Automated robotic in-process inspection of 3D printed & welded metal components

传统上，制造部件的3D打印和焊接以及此类接头的质量控制检查是供应链中截然不同的过程，这最终限制了生产率，吞吐量并增加了返工。通过新的传感器、自动化、机器人和控制技术，这些技术可以在制造点直接结合起来，实现全球上级高效制造。该提案旨在研究高价值工业部件的实时超声检测的潜力，这些部件主要具有相当大的厚度和复杂的几何形状。为了实现这一总体目标，需要在超声波传感器设计和部署方面进行根本性的改变，以实现自动化，研究机器人交付，零件和传感器温度限制，声学耦合，最小缺陷尺寸以及整体检测精度。该提案与许多工业部门直接相关，这些部门在制造和资产改造/维修时容易包含安全关键熔焊-（核，航空航天，石油和天然气，海洋，国防和一般高价值制造）。它还具有对基于电弧的金属“3D打印”增材制造（Wire & Arc Additive Manufacturing（WAAM））的跨领域适用性，这些增材制造在大面积/体积制造中的行业应用越来越多。该项目将广泛利用结构测试创新和研究设施，学生将获得行业领先的硬件和软件，包括价值超过130万英镑的新型自动化机器人，传感和焊接设备。学生将在一个国际知名的和不断增长的团队中工作，该团队由多样化和多学科的研究人员和工程师，物理学家和数学家组成，并将有机会与行业合作伙伴合作，并花时间在现场工作，以更好地了解特定的工业挑战和机遇。此外，学生将有机会参加，并进行一些行业领先的机器人检测和软件培训课程。

Traditionally 3D printing and welding of manufactured components and quality control inspection of such joints are distinctly separate processes in the supply chain, which ultimately limits productivity, throughput and increases re-work. The opportunity exists, through novel sensors, automation, robotics and control techniques to allow these practices to be combined directly at the point of manufacture for superior globally efficient fabrication. This proposal seeks to investigate the potential for real-time ultrasonic inspection of high-value industrial components predominately of substantial thickness and complex geometry. To achieve this overarching aim requires a fundamental step-change in ultrasonic sensor design and deployment for automation, investigating robotic delivery, part and transducer temperature limits, acoustic coupling, minimum defect sizing and therefore overall inspection accuracy. The proposal is directly relevant to the many industrial sectors who readily encompass safety critical fusion welds at point of manufacture and asset modification/repair - (Nuclear, Aerospace, Oil & Gas, Marine, Defence & general High Value Manufacturing). It also has cross-cutting applicability to arc-based metal "3D printing" additive manufacturing (Wire & Arc Additive Manufacture (WAAM)) which are seeing increasing industry uptake in large area/volume fabrications. The project will make extensive use of the Facility for Innovation and Research in Structural Testing and the student will have access to industry leading hardware and software including new automated robotic, sensing and welding equipment worth > £1.3 Million. The student will work within an internationally renowned and growing team of diverse and multi-disciplinary researchers and engineers, physicists and mathematicians and will have the opportunity to work in collaboration and spend time on-site working with industry partners to gain a greater appreciation of the specific industrial challenges and opportunity for automated inspection during fusion welding. Additionally, the student will have the opportunity to attend, and undertake a number of industry-leading robotic inspection and software training courses.