激光沉积制造过程中, 单道沉积宽度主要受激光熔池宽度的制约, 稳定的熔池是保证成形精度的前提。为了建立工艺参数激光功率、扫描速度以及送粉速率与熔池尺寸之间的经验模型, 采用非匀速段关光控制及卡尔曼滤波技术对采集的熔池测量数据进行去噪处理, 以实现成形过程熔池宽度的精确检测, 为熔池宽度预测精度提供了保证。基于正交试验建立了多元回归模型, 其拟合优度可达94%, 最大误差不超过4.5%。经单一变量试验方法验证, 结果表明熔池宽度与激光功率呈正相关, 与扫描速度呈负相关, 实验结果与回归分析结果具有较好的一致性。

During laser deposition manufacturing process, the forming width of the single track is mainly controlled by the melt pool width. However, high geometric accuracy is premised on the stable size of the melt pool. In order to establish an empirical model described relationship between the melt pool width and main process parameters (laser power, scanning speed, and powder feeding rate), turn off laser control in uneven speed stage was used and Kalman filtering was applied to denoise the measured data of the melt pool width. An empirical model between the process parameters of laser deposition and the width of molten pool was established based on orthogonal experimental design with a goodness-of-fit of 94%, and the maximum error was less than 4.5%. The results of single variable experiments conducted to the model show that the melt pool width has a positive correlation to the laser power and a negative to the scanning speed. The experimental results were in good agreement with the regression analysis.