激光熔丝增材制造丝材过渡状态的电磁振动监测方法
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摘要
提出一种在线监测激光熔丝增材制造中微细丝材(1~2 mm)过渡状态的电磁振动监测方法,建立监测系统的数学模型并研制原型装置。通过设计试验,采用磁性以及非磁性微细丝材对监测系统的振动发生、信号采集等功能进行测试与验证,发现可获得强度显著大于环境噪声的稳定振动信号,证实了监测方法的可行性。基于该装置,开展了激光熔丝增材制造工艺中丝材过渡状态的监测试验研究。结果表明:滴状过渡时,成形中,基板接收到的振动信号低于环境噪声强度(约为-70 d B);而液桥过渡时,可获得清晰的振动信号(强度-67~-62 d B),高于环境噪声强度。综上,采用所研制的原型装置可清晰分辨滴状过渡与液桥过渡这两种典型的丝材过渡状态,能对激光熔丝增材制造工艺的丝材过渡状态进行有效监测。
An electromagnetic vibration(EMV) method is proposed to monitor the molten drop transition form of the fusing wire(1-2 mm) during Laser Additive Manufacturing(LAM).The theoretic and mathematical model of monitoring system is established and the new prototype device is developed.Two different kinds of wire(magnetic and nonmagnetic fine welding wires) are respectively utilized to test and verify the ability of the vibration excitation and signal collection of the monitoring system.The experimental results show that the proposed EMV method is available.Based on the developed device,the relations is investigated between the molten drop transition form of fusing wire and the strength difference of the vibration excitation signal and environmental noise signal.The results show that the strength difference of the vibration excitation signal is lower than that of the environmental noise signal(about-70 d B) in droplet transition form while the former(about-67-62 d B) is stronger than the latter in liquid bridge transition.The present work is useful to monitor the molten drop transition form of fusing wire in LAM.
An electromagnetic vibration(EMV) method is proposed to monitor the molten drop transition form of the fusing wire(1-2 mm) during Laser Additive Manufacturing(LAM).The theoretic and mathematical model of monitoring system is established and the new prototype device is developed.Two different kinds of wire(magnetic and nonmagnetic fine welding wires) are respectively utilized to test and verify the ability of the vibration excitation and signal collection of the monitoring system.The experimental results show that the proposed EMV method is available.Based on the developed device,the relations is investigated between the molten drop transition form of fusing wire and the strength difference of the vibration excitation signal and environmental noise signal.The results show that the strength difference of the vibration excitation signal is lower than that of the environmental noise signal(about-70 d B) in droplet transition form while the former(about-67-62 d B) is stronger than the latter in liquid bridge transition.The present work is useful to monitor the molten drop transition form of fusing wire in LAM.
引文
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[3]王华明.高性能大型金属构件激光增材制造:若干材料基础问题[J].航空学报,2014,35(10):2690-2698.WANG Huaming.Materials’fundamental issues of laser additive manufacturing for high-performance large metallic components[J].Acta Aeronautica et Astronautica Sinica,2014,35(10):2690-2698.
[4]张小伟.金属增材制造技术在航空发动机领域的应用[J].航空动力学报,2016,31(1):10-16.ZHANG Xiaowei.Application of metal additive manufacturing in aero-engine[J].Journal of Aerospace Power,2016,31(1):10-16.
[5]宋晓艳,邢金峰.双光子聚合3D打印[J].化工学报,2015,66(9):3324-3332.SONG Xiaoyan,XING Jinfeng.3D printing technology based on two-photon polymerization[J].CIESC Journal,2015,66(9):3324-3332.
[6]WANG Z,WANG H,LIU D.Microstructure and mechanical properties of AF1410 ultra-high strength steel using laser additive manufacture technique[J].Chinese Journal of Lasers,2016,43(4):0403001.
[7]CHEN H,GU D,GU R,et al.Microstructure evolution and mechanical properties of 5Cr Ni4Mo die steel parts by selective laser melting additive manufacturing[J].Chinese Journal of Lasers,2016,43(2):0203003.
[8]AGAPAKIS J E,BOLSTAD J.Vision-aided monitoring and control of thermal spray,spray forming,and welding processes[C/CD]//Technology 2002:The Third National Technology Transfer Conference and Exposition,Volume1,1993.
[9]SOKOLOWSKI W,HERZIGER G,BEYER E.Spectroscopic study of laser-induced plasma in the welding process of steel and aluminium[C]//1989 Intl Congress on Optical Science and Engineering.International Society for Optics and Photonics,1989:288-295.
[10]SHIMADA W,OHMINE M,HOSHINOUCHI S,et al.A study on in-process assessment of joint efficiency in the laser welding process[J].Fundamental and Practical Approaches to the Reliability of Welded Structures,1982,1:175-180.
[11]BLUG A,CARL D,H?FLER H,et al.Closed-loop control of laser power using the full penetration hole image feature in aluminum welding processes[J].Physics Procedia,2011,12:720-729.
[12]LI L,STEEN W,MODERN P.Melt pool behaviour detection and adaptive control of laser surface treatment through machine vision[C]//Proceedings of SPIE-The International Society for Optical Engineering,1994,2306(1):119-133.
[13]高会栋.电磁超声技术在焊缝检测中的应用[J].无损检测,2010,32(11):850-853.GAO Huidong.EMAT and its application in weld inspection[J].Non Destructive Testing,2010,32(11):850-853.
[14]JAFARI-SHAPOORABADI R,KONRAD A,SINCLAIR A N.Improved finite element method for EMAT analysis and design[J].IEEE Transactions on Magnetics,2001,37(4):2821-2823.
[15]李鹏,黄松岭,王珅,等.一种电磁超声检测用脉冲激励电源的研制[J].电测与仪表,2012,49(2):76-79.LI Peng,HUANG Songling,WANG Shen,et al.Development of a pulse exciting source for electromagnetic ultrasonic detection[J].Electrical Measurement&Instrumentation,2012,49(2):76-79.
[16]郝宽胜,黄松岭,赵伟,等.基于二阶矢量位的矩形截面回折线圈阻抗和脉冲磁场的解析建模与计算[J].物理学报,2011,60(7):791-800.HAO Kuansheng,HUANG Songling,ZHAO Wei,et al.Analytical modelling and calculation of impedance and pulsed magnetic field for rectangular meander coil based on second order potential[J].Acta Physica Sinica,2011,60(7):791-800.
[17]JIAN X,DIXON S,EDWARDS R S,et al.Coupling mechanism of an EMAT[J].Ultrasonics,2006,44:e653-e656.
[18]TIAN L,XU Z P,XIE S,et al.Experimental study of magnetostrictive ultrasonic guided wave for pipeline corrosion testing[J].Petro-Chemical Equipment,2015,44(6):16-21.
[19]胡广书.数字信号处理理论、算法和实现[M].北京:清华大学出版社,1997.HU Guangshu.Digital signal processing principles,algorithms,and realization[M].Beijing:Tsinghua University Press,1997.
[20]于润祥,石庚辰,隋丽,等.一种新型压电加速度传感器研究[J].北京理工大学学报,2014,34(3):273-276.YU Runxiang,SHI Gengchen,SUI Li,et al.A novel piezoelectric accelerometer with switch characteristic[J].Transactions of Beijing Institute of Technology,2014,34(3):273-276.