Welding bead modeling method for wire-arc additive manufacturing, device therefor and system therefor

Patent metadata

Field	Value
Publication number	US-12403540-B2
Application number	US-202017310905-A
Country	US
Kind code	B2
Filing date	Dec 23, 2020
Priority date	Dec 24, 2019
Publication date	Sep 2, 2025
Grant date	Sep 2, 2025

Abstract

A welding bead modeling method for wire-arc additive manufacturing, a device therefor and a system therefor including using a dynamic parameter method, and using different welding process parameters in the same welding bead in the a wire-arc additive manufacturing process to obtain a welding bead with synchronous and dynamic changes in profile along with the dynamic changes of the welding process parameters. The method further comprising using a line laser sensor for scanning to obtain the segmented profile of the processed welding bead, and corresponding each welding bead profile to the welding process parameters one by one to train the neural network as training data, so as to obtain a welding bead modeling model capable of obtaining the corresponding welding bead profile according to the input welding process parameters.

First claim

What is claimed is:

1. A welding bead modeling method for wire-arc additive manufacturing, wherein the method comprises an off-line training stage and an on-line modeling stage;
the off-line training stage comprises the steps of:
step 1:
using a dynamic parameter method, and using different welding process parameters in the same welding bead in the wire-arc additive manufacturing process to obtain a welding bead with synchronous and dynamic changes in profile along with the dynamic changes of the welding process parameters; wherein the welding process parameters comprise welding bead temperature, welding current, welding voltage, wire feeding speed and travelling speed; in the welding process, acquiring the temperature of the welding bead in real time by an infrared thermal imager;
using a line laser sensor for scanning to obtain the segmented profile of the welding bead obtained by the dynamic parameter method, and corresponding each welding bead profile to the welding process parameters one by one as training data; wherein the welding bead profile comprises a welding bead height and a welding bead width;
step 2: conducting model training
using welding process parameters as the input of neural network, using the welding bead profile corresponding to the input welding process parameters as the output of neural network, and training the neural network, so as to obtain a welding bead modeling model capable of obtaining the corresponding welding bead profile according to the input welding process parameters;
the on-line modeling stage comprises the steps of:
step 3, acquiring welding process parameters in real time in the wire-arc additive manufacturing process, and inputting the acquired welding process parameters into the welding bead modeling model obtained by off-line training in step 2 to obtain the welding bead profile.

2. The welding bead modeling method for wire-arc additive manufacturing according to claim 1 , wherein in step 1, the welding process parameters and the welding bead profile of the arc starting head and the arc extinguishing tail of the weld are ignored, and only the welding process parameters and the welding bead profile of a welding bead between the arc starting head and the arc extinguishing tail are acquired as valid data for model training in step 2.

3. The welding bead modeling method for wire-arc additive manufacturing according to claim 2 , wherein in step 1, the welding process parameters are dynamically changed from the arc starting point to the arc ending point in sections within the range of a welding bead between the arc starting head and the arc extinguishing tail, so as to obtain a large amount of valid training data through a welding test.

4. The welding bead modeling method for wire-arc additive manufacturing according to claim 1 , wherein in step 1, the welding voltage is automatically adjusted by a welding machine according to the welding current, and the temperature is passively changed with the change of the welding current in the welding process; the three parameters of travelling speed, wire feeding speed and welding current are dynamically and actively changed in a preset way.

5. A computer-readable storage medium, wherein a computer program is stored on the computer-readable storage medium, and the computer program, when executed by a processor, implements the method according to claim 1 .

6. A welding bead modeling device for wire-arc additive manufacturing, comprising the computer-readable storage medium according to claim 5 and a processor for calling and processing a computer program stored in the computer-readable storage medium.

7. A welding bead modeling system for wire-arc additive manufacturing, comprising an infrared thermal imager, a Hall sensor, a numerical control machine tool, a welding machine, a current sensor, a welding machine control board, a line laser scanner and the device according to claim 6 ;
wherein the infrared thermal imager is configured to acquire the temperature of the welding bead, the Hall sensor is configured to acquire the welding voltage, the numerical control machine tool is configured to control the travelling speed of the welding machine, the current sensor is configured to acquire the welding current, the welding machine control board is configured to control the wire feeding speed of the welding machine, and the line laser scanner is configured to scan the welding bead to obtain the welding bead profile.

8. The welding bead modeling method for wire-arc additive manufacturing according to claim 2 , wherein in step 1, the welding voltage is automatically adjusted by a welding machine according to the welding current, and the temperature is passively changed with the change of the welding current in the welding process; the three parameters of travelling speed, wire feeding speed and welding current are dynamically and actively changed in a preset way.

9. The welding bead modeling method for wire-arc additive manufacturing according to claim 3 , wherein in step 1, the welding voltage is automatically adjusted by a welding machine according to the welding current, and the temperature is passively changed with the change of the welding current in the welding process; the three parameters of travelling speed, wire feeding speed and welding current are dynamically and actively changed in a preset way.

10. The computer-readable storage medium according to claim 5 , wherein in step 1, the welding process parameters and the welding bead profile of the arc starting head and the arc extinguishing tail of the weld are ignored, and only the welding process parameters and the welding bead profile of a welding bead between the arc starting head and the arc extinguishing tail are acquired as valid data for model training in step 2.

11. The computer-readable storage medium according to claim 10 , wherein in step 1, the welding process parameters are dynamically changed from the arc starting point to the arc ending point in sections within the range of a welding bead between the arc starting head and the arc extinguishing tail, so as to obtain a large amount of valid training data through a welding test.

12. The computer-readable storage medium according to claim 5 , wherein in step 1, the welding voltage is automatically adjusted by a welding machine according to the welding current, and the temperature is passively changed with the change of the welding current in the welding process; the three parameters of travelling speed, wire feeding speed and welding current are dynamically and actively changed in a preset way.

13. The computer-readable storage medium according to claim 10 , wherein in step 1, the welding voltage is automatically adjusted by a welding machine according to the welding current, and the temperature is passively changed with the change of the welding current in the welding process; the three parameters of travelling speed, wire feeding speed and welding current are dynamically and actively changed in a preset way.

14. The computer-readable storage medium according to claim 11 , wherein in step 1, the welding voltage is automatically adjusted by a welding machine according to the welding current, and the temperature is passively changed with the change of the welding current in the welding process; the three parameters of travelling speed, wire feeding speed and welding current are dynamically and actively changed in a preset way.

15. The welding bead modeling device for wire-arc additive manufacturing according to claim 6 , wherein in step 1, the welding process parameters and the welding bead profile of the arc starting head and the arc ex

Assignees

• Univ Huazhong Science Tech

Inventors

• Zhang Hai'Ou
• Wang Guilan
• Tang Shangyong
• Zhou Siyu
• Li Runsheng

Classifications

• B23K9/0953 Primary

  using computing means · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B23K31/006

  relating to using of neural networks · CPC title

• B23K31/125

  Weld quality monitoring · CPC title

• B23K9/32

  Accessories · CPC title