Cluster: novel quantitative nondestructive quality evaluation of advanced joining and consolidation manufacturing processes

该项目的重点是开发新的非破坏性定量质量表征材料接头，包括接头质量的真实的时间监测，这是非常重要的控制可靠的材料接头的形成。焊接件或涂层/基体结构等连接材料之间的冶金结合强度在很大程度上取决于界面的微观结构和质量。对于不同类型的材料接头，结合机制的性质可以显著变化，并且包括机械互锁、扩散结合、熔化/固化以及其他化学和物理结合机制。由于材料接头的结合强度与界面的质量直接相关，因此界面的表征对于及时调整材料接头形成过程的工艺参数变得至关重要，并且因此允许提高工艺过程效率。从这个观点出发，表达材料接缝的表征 对于焊接和涂层技术的工业用户来说，质量是最重要的，因为它能够快速控制产品，从而满足先进的制造需求。在材料连接的快速表征方法中，超声无损评价（NDE）是公认的领导者。拟议项目的总体目标是开发超声无损检测方法和用于定量材料连接质量评价的便携式系统，并将其应用于两种材料连接技术：（i）低压冷喷涂形成的复合涂层/基底结构（ii）钢、铝和异种金属的电阻点焊成形接头（将开发过程中超声波监测系统）。 开发的材料粘接技术和粘接质量评估设备将在项目工业合作伙伴指定的地点进行试验。

The project is focused on the development of new non-destructive quantitative quality characterization of material joints, including real time monitoring of joint quality, which is very important for controlling the formation of reliable material joints. The strength of metallurgical bonding between joint materials such as a weldment or coating/substrate structure greatly depends on the microstructure and quality of the interface. The nature of the bonding mechanism may considerably vary for different types of material joints and includes mechanical interlocking, diffusion bonding, melting/solidification, and other chemical and physical bonding mechanisms. Since bonding strength of material joints directly correlates with the quality of the interface, the characterization of the interface becomes critical for the timely adjustment of the technological parameters of the material joint forming process, and, thus, allows for the improvement of the technological process efficiency. From this viewpoint, express characterization of material joints quality is of primary importance to the industrial users of welding and coating technologies, since it enables rapid control of the product and, therefore, answers advanced manufacturing needs. Among methods for express characterization of material joints, ultrasonic non-destructive evaluation (NDE) is a proven leader.The overall goal of the proposed project is the development of ultrasonic nondestructive testing methodology and portable systems for quantitative material bond quality evaluation, and the application of these to two material bonding technologies:(i) Low Pressure Cold Spray-formed composite coating/substrate structures (hand-held ultrasonic rapid evaluation device will be developed) and (ii) Resistance Spot Weld-formed joints of steel, aluminum and dissimilar metals (in-process ultrasonic monitoring system will be developed). Both the developed material bonding technologies and the bond quality evaluation devices will be trialed at sites designated by the project industrial partners.