Digital Lifecycle Manufacturing / Laser Welding Applications Lab

项目描述：这个iCASE博士项目的范围是对6xxx高强度铝挤压件的RLW中焊缝裂纹的形成和扩展进行建模和模拟，并将这些模型与现有的传感器集成在一起，以便对RLW焊接件进行过程监控。在这个项目中，我们将通过物理驱动的CAE模拟来补充由进程内探测器收集并通过机器学习技术处理的传感器数据流。物理驱动的CAE模拟将结合有关激光与材料相互作用、凝固机制、热力学和材料微观结构的知识。此外，物理驱动的模拟方法也将在早期设计阶段作为一个独立的工具来支持焊接参数的选择，并对特定铝合金的裂纹敏感性做出更有信息的决定。该项目将开发6xxx高强度铝型材开裂机制建模和表征的新能力，项目成果将为以下方面提供信息：(1)焊接工艺参数的选择和优化；(2)焊缝裂纹的过程监测；(3)自适应闭环过程控制，最终实现焊缝无缺陷。iCASE项目的目标如下：(1)回顾现有的模型，用于焊接开裂机制的建模和预测(2)发展物理驱动CAE仿真(3)提出整合物理驱动CAE仿真和传感器数据流的策略(4)用相关材料（根据Constellium的输入选择合金和核心应用）验证和验证所提出的模型。符合EPSRC主题：该项目直接解决了ESPRC的主题“制造未来”。它还直接促进了ESPRC的研究领域，如制造技术和材料工程-金属和合金。

Project Description: The scope of this iCASE PhD project is to model and simulate the formation and propagation of weld cracks in RLW of 6xxx high strength aluminium extrusions and to integrate those models with readily available sensors in order to enable in-process monitoring of RLW weldments. During this project, we will complement sensor data streams, gathered by in-process detectors and processed via machine learning techniques, with physics-driven CAE simulation. The physics-driven CAE simulation will combine knowledge about the laser-to-material interaction, solidification mechanisms, thermo-dynamics and material microstructure. Besides, the physics-driven simulation approach will also be used as a standalone tool during the early design stages to support the selection of welding parameters and make a more informative decision about the crack sensitivity of specific aluminium alloys. This project will develop new capabilities for modelling and characterising cracking mechanisms in 6xxx high strength aluminium extrusions, and the outcomes of the project will inform: (1) selection and optimisation of welding process parameters; (2) in-process monitoring of weld cracks; (3) adaptive closed-loop process control, with the final aim to achieving defect-free welds.Project Summary and workplanObjectives of the iCASE program are as follows:(1) Review existing models for modelling and prediction of mechanisms of weld cracking(2) Development of physics-driven CAE simulation(3) Propose strategy for integrating physics-driven CAE simulation and sensor data streams(4) Verification and validation of proposed models with relevant materials (alloys and core applications to be selected based on Constellium's input).Fit to EPSRC Themes: The project directly addresses the ESPRC theme 'Manufacturing the Future'. It also directly contributes to ESPRC research areas such as Manufacturing Technologies and Materials Engineering - Metals and Alloys.