Sensing, modeling and control for laser-based additive manufacturing

Laser-Based Additive Manufacturing (LBAM) is a promising manufacturing technology that can be widely applied to part preparation, surface modification, and Solid Freeform Fabrication (SFF). A large number of parameters govern the LBAM process. These parameters are sensitive to the environmental variations, and they also influence each other. This paper introduces the research work in RCAM on improving the performance of the LBAM process. Metal powder delivery real-time sensing and control is studied to achieve a controllable powder delivery for fabrication of functionally graded material. A closed-loop control system based on infrared image sensing is built for control of the heat input and size of the molten pool in the LBAM process. The closed-loop control results show a great improvement in the geometrical accuracy of the built features. A three-dimensional finite element model is also established to explore the thermal behavior of the molten pool in the closed-loop controlled LBAM process.     

The significance of deposition point standoff variations in multiple-layer coaxial laser cladding (coaxial cladding standoff effects)

Direct laser deposition (DLD) is an additive manufacturing process that builds up a part layer-by-layer by fusing metal powder to a solid substrate. A coaxial laser and powder delivery head is commonly used, and here a critical process variable is the standoff distance between the nozzle and the material deposition point. This contribution investigates the role of this variable and the effect that it has on the final part geometry. The experimental results show that good layer consistency can, in fact, be obtained with no movement of the substrate between layers for more than 20 layers, or 10 mm under tested conditions, and that poorer results are obtained by regular movement of the substrate by a badly chosen constant amount. A theoretical analysis of the situation establishes a method to estimate melt pool size using an analytically calculated temperature near the heat source. Based on this, simple heat and mass flow models are established to allow some of the results to be explained.     

Development of theoretical process maps to study the role of powder preheating in laser cladding

Cladding is the process of depositing a superior built-up layer by fusion on a substrate. In blown powder laser cladding process, the powder travels across the laser path, gets heated up by absorbing laser energy, and finally melts on the substrate under the intense laser beam; as the substrate moves away this melt pool solidifies to form a continuous built-up layer. The laser energy is partly absorbed by the solid powder during its flight path (termed preheating) and partly by the top surface of the melt pool. In the present study a two-dimensional conduction heat transfer equation has been solved using finite-volume method to model the cladding process. It is observed that preheating allows higher scanning speed resulting in thin clad layer with low dilution. Preheating also permits high powder feed rate resulting in thick cladding with low dilution.     

Masonry Cladding Stress Failures in Older Buildings

Cracked and crumbling masonry cladding on older buildings in the urban environment is often clearly evident with just casual observations. Aside from the potential hazard of unstable masonry over busy city sidewalks, cladding distress leads to the accelerating decay of underlying wall elements. In order to effectively treat deteriorating masonry cladding, a clear understanding of the fundamental causes of failure is necessary. Much of this cladding trouble is caused by stress buildup due to an interaction between the massive exterior masonry walls and the interlaced structural frame, a design common to tall buildings constructed in the early 1900s. This paper reviews the mechanism of masonry cladding stress buildup in these older structures and some remedial measures which have proven effective.     

高层建筑玻璃幕墙设计方法评述

本文全面而系统地评述了高层建筑玻璃幕墙设计方法在国内外的研究进展情况，介绍了几种用于工程实践的实用设计方法，并对今后的研究工作提出建议。     

激光熔覆速率对熔覆层显微组织及耐磨性的影响研究

分别采用高速和常规的熔覆速率,进行了高硼不锈钢合金粉末的激光熔覆试验.试验结果表明,相同功率条件下,熔覆速率对组织的影响较大.熔覆速率越快,枝晶尺寸越细小.高速激光熔覆下,熔覆层晶粒尺寸可达1～2μm,且组织更均匀.高速激光熔覆制备的熔覆层中奥氏体含量偏高,从而熔覆层的耐磨性能有所下降.     

层状金属可控气氛保护热复合技术及设备研究

复合金属材料在国民经济中的应用越来越广泛,需求量也越来越多。为此,研究开发了可控气氛保护热复合(control atmosphere简称CA复合)生产线和相关技术,利用该技术可连续生产质量优良的成卷产品,具有良好的经济效益和发展前景。     

Lower limit law of welding windows for explosive welding of dissimilar metals

The influence of explosive charge thickness on the quality of explosive welding of dissimilar metals was in-vestigated.The lower limit law should be followed in the course of explosive welding.Three welding ex-periments of stainless steel (410S) and steel (Q345R) were carried out in three different kinds of explo-sive charge thicknesses, namely 15, 25 and 35 mm.Interfaces of morphology and mechanical properties of three samples were observed and tested.It was found that micro and small wavy bonding is mainly formed for charge thickness of 15 mm whose strength is the highest with minor deformation and few defects in the interface; small and middle wavy bonding are mainly formed for charge thickness of 25 mm whose strength is comparatively mediocre; big wavy bonding is mainly formed for charge thickness of 35 mm whose strength is the lowest.The cause of high bonding strength of the micro and small wavy interface was analyzed and verified on the basis of the results of Electron Probe Micro-Analyzer (EPMA) tests of three selected samples.     

激光熔覆成形预热基板设计及试验研究

为了降低激光熔覆成形过程中熔覆层热应力和减少裂纹的产生,以热传导理论和激光快速成形理论为依据,进行了预热基板的结构和控制设计;并进行了不同预热温度下单道熔覆和平面熔覆的试验研究.结果表明,通过智能PID控制器可对预热温度进行良好控制,通过热电偶温度采集模块可以实现对基板预热温度的连续、实时检测;在基板预热条件下进行激光熔覆成形可以显著改善试样的成形质量,并有效降低成形过程的热应力,减少了熔覆层裂纹的产生.     

Interaction of Zn and Zn–4Al,Zn–15Al (wt-%) solder alloys with aluminium

The interaction of pure zinc and Zn–4Al, Zn–15Al (wt-%) solder alloys with aluminium has been investigated. Two different experimental techniques were used: (i) the aluminium samples soldering and (ii) the holding of liquid solder alloys inside the hollow in an aluminium base. The aluminium content was determined in samples after contact with aluminium at various temperatures and various holding times. It is shown that in soldered seams and solder alloys that had been held inside the aluminium base, the content of the aluminium was higher than at the points on the liquidus line on the Zn–Al equilibrium phase diagram at the corresponding temperatures and increases along with an increase in the holding time. This was apparently due to isothermal solidification.