Fig. 1. Closed-loop control system of forming of eccentric ring structure
Fig. 2. Schematic of hollow laser beam internal powder feeding
Fig. 3. Thickness-variable ring. (a) Physical model; (b) light spots at different widths
Fig. 4. Schematic of point on circle
Fig. 5. Schematic of transition
Fig. 6. (a) Triangle relationship between lifting capacity and arc length; (b) triangle relationship between speeds
Fig. 7. Principle of self-healing
Fig. 8. Forming process of thickness-variable eccentric ring
Fig. 9. Height variation curves of segments. (a) No.1; (b) No.2; (c) No.3; (d) No.4; (e) No.5
Fig. 10. Thickness-variable eccentric ring after forming. (a) Top view; (b) front view
Fig. 11. SEM images at different positions marked in Fig.10. (a) ①; (b) ②; (c) ③
Segment number | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
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Defocusing D /mm | -8 | -7 | -6 | -5 | -4 | -4 | -5 | -6 | -7 | -8 | Laser power P /W | 1200 | 1050 | 920 | 780 | 650 | 650 | 780 | 920 | 1050 | 1200 | Expected width /mm | 6.25 | 5.55 | 4.65 | 3.50 | 2.50 | 2.50 | 3.50 | 4.65 | 5.55 | 6.25 | Scanning speed v /(mm·s-1) | 4 | 5 | 6 | 11 | 13 | 13 | 11 | 6 | 5 | 4 |
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Table 1. Initial parameter matching table
Segment No. | Scanning speed v /(mm·s-1) | Actual height /mm | Reference heighthr /mm | Total depositedheight error /mm |
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1 | 3.61680 | 29.1009 | 29.90 | -0.7991 | 2 | 4.44240 | 29.5128 | 29.90 | -0.3872 | 3 | 6.29560 | 29.9076 | 29.90 | 0.0076 | 4 | 11.76250 | 29.9621 | 29.90 | 0.0621 | 5 | 16.97500 | 29.1515 | 29.90 | -0.7485 | 6 | 13.91860 | 28.9230 | 29.90 | -0.9770 | 7 | 9.37676 | 29.1553 | 29.90 | -0.7447 | 8 | 5.58236 | 29.8236 | 29.90 | -0.0764 | 9 | 4.26298 | 29.8743 | 29.90 | -0.0257 | 10 | 4.00730 | 29.6005 | 29.90 | -0.2995 |
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Table 2. Parameters of each segment
Segment number | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
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Expected width /mm | 6.25 | 5.55 | 4.65 | 3.50 | 2.50 | 2.50 | 3.50 | 4.65 | 5.55 | 6.25 | Actual width /mm | 6.28 | 5.52 | 4.72 | 3.84 | 3.18 | 2.14 | 2.96 | 4.02 | 5.58 | 6.10 |
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Table 3. Width of each segment of eccentric ring