Propagation characteristics of ultrasonic weld-guided waves in Friction stir welding joint of same material

Welding is a major manufacturing process that joins two or more pieces of materials together through heating/mixing them followed by cooling/solidification. The goal of welding manufacturing is to join materials together to meet service requirements at lowest costs. Advanced welding manufacturing is to use scientific methods to realize this goal. This paper views advanced welding manufacturing as a three step approach: (1) pre-design that selects process and joint design based on available processes (properties, capabilities, and costs); (2) design that uses models to predict the result from a given set of welding parameters and minimizes a cost function for optimizing the welding parameters; (3) real-time sensing and control that overcome the deviations of welding conditions from their nominal ones used in optimizing the welding parameters by adjusting the welding parameters based on such real-time sensing and feedback control. The paper analyzes how these three steps depend on process properties/capabilities, process innovations, predictive models, numerical models for fluid dynamics, numerical models for structures, real-time sensing, and dynamic control. The paper also identifies the challenges in obtaining ideal solutions and reviews/analyzes the existing efforts toward better solutions. Special attention and analysis have been given to (1) gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) as benchmark processes for penetration and materials filling; (2) keyhole plasma arc welding (PAW), keyhole-tungsten inert gas (K-TIG), and keyhole laser welding as improved/capable penetrative processes; (3) friction stir welding (FSW) ......

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“…In Ref. [234], the propagation characteristics of ultrasonic weld-guided waves in FSW haves been comprehensively investigated.…”

Section: Sensing and Controlmentioning

confidence: 99%

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Zhang

Yang

Wei

et al. 2020

Journal of Manufacturing Science and Engineering

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“…with conventional point-by-point scanning of the ultrasonic detection method, the guided wave can detect a large waveguide structure workpiece as its sound field can spread over the entire structure and its attenuation is slow when it propagates over a long distance [4]. Thus, the guided wave is often used for long-distance and large-scale detection of typical waveguide structures such as plates, tubes, rods [5,6]. The guided waves in the plate (i.e.…”

Section: Introductionmentioning

confidence: 99%

Damage quantification of aluminum plates using SC-DTW method based on Lamb waves

Wei

Liu

Wang

et al. 2022

Meas. Sci. Technol.

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Lamb waves were utilized to quantify micro-crack damage in aluminum plates, and the scattering and mode conversion of Lamb waves passing through cracks were analyzed. The dynamic time warping (DWT) method was used to match and compare each Lamb wave time series that represented different damage degrees. The matching difference between the damaged plate and undamaged plate was taken as a marker to measure the damage degree of the workpiece. At the same time, due to the pathological alignment of traditional DTW methods, the shape context (SC) profile recognition method was introduced to optimize the algorithm for calculating the distance between sampling points in the DTW method and solve the pathological alignment problem. Finally, the SC-DTW method based on Lamb waves was verified by the finite element simulation model and bending test of aluminum plates. The results showed that the method was feasible for quantifying the damage degree of aluminum plates and had a great advantage in the analysis and processing of time series in low-sampling frequency and high-noise scenarios.

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“…Different types of lightweight sensor networks are permanently integrated on the surface or embedded within the structure to obtain information on load, deformation, and damage expansion of key structural regions. Many advanced SHM techniques have emerged, such as ultrasonic guided waves (Villegas, 2019;Wang et al, 2019), optical fiber gratings (Lau, 2014), vibration-based (Zhang et al, 2018), eddy current (Bohacova, 2013), acoustic emission (Michalcová and Růžek, 2016), and mechanical impedance (Min et al, 2012). However, most of these techniques are based on single-type sensors, which is difficult to meet the requirements of complex structure and multi-physical field monitoring.…”

Section: Introductionmentioning

confidence: 99%

Improved Kalman Filtering-Based Information Fusion for Crack Monitoring Using Piezoelectric-Fiber Hybrid Sensor Network

Wang

Sun

et al. 2020

Front. Mater.

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Multifunctional sensor network has become a research focus in the field of structural health monitoring. To improve the reliability and stability of the diagnosis results, it is necessary to fuse heterogeneous signals under the interference of the external load and damage. In this paper, a piezoelectric-fiber hybrid sensor network is integrated to monitor the crack growth around the hole in the aviation aluminum plate. The effect of the load change on the signals of piezoelectric transducers (PZTs) and optical fiber sensors is analyzed. To improve the damage diagnosis result obtained by ultrasonic guided wave imaging diagnosis based on PZTs and strain damage identification based on distributed optical fiber sensor, a fusion strategy of heterogeneous signals based on a two-stage Kalman filtering algorithm is proposed. In the first stage, the features extracted from two types of sensors are fused at a specific time at the feature level, and then the location of the damage center is predicted. Then, the second fusion is to fuse the predicted damage location results at multiple specific times at the decision level. Crack growth monitoring experiments in hot spots of metallic material under bending moment loading is carried out to verify the feasibility of the proposed fusion method. The experimental results indicate that the fusion damage diagnosis results are more stable, moreover, the accuracy of damage location and quantification is improved than the single signal diagnosis results.

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Propagation characteristics of ultrasonic weld-guided waves in Friction stir welding joint of same material

Cited by 17 publications

References 32 publications

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Damage quantification of aluminum plates using SC-DTW method based on Lamb waves

Improved Kalman Filtering-Based Information Fusion for Crack Monitoring Using Piezoelectric-Fiber Hybrid Sensor Network

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