GOALI: Enabling Real-Time Detection and Identification of Friction Stir Welding Defects Through the Use of Physics-Based Process Dynamic Modeling

这项学术与工业联系机会(GOALI)奖为研究和开发一种材料连接过程的实时缺陷检测方法提供资金，这种方法称为搅拌摩擦焊接。缺陷检测方法将使用基于物理的过程和缺陷动态建模来过滤或调节实时过程测量，以显著提高检测的可靠性。该研究项目将开发和验证基于物理的过程和缺陷扰动模型，方法是使用计算和实验数据进行过程级系统识别，以及系统级验证，包括实时就地缺陷检测能力的验证。该项目将调查整体缺陷检测方法的局限性和适用性，以包括对缺陷大小和缺陷类型变化的敏感性的评估，以及在存在非缺陷相关工艺干扰的情况下对该方法的稳健性的评估。如果成功，实时焊接缺陷检测将通过减少或消除昂贵的后处理检查工作，大大降低搅拌摩擦焊接的总成本。此外，工艺和缺陷形成模型的开发和验证将提高我们对复杂的固态搅拌摩擦焊接过程的理解。由此产生的成本降低和工艺理解的增加将有助于加速将其作为连接工艺采用，从而提供广泛采用搅拌摩擦焊接和搅拌摩擦加工将带来的显著的经济、环境和节能优势。最后，该项目将通过为研究生和本科生研究人员提供一个综合的教育和研究环境，包括那些通过现有的大学奖学金计划在代表性不足的群体中的研究人员，来加强培训和指导工作。

This Grant Opportunities for Academic Liaison with Industry (GOALI) award provides funding for the investigation and development of a real-time defect detection approach for the material joining process known as friction stir welding. The defect detection approach will use physics-based process and defect dynamic modeling to filter or condition real-time process measurements to significantly improve the reliability of detection. The research project will develop and validate the physics-based process and defect disturbance models through a combination of process-level system identification, using both computational and experimental data, and system level validation, including verification of real-time in-situ defect detection capabilities. The project will investigate the limitations and applicability of the overall defect detection approach to include the evaluation of the sensitivity to variations in defect size and defect type and the evaluation of the robustness of the approach in the presence of non-defect related process disturbances. If successful, real-time weld defect detection would substantially reduce the total cost of friction stir welding by reducing or eliminating the need for costly post-process inspection work. In addition, the development and validation of process and defect formation models will improve our understanding of the complex solid-state friction stir welding process. The resulting reduction in cost and increase in process understanding would help accelerate its adoption as a joining process - providing the substantial economic, environmental, and energy conservation advantages that wide-spread adoption of friction stir welding and friction stir processing would bring. Finally, the project will have a strong training and mentoring focus by providing an integrated educational and research environment for graduate and undergraduate student researchers - including those in underrepresented groups through established University fellowship programs.