A laser directed energy deposition method and system with dynamic reconfiguration of composite energy field

Abstract

The present application belongs to the technical field of laser additive manufacturing, and provides a laser directional energy deposition method and system with dynamic reconstruction of composite energy field, aiming at the problems of existing single Gaussian beam heat input concentration, fixed parameters of point-ring beam and lack of dynamic regulation and control, the present application establishes a target heat input field, initializes a point-ring composite energy field, and obtains an actual heat input field based on molten pool heat behavior prediction, and then constructs a deviation analysis model, when the deviation exceeds the threshold, the power ratio, action radius and spatial energy distribution of the center point beam and the ring beam are dynamically adjusted to minimize the heat input field deviation, realizing real-time reconstruction of the energy field. At the same time, the closed-loop optimization control mechanism is constructed combined with online monitoring. The present application can change the traditional fixed parameter control into adaptive regulation and control based on the deviation of heat input spatial distribution, effectively improve the uniformity of molten pool temperature field, inhibit local overheating, spatter and porosity defects, and is suitable for stable forming of complex components such as thin-walled and corner components.

Description

Technical Field

[0001] This invention belongs to the field of laser additive manufacturing technology, and particularly relates to a laser-directed energy deposition method and system for dynamic reconstruction of composite energy fields. Background Technology

[0002] Large-scale, integrated, complex metal components are widely used in spacecraft structures, load-bearing frames, module connection structures, and critical engine components. These components typically exhibit characteristics such as large size span, high structural complexity, thin walls, and multiple scale features. Traditional forging, casting, and machining methods are insufficient to meet the demands for rapid manufacturing of complex structures and improved material utilization. Laser Directed Energy Deposition (LDED), with its advantages of high material utilization, high degree of freedom in forming, and applicability to the manufacture of large components, has become an important technology for the rapid manufacturing and repair of large aerospace metal components.

[0003] However, during the LDED manufacturing process of large and complex aerospace components, the heat transfer conditions and heat accumulation states in different regions vary significantly due to the large size of the components, the obvious differences in the structure of the deposition areas, and the continuous changes in the deposition path.

[0004] Currently, industrial LDED systems commonly use a single Gaussian beam as the laser heat source, with energy distribution mainly concentrated in the central region of the beam. In the manufacturing of large, thin-walled, and complex curved aerospace components, a single Gaussian heat source can easily lead to excessively high energy density in the central region, while insufficient heat input occurs at the edge of the molten pool, resulting in significant spatial thermal inhomogeneity within the molten pool. When the deposition path changes or continuous deposition leads to increased local heat accumulation, traditional fixed heat sources struggle to adapt to changes in heat demand in different regions, easily causing problems such as molten pool fluctuations, increased spatter, keyhole formation, porosity defects, microstructure coarsening, and forming deformation, severely impacting the dimensional accuracy and service performance of large aerospace components.

[0005] In recent years, center-ring beam technology has been proposed to improve the energy concentration problem of traditional single Gaussian beams. It provides high energy density input through a central point beam while utilizing an outer ring beam to expand the thermal impact range, thus optimizing the spatial distribution of laser energy. However, existing center-ring beam technologies primarily focus on optimizing pre-process parameters. The power ratio, impact range, and energy distribution between the central point beam and the ring beam are typically pre-set based on fixed process conditions, making real-time adjustments impossible based on the structural characteristics, thermal history, and deposition state changes of different regions in large, complex aerospace components. Summary of the Invention

[0006] To address at least one of the technical problems mentioned above, this invention provides a laser-directed energy deposition method and system for dynamic reconstruction of a composite energy field. By establishing a point-ring composite energy field dynamic reconstruction strategy for the entire deposition process of complex components, the laser thermal input can be adaptively optimized and allocated according to different regions, different times, and different deposition states, thereby achieving active regulation of the molten pool thermal behavior and stable control of forming quality.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: The first aspect of the present invention provides a laser-directed energy deposition method for dynamic reconstruction of a composite energy field, comprising the following steps: Establish a set of target thermal input parameters for each deposition region of the component to be manufactured, and form a target thermal input field based on the set of target thermal input parameters; A mathematical model of the point-ring composite energy field is established based on the propagation characteristics of the laser beam and the absorption characteristics of the material. The energy is initialized and configured in accordance with the energy field configuration principle to generate a point-ring composite energy field that matches the target heat input requirements of the current deposition area. Establish a mapping relationship between laser energy input and material temperature response, predict the spatial temperature field under the current deposition state based on the point-ring composite energy field and mapping relationship, determine the range of the molten pool region, extract thermal behavior characteristics from the spatial temperature field, and construct the actual thermal input field based on the predicted thermal behavior characteristics; Based on the spatial deviation analysis between the target heat input field and the actual heat input field, the dynamic reconstruction requirements of the point-loop composite energy field are determined. If reconstruction is required, a dynamic reconstruction model of the point-ring composite energy field is established based on the spatial deviation analysis results between the target heat input field and the actual heat input field. The optimization objective is to reduce the spatial deviation between the target heat input field and the actual heat input field. By adjusting the energy distribution relationship between the central point beam and the outer ring beam of the point-ring composite energy field, the active control of the spatial distribution of heat input during the deposition process of large aerospace components can be achieved.

[0008] Furthermore, the establishment of the target thermal input parameter set for each deposition region of the component to be manufactured specifically includes: The obtained 3D model of the component to be manufactured is sliced ​​and a deposition path is planned. Based on the slice results, the components were geometrically analyzed layer by layer to identify the geometric features of different sedimentary regions; A component thermal demand analysis model was established by combining the geometric characteristics of different depositional regions, material thermal properties, environmental heat dissipation conditions, and deposition path planning. Based on the differences in heat demand in different regions, a target heat input planning is carried out for the entire deposition process through a component heat demand analysis model, generating a target heat input parameter set corresponding to each deposition region.

[0009] Furthermore, the point-ring composite energy field model is as follows: , , , in, This represents the total energy distribution of the point-ring composite energy field. This represents the distribution of light energy field at the center point. Indicates the energy distribution of the ring beam. Indicates the optical power at the center point. Indicates the radius of the point light. Indicates the ring light power. and Indicates the inner and outer radii of the ring light. Represents the radial coordinates in polar coordinates. Indicates the radius of the ring peak. The standard deviation of the radial distribution of the ring light. This indicates the material's absorption rate.

[0010] Furthermore, when generating an initial point-ring composite energy field that matches the target heat input requirements of the current depositional area, the configuration principle is as follows: Based on the obtained target thermal input parameter set for each sedimentary region, the target thermal input of the i-th sedimentary region is used as an example. Target temperature range Target molten pool width Target molten pool depth and target temperature gradient As an initial constraint, combined with the point-ring composite energy field model, the power of the beam at the center point is... Center point beam radius Ring beam power Inner radius of the annular beam Outer radius Peak radius of the ring beam and radial distribution standard deviation Initial configuration is performed to obtain an initial point-ring composite energy field that matches the target heat input requirements of the current deposition area.

[0011] Furthermore, the prediction of the spatial temperature field under the current deposition state based on the point-ring composite energy field and mapping relationship, and the determination of the melt pool region range, includes: Based on the process parameters and material thermophysical parameters of the current deposition area, a transient heat conduction calculation model for the current deposition area is established. A point-ring composite energy field is applied to the current laser action area as a heat source input, and the internal heat conduction of the material and the convective heat transfer and radiative heat dissipation on the surface of the component are considered. By solving the transient heat conduction calculation model in time steps, the temperature response at different spatial locations of the deposition area is obtained. Based on the material melting temperature threshold, the predicted temperature field is compared spatially location by location. The temperature value at each spatial location in the predicted temperature field is compared with the material melting temperature threshold. When a certain spatial location meets the threshold... When the temperature is greater than or equal to the material's melting temperature threshold, the location is determined to be in a melting state, and the area composed of all consecutive melting state spatial locations is defined as the molten pool area of ​​the current deposition process. The boundary of the molten pool is determined by the location of the intersection between the molten pool area and the non-molten area, thereby obtaining the range of the molten pool area.

[0012] Furthermore, the determination of the dynamic reconstruction requirements of the point-loop composite energy field based on the spatial deviation analysis between the target heat input field and the actual heat input field includes: Calculate the thermal input deviation between the target state and the actual state; Establish the spatial correspondence between the target heat input field and the actual heat input field; Based on the obtained spatial correspondence, the target heat input state and the actual heat input state are compared and analyzed to extract heat input deviation characteristics, including heat input deviation in the central region. Heat input deviation in the outer area Heat input uniformity deviation and thermal accumulation deviation ; The dynamic reconstruction requirement of the point-ring composite energy field is determined based on the thermal input deviation results. Each type of thermal input deviation is compared with its corresponding allowable thermal input deviation threshold. When any thermal input deviation exceeds the corresponding allowable deviation threshold, it is determined that there is an excessive deviation between the current point-ring composite energy field and the target thermal input field, and dynamic reconstruction is required. When all types of thermal input deviations are within the corresponding allowable deviation range, it is determined that the current point-ring composite energy field meets the target thermal input requirements of the current deposition area, and the current point-ring composite energy field state is maintained without adjustment.

[0013] Furthermore, the adjustment specifically includes: determining the adjustment direction of the point-loop composite energy field based on the characteristics of the heat input deviation; and dynamically adjusting the point-loop power ratio and spatial distribution parameters according to the determined adjustment direction of the point-loop composite energy field, including: When the heat input deviation in the central area When the upper limit of the corresponding allowable deviation range is exceeded, it is determined that the actual heat input in the central region is higher than the target heat input requirement, and the beam power at the center point is reduced. Alternatively, reduce the point-to-ring power distribution ratio and correspondingly increase the ring beam energy contribution, so that the heat input is redistributed from the central region to the outer region; When the heat input deviation in the central area When the actual heat input in the central region is below the lower limit of the corresponding allowable deviation range, it is determined that the actual heat input in the central region is lower than the target heat input requirement, and the beam power at the center point is increased. Alternatively, the point-loop power distribution ratio can be increased to improve the energy density in the central region; When the heat input deviation in the outer area When the actual heat input in the peripheral region is below the lower limit of the corresponding allowable deviation range, it is determined that the actual heat input is lower than the target heat input requirement, and the power of the ring beam is increased. To increase the energy contribution of the ring beam or expand the effective range of the ring beam, thereby increasing the heat input in the peripheral region; When the heat input deviation in the outer area When the upper limit of the corresponding allowable deviation range is exceeded, it is determined that the actual heat input in the outer region is higher than the target heat input requirement, and the power of the ring beam is reduced. Reduce the energy contribution of the ring beam or decrease the effective range of the ring beam to suppress the diffusion of heat to non-target areas; When heat input uniformity deviation When the deviation exceeds the corresponding allowable range, it is determined that there is a significant difference in heat input between the central region and the outer region. and The deviation direction determines the power distribution ratio between the center beam and the ring beam, as well as the adjustment direction of the ring beam's effective range. When heat accumulation deviation If the deviation exceeds the allowable range, it is determined that there is local heat accumulation in the deposition area of ​​the large aerospace component. In this case, the laser energy input in the corresponding area is reduced, and the beam power at the center point is adjusted according to whether the heat accumulation mainly occurs in the central or peripheral area. or ring beam power And the range of action of the ring beam.

[0014] When multiple thermal input deviation conditions are met simultaneously, the priority adjustment direction is determined based on the degree to which each deviation exceeds the corresponding allowable deviation range, and the center point beam power is determined comprehensively. Ring beam power The adjustment direction of the point-to-ring power distribution ratio and the effective range of the ring beam. A second aspect of the present invention provides a laser-directed energy deposition system for dynamic reconstruction of a composite energy field, comprising: The target heat input planning module is used to establish a set of target heat input parameters for each deposition area of ​​the component to be manufactured, and to form a target heat input field based on the set of target heat input parameters. The point-ring composite energy field initialization module is used to establish a mathematical model of the point-ring composite energy field based on the laser beam propagation characteristics and material absorption characteristics, and to perform energy initialization configuration in combination with the energy field configuration principle to generate a point-ring composite energy field that matches the target heat input requirements of the current deposition area. The actual thermal prediction module is used to establish the mapping relationship between laser energy input and material temperature response. Based on the point-ring composite energy field and the mapping relationship, it predicts the spatial temperature field under the current deposition state, determines the range of the molten pool region, extracts thermal behavior characteristics from the spatial temperature field, and constructs the actual thermal input field based on the predicted thermal behavior characteristics. The dynamic energy field reconstruction module is used to determine the dynamic reconstruction requirements of the point-ring composite energy field based on the spatial deviation analysis between the target heat input field and the actual heat input field. If reconstruction is required, a dynamic reconstruction model of the point-ring composite energy field is established based on the spatial deviation analysis results between the target heat input field and the actual heat input field. The optimization objective is to reduce the spatial deviation between the target heat input field and the actual heat input field. By adjusting the energy distribution relationship between the central point beam and the outer ring beam of the point-ring composite energy field, the active control of the spatial distribution of heat input during the deposition process of large aerospace components can be achieved.

[0015] A third aspect of the present invention provides a computer-readable storage medium.

[0016] A computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of a laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described above.

[0017] A fourth aspect of the present invention provides a computer device.

[0018] A computer device includes a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the steps of a laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described above.

[0019] Compared with the prior art, the beneficial effects of the present invention are: This invention addresses the problems of concentrated heat input, fixed point-ring beam parameters, and lack of dynamic control in existing single Gaussian beams. It establishes a target heat input field, initializes the point-ring composite energy field, and obtains the actual heat input field based on molten pool thermal behavior prediction. A deviation analysis model is then constructed. When the deviation exceeds a threshold, the power ratio, radius of action, and spatial energy distribution of the center point beam and the ring beam are dynamically adjusted with the goal of minimizing the heat input field deviation, achieving real-time energy field reconstruction. Simultaneously, a closed-loop optimization control mechanism is constructed in conjunction with online monitoring. This invention transforms traditional fixed-parameter control into adaptive control based on the spatial distribution deviation of the heat input, effectively improving the uniformity of the molten pool temperature field, suppressing local overheating, spatter, and porosity defects, and is suitable for the stable forming of complex components such as thin-walled and corner-shaped parts.

[0020] Existing laser-directed energy deposition processes typically employ fixed Gaussian beams or fixed-parameter point-ring composite beams, resulting in a constant spatial distribution of laser energy throughout the deposition process. This makes it difficult to adapt to the varying thermal demands of different regions within complex components. This invention addresses this by establishing a point-ring composite energy field model. The central point beam and the outer ring beam are treated as two mutually cooperating energy control units. The energy distribution between these two units is dynamically adjusted based on the deposition state, enabling proactive changes in the spatial distribution of the laser heat source. This allows the laser heat input to be matched in real-time to changes in the component's structure and thermal state.

[0021] This invention differs from traditional methods that directly control process parameters such as laser power and scanning speed. Instead, it establishes a target heat input field tailored to the thermal requirements of the deposition area. The subsequent control process is driven by the deviation between the actual and target heat input fields, transforming laser energy regulation from a traditional parameter-based approach to a heat input field-based control method. This method comprehensively considers the structural characteristics, heat dissipation conditions, and deposition state of different regions of the component, achieving precise matching of heat input requirements across different areas.

[0022] This invention establishes a deviation analysis model between the target heat input field and the actual heat input field, spatially representing regions with insufficient heat input, excessive heat input, and abnormal heat input distribution. Based on the characteristics of the deviation field, it coordinates the adjustment of point light energy and ring light energy. Compared to traditional methods that rely solely on feedback adjustment based on a single temperature value or molten pool size, this invention proactively compensates for uneven spatial distribution of heat input, effectively reducing problems such as local overheating, insufficient edge fusion, molten pool fluctuations, and heat accumulation.

[0023] This invention utilizes the independent controllability between the central point beam and the outer ring beam in a point-ring composite energy field, enabling the system to distribute heat input differently according to the needs of different structural regions. For example, for thin-walled regions, enhancing the energy of the central point beam improves the stability of the melting depth; for thick-walled regions or regions with heat accumulation, enhancing the effect of the ring beam improves the uniformity of heat diffusion; for corners and complex curved surfaces, adjusting the coverage of the ring energy reduces the local temperature gradient, thereby improving the adaptability of the manufacturing process for complex structures.

[0024] This invention constructs a closed-loop control system that includes target heat input planning, actual heat input acquisition, deviation analysis, energy field reconstruction, and feedback updates, enabling the point-loop composite energy field to be continuously optimized as the deposition process changes. Compared to traditional methods that set process parameters only once, this invention can effectively compensate for thermal state changes caused by interlayer heat accumulation, structural variations, and environmental disturbances, improving component dimensional consistency and manufacturing reliability during long-term continuous deposition.

[0025] Advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0026] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0027] Figure 1 This is a flowchart of a laser-directed energy deposition method for dynamic reconstruction of a composite energy field provided in an embodiment of the present invention. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0029] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0030] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0031] In summary, while existing technologies have proposed methods such as point-ring composite beams and online process parameter adjustment, a control method that can comprehensively consider the geometric characteristics of the component, its real-time thermal state, and the deposition evolution process, and dynamically reconstruct the laser spatial energy distribution, is still lacking. How to establish a dynamic reconstruction strategy for the point-ring composite energy field throughout the entire deposition process of complex components, enabling adaptive optimization of laser thermal input based on different regions, times, and deposition states, thereby achieving proactive control of molten pool thermal behavior and stable control of forming quality, remains a key technical problem that urgently needs to be solved in the field of laser-directed energy deposition.

[0032] To address the aforementioned problems, this invention proposes a laser-directed energy deposition method and system with dynamic reconstruction of a point-ring composite energy field. Unlike traditional methods, this invention does not complete the entire deposition process with fixed beam parameters. Instead, it integrates the geometric characteristics of the component, the target heat input requirements, the real-time state of the molten pool, and the deposition evolution law into a unified energy field control framework. By establishing a point-ring composite energy field model, a target heat input planning model, a molten pool state evaluation model, and an energy field dynamic reconstruction model, it achieves real-time optimization and adjustment of the spatial distribution of laser heat input, ensuring that the energy input of the central and peripheral regions always dynamically matches the current deposition state.

[0033] This invention uses "target heat input" rather than "fixed power parameters" as the control object, "dynamic energy field reconstruction" rather than "total power adjustment" as the core control strategy, and "geometric perception - thermal state evaluation - energy reconstruction - closed-loop optimization" as the overall technical route to achieve active control of heat input during laser directional energy deposition of complex components, thereby improving the stability of the molten pool, the uniformity of the microstructure, and the forming quality of the components.

[0034] like Figure 1 As shown, as an embodiment of the present invention, this embodiment provides a laser-directed energy deposition method for dynamic reconstruction of a composite energy field, comprising the following steps: S1. Establish the target thermal input parameter set for each deposition region of the component to be manufactured, and form the target thermal input field based on the target thermal input parameter set; This embodiment uses a thin-walled frame-like component made of TC4 titanium alloy for aerospace applications as the manufacturing object. This component is characterized by its thin walls, variable cross-section, curved surface connections, and significant differences in thermal response across multiple regions. Unlike traditional methods that directly set the laser power, this embodiment first establishes the target thermal input requirements for different regions of the component. This allows the subsequent energy regulation process to move away from controlling fixed process parameters and instead optimize for meeting the target thermal input requirements, achieving active matching between the thermal input requirements and the component's geometric characteristics. Specifically, this includes the following steps: S101. Perform model slicing and deposition path planning on the 3D model of the component to be manufactured; First, a three-dimensional CAD model of the component to be manufactured is obtained. According to the preset layer thickness parameters, the three-dimensional model is sliced ​​layer by layer along the deposition direction to convert the continuous three-dimensional structure into multiple two-dimensional cross-sectional contours. The contour boundary, area, scan length and local structural change information of each deposition layer are obtained. Furthermore, based on the component manufacturing requirements, deposition path planning is performed for each slice layer to determine the laser scanning trajectory, scanning direction, overlapping area, and path sequence, and the spatial coordinate information corresponding to different deposition locations is recorded. The deposition path planning information includes: the current deposition layer number, laser movement trajectory, scanning speed, scanning direction, overlapping relationship between adjacent channels, and distribution of already deposited areas.

[0035] Through the above processing, the component to be manufactured is transformed into a digital deposition model containing geometric and manufacturing process information, providing basic data for subsequent regional thermal demand analysis.

[0036] S102. Based on the slice results, perform layer-by-layer geometric analysis on the components to identify the geometric features of different sedimentary regions; Specifically, each deposition layer is divided into multiple thermal demand analysis units, each corresponding to a local deposition region, and the corresponding geometric feature parameters of that region are extracted.

[0037] Furthermore, the geometric feature parameters include: wall thickness: used to describe the material accumulation thickness in the current region, which affects the laser energy penetration depth and heat diffusion capability; curvature: used to describe the degree of local surface change, which affects the laser action area and heat dissipation path; corner features: used to describe areas where the path direction changes, which are prone to local temperature rise due to changes in scanning speed and heat accumulation effect; overhanging region: used to describe areas with poor heat dissipation conditions, which require additional heat input compensation; overlap region: used to describe the material fusion region between adjacent deposition channels, whose heat input affects the interface bonding quality; heat-sensitive region: regions that are prone to overheating, undermelting, or abnormal structure, determined based on historical deposition processes or thermal simulation results.

[0038] The above geometric feature parameters are normalized to form the first... i Geometric feature vectors of each sedimentary region: , in, Indicates the first i The nth type of geometric characteristic parameters corresponding to each region. S103. Establish a component thermal demand analysis model by combining the geometric characteristics of different deposition regions, material thermal properties, environmental heat dissipation conditions, and deposition path planning; In this embodiment, the component thermal demand analysis model is not a direct adoption of an existing fixed model, but rather a regional thermal demand evaluation model is established based on the main factors affecting the regional thermal state during laser directional energy deposition.

[0039] The specific construction process is as follows: First, based on the regional geometric characteristic parameters obtained from S102, and combined with material thermal property parameters, environmental heat dissipation conditions, and deposition path information, a set of factors influencing the regional thermal state is established.

[0040] For the i-th depositional region, the influencing factors are expressed as follows: , in, Represents the geometric characteristic parameters of the region; Indicates the thermophysical properties of the material Indicates the environmental heat dissipation conditions; This indicates the deposition path and thermal history parameters.

[0041] Material thermal properties include: thermal conductivity, specific heat capacity, density, melting point, and latent heat; environmental heat dissipation conditions include: distance from the substrate, surface convective heat transfer coefficient, and radiative heat transfer conditions; deposition path parameters include: scanning direction, current layer number, adjacent scanning trajectories, and thermal effects of already deposited areas.

[0042] Subsequently, a heat demand evaluation function was established based on the degree of influence of different factors on the regional thermal state: , in: Indicates the first i Evaluation values ​​of heat demand in each sedimentary region 、 、 and This indicates the weight of different influencing factors.

[0043] This model transforms the structural, material, and thermal history differences of different regions of complex components into a unified thermal demand evaluation index, enabling a quantitative description of the thermal demand in different regions.

[0044] S104. Based on the differences in heat demand in different regions, the target heat input is planned for the entire deposition process using the component region heat demand evaluation model, and a target heat input parameter set corresponding to each deposition region is generated. Based on the regional heat demand evaluation values ​​obtained from S103, the target heat input parameters corresponding to different sedimentary regions are planned.

[0045] The target heat input is obtained by correcting the baseline heat input based on the regional heat demand assessment value, and is expressed as follows: , in, Indicates the first i The target heat input for each sedimentary region Indicates the base heat input. This is the heat demand adjustment coefficient. When wall thickness increases, heat dissipation is enhanced, and overlap requirements increase, it will lead to… R i Increasing the heat input increases the target heat input. When heat accumulation increases, the temperature rise in the corner region is too high, and the temperature in the already deposited region is too high, it can lead to… R i Reducing the input decreases the target heat input.

[0046] S105. Form a target heat input field based on the target heat input parameter set of each deposition region; Furthermore, based on the spatial coordinates of the sedimentary region obtained in S104, the first... i The target heat input H of the deposition area i Assign it a corresponding spatial region, thereby establishing a mapping relationship between the target heat input and its spatial location: , in, This represents the target heat input at spatial location (x, y, z).

[0047] When a large aerospace component to be manufactured contains multiple deposition regions, the target heat inputs corresponding to each deposition region are combined according to their spatial location to form the target heat input field of the entire component:

[0048] in, N Indicates the total number of sedimentary areas. I i (x,y,z) represents the x-th... i The spatial mapping function of the deposition region; when the spatial location (x,y,z) is located in the th deposition region. i When in a sedimentary region I i (x,y,z)=1, otherwise I i (x,y,z)=0.

[0049] Finally, the target heat inputs obtained from each deposition region in S104 are uniformly mapped to the three-dimensional spatial location of the large aerospace component, forming a target heat input field corresponding to the component's geometry and deposition path. This serves as the target control basis for the initialization of the S2 point-loop composite energy field and the subsequent S4 heat input deviation analysis.

[0050] S2. Establish a mathematical model of the point-ring composite energy field based on the propagation characteristics of the laser beam and the absorption characteristics of the material. Combine the energy field configuration principle to perform energy initialization configuration and generate an initial point-ring composite energy field that matches the target heat input requirements of the current deposition area. The initial constraints of the point-ring composite energy field are determined based on the target heat input parameter set of each deposition area, and a point-ring composite energy field model is established. The point-ring composite energy field model is used to initially configure the center point beam power, ring beam power, point-ring power distribution ratio, ring radius of action and energy density gradient to generate an initial point-ring composite energy field that matches the target heat input requirements of the current deposition area. In this embodiment, after completing the analysis of the component's geometric features and the planning of the target heat input, the initialization constraints of the point-ring composite energy field are determined based on the target heat input parameter set of each deposition region obtained in S1. A point-ring composite energy field model is then established, transforming the traditional single Gaussian laser heat source into a spatial composite heat source structure composed of a central point-shaped high-energy region and an outer ring-shaped auxiliary energy region. Therefore, the point-ring composite energy field is formed by the superposition of the central beam energy distribution function and the ring beam energy distribution function. By adjusting the energy density distribution between the central and outer regions, the laser heat input is redistributed within the spatial range.

[0051] As a further embodiment, a point-ring composite energy field model is established, specifically including: A mathematical model of the point-ring composite energy field was established based on the laser beam propagation characteristics and material absorption characteristics, and the model parameters were determined according to the target heat input requirements of the deposition area. The central point beam provides a local high energy density input to ensure rapid powder melting and stable molten pool formation; the outer ring beam regulates the heat input in the outer region of the molten pool, providing auxiliary heating to the edge of the molten pool and improving temperature uniformity and material wetting ability in the boundary region.

[0052] The point-ring composite energy field model is expressed as follows: , , , in, This represents the total energy distribution of the point-ring composite energy field. This represents the distribution of light energy field at the center point. Indicates the energy distribution of the ring beam. Indicates the optical power at the center point. Indicates the radius of the point light. Indicates the ring light power. and Indicates the inner and outer radii of the ring light. Represents the radial coordinates in polar coordinates. Indicates the radius of the ring peak. The standard deviation of the radial distribution of the ring light. Indicates the material's absorption rate; During the initialization of the point-ring composite energy field, the system uses the target thermal input parameter set of each depositional region obtained by S1, with the target thermal input of the i-th depositional region as the parameter. Target temperature range Target molten pool width Target molten pool depth and target temperature gradient As an initial constraint, combined with the point-ring composite energy field model, the power of the beam at the center point is... Center point beam radius Ring beam power Inner radius of the annular beam Outer radius Peak radius of the ring beam and radial distribution standard deviation Initial configuration is performed to obtain an initial point-ring composite energy field that matches the target heat input requirements of the current deposition area.

[0053] Specifically, firstly, based on the target heat input Determine the total energy input requirement of the point-ring composite energy field, and determine the beam power at the center point. With ring beam power The power is allocated so that the two together form a composite energy field that meets the target heat input requirements; wherein, the point-loop power allocation ratio is determined by... and The relative size is determined based on the target molten pool depth. Configure the center point beam parameters to increase the local melting depth or local energy density in the deposition area. Or appropriately reduce This allows the central region to achieve a higher energy density; however, when there is strong heat accumulation in the depositional area or the temperature in the central region is too high, it reduces... The power allocation ratio, and correspondingly increased This causes some of the heat input to shift to the outer area of ​​the molten pool.

[0054] Furthermore, based on the target molten pool width Based on the local geometry of the current deposition area, the spatial range of the annular beam is configured by adjusting the inner radius of the annular beam. and outer radius Determine the coverage area of ​​the annular beam; simultaneously, based on the target molten pool width. In accordance with the heat input requirements around the molten pool, the peak radius rm of the annular beam is adjusted so that the energy peak position of the annular beam matches the outer region of the target molten pool.

[0055] Furthermore, based on the target temperature gradient The radial energy distribution of the ring beam is adjusted by adjusting the radial distribution standard deviation. Changing the energy of the ring beam at its peak radius The degree of radial diffusion in the vicinity. When the target temperature gradient is large or there is a significant temperature difference between the center and edge of the deposition area, increase... This allows the annular energy to be distributed more gently in the radial direction, reducing the local temperature gradient; when it is necessary to enhance the local heating effect of a specific peripheral area, the [temperature gradient] is reduced. This makes the ring energy more concentrated in nearby.

[0056] Therefore, for the i-th sedimentary region, a formation of... , , , , , and The initial point-ring composite energy field parameters are constructed, and these parameters are substituted into the point-ring composite energy field model to obtain the corresponding parameters. The calculated composite energy field is related to the target heat input. Perform matching, adjusting the above parameters until the desired result is achieved. By satisfying the target heat input constraints of the current deposition area, the initial point-ring composite energy field of the area is obtained.

[0057] Among them, the material absorption rate η is determined based on the deposition material and its surface condition used in current aerospace large components. It serves as a material property parameter in the calculation of the point-ring composite energy field and does not participate in the independent adjustment of the point-ring power distribution ratio.

[0058] Furthermore, the obtained initial point-ring composite energy field is not used as a fixed heat source parameter for the entire deposition process, but rather as the initial energy distribution basis for subsequent analysis of actual heat input state and dynamic reconstruction of the point-ring composite energy field.

[0059] S3: Based on the point-ring composite energy field distribution, establish a thermal behavior response model of the molten pool of large aerospace components to obtain the actual thermal input field; After completing the target heat input field planning and the initial configuration of the point-ring composite energy field, this embodiment further establishes a molten pool thermal behavior response model driven by the point-ring composite energy field to address the problems of large structural size, complex deposition path, and significant local heat accumulation in the laser-directed energy deposition process of large aerospace components. The specific steps include the following: S301: Establish the mapping relationship between laser energy input and material temperature response; To address the characteristics of different regions in the deposition process of large aerospace components, such as variations in wall thickness, curvature, complex rotations, and continuous heat accumulation, a mapping relationship between laser energy input and local thermal response of the component under the action of a point-ring composite energy field was established.

[0060] Specifically, the point-ring composite energy field obtained from S2 As a representation of the spatial energy input of the current sedimentary region, and in conjunction with the current sedimentary region, a mapping relationship between the actual thermal input state and the above input parameters is established: , in, Indicates the actual heat input state. Indicates laser power parameters, Indicates the scanning speed. Indicates the thermophysical properties of the material. This indicates the deposition path and thermal history information; it also shows the actual thermal input state. This is equivalent to a solvable physical quantity, namely the spatial temperature response of the depositional region. Specifically, the point-ring composite energy field As the spatial heat source input for the current laser action area, and combined with laser power parameters Scanning speed Material thermophysical parameters And information on depositional paths and thermal history Considering the internal heat conduction of the material as well as the convective and radiative heat transfer on the surface of the component, the transient heat conduction process is discretized and iteratively calculated to finally obtain the transient temperature field at different spatial locations under the current deposition state. This establishes a point-ring composite energy field. Response to space temperature The correspondence between them, and the actual heat input state through the temperature response. Characterization is performed to provide a foundation for subsequent identification of the molten pool region and extraction of thermal behavior features.

[0061] S302: Based on the point-ring composite energy field and mapping relationship, predict the spatial temperature field under the current deposition state, determine the range of the molten pool region, and extract thermal behavior characteristics from the spatial temperature field; Specifically, the point-ring composite energy field obtained by S2 Using laser thermal input boundary conditions, and combining the current deposition area's process parameters, material thermal properties, deposition path information, and established mapping relationships, we can predict the material temperature response and molten pool evolution process under laser irradiation.

[0062] Specifically, based on the process parameters and material thermophysical properties of the current deposition area, a transient heat conduction calculation model for the current deposition area is established; the point-ring composite energy field is then considered. The heat source input is applied to the current laser-affected area, and considering internal heat conduction in the material as well as convective and radiative heat transfer on the surface of the component, the temperature response at different spatial locations in the deposition area is obtained by solving the transient heat conduction calculation model in time steps, thus forming the spatial temperature field under the current deposition state. , which represents the spatial temperature distribution in the depositional area.

[0063] Furthermore, the predicted temperature field is based on the material melting temperature threshold. A spatial location comparison is performed, comparing the temperature value at each spatial location in the predicted temperature field with the material's melting temperature threshold. When a certain spatial location meets the threshold... When the temperature is greater than or equal to the material's melting temperature threshold, the location is determined to be in a molten state, and the area composed of all continuous molten state spatial locations is determined as the molten pool area of ​​the current deposition process; further, the molten pool boundary is determined based on the boundary position between the molten pool area and the non-molten area, thereby obtaining the molten pool area range.

[0064] Specifically, from the predicted space temperature field Extracting various thermal behavior characteristic parameters: maximum temperature of the molten pool The maximum temperature value within the molten pool region is used to evaluate the energy concentration of the beam at the center point; molten pool width. Take the maximum lateral dimension and depth of the molten pool region in the cross section perpendicular to the deposition direction. The maximum depth of the molten pool region extending into the matrix along the deposition direction is used to evaluate the melting range of the material; temperature gradient. Calculated based on the temperature difference and corresponding spatial distance between adjacent locations, it is used to evaluate the heat diffusion state and degree of heat accumulation under the influence of a point-ring composite energy field. This method, based on cumulative calculations of temperature changes in the same spatial region at different time points during continuous deposition, is used to evaluate local temperature rise during the continuous deposition of large aerospace components. Through this approach, the differences in thermal state among different structural regions (such as thin-walled regions, stiffening rib regions, curved surface regions, and corner regions) can be predicted.

[0065] S303. Construct the actual heat input field based on the predicted thermal behavior characteristics; Based on the molten pool thermal behavior parameters obtained from S301, the actual heat input state of the current deposition area is characterized: ,in, This represents the actual heat input field.

[0066] Furthermore, based on the actual heat input states corresponding to different spatial locations of large aerospace components, the heat input information of each region is spatially combined to form the actual heat input field during the entire component deposition process. The actual heat input field is used to describe the actual heat input state obtained by the material after the action of the point-ring composite energy field, including: the degree of energy concentration in the central region, the range of heat diffusion in the outer region, and the differences in heat input between different deposition regions.

[0067] S304. Dynamically correct the actual heat input field by combining online monitoring data; Due to changes in material state, environmental disturbances, and model prediction errors during the deposition of large aerospace components, it is difficult to fully reflect the actual state of the molten pool by relying solely on thermal behavior prediction models.

[0068] Therefore, this embodiment further incorporates online monitoring data to correct the predicted actual heat input field.

[0069] Specifically, information on melt pool temperature, melt pool size, melt pool morphology, and temperature changes during continuous deposition is acquired through a coaxial vision module, an infrared thermometry module, or a photoelectric detection module. Specifically, the infrared thermometry module or photoelectric detection module acquires melt pool temperature and its time-varying information, while the coaxial vision module acquires melt pool morphology information such as melt pool outline, width, and length. Characteristic parameters corresponding to melt pool width and depth are obtained by combining melt pool outline changes and temperature spatial distribution. Temperature changes and heat accumulation characteristics at different deposition times are obtained through continuous sampling. Furthermore, the highest melt pool temperature, melt pool width, melt pool depth, temperature gradient, and degree of heat accumulation corresponding to the predicted results are extracted from the aforementioned online monitoring data and matched and compared with the corresponding predicted thermal behavior characteristic parameters to obtain the deviation between the predicted results and the actual monitoring results.

[0070] When the monitoring results are consistent with the prediction results, maintain the current actual heat input status; when an increase in molten pool temperature, expansion of molten pool, or increase in heat accumulation is detected, increase the actual heat input evaluation value; when an insufficient molten pool temperature or reduction in melting area is detected, decrease the actual heat input evaluation value.

[0071] Finally, the actual heat input field is obtained after dynamic updates. And input it into S4, which is the target heat input field established with S1. Perform deviation analysis.

[0072] S4: Based on the spatial deviation analysis between the target heat input field and the actual heat input field, determine the dynamic reconstruction requirements of the point-loop composite energy field; The target heat input field established by S1 is obtained. The actual heat input field obtained from S3 Subsequently, in response to the problem of local thermal input deviation in different regions during the laser-directed energy deposition process of large aerospace components due to differences in structural characteristics, heat dissipation conditions, and thermal history, this embodiment further establishes a deviation analysis method between the target thermal input field and the actual thermal input field.

[0073] By matching the spatial location and state characteristics of the target thermal input state with the actual thermal input state, the thermal input deviation characteristics of different depositional regions are obtained, and the degree of deviation is used to determine whether the current point-ring composite energy field needs to be dynamically adjusted.

[0074] S401. Calculate the thermal input deviation between the target state and the actual state; Specifically, the large aerospace components to be manufactured are divided into multiple space heat input analysis units according to the deposition path, and each analysis unit corresponds to a local deposition area.

[0075] For the i For each deposition region, the target thermal input state was obtained: Actual heat input status: Then, the thermal input deviation between the target state and the actual state is calculated: , in, Indicates the first i Thermal input deviation in each depositional region.

[0076] The above calculations yielded the heat input deviation distribution throughout the entire deposition process of large aerospace components: This ultimately results in a spatial heat input deviation.

[0077] S402. Establish the spatial correspondence between the target heat input field and the actual heat input field; Since large aerospace components typically have large dimensions, complex curved surfaces, and multi-regional combined structures, the thermal state requirements at different locations vary significantly. Therefore, the spatial location of the target thermal input field and the actual thermal input field is first matched based on the deposition path coordinate information.

[0078] Specifically, based on the target heat input field obtained from S1 And the actual heat input field obtained by S3 The components are divided into multiple thermal input evaluation areas based on their corresponding spatial coordinate positions.

[0079] For each spatial location The target heat input value and the actual heat input value are obtained respectively. Through spatial mapping, the same region in the target heat input field and the actual heat input field are made comparable, providing a basis for subsequent deviation calculation.

[0080] S403. Extract heat input deviation characteristics based on spatial heat input differences; Based on the spatial correspondence obtained in S402, the target heat input state and the actual heat input state are compared and analyzed.

[0081] For typical thermal failure regions during the deposition process of large aerospace components, different types of thermal input deviation characteristics are extracted according to the steps in S401, specifically including: (1) Heat input deviation in the central region Used to determine the degree of energy concentration in a point light region.

[0082] When the actual heat input field is greater than the target heat input field, it indicates that the actual heat input in the central region is too high, which may lead to local overheating, molten pool fluctuations, and increased splashing; when the actual heat input field is less than the target heat input field, it indicates that the energy in the central region is insufficient, which may lead to insufficient melting depth or incomplete powder melting.

[0083] (2) Heat input deviation in the peripheral area Used to evaluate the auxiliary heating effect of the annular beam on the edge region of the molten pool.

[0084] When the actual heat input in the outer area is lower than the target requirement, it indicates that the ring energy is insufficient, which may cause insufficient fusion of the overlapping area and unstable boundary formation.

[0085] (3) Deviation in heat input uniformity Used to evaluate whether the spatial distribution of the point-loop composite energy field is reasonable.

[0086] When the difference in heat input between the central region and the peripheral region is too large, it indicates that there is a significant concentration of energy distribution, and the point-loop power ratio needs to be readjusted.

[0087] (4) Heat accumulation deviation Used to evaluate the local temperature rise during the continuous deposition of large aerospace components.

[0088] When the actual heat input in a continuous depositional region is consistently higher than the target state, it indicates a risk of heat accumulation, and it is necessary to reduce the local energy input.

[0089] Establish a thermal input deviation matrix based on the different types of deviations mentioned above: .

[0090] S404. Determine the dynamic reconstruction requirements of the point-loop composite energy field based on the heat input deviation results. Based on the heat input deviation matrix obtained from S403, each type of heat input deviation is compared with its corresponding allowable heat input deviation threshold to determine whether the current point-loop composite energy field meets the target heat input requirements.

[0091] When any thermal input deviation exceeds the corresponding allowable deviation threshold, it is determined that there is an excessive deviation between the current point-ring composite energy field and the target thermal input field, and dynamic reconstruction is required; when all types of thermal input deviations are within the corresponding allowable deviation range, it is determined that the current point-ring composite energy field meets the target thermal input requirements of the current deposition area, and the current point-ring composite energy field state is maintained without adjustment.

[0092] After determining that dynamic reconstruction is necessary, the specific control direction is determined based on the sign and degree of deviation of each component in the heat input deviation matrix E: when the heat input deviation in the central region... When the energy input in the center point light region exceeds the allowable range, it is determined that the energy input is too high, and the power of the center point beam is reduced. Or point-loop power distribution ratio; when the heat input deviation in the peripheral area If the power is below the allowable range, the ring beam auxiliary heating is deemed insufficient, and the ring beam power is increased. Its energy contribution; when the heat input uniformity deviation When the range exceeds the allowable limit, the spatial distribution of the point-ring composite energy field is deemed unreasonable, and the power distribution ratio between the center point beam and the ring beam, as well as the ring's effective range, are adjusted; when the heat accumulation deviation... If the local total heat input is exceeded, the local total heat input will be reduced or the range of annular energy action will be expanded according to the direction of heat accumulation deviation in order to reduce local heat accumulation.

[0093] Furthermore, to avoid misadjustment caused by a single thermal disturbance, this embodiment makes a judgment based on the trend of heat input deviation during continuous deposition.

[0094] When the heat input deviation continues to exceed the set threshold and the deviation area has a stable expansion trend, it is determined that the current point-ring composite energy field cannot meet the target heat input requirements, and enters the S5 dynamic reconstruction process. If the thermal input deviation gradually decreases over time and remains within the target range, the current deposition state continues.

[0095] The above method transforms the traditional LDED process based on laser power parameter adjustment into a spatial evaluation method based on the difference between the target thermal input field and the actual thermal input field, providing a control basis for the subsequent dynamic reconstruction of the point-ring composite energy field.

[0096] S5: If reconstruction is required, a dynamic reconstruction model of the point-loop composite energy field is established based on the thermal input deviation results to achieve active control of the spatial distribution of thermal input during the deposition process of large aerospace components. Based on the deviation analysis results between the target heat input field and the actual heat input field obtained in S4, when it is detected that the actual heat input state of the current deposition area deviates from the target heat input requirement, this embodiment further establishes a dynamic reconstruction model of the point-ring composite energy field.

[0097] The model aims to reduce the spatial deviation between the target thermal input field and the actual thermal input field. It achieves active optimization of the spatial distribution of laser thermal input by adjusting the energy distribution relationship between the central point beam and the outer ring beam in the point-ring composite energy field.

[0098] S501. Establish the mapping relationship between heat input deviation and point loop energy distribution parameters; Specifically, the thermal input deviation matrix E obtained from S4 is used as the input to the dynamic reconstruction model, and the point-loop composite energy field is used as the input. As the control object, a mapping relationship between heat input deviation and point loop energy distribution parameters is established: , in, This represents the point-ring composite energy field after dynamic reconstruction. This represents the current point-loop composite energy field; E represents the deviation between the target heat input field and the actual heat input field.

[0099] Based on the above model, the energy of the point light region and the ring light region is redistributed according to the thermal input deviation in different spatial regions, so that the newly generated point-ring composite energy field can reduce the degree of thermal input deviation.

[0100] S502. Determine the adjustment direction of the point-loop composite energy field based on the characteristics of heat input deviation; dynamically adjust the point-loop power ratio and spatial distribution parameters based on the determined adjustment direction of the point-loop composite energy field. Based on the thermal input deviation matrix obtained from S4, the thermal state of the current deposition area of ​​large aerospace components is assessed, and the adjustment directions of the center point beam and the ring beam are determined. Specifically: When the heat input deviation in the central area If the actual heat input in the central region exceeds the upper limit of the corresponding allowable deviation range, it is determined that the actual heat input in the central region is higher than the target heat input requirement, indicating that the energy input in the current point beam region is too strong. Therefore, it is determined to reduce the power of the central point beam. Alternatively, reduce the point-to-ring power distribution ratio and correspondingly increase the ring beam energy contribution, so that the heat input is redistributed from the central region to the outer region; When the heat input deviation in the central area If the actual heat input in the central region is below the lower limit of the corresponding allowable deviation range, it is determined that the actual heat input in the central region is lower than the target heat input requirement, indicating that the current energy input in the central region is insufficient. Therefore, it is determined to increase the beam power at the center point. Alternatively, the point-loop power distribution ratio can be increased to improve the energy density in the central region; When the heat input deviation in the outer area If the actual heat input in the peripheral region is below the lower limit of the corresponding allowable deviation range, it is determined that the actual heat input is lower than the target heat input requirement, indicating that the ring beam auxiliary heating is insufficient. Therefore, it is determined to increase the ring beam power. To increase the energy contribution of the ring beam or expand the effective range of the ring beam, thereby increasing the heat input in the peripheral region; When the heat input deviation in the outer area If the actual heat input in the peripheral region exceeds the upper limit of the corresponding allowable deviation range, it is determined that the actual heat input is higher than the target heat input requirement, indicating that the effective range or energy contribution of the ring beam is too large. Therefore, it is determined to reduce the power of the ring beam. Reduce the energy contribution of the ring beam or decrease the effective range of the ring beam to suppress the diffusion of heat to non-target areas; When heat input uniformity deviation When the deviation exceeds the corresponding allowable range, it is determined that there is a significant difference in heat input between the central region and the outer region. and The deviation direction determines the power distribution ratio between the center beam and the ring beam, as well as the adjustment direction of the ring beam's effective range. When heat accumulation deviation If the deviation exceeds the allowable range, it is determined that there is local heat accumulation in the deposition area of ​​the large aerospace component. In this case, the laser energy input in the corresponding area is reduced, and the beam power at the center point is adjusted according to whether the heat accumulation mainly occurs in the central or peripheral area. or ring beam power And the range of action of the ring beam.

[0101] When multiple thermal input deviation conditions are met simultaneously, the priority adjustment direction is determined based on the degree to which each deviation exceeds the corresponding allowable deviation range, and the center point beam power is determined comprehensively. Ring beam power The adjustment direction of the point-to-ring power distribution ratio and the effective range of the ring beam.

[0102] Furthermore, the effective range of the annular beam is adjusted based on the heat input status of the peripheral region. When edge fusion is insufficient, the effective range of the annular beam is expanded to provide more auxiliary heat input to the peripheral region; when heat accumulation in the periphery increases, the effective range of the annular beam is reduced to decrease heat input to non-target regions. Ultimately, a dynamic point-ring composite energy field is obtained that meets the target heat input requirements of the current deposition area. .

[0103] S504. Subsequent deposition control is based on the dynamically reconstructed point-ring composite energy field. The dynamic reconstructed point-ring composite energy field obtained from S502 is applied to the subsequent deposition process of large aerospace components, so that different structural regions can obtain space energy input that matches their thermal requirements.

[0104] For different typical regions in large aerospace components: For thin-walled regions, due to rapid heat dissipation and poor molten pool stability, the molten depth is stabilized by increasing the proportion of beam energy at the center point. For thick-walled regions, where heat accumulation is significant, the central heat concentration can be reduced by increasing the heat input assisted by the ring beam. For curved areas, the energy distribution changes due to the change in the laser's action angle. The edge temperature uniformity can be improved by adjusting the annular action range. For corner regions, local heat accumulation occurs due to changes in scanning direction. Overheating is suppressed by reducing the concentration of energy at the center.

[0105] By dynamically adjusting the spatial energy distribution relationship between the point light and the ring light, the laser thermal input is always kept near the target thermal input field.

[0106] Furthermore, during subsequent deposition processes, the system continuously executes the process from Ht to Ha to E to... The closed-loop optimization process.

[0107] When the new actual heat input state deviates from the target state again, the S4 heat input deviation analysis is re-executed, and the point-loop composite energy field is updated according to the new deviation results, so as to realize continuous dynamic control in the entire manufacturing process of large aerospace components.

[0108] As an embodiment of the present invention, this embodiment provides a laser-directed energy deposition system for dynamic reconstruction of a composite energy field, comprising: The target heat input planning module is used to establish a set of target heat input parameters for each deposition area of ​​the component to be manufactured, and to form a target heat input field based on the set of target heat input parameters. The point-ring composite energy field initialization module is used to establish a mathematical model of the point-ring composite energy field based on the laser beam propagation characteristics and material absorption characteristics, and to perform energy initialization configuration in combination with energy field configuration principles to generate a point-ring composite energy field that matches the target heat input requirements of the current deposition area; the actual heat prediction module is used to establish the mapping relationship between laser energy input and material temperature response, predict the thermal behavior characteristics of the deposition area based on the point-ring composite energy field and the mapping relationship, and construct the actual heat input field based on the predicted thermal behavior characteristics; The dynamic energy field reconstruction module is used to determine the dynamic reconstruction requirements of the point-ring composite energy field based on the spatial deviation analysis between the target heat input field and the actual heat input field. If reconstruction is required, a dynamic reconstruction model of the point-ring composite energy field is established based on the spatial deviation analysis results between the target heat input field and the actual heat input field. The optimization objective is to reduce the spatial deviation between the target heat input field and the actual heat input field. By adjusting the energy distribution relationship between the central point beam and the outer ring beam of the point-ring composite energy field, the active control of the spatial distribution of heat input during the deposition process of large aerospace components can be achieved.

[0109] It should be noted that the specific implementation of the laser directional energy deposition system with dynamic reconstruction of composite energy field in this embodiment of the invention is similar to the specific implementation of the laser directional energy deposition method with dynamic reconstruction of composite energy field in this embodiment of the invention. For details, please refer to the description in the method section. To reduce redundancy, it will not be repeated here.

[0110] As an embodiment of the present invention, this embodiment provides a computer-readable storage medium storing a computer program thereon, which, when executed by a processor, implements the steps of the laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described above.

[0111] As an embodiment of the present invention, this embodiment provides a computer device, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the program, it implements the steps in the laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described above.

[0112] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A laser-directed energy deposition method for dynamic reconstruction of a composite energy field, characterized in that, Includes the following steps: Establish a set of target thermal input parameters for each deposition region of the component to be manufactured, and form a target thermal input field based on the set of target thermal input parameters; A mathematical model of the point-ring composite energy field is established based on the propagation characteristics of the laser beam and the absorption characteristics of the material. The energy is initialized and configured in accordance with the energy field configuration principle to generate a point-ring composite energy field that matches the target heat input requirements of the current deposition area. Establish a mapping relationship between laser energy input and material temperature response, predict the spatial temperature field under the current deposition state based on the point-ring composite energy field and mapping relationship, determine the range of the molten pool region, extract thermal behavior characteristics from the spatial temperature field, and construct the actual thermal input field based on the predicted thermal behavior characteristics; Based on the spatial deviation analysis between the target heat input field and the actual heat input field, the dynamic reconstruction requirements of the point-loop composite energy field are determined. If reconstruction is required, a dynamic reconstruction model of the point-ring composite energy field is established based on the spatial deviation analysis results between the target heat input field and the actual heat input field. The optimization objective is to reduce the spatial deviation between the target heat input field and the actual heat input field. By adjusting the energy distribution relationship between the central point beam and the outer ring beam of the point-ring composite energy field, the active control of the spatial distribution of heat input during the deposition process of large aerospace components can be achieved.

2. The laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described in claim 1, characterized in that, The establishment of the target thermal input parameter set for each deposition region of the component to be manufactured specifically includes: The obtained 3D model of the component to be manufactured is sliced ​​and a deposition path is planned. Based on the slice results, the components were geometrically analyzed layer by layer to identify the geometric features of different sedimentary regions; A component thermal demand analysis model was established by combining the geometric characteristics of different depositional regions, material thermal properties, environmental heat dissipation conditions, and deposition path planning. Based on the differences in heat demand in different regions, a target heat input planning is carried out for the entire deposition process through a component heat demand analysis model, generating a target heat input parameter set corresponding to each deposition region.

3. The laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described in claim 1, characterized in that, The point-ring composite energy field model is as follows: ， ， ， in, This represents the total energy distribution of the point-ring composite energy field. This represents the distribution of light energy field at the center point. Indicates the energy distribution of the ring beam. Indicates the optical power at the center point. Indicates the radius of the point light. Indicates the ring light power. and Indicates the inner and outer radii of the ring light. Represents the radial coordinates in polar coordinates. Indicates the radius of the ring peak. The standard deviation of the radial distribution of the ring light. This indicates the material's absorption rate.

4. The laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described in claim 1, characterized in that, When generating an initial point-ring composite energy field that matches the target heat input requirements of the current depositional area, the configuration principle is as follows: Based on the obtained target thermal input parameter set for each sedimentary region, the target thermal input of the i-th sedimentary region is used as an example. Target temperature range Target molten pool width Target molten pool depth and target temperature gradient As an initial constraint, combined with the point-ring composite energy field model, the power of the beam at the center point is... Center point beam radius Ring beam power Inner radius of the annular beam Outer radius Peak radius of the ring beam and radial distribution standard deviation Initial configuration is performed to obtain an initial point-ring composite energy field that matches the target heat input requirements of the current deposition area.

5. The laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described in claim 1, characterized in that, The method of predicting the spatial temperature field under the current deposition state based on the point-ring composite energy field and mapping relationship, and determining the range of the melt pool region, includes: Based on the process parameters and material thermophysical parameters of the current deposition area, a transient heat conduction calculation model for the current deposition area is established. A point-ring composite energy field is applied to the current laser action area as a heat source input, and the internal heat conduction of the material and the convective heat transfer and radiative heat dissipation on the surface of the component are considered. By solving the transient heat conduction calculation model in time steps, the temperature response at different spatial locations of the deposition area is obtained. Based on the material melting temperature threshold, the predicted temperature field is compared spatially location by location. The temperature value at each spatial location in the predicted temperature field is compared with the material melting temperature threshold. When a certain spatial location meets the threshold... When the temperature is greater than or equal to the material's melting temperature threshold, the location is determined to be in a melting state, and the area composed of all consecutive melting state spatial locations is defined as the molten pool area of ​​the current deposition process. The boundary of the molten pool is determined by the location of the intersection between the molten pool area and the non-molten area, thereby obtaining the range of the molten pool area.

6. The laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described in claim 1, characterized in that, The determination of the dynamic reconstruction requirements of the point-loop composite energy field based on the spatial deviation analysis between the target heat input field and the actual heat input field includes: Calculate the thermal input deviation between the target state and the actual state; Establish the spatial correspondence between the target heat input field and the actual heat input field; Based on the obtained spatial correspondence, the target heat input state and the actual heat input state are compared and analyzed to extract heat input deviation characteristics, including heat input deviation in the central region. Heat input deviation in the outer area Heat input uniformity deviation and thermal accumulation deviation ; The dynamic reconstruction requirement of the point-ring composite energy field is determined based on the thermal input deviation results. Each type of thermal input deviation is compared with its corresponding allowable thermal input deviation threshold. When any thermal input deviation exceeds the corresponding allowable deviation threshold, it is determined that there is an excessive deviation between the current point-ring composite energy field and the target thermal input field, and dynamic reconstruction is required. When all types of thermal input deviations are within the corresponding allowable deviation range, it is determined that the current point-ring composite energy field meets the target thermal input requirements of the current deposition area, and the current point-ring composite energy field state is maintained without adjustment.

7. The laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described in claim 6, characterized in that, The adjustment process specifically includes: determining the adjustment direction of the point-loop composite energy field based on the characteristics of the heat input deviation; and dynamically adjusting the point-loop power ratio and spatial distribution parameters according to the determined adjustment direction, including: When the heat input deviation in the central area When the upper limit of the corresponding allowable deviation range is exceeded, it is determined that the actual heat input in the central region is higher than the target heat input requirement, and the beam power at the center point is reduced. Alternatively, reduce the point-to-ring power distribution ratio and correspondingly increase the ring beam energy contribution, so that the heat input is redistributed from the central region to the outer region; When the heat input deviation in the central area When the actual heat input in the central region is below the lower limit of the corresponding allowable deviation range, it is determined that the actual heat input in the central region is lower than the target heat input requirement, and the beam power at the center point is increased. Alternatively, the point-loop power distribution ratio can be increased to improve the energy density in the central region; When the heat input deviation in the outer area When the actual heat input in the peripheral region is below the lower limit of the corresponding allowable deviation range, it is determined that the actual heat input is lower than the target heat input requirement, and the power of the ring beam is increased. To increase the energy contribution of the ring beam or expand the effective range of the ring beam, thereby increasing the heat input in the peripheral region; When the heat input deviation in the outer area When the upper limit of the corresponding allowable deviation range is exceeded, it is determined that the actual heat input in the outer region is higher than the target heat input requirement, and the power of the ring beam is reduced. Reduce the energy contribution of the ring beam or decrease the effective range of the ring beam to suppress the diffusion of heat to non-target areas; When heat input uniformity deviation When the deviation exceeds the corresponding allowable range, it is determined that there is a significant difference in heat input between the central region and the outer region. and The deviation direction determines the power distribution ratio between the center beam and the ring beam, as well as the adjustment direction of the ring beam's effective range. When heat accumulation deviation If the deviation exceeds the allowable range, it is determined that there is local heat accumulation in the deposition area of ​​the large aerospace component. In this case, the laser energy input in the corresponding area is reduced, and the beam power at the center point is adjusted according to whether the heat accumulation mainly occurs in the central or peripheral area. or ring beam power and the range of action of the ring beam; When multiple thermal input deviation conditions are met simultaneously, the priority adjustment direction is determined based on the degree to which each deviation exceeds the corresponding allowable deviation range, and the center point beam power is determined comprehensively. Ring beam power The adjustment direction of the point-to-ring power distribution ratio and the effective range of the ring beam.

8. A laser-directed energy deposition system for dynamic reconstruction of a composite energy field, characterized in that, include: The target heat input planning module is used to establish a set of target heat input parameters for each deposition area of ​​the component to be manufactured, and to form a target heat input field based on the set of target heat input parameters. The point-ring composite energy field initialization module is used to establish a mathematical model of the point-ring composite energy field based on the laser beam propagation characteristics and material absorption characteristics, and to perform energy initialization configuration in combination with the energy field configuration principle to generate a point-ring composite energy field that matches the target heat input requirements of the current deposition area. The actual thermal prediction module is used to establish the mapping relationship between laser energy input and material temperature response. Based on the point-ring composite energy field and the mapping relationship, it predicts the spatial temperature field under the current deposition state, determines the range of the molten pool region, extracts thermal behavior characteristics from the spatial temperature field, and constructs the actual thermal input field based on the predicted thermal behavior characteristics. The dynamic energy field reconstruction module is used to determine the dynamic reconstruction requirements of the point-ring composite energy field based on the spatial deviation analysis between the target heat input field and the actual heat input field. If reconstruction is required, a dynamic reconstruction model of the point-ring composite energy field is established based on the spatial deviation analysis results between the target heat input field and the actual heat input field. The optimization objective is to reduce the spatial deviation between the target heat input field and the actual heat input field. By adjusting the energy distribution relationship between the central point beam and the outer ring beam of the point-ring composite energy field, the active control of the spatial distribution of heat input during the deposition process of large aerospace components can be achieved.

9. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the program is executed by the processor, it implements the steps in the laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described in any one of claims 1-7.

10. A computer device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the program, it implements the steps in the laser-directed energy deposition method for dynamic reconstruction of a composite energy field as described in any one of claims 1-7.

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