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

目标：通过使用基于物理的过程动态建模实现搅拌摩擦焊缺陷的实时检测和识别

• 批准号: 1332738
• 负责人: Michael Zinn
• 金额: $ 37.49万
• 依托单位: University of Wisconsin-Madison
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2013
• 资助国家: 美国
• 起止时间: 2013-08-01 至 2017-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1332738&HistoricalAwards=false
• 关键词: GOALI; Enabling; Real; Time; Detection

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.

该奖项为学术界与工业界联系的赠款机会（GOALI）奖提供资金，用于研究和开发被称为搅拌摩擦焊的材料连接过程的实时缺陷检测方法。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干扰模型，通过结合过程级系统识别，使用计算和实验数据，以及系统级验证，包括实时原位缺陷检测能力的验证。该项目将研究整体缺陷检测方法的局限性和适用性，包括对缺陷尺寸和缺陷类型变化的敏感性评估，以及在存在非缺陷相关过程干扰的情况下该方法的稳健性评估。如果成功的话，实时焊接缺陷检测将通过减少或消除对昂贵的后处理检测工作的需求来大幅降低搅拌摩擦焊的总成本。此外，过程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其作为连接工艺的采用-提供广泛采用摩擦搅拌焊接和摩擦搅拌加工将带来的实质性经济，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综合的教育和研究环境，包括那些通过既定的大学奖学金计划代表性不足的群体，来加强培训和指导。