In-process Material Evaluation of Welding and Additive Manufacturing

该项目与名为“迈向工业4.0：焊接和线材增材制造（IRWWAM）的过程修复”的五年计划中的关键成果直接一致，该计划与EEE和DMEM联合任命的斯特拉斯克clyde校长研究员共同任命的主要主管（Javadi博士）有关。这一雄心勃勃的计划的核心是机器人焊接和线弧增材制造（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仿真相结合时，该项目将提供一个采用工业4.0的系统，在该系统中，样品可以进行全面检查，重要的是，在制造过程中进行修复，如果系统认为有必要的话。现场测量系统还将与制造系统联系起来，以改进质量控制和创建闭环反馈系统。在IRWWAM框架内的制造将节省时间和能源（通常浪费在制造和检测站之间的反向传输中），因此对环境更好。主要计划与英国政府的新冠肺炎后恢复计划保持一致。该博士将专注于焊接和增材制造过程中材料演变的过程监测。超声工程中心（CUE）在建立多道次焊接的过程中检测时，证明了“过程中”评估的必要性[Javadi等人，Materials & Design, vol . 191, 2020]。然而，这并没有扩展到残余应力和材料评估，目前还没有无损检测方法来监测焊接和增材制造过程中的残余应力。本项目将考虑过程中残余应力和材料评估，研究中将涉及以下研究和技术活动：无损检测材料评估、有限元模拟、过程建模和验证、过程中检验、残余应力的过程测量和工业4.0。该项目将在新的工程学院设施“机器人传感（RES）”实验室进行，并将直接与CUE及其技术与创新中心（TIC）实验室内的NDE研究团队联系起来。通过CUE，该项目将补充Strathclyde目前与英国NDE研究中心（RCNDE）的合作。在由FUSE、FIND和Advanced Photonics主办的CDTs中，也将有培训和合作机会。

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.