress; the scanning strategy is optimized based on G-code to avoid heat accumulation caused by multiple overlaps; simulations show that this strategy results in deformation ≤0.1 mm and uniform stress distribution; in experimental verification, single-pass scanning of thin-walled areas controls the heat-affected zone to 2-3 mm, and a 70% overlap rate in non-thin-walled areas ensures tight interlayer bonding. Overall path planning reduces the number of laser start-stop cycles, improves deposition efficiency by 25%, and provides a standardized template for manufacturing complex parts. The process compensation targets large overhang angles and non-thin-walled areas, suppressing deformation through reserved allowances and parameter adjustments. For overhang angle areas, a speed-reduction and power-increase strategy is employed: scanning speed is reduced to 600 mm / min, while laser power is increased to 1100W. For non-thin-walled areas, a machining allowance (3 mm in the contour direction and 4 mm in the thickness direction) is reserved to allow for subsequent finishing. After compensation, the dimensional accuracy reaches 0.5 mm / 500 mm with no deformation. Thermal deformation compensation is based on simulation results, reserving 0.2 mm of deformation. Dimensional compensation considers the shrinkage rate (approximately 2% shrinkage rate for 316L stainless steel), pre-compensating key dimensions. Thus, through these compensation measures, the final part dimensional error is ≤0.05 mm, surface quality is improved, and subsequent processing costs are reduced.

[0153] In some examples of this application, the process simulation verification uses Abaqus software for thermo-mechanical coupling analysis to predict the temperature field, stress field, and deformation field, ensuring the feasibility of the process scheme. The method of printing one ring equivalent to the entire ring component is adopted, and the simulation analysis focuses on the printing process of the circular structure. Specifically, 316L stainless steel is used as the printing material in the simulation, and the simulation conditions include: laser power of 1600 W, scanning speed of 800 mm / s, powder feed rate of 5 g / min, and spot diameter of 2.2 mm.

[0154] In the temperature field simulation, during the 1 / 4-turn forming stage, the laser beam begins to act on the substrate, resulting in a high-intensity gradient temperature field. The temperature in the molten pool region rapidly rises to approximately 1500°C, while the substrate temperature remains relatively low, leading to thermal stress concentration around the molten pool. Simulation results show that while the temperature distribution is localized during the 1 / 4-turn stage, no overheating occurs, indicating effective heat input control. Entering the 3 / 4-turn printing stage, the temperature field gradually becomes more uniform as the deposition area expands. The molten pool temperature stabilizes at around 1450°C, but the temperature gradient remains within a controllable range, with no risk of localized overheating. This stage demonstrates that the parameter combination can maintain thermal balance and avoid excess energy. After completing one full turn of printing, the temperature field reaches a stable state. The initially deposited area cools to ambient temperature, exhibiting a uniform overall distribution, with no significant increase in the maximum temperature. Figure 17 As shown.

[0155] The stress field and deformation analysis were based on the same simulation model, focusing on residual stress accumulation and structural deformation during the DED process. Through thermo-mechanical coupling analysis, the stress evolution and deformation trend of the ring-shaped part during printing were revealed. In the 1 / 4-cycle stage, the stress field was concentrated around the molten pool, with a peak equivalent stress of 179 MPa, lower than the yield strength of 316L stainless steel, indicating no risk of cracking. The stress distribution was uniform, with no significant local concentration, indicating reasonable initial parameter settings. At the 3 / 4-cycle stage, the stress increased to 199.93 MPa due to thermal cycling, but the stress concentration area remained limited to the edge of the molten pool and did not diffuse to the overall structure. Simulations showed that this stress level was within the material's safe range and would not cause plastic deformation or failure. After a complete cycle of printing, the peak residual stress reached 224 MPa, concentrated in the flange bolts and sharp corner areas of the wall, but far below the material's tensile strength (470 MPa). Figure 18 As shown in the figure, deformation analysis shows that the maximum deformation is 0.07 mm, which is lower than the allowable threshold (0.5 mm / 500 mm), and the deformation mode is uniform elastic deformation without warping or instability.

[0156] In some embodiments of this application, preliminary experiments can also be conducted using fused deposition modeling (FDM) technology. Specifically, small plastic parts are manufactured first using FDM technology for low-cost physical verification. Plastic prototypes can visually verify the assembly interface matching, motion mechanism interference, and ergonomic rationality of large parts, with verification efficiency approximately 3-5 times higher than that of pure digital models. Plastic prototypes can quickly expose potential stress concentration areas in the structure (such as sharp angle transitions and thin-walled support defects), providing a visual basis for subsequent modifications to the layout of metal reinforcement ribs. This process significantly reduces the high remanufacturing costs caused by failures in later directional energy deposition additive manufacturing. As a physical reference benchmark, plastic parts can help confirm the necessary support structure positioning points and thermal deformation compensation schemes for the directional energy deposition additive manufacturing process, avoiding substrate peeling failure during metal printing. At the same time, plastic prototypes support early intervention and evaluation by end users, ensuring that functional requirements permeate the final metal part design stage and reducing engineering change requirements after product delivery.

[0157] Figure 19 A schematic diagram of the module connections of an exemplary aerospace structural component performance evaluation device 200 according to some embodiments of this application is shown.

[0158] refer to Figure 19 As shown; some embodiments of this application provide a performance evaluation device 200 for directional energy deposition additive manufacturing of aerospace structural components. The device includes: a structural analysis module 201, used to construct a structural performance analysis model based on a three-dimensional structural model of the aerospace structural component and to perform load analysis and boundary condition definition on the structural performance analysis model under preset service conditions; a coupled simulation module 202, used to introduce manufacturing constraints matching the directional energy deposition additive manufacturing process characteristics into the structural performance analysis model and to construct a thermo-mechanical coupled simulation model using the finite element method to generate simulation results of directional energy deposition of the aerospace structural component; a model correction module 203, used to extract the target structural features of the aerospace structural component based on the simulation results to construct a simulated sample matching the target structural features, and then obtain preset performance parameters of the simulated sample manufactured under the same process conditions as the aerospace structural component, and construct model correction parameters based on the preset performance parameters and simulation results to correct the thermo-mechanical coupled simulation model; and a performance evaluation module 204, used to evaluate the overall performance of the aerospace structural component based on the corrected thermo-mechanical coupled simulation model and combined with preset index data, and generate and output performance judgment results and process adaptation evaluation results.

[0159] It should be understood that the device embodiments and method embodiments can correspond to each other, and similar representations can be referred to in the method embodiments. To avoid repetition, further details are omitted here. Specifically, the aerospace structural component performance evaluation device 200 can correspond to the corresponding subject in the performance evaluation method 100 of the present application embodiments, and each unit in the aerospace structural component performance evaluation device 200 is for implementing the corresponding process in the performance evaluation method 100, which will not be described in detail here for the sake of brevity.

[0160] It should also be understood that the various units in the aerospace structural component performance evaluation device 200 involved in the embodiments of this application are based on logical functional division. In practical applications, the function of one unit can also be implemented by multiple units, or the function of multiple units can be implemented by one unit. Furthermore, these functions can also be implemented with the assistance of one or more other units. For example, some or all of the aerospace structural component performance evaluation device 200 can be merged into one or more additional units. As another example, some units(s) in the aerospace structural component performance evaluation device 200 can be further divided into multiple functionally smaller units, which can achieve the same operation without affecting the technical effects of the embodiments of this application. Furthermore, the aerospace structural component performance evaluation device 200 can also include other units. In practical applications, these functions can also be implemented with the assistance of other units, and can be implemented collaboratively by multiple units.

[0161] It should also be understood that the terms "module" or "unit" used in the embodiments of this application refer to a computer program or part of a computer program that has a predetermined function and works with other related parts to achieve a predetermined goal, and can be implemented wholly or partially using software, hardware (such as processing circuitry or memory), or a combination thereof. Similarly, a processor (or multiple processors or memory) can be used to implement one or more modules or units. Furthermore, each module or unit can be part of an overall module or unit that includes the functionality of that module or unit.

[0162] For example, the aerospace structural component performance evaluation device 200 according to the embodiments of this application, and the method of the embodiments of this application, can be constructed and implemented by running a computer program (including program code) capable of executing the steps involved in the corresponding method on a general-purpose computing device including processing elements and storage elements such as a central processing unit (CPU), random access memory (RAM), and read-only memory (ROM). The computer program can be recorded on, for example, a computer-readable storage medium and loaded into an electronic device through the computer-readable storage medium. The computer program is used to implement the corresponding method of the embodiments of this application. In other words, the units mentioned above can be implemented in hardware, in software instructions, or in a combination of hardware and software. Specifically, the steps of the method embodiments in the embodiments of this application can be completed by the integrated logic circuits of the hardware in the processor and / or the instructions in software. The steps of the method disclosed in the embodiments of this application can be directly embodied as being executed by a hardware decoding processor, or by a combination of hardware and software in the decoding processor. Optionally, the software can be located in a mature storage medium in the art, such as random access memory, flash memory, read-only memory, programmable read-only memory, electrically erasable programmable memory, registers, etc. The software in the memory can be run by a processor to perform the steps described in the method embodiments above.

[0163] Figure 20 A schematic diagram of the structure of an exemplary electronic device 300 according to some embodiments of this application is shown.

[0164] refer to Figure 20 As shown. The electronic device 300 includes at least a processor 310 and a computer-readable storage medium 320. The processor 310 and the computer-readable storage medium 320 can be connected via a bus or other means. The computer-readable storage medium 320 stores a computer program 321, which includes computer instructions. The processor 310 executes the computer instructions stored in the computer-readable storage medium 320. The processor 310 is the computing and control core of the electronic device 300, and is adapted to implement one or more computer instructions, specifically to load and execute one or more computer instructions to achieve a corresponding method flow or function.

[0165] As an example, processor 310 may also be referred to as a central processing unit (CPU). Processor 310 may include, but is not limited to: general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete component gate or transistor logic devices, discrete hardware components, etc.

[0166] As an example, the computer-readable storage medium 320 may be a high-speed RAM memory or a non-volatile memory, such as at least one disk storage device; optionally, it may also be at least one computer-readable storage medium located remotely from the aforementioned processor 310. Specifically, the computer-readable storage medium 320 includes, but is not limited to, volatile memory and / or non-volatile memory. The non-volatile memory may be read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or flash memory. The volatile memory may be random access memory (RAM), which serves as an external cache. By way of example, but not limitation, many forms of RAM are available, such as Static RAM (SRAM), Dynamic RAM (DRAM), Synchronous DRAM (SDRAM), Double Data Rate SDRAM (DDR SDRAM), Enhanced SDRAM (ESDRAM), Synchronous Link DRAM (SLDRAM), and Direct Rambus RAM (DR RAM).

[0167] refer to Figure 20 As shown, the electronic device 300 may also include a transceiver 330.

[0168] The processor 310 can control the transceiver 330 to communicate with other devices; specifically, it can send information or data to other devices or receive information or data sent by other devices. The transceiver 330 may include a transmitter and a receiver. The transceiver 330 may further include antennas, and the number of antennas may be one or more.

[0169] It should be understood that the various components in the electronic device 300 are connected through a bus system, which includes a data bus, a power bus, a control bus, and a status signal bus. It is worth noting that the electronic device 300 can be any type of electronic device with data processing capabilities; the computer-readable storage medium 320 stores first computer instructions; the processor 310 loads and executes the first computer instructions stored in the computer-readable storage medium 320 to implement the corresponding steps in the method embodiments of this application; in specific implementations, the first computer instructions in the computer-readable storage medium 320 are loaded and executed by the processor 310, and to avoid repetition, this will not be described further here.

[0170] According to another aspect of this application, embodiments of this application provide a chip. This chip can be an integrated circuit chip with signal processing capabilities, capable of implementing or executing the methods, steps, and logic block diagrams disclosed in the embodiments of this application. The chip can also be referred to as a system-on-a-chip (SoC), system-on-a-chip (SoC), chip system, or system-on-chip, etc. This chip can be applied to various electronic devices capable of mounting chips, enabling the device with the chip mounted to execute the corresponding steps in the methods or logic block diagrams disclosed in the embodiments of this application. For example, the chip may be suitable for implementing one or more computer instructions, specifically suitable for loading and executing one or more computer instructions to achieve a corresponding method flow or corresponding function.

[0171] According to another aspect of this application, embodiments of this application provide a computer-readable storage medium (Memory). This computer-readable storage medium is a computer's memory device used to store programs and data. It is understood that the computer-readable storage medium here may include both built-in storage media within the computer and, of course, extended storage media supported by the computer. The computer-readable storage medium provides storage space that stores the operating system of an electronic device. This storage space contains computer instructions suitable for loading and execution by a processor. When these computer instructions are read and executed by the processor of the computer device, they cause the computer device to perform the corresponding steps in the methods or logic diagrams disclosed in the embodiments of this application.

[0172] According to another aspect of this application, embodiments of this application provide a computer program product or computer program. The computer program product or computer program includes computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform corresponding steps in the methods or logic block diagrams disclosed in the embodiments of this application. In other words, when the solutions provided in this application are implemented using software, they can be implemented in whole or in part as a computer program product or computer program. The computer program product or computer program includes one or more computer instructions. When these computer program instructions are loaded and executed on a computer, all or part of the processes of the embodiments of this application are run or the functions of the embodiments of this application are implemented.

[0173] It is worth noting that the computer involved in this application can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions involved in this application can be stored in a computer-readable storage medium, or can be transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired (e.g., coaxial cable, fiber optic, digital subscriber line (DSL)) or wireless (e.g., infrared, wireless, microwave, etc.) means.

[0174] Those skilled in the art will recognize that the units and process steps of the various examples characterized in conjunction with the embodiments disclosed herein can be implemented in electronic hardware or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. In other words, those skilled in the art can use different methods to implement the characterized functions for each specific application, but such implementation should not be considered beyond the scope of protection of this application.

[0175] Finally, it should be noted that the above content is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims. For example, the various specific technical features characterized in the above specific embodiments can be combined in any suitable manner without contradiction. Furthermore, various different embodiments of this application can also be arbitrarily combined, as long as they do not violate the basic idea of ​​this application, and they should also be considered as the content disclosed in this application.

Claims

1. A performance evaluation method for directional energy deposition additive manufacturing of aerospace structural components, characterized in that, The method includes: A structural performance analysis model is constructed based on the three-dimensional structural model of the aerospace structural component, and load analysis and boundary condition definition are performed on the structural performance analysis model under preset service conditions. In the structural performance analysis model, manufacturing constraints matching the characteristics of the directional energy deposition additive manufacturing process are introduced, and a thermo-mechanical coupling simulation model is constructed using the finite element method to generate simulation results of the directional energy deposition of the aerospace structural component. Based on the simulation results, the target structural features of the aerospace structural component are extracted to construct a simulated specimen matching the target structural features. Then, preset performance parameters of the simulated specimen manufactured under the same process conditions as the aerospace structural component are obtained. Based on the preset performance parameters and the simulation results, model correction parameters are constructed to correct the thermo-mechanical coupling simulation model; and... Based on the modified thermo-mechanical coupling simulation model and combined with preset index data, the overall performance of the aerospace structural component is evaluated, and performance judgment results and process adaptation evaluation results are generated and output. The manufacturing constraints introduced into the structural performance analysis model that match the characteristics of the directional energy deposition additive manufacturing process include: Based on the characteristics of directional energy deposition additive manufacturing process, a minimum feature size threshold, a droop angle threshold, and a minimum wall thickness limit are set, wherein the droop angle threshold is not lower than a preset critical angle. The deposition direction is defined as the principal anisotropic direction of the material, and direction-dependent elastoplastic constitutive parameters are introduced into the structural performance analysis model. Based on the thermal input characteristics of directional energy deposition additive manufacturing, an interlayer thermal cycling effect function is introduced to characterize the impact of different scanning strategies on residual stress accumulation; and... Identify structural regions that deviate from process constraints and perform structural correction or local rounding on the structural regions; The process of constructing a thermo-coupling simulation model using the finite element method to output simulation results of the aerospace structural component during directional energy deposition includes: The finite element mesh is generated based on the three-dimensional structural model, and the same layer-by-layer activation element strategy as the directional energy deposition path is defined. A moving heat source model is introduced into the structural performance analysis model, and laser power, scanning speed, spot diameter and interlayer dwell time are used as input parameters to solve the transient temperature field of the deposition process; A coupling term between thermal expansion strain and phase transformation strain was established, and the thermal stress evolution and residual stress distribution during the deposition process were calculated using a time-stepping method; and, The output should include simulation results of temperature field distribution, residual stress evolution, and forming deformation behavior.

2. The method according to claim 1, characterized in that, The process of constructing a structural performance analysis model based on a three-dimensional structural model of an aerospace structural component and performing load analysis and boundary condition definition on the structural performance analysis model under preset service conditions includes: The preset loads of the aerospace structural components in the actual service environment are classified and analyzed, and the assembly constraint relationship is modeled to transform the preset boundary region of the aerospace structural components into finite element boundary conditions. A load spectrum construction method was employed for multi-condition combined analysis, and superimposed calculations were performed on different extreme conditions, fatigue-sensitive conditions, and control conditions to obtain the stress distribution, displacement response, and safety margin parameters of the aerospace structural component under various conditions. The maximum principal stress, equivalent stress, and deformation of the critical section were extracted as input parameters for performance evaluation, and a structural performance analysis model was constructed. The preset load includes one or more of constant static load, periodic variable load, impact load and thermal stress load, and the preset boundary region includes connection interface, mounting flange surface and positioning hole features.

3. The method according to claim 1 or 2, characterized in that, The step of extracting the target structural features of the aerospace structural component based on the simulation results to construct a simulated specimen matching the target structural features includes: Based on the simulation results and preset load distribution data, the dangerous areas in the aerospace structural components are identified, wherein the dangerous areas include at least the high equivalent stress area, the high strain gradient area, the geometric change area, and the potential fatigue sensitive area. The hazardous areas are classified according to their structural morphology, forming a set of structural feature parameters including local wall thickness, radius of curvature, aperture size, transition fillet radius, and internal cavity size; The set of structural feature parameters is screened based on the characteristics of the directional energy deposition additive manufacturing process, and features that do not meet the minimum feature size, overhang angle threshold and minimum wall thickness are removed. The retained features in the set of structural feature parameters are used to construct target structural features for independent testing, and the target structural features maintain the same geometric proportions and deposition direction parameters as the original structure; and... Based on the target structural features, a directional energy deposition path and process parameters are generated, and a simulated sample matching the target structural features is manufactured under the same process conditions.

4. The method according to claim 3, characterized in that, The step of extracting the target structural features of the aerospace structural component based on the simulation results to construct a simulated specimen matching the target structural features further includes: Under the same equipment, material batch, and process parameters used in the directional energy deposition additive manufacturing of the aerospace structural component, a simulated specimen of the target structural feature of the aerospace structural component is manufactured based on the simulation results; wherein the deposition direction of the simulated specimen is the same as or at a preset angle to the forming direction of the aerospace structural component; and, After manufacturing, the simulated sample undergoes the same post-processing and heat treatment as the aerospace structural component to maintain the same microstructure.

5. The method according to claim 4, characterized in that, The process of obtaining preset performance parameters for a simulated specimen manufactured under the same process conditions as the aerospace structural component includes: The manufactured simulated sample is subjected to coordinate measuring or non-contact three-dimensional scanning to obtain the spatial coordinate point cloud data of the simulated sample. The spatial coordinate point cloud data is overlaid and registered with the 3D structural model; dimensional deviations and geometrical deviations are calculated; independent tolerance thresholds are set for critical areas, and relaxed tolerance thresholds are set for non-critical areas; and... The preset performance parameters of the simulated specimen after tensile, compression and torsion tests are obtained and statistically analyzed to calculate the mean, standard deviation and anisotropy ratio, thereby identifying deformation trends and local manufacturing defects.

6. The method according to claim 5, characterized in that, The step of constructing model correction parameters based on the preset performance parameters and simulation results to correct the thermo-coupling simulation model includes: The preset performance parameters are compared with the simulation results of the thermo-coupling simulation model to establish a simulation prediction error function, and the material constitutive parameters, heat source model parameters and boundary heat transfer coefficient are reversed according to the simulation prediction error function. A mapping relationship between process parameters, residual stress, and structural deformation is constructed based on preset experimental data, and model correction coefficients are generated based on the mapping relationship; and... The thermo-coupling simulation model is corrected using the model correction coefficients.

7. The method according to claim 6, characterized in that, The process of evaluating the overall performance of the aerospace structural component based on the modified thermo-mechanical coupling simulation model and preset index data, generating and outputting performance judgment results and process adaptability evaluation results, includes: Establish a comprehensive evaluation index that includes geometric accuracy indicators, material mechanical property indicators, residual stress indicators and structural response indicators, and set qualified threshold ranges for each indicator; The corrected simulation results of directional energy deposition for the aerospace structural components were generated using the modified thermo-mechanical coupling simulation model. Based on the corrected simulation results and comprehensive evaluation indicators, a comprehensive performance score is generated, and the aerospace structural component is pre-classified according to the comprehensive performance score to generate corresponding performance judgment results. Furthermore, the performance judgment results are correlated with the directional energy deposition additive manufacturing process parameters to form a process adaptation evaluation result; and... Output the performance determination results and process adaptation evaluation results.

8. An electronic device, characterized in that, include: Processor, adapted to execute computer programs; and, A computer-readable storage medium storing a computer program that, when executed by the processor, implements the method of any one of claims 1 to 7.

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