In-process Material Evaluation of Welding and Additive Manufacturing

该项目直接与5年计划中的一个关键交付成果保持一致，该计划题为“迈向工业4.0：焊接和线材增材制造的过程中修复（IRWWAM）”，与斯特拉斯克莱德校长的初级主管奖学金（Javadi博士）相关。该雄心勃勃的计划的核心是机器人焊接和电弧增材制造（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，该项目将提供一个采用工业4.0的系统，在该系统中，样品可以在制造过程中进行全面检查，重要的是，如果系统认为有必要，可以进行维修。现场测量系统还将与制造系统连接，以改善质量控制并创建闭环反馈系统。IRWWAM框架内的制造将节省时间和能源（通常在制造和检测站之间的反向传输中浪费），因此对环境更有利。主要计划与英国政府的COVID后复苏计划保持一致。该博士学位将专注于焊接和增材制造过程中材料演变的过程监测。当为多道焊接建立过程中检查时，超声工程中心（CUE）已经证明了“过程中”评估的必要性[Javadi等人，材料与设计，第191卷，2020年]。然而，这并没有扩展到材料评估（重点是残余应力），目前还没有NDT方法来监测焊接和增材制造过程中的残余应力。过程中的材料评估将被考虑在这个项目中，然后希望候选人熟悉（或热心学习）以下研究和技术活动：NDE材料评估、残余应力、工艺建模和验证，该项目将基于新的工程学院设施“传感器启用自动化机器人与控制中心"（实验室，并将直接与无损检测研究小组在CUE内运作。有一个很好的机会，以提高世界上第一个自动化机器人AM设施的能力与综合无损检测（RoboWAAM细胞目前安装在AFRC）通过该项目的输出。因此，有一个明显的路线进入AFRC，轻型制造中心（LMC）和苏格兰国家制造研究所（NMIS）的活动和工业网络。通过CUE，该项目将补充斯特拉斯克莱德目前的英国无损检测研究中心（RCNDE）的研究，这将提供机会，在RCNDE学术和工业会员合作。

This project aligns directly with one key deliverable 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 Fellowship for the primary supervisor (Dr Javadi). The core of this ambitions 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's 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 material evaluation (with the focus on the residual stress) and there is currently no NDT method to monitor the residual stress during the welding and additive manufacturing. The in-process material evaluation will be considered in this project and it is then desired that the candidate is familiar with (or enthusiastic to learn) the following research and technical activities: NDE material evaluation, residual stress, process modelling and verification, in-process inspection and Industry 4.0.This project will be based in the new Faculty of Engineering facility "Sensor Enabled Automation Robotics & Control Hub (SEARCH) laboratory and will link directly with the NDE research team operating within the CUE. There is an excellent opportunity to enhance the capabilities of the world's first automated robotic AM facility with integrated NDE (RoboWAAM cell currently installed at AFRC) through the output of this project. Hence, there is an obvious route into the AFRC, Lightweight Manufacturing Centre (LMC) and National Manufacturing Institute Scotland (NMIS) activities and industrial network. Through CUE, the project will complement Strathclyde's current The UK Research Centre in NDE (RCNDE) research, which will offer opportunities to collaborate within the RCNDE academic and industrial membership.