Optimization of dilution rate of laser cladding repair based on deep learning
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ORIGINAL ARTICLE
Optimization of dilution rate of laser cladding repair based on deep learning Shichao Zhu 1 & Wenliang Chen 1 & Xiaohong Zhan 2 & Liping Ding 1 & Erhua Wang 3 Received: 6 April 2020 / Accepted: 17 August 2020 / Published online: 24 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract During the laser cladding repair, the heat accumulation effect is produced due to the continuous input of energy, which leads to the increase of dilution rate under the same process parameters. In order to get the appropriate dilution rate, an accurate finite element model was established based on the experiment, and the variation of dilution rates under different power functions was analyzed. According to the results of finite element analysis, different power functions and dilution rates at different times were collected, and the dilution rate was optimized through deep learning, and the ideal power function was obtained. The results show that the dilution rate of the whole cladding layer fluctuates around the ideal value all the time by adjusting the laser power in real time, and the results are satisfactory. The maximum error of dilution rate is 21.75%, the minimum error is 0, and the average error is 5.79%. Keywords Invar alloy . Dilution rate . Deep learning . Finite element analysis
1 Introduction The LCR (laser cladding repair) is an advanced additive fabricating technology. The laser beam shines on and melts the particles and the surface of the substrate, fusing them together. The laser beam, as a heat source, melts the powder particles as they are ejected out of the nozzle, and creates a molten pool on the substrate. The fusion and diffusion leave an excellent metallurgical bonding between the cladding layer and the substrate [1–3]. The LCR exhibits many advantages: less heat input, smaller heat-affected zone (HAZ), lower thermal deformation and dilution rate, fast cooling rate, excellent * Shichao Zhu [email protected] * Liping Ding [email protected] 1
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, People’s Republic of China
2
College of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 211106, People’s Republic of China
3
Changzhou College of Information Technology, Changzhou 213164, People’s Republic of China
metallurgical bond between the cladding layer and substrate, perfect mechanical properties, high-precision geometrical characteristics of cladding layer, and facilitation in automation contrasting with the traditional welding procedure [4, 5]. Hence, the marvelous idea is to provide various powder particles over the damaged surfaces to return to desired size and shape [6–8]. So, the LCR can be employed for a good many of parts, varying from oil and gas, aerospace, automobile, defense, mould, and nuclear industries. The extensive use of the Invar alloy mould can create a myriad of problems in the aviation manufacturing: such as shrinking, undercutting
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