چکیده
Laser cladding deposition technology, as an important branch of additive manufacturing, offers advantages such as the ability to manufacture macroscopic structures and microscopic organizations simultaneously, create parts with complex features, process refractory metal materials, and form gradient materials. However, it faces challenges such as high production costs, low manufacturing efficiency, lower precision, and the need for support when creating cantilever structures. To address these challenges, laser cladding deposition combined with machining hybrid manufacturing technology has emerged. This article reviews the development of this technology both domestically and internationally, highlighting that foreign research in equipment and process technology is more advanced, while domestic research remains relatively limited. This paper focuses on the first domestic five-axis additive-subtractive hybrid manufacturing equipment developed by Xi’an Jiaotong University. This equipment integrates metal part manufacturing, processing, and repair functions, providing a platform for researching key technologies in laser cladding deposition and machining hybrid processes. Key technologies include extracting the three-dimensional features of complex parts, dividing substructures using Boolean operations to generate additive paths, rationally arranging additive and subtractive processes based on substructures, and utilizing five-axis linkage to seamlessly switch between additive and subtractive forming processes. The paper further outlines the difficulties and challenges faced by this technology, such as the need to develop dual-station five-axis hybrid equipment, feature recognition layering software, path planning and process simulation software, optimizing typical part processes, and establishing standards. Finally, the article explores the future application prospects of this technology in industries such as aerospace.

Introduction
Laser cladding deposition technology, a critical component of additive manufacturing, has gained attention due to its versatility in creating complex parts, forming gradient materials, and processing difficult-to-machine metals. However, it also faces significant limitations related to high production costs, low efficiency, and challenges in precision, especially for complex geometries. These limitations have spurred the development of laser cladding deposition combined with machining (hybrid manufacturing) technology, which seeks to integrate the advantages of both techniques to overcome these challenges.

Development Status of Laser Cladding Deposition and Machining Hybrid Manufacturing Technology

International Development
Internationally, laser cladding technology has seen extensive research and development, particularly in the areas of equipment and process optimization. Countries like the United States and Germany have led advancements in hybrid manufacturing systems that combine laser cladding and subtractive machining, resulting in high-precision, efficient systems that can handle complex part geometries. These systems enable the production of near-net shape parts with enhanced material properties, which are essential for applications in high-performance industries such as aerospace and defense.

Domestic Development
In China, research on laser cladding deposition technology and its integration with machining is still in its early stages compared to international developments. However, Xi’an Jiaotong University has made significant strides by developing the first domestic five-axis additive-subtractive hybrid manufacturing system. This cutting-edge equipment allows for the manufacturing, processing, and repair of metal parts using both laser cladding deposition and traditional machining processes, offering a versatile solution for complex part fabrication and repair.

Key Technologies and Innovations

Xi’an Jiaotong University’s hybrid system incorporates several key technological advancements:

Three-Dimensional Feature Extraction: Complex parts are analyzed and divided into substructures using Boolean operations to generate appropriate additive paths.

Additive and Subtractive Process Integration: Subtractive machining paths are generated based on the remaining material from the additive deposition, allowing seamless integration of both processes to achieve optimal precision.

Five-Axis Linkage: This advanced feature enables the equipment to freely switch between additive deposition and subtractive machining, offering greater flexibility in manufacturing and repair operations.

Challenges and Difficulties
Despite the promising advancements in hybrid manufacturing, several challenges remain:

Development of dual-station five-axis hybrid equipment to enhance production efficiency.

Creation of feature recognition and layering software for complex parts to automate process planning.

Path planning and process simulation software to optimize manufacturing steps and reduce the chance of errors.

Standardization of the hybrid manufacturing process to ensure consistent quality and performance in mass production.

Future Outlook and Application in High-End Manufacturing

Looking ahead, laser cladding deposition and machining hybrid manufacturing technology holds great potential, particularly in high-end manufacturing sectors such as aerospace and defense. Key developments should focus on:

Improving Precision and Efficiency: Further optimization of the synergistic control strategies between laser cladding and machining processes will be crucial to enhancing the overall precision and efficiency of hybrid manufacturing systems.

Software Development: The development of specialized software for feature recognition, path planning, and process simulation will help streamline the manufacturing process and enable greater automation.

Industry-Specific Applications: Testing and standardizing manufacturing processes for typical parts in industries like aerospace will accelerate the adoption of this technology. Establishing industry standards will further promote the widespread use of laser cladding deposition and machining hybrid manufacturing technology.

نتیجه‌گیری
Laser cladding deposition combined with machining hybrid manufacturing technology represents a significant step forward in the field of additive manufacturing. By integrating laser cladding with subtractive processes, this hybrid technology can overcome many of the challenges faced by traditional additive manufacturing techniques, including precision, material efficiency, and cost-effectiveness. With continued research and development, particularly in the creation of new software tools and equipment, the future of this technology looks promising, especially for applications in high-performance sectors such as aerospace and defense.