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

该学术与工业联络机会 (GOALI) 奖项为研究和开发材料连接过程（称为搅拌摩擦焊）的实时缺陷检测方法提供资金。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，以显着提高检测的可靠性。该研究项目将通过结合使用计算和实验数据的过程级系统识别以及系统级验证（包括验证实时原位缺陷检测能力）来开发和验证基于物理的过程和缺陷扰动模型。该项目将研究整个缺陷检测方法的局限性和适用性，包括评估对缺陷尺寸和缺陷类型变化的敏感性，以及评估该方法在存在非缺陷相关过程干扰的情况下的稳健性。如果成功，实时焊接缺陷检测将减少或消除昂贵的后处理检查工作，从而大大降低搅拌摩擦焊的总成本。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固态搅拌摩擦焊工艺的理解。由此带来的成本降低和工艺理解的增加将有助于加速其作为一种连接工艺的采用——提供广泛采用搅拌摩擦焊和搅拌摩擦加工所带来的巨大的经济、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（包括通过已建立的大学奖学金计划属于代表性不足群体的研究人员）提供综合的教育和研究环境，重点关注培训和指导。

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.