CN-117718562-B - Device for adding material to auxiliary consumable electrode arc of ultrasonic vibration wire

CN117718562BCN 117718562 BCN117718562 BCN 117718562BCN-117718562-B

Abstract

The invention discloses an ultrasonic vibration wire auxiliary consumable electrode electric arc material adding device which comprises a wire feeding mechanism, a welding gun mechanism and an ultrasonic vibration mechanism, wherein the wire feeding mechanism is used for providing power for welding wires and conveying the welding wires to the direction of the welding gun mechanism, the welding gun mechanism is used for adding current to the welding wires and driving the welding wires to a working area, the ultrasonic vibration mechanism is arranged between the wire feeding mechanism and the welding gun mechanism, and ultrasonic vibration is applied to the welding wires through a transducer and an amplitude transformer, so that during welding, the ultrasonic vibration is conducted to a molten pool along with the welding wires, and the molten pool is stirred. In the embodiment, ultrasonic vibration is conducted into a molten pool through wires, molten drop transition is improved through cavitation effect, acoustic flow effect, mechanical effect and thermal effect, molten pool flow is pushed, molten pool components are uniform, coarse grains are crushed, and finally mechanical properties such as microhardness, tensile strength and the like of an additive component are improved.

Inventors

PENG YONG
LV QINGQUAN
WANG KEHONG
DUAN MENGWEI
CHENG YUAN
ZHANG YUE
YUAN YURONG

Assignees

南京理工大学
南京英尼格玛工业自动化技术有限公司

Dates

Publication Date: 20260512
Application Date: 20240201

Claims (7)

1. Device of supplementary consumable electrode electric arc material increase of ultrasonic vibration wire, its characterized in that includes: The wire feeding mechanism is used for providing power for the welding wire and conveying the welding wire to the direction of the welding gun mechanism; the welding gun mechanism is used for applying current to the welding wire and driving the welding wire to a working area; The ultrasonic vibration mechanism is arranged between the wire feeding mechanism and the welding gun mechanism, and ultrasonic vibration is applied to the welding wire through the transducer and the amplitude transformer, so that during welding, the ultrasonic vibration is conducted to the molten pool along with the welding wire, and the molten pool is stirred; the device for adding materials to the ultrasonic vibration wire auxiliary consumable electrode arc further comprises a speckle structure light assembly moving along with the welding gun, and the device comprises: a structural laser transmitter for guiding laser to the welding work area and transmitting the laser to the molten pool area; The structural laser receiver receives laser reflected by the molten pool area and guides the laser to the laser imaging unit; The multichannel laser processing module comprises a vibration channel unit, a molten pool form channel unit, a welding temperature channel unit and an attention module arranged between the channels; Acquiring data of a laser imaging unit, preprocessing, and then respectively sending the data into a vibration channel unit, a molten pool form channel unit and a welding temperature channel unit for processing; the vibration channel unit includes: The molten pool image extraction unit is used for acquiring data of the laser imaging unit, denoising and enhancing the data, acquiring a molten pool area image, and dividing the molten pool area image into a plurality of overlapped image subareas, wherein each image subarea comprises at least one calculation point and a preset number of pixel points, and the integral shapes of the image subareas are similar; the displacement field calculation unit compares the corresponding image subareas in the reference molten pool image and the target molten pool image, and solves the displacement vector of each calculation point, thereby obtaining the displacement field of the molten pool area; a vibration parameter extraction unit that extracts vibration parameters based on the change characteristics of the displacement field; The displacement field calculation unit is further configured to: searching an image subarea which is most similar to an image subarea in a reference molten pool image in the target molten pool image, and taking the coordinate difference of the center point of the image subarea as an initial displacement value; reading and carrying out taylor expansion on a correlation function or a correlation coefficient, solving sub-pixel displacement by using an iterative least square method, and carrying out gray interpolation on the sub-pixel position in a target image in the iterative solving process so as to obtain a gray value of the sub-pixel position; diffusing the initial value between adjacent calculation points through a reliability guiding method, and calculating full-field displacement to obtain a final displacement field; And smoothing the final displacement field, and calculating different strains and deformations through different strain and deformation calculation formulas.
2. The ultrasonic vibration wire assisted melt pole arc additive apparatus of claim 1, wherein the ultrasonic vibration mechanism comprises: the energy converter is electrically connected with the ultrasonic power supply and converts electric energy into vibration when in operation; a horn connected to the transducer for focusing energy from the transducer and applying it to the tool head; and one end of the tool head is fixed on the amplitude transformer, and the other end of the tool head is abutted with the wire guide tube of the welding wire during working to transfer vibration energy to the welding wire.
3. The ultrasonic vibration wire assisted consumable electrode arc additive device of claim 1 wherein the welding gun mechanism comprises: A welding gun body provided with a welding wire passing hole, the welding wire passes through the welding wire and reaches a welding working area; the wire feeding wheel is arranged at the wire feeding end of the welding gun body and used for providing power for welding wires; the gas cylinder is communicated with a gas channel arranged on the welding gun body and extends to the welding area, and when the welding gun works, gas is conveyed to the welding operation area; And the welding power supply is connected with the welding wire and the substrate.
4. The ultrasonic vibration wire assisted melt electrode arc additive apparatus of claim 1, wherein the welding temperature channel unit is further: The temperature calculating unit is used for reading the intensity and the wavelength of the preprocessed laser reflection signals and calculating the temperature and the absorptivity by adopting a preset model; T=hc/(λ×k b ×ln（2hc 2 /λ 5 I R +1））;α=（aI 0 -bI R ）/I 0 ; h is Planck's constant, c is the speed of light, k b is Boltzmann constant, λ is the laser wavelength, I 0 is the incident laser intensity, I R is the reflected laser intensity, a and b are correction coefficients; And a temperature correction unit for comparing the actual temperature of the molten pool area measured by the infrared sensor with the estimated value of the laser reflection signal and correcting according to the error.
5. The ultrasonic vibration wire assisted melt electrode arc additive apparatus of claim 1, wherein the melt pool morphology channel unit is further: the edge detection unit is used for acquiring data of the laser imaging unit, generating an image sequence, converting the image sequence into a gray level image, and carrying out filtering and enhancement treatment on the gray level image; The contour extraction unit is used for extracting the contour of the edge image through a boundary tracking method to obtain contour information of a molten pool, and the edge of the molten pool is represented by a group of ordered points or line segments; And the morphology generating unit is used for constructing a gray level co-occurrence matrix to perform feature extraction on an image or an outline of the molten pool to obtain molten pool parameters including surface roughness, surface tension and surface temperature distribution of the molten pool so as to convert image information of the molten pool into numerical value information, so that the subsequent neural network processing is facilitated.
6. The apparatus for ultrasonic vibration wire assisted consumable electrode arc material addition of claim 4 further comprising a temperature field construction module for calculating a temperature distribution of the true temperature of the molten bath based on a fitting method, obtaining a temperature distribution map and a temperature gradient of the molten bath, and analyzing a spatial distribution and a change rule of the temperature field of the molten bath.
7. The apparatus for ultrasonic vibration wire assisted melt electrode arc additive of claim 1, wherein the vibration parameter extraction unit is further: And smoothing, interpolating and fitting the final displacement field, and then extracting the vibration characteristics of the molten pool by adopting Fourier transformation and wavelet transformation.

Description

Device for adding material to auxiliary consumable electrode arc of ultrasonic vibration wire Technical Field The invention relates to additive manufacturing, in particular to an ultrasonic arc additive manufacturing device. Background The arc additive manufacturing technology has become one of the important development directions in the metal manufacturing field because of the advantages of no need of a die, simple process flow, high forming efficiency and the like. The arc additive manufacturing (WIRE ARC ADDITIVE manufacturing, WAAM) technology is based on the concept of surfacing, takes an arc as a heat source and wires as filling materials, performs slicing treatment on a component by means of three-dimensional software, and forms the component according to a formulated path, and has the advantages of high forming efficiency, low cost, multiple applicable materials and capability of adding large and complex components. In addition, arc additive technology can be used for repairing metal components. The arc additive manufacturing opens a new idea for manufacturing parts, but at the same time, a plurality of problems such as poor flowability of a molten pool, uneven components of an additive component, coarse grains of the additive component, larger residual stress of the additive component, easiness in generating air holes of the additive component and the like exist in the arc additive manufacturing, and the problems not only influence the forming quality of the component, but also greatly weaken the mechanical property of the component and reduce the service life of the component. The most significant problem in arc additive is that the grains are easily coarse due to the fact that the arc can generate large heat input as a heat source, and the environment for arc additive manufacturing is in a room temperature environment, so that a molten pool can be subjected to rapid heating and rapid cooling, a large temperature gradient exists in the molten pool, and coarse columnar grains are formed in an additive forming component. It is known from the Hall-Petch law that the larger the grain size, the lower the yield strength and the poorer the mechanical properties of the component. Therefore, in order to obtain an additive member having good mechanical properties, the crystal grains of the member must be finely and uniformly distributed. This makes grain refinement an important issue in arc additive manufacturing. In recent years, many expert scholars at home and abroad achieve the purposes of grain refinement and pore reduction by combining other energy fields with electric arc additive, such as magnetic field, ultrasonic energy field, laser combination and the like. The invention relates to ultrasonic energy field and arc additive composition, so the ultrasonic energy field composition is mainly described below. The main mechanism of the ultrasonic energy field acting on the arc additive is that the ultrasonic wave can generate cavitation effect, acoustic flow effect, thermal effect and the like in a molten pool, and the effects can reduce the grain size, reduce the generation of air holes and reduce the residual stress. The ultrasonic vibration wire auxiliary consumable electrode arc additive manufacturing is a technology for realizing rapid forming of metal components by utilizing the composite action of an ultrasonic energy field and an electric arc energy field. At present, the ultrasonic-assisted arc additive manufacturing is mainly divided into two types, namely, ultrasonic vibration action is used on a substrate or a deposition layer, and ultrasonic vibration action is used on a wire or a molten pool. The former has disadvantages in that the range and intensity of ultrasonic vibration are affected by factors such as shape, size, thickness, surface roughness, etc. of the substrate or the deposition layer, and the direction of ultrasonic vibration is inconsistent with the moving direction of the molten pool, possibly resulting in uneven effect of the molten pool, while the latter has disadvantages in that the range and intensity of ultrasonic vibration are affected by factors such as diameter, material, feeding speed, etc. of the wire, and ultrasonic vibration may affect the conveyance of the wire and the transition of the molten drop. The ultrasonic device applies a certain pressure to bear on the deposition layer, but the surface of the deposition layer is not necessarily smooth and flat enough, so that ultrasonic energy loss is caused by overlarge friction. In summary, there are some technical difficulties in the prior art that need to be resolved. Disclosure of Invention The invention aims to provide a device for assisting melting electrode arc material increase by ultrasonic vibration wires, which aims to solve the problems in the prior art. Technical scheme, device of supplementary consumable electrode electric arc material adding of ultrasonic vibration wire includes: The wire feeding mechanis