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

传统上，制造部件的3D打印和焊接以及这些接头的质量控制检查在供应链中是截然不同的过程，这最终限制了生产率、吞吐量并增加了返工。通过新颖的传感器、自动化、机器人和控制技术，这些实践可以直接在制造点结合起来，实现卓越的全球高效制造。本提案旨在研究实时超声检测高价值工业部件的潜力，主要是实质性厚度和复杂的几何形状。为了实现这一总体目标，需要对超声波传感器的设计和自动化部署进行根本性的逐步改变，研究机器人交付、部件和换能器温度限制、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，这些工业部门在制造和资产修改/维修时很容易包含安全关键的熔焊-（核能，航空航天，石油和天然气，船舶，国防和一般高价值制造）。它还具有电弧金属“3D打印”增材制造（电线和电弧增材制造（WAAM））的交叉适用性，这在大面积/批量制造中越来越多地应用于行业。该项目将广泛使用结构测试创新和研究设施，学生将有机会使用行业领先的硬件和软件，包括价值130万英镑的新型自动化机器人、传感和焊接设备。该学生将在一个国际知名且不断壮大的团队中工作，该团队由多元化和多学科的研究人员、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，花时间在现场工作，以获得对熔焊过程中自动化检测的特定工业挑战和机会的更大的认识。此外，学生将有机会参加并承担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.