In-process Material Evaluation of Welding and Additive Manufacturing

该项目与题为“迈向工业4.0：焊接和电线添加剂制造的过程中维修(IRWWAM)”的五年计划中的主要成果直接一致，该五年计划与Strathclyde总理共同任命EEE和DMEM为主要主管(博士贾瓦迪博士)有关。这项雄心勃勃的计划的核心是机器人焊接和焊丝电弧添加剂制造(WAAM)中的全自动无损评估(NDE)，其中三个主要研究主题是：(I)过程中缺陷检测，(Ii)过程中残余应力测量和(Iii)过程中材料评估。当这三个核心研究主题与过程建模和模拟相结合时，该项目将提供一个Industry 4.0采用的系统，在该系统中，样品可以进行全面检查，重要的是，如果系统认为有必要，还可以在制造过程中进行修复。现场测量系统还将与制造系统连接，以改进质量控制和建立闭环反馈系统。IRWWAM框架内的制造将节省时间和能源(通常浪费在制造和检查站之间的反向传输中)，因此对环境更有利。然后，主要计划与英国国家政府的COVID后恢复计划保持一致。该博士将专注于焊接和添加剂制造过程中材料演变的过程监控。超声工程中心(CUE)在为多道焊接建立了过程中检查时，证明了“过程中”评估的必要性[贾瓦迪等人，材料与设计，第191卷，2020]。然而，这并没有扩展到残余应力和材料评价，目前还没有无损检测方法来监测焊接和添加剂制造过程中的残余应力。该项目将考虑过程中的残余应力和材料评估，并将涉及以下研究和技术活动：NDE材料评估、有限元模拟、过程建模和验证、过程中检测、过程中的残余应力测量和工业4.0。该项目将基于新的工程学院设施“机器人使能传感(RES)”实验室，并将与在CUE及其技术与创新中心(TIC)实验室内运作的无损检测研究团队直接联系。通过CUE，该项目将补充Strathclyde目前与英国研究中心在NDE(RCNDE)研究方面的合作。与FUSE、FIND和Advanced Photonics共同主办的CDTS还将提供培训和合作机会。

This project aligns directly with the key deliverables in the 5-year plan entitled "Towards Industry 4.0: In-process Repair of Welding and Wire Additive Manufacturing (IRWWAM)" associated with the Strathclyde Chancellor's Fellow joint appointment between the EEE and DMEM for the primary supervisor (Dr Javadi). The core of this ambitious plan is fully automated Non-Destructive Evaluation (NDE) in robotic welding and Wire Arc Additive Manufacturing (WAAM), where the three main research themes are: (I) in-process defect detection, (II) in-process residual stress measurement and (III) in-process material evaluation. When these three core research themes are coupled with process modelling and simulation, the project will deliver an Industry 4.0 adopted system in which the sample can be fully inspected and importantly, repaired during the manufacturing process, if deemed necessary by the system. The in-situ measurement systems will be also linked to the manufacturing system for improving the quality control and creation of a closed-loop feedback system. Manufacturing within the IRWWAM framework will save time and energy (which is usually wasted in backward transmissions between the manufacturing and inspection stations) and hence will be better for the environment. The main plan is then in line with the national UK government post-COVID recovery plan.This PhD will focus on the in-process monitoring of the material evolution during welding and additive manufacturing. The necessity of "in-process" evaluation has been justified by the Centre for Ultrasonic Engineering (CUE) when the in-process inspection was established for the multi-pass welding [Javadi et al, Materials & Design, Volume 191, 2020]. However, this was not extended to the residual stress and material evaluation and there is currently no NDT method to monitor the residual stress during the welding and additive manufacturing. The in-process residual stress and material evaluation will be considered in this project and the following research and technical activities shall be involved in the studies: NDE material evaluation, finite element simulation, process modelling and verification, in-process inspection, in-process measurement of the residual stress, and Industry 4.0.The project will be based in the new Faculty of Engineering facility "Robotically Enabled Sensing (RES)" laboratory and will link directly with the NDE research team operating within CUE and its Technology & Innovation Centre (TIC) laboratories. Through CUE, the project will complement Strathclyde's current collaboration with The UK Research Centre in NDE (RCNDE) research. There will also be both training and collaboration opportunities within the CDTs hosted with FUSE, FIND and Advanced Photonics.