In-process Material Evaluation of Welding and Additive Manufacturing

该项目与五年计划“迈向工业4.0：焊接和线材增材制造（IRWWAM）的过程修复”中的一个关键成果直接一致，该计划与斯特拉斯克莱德校长奖学金的主要主管（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。主要计划与英国国家政府的后covid恢复计划一致。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，这并没有扩展到材料评估（重点是残余应力），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的材料评估，然后希望候选人熟悉（或热情学习）以下研究和技术活动：无损检测材料评估，残余应力，过程建模和验证，过程中检测和工业4.0。该项目将在新的工程学院设施“传感器自动化机器人与控制中心（SEARCH）实验室”中进行，并将直接与CUE内的NDE研究团队联系起来。通过这个项目的输出，有一个很好的机会来提高世界上第一个集成NDE（目前安装在AFRC的RoboWAAM单元）的自动化机器人AM设施的能力。因此，有一个明显的途径进入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大学目前的英国NDE研究中心（RCNDE）的研究，这将为RCNDE学术和工业成员提供合作机会。

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.