Torque-Based Temperature Control in Friction Stir Welding by Using a Digital Twin

Sigl, Martina E.; Bachmann, Andreas; Mair, Thomas; Zaeh, Michael F.

doi:10.3390/met10070914

Cited by 9 publications

(3 citation statements)

References 31 publications

(59 reference statements)

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“…The control algorithm was implemented in a real-time system (MicroLabBox, dSPACE GmbH, Paderborn, Germany). Further information regarding the research machine setup is given in [12].…”

Section: Methodsmentioning

confidence: 99%

Efficient Build-Up of High-Strength Aluminum Structures Using Friction Stir Additive Manufacturing

Sigl

Danninger

Bernauer

et al. 2022

KEM

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Friction Stir Additive Manufacturing (FSAM) is a novel process with which large-scale aluminum structures can be produced from high-strength alloys such as the 7xxx series. Due to the prevalence of these alloys in airplanes and rockets, the process offers high application potential, for example in fabricating stringers and stiffeners. The building process in FSAM is characterized by sequentially stacking and friction stir lap welding (FSLW) metal sheets. Before adding the next layer, the surface is machined (i.e., by milling). So far, this is a necessary step to enable gap-free welding of the layers, which results in increased costs and reduced layer heights. The investigations described in this paper were aimed at improving the weld surface quality to enable defect-free FSAM without the additional machining step. For this, FSLW was conducted using different welding tools. The resulting welds were evaluated based on superficial and internal characteristics as well as the mechanical properties (shear strength). With a welding tool in which both a rotating and a stationary shoulder were combined, defect-free weld seams with a mean underfill and a mean flash height of 0.07 mm were produced. In a subsequent study, it was proven that defect-free FSAM without surface machining is possible up to the fifth layer using the combined welding tool.

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“…The control algorithm was implemented in a real-time system (MicroLabBox, dSPACE GmbH, Paderborn, Germany). Further information regarding the research machine setup is given in [12].…”

Section: Methodsmentioning

confidence: 99%

Efficient Build-Up of High-Strength Aluminum Structures Using Friction Stir Additive Manufacturing

Sigl

Danninger

Bernauer

et al. 2022

KEM

Self Cite

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“…Chen et al [20] introduced a digital twin modeling approach for FSW using sensor-based numerical simulation, achieving the synchronization of the simulation and physical process with a high temporal precision for effective cyber-physical integration. Sigl et al [21] proposed a new welding temperature feedback system for the FSW process, using a digital twin and an adaptive controller. It demonstrates improved weld quality through experimental validation.…”

Section: Introductionmentioning

confidence: 99%

Digital Twin Virtual Welding Approach of Robotic Friction Stir Welding Based on Co-Simulation of FEA Model and Robotic Model

Chen,

Zong,

Kang

et al. 2024

Sensors

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Robotic friction stir welding has become an important research direction in friction stir welding technology. However, the low stiffness of serial industrial robots leads to substantial, difficult-to-measure end-effector deviations under the welding forces during the friction stir welding process, impacting the welding quality. To more effectively measure the deviations in the end-effector, this study introduces a digital twin model based on the five-dimensional digital twin theory. The model obtains the current data of the robot and six-axis force sensor and calculates the real-time end deviations using the robot model. Based on this, a virtual welding model was realized by integrating the FEA model with the digital twin model using a co-simulation approach. This model achieves pre-process simulation by iteratively cycling through the simulated force from the FEA model and the end displacement from the robot model. The virtual welding model effectively predicts the welding outcomes with a mere 6.9% error in lateral deviation compared to actual welding, demonstrating its potential in optimizing welding parameters and enhancing accuracy and quality. Employing digital twin models to monitor, simulate, and optimize the welding process can reduce risks, save costs, and improve efficiency, providing new perspectives for optimizing robotic friction stir welding processes.

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“…Afterwards (third step), the tool is retracted (retract speed vr), thereby leaving a characteristic negative imprint and flash on the surface. The process is highly automated and is typically monitored by using inline measured signals of the axial force Fz and the spindle torque Mz (process variables) [18][19][20]. A recent study [21] revealed the high potential of the process for cell-internal contacting.…”

Section: Introduction and State Of The Artmentioning

confidence: 99%

Cell-Internal Contacting of Prismatic Lithium-Ion Batteries Using Micro-Friction Stir Spot Welding

et al. 2022

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The reliable production of high-quality lithium-ion battery components still poses a challenge, which must be met to cope with their rising demand. One key step in the production sequence is the process of cell-internal contacting, during which the electrode carrier foils of the anode and the cathode are joined with the arrester. This is usually done with ultrasonic or laser beam welding. Both joining processes, however, show limitations concerning the quality of the weld. This paper presents a new approach for cell-internal contacting by using micro-friction stir spot welding. Welding experiments were conducted in which joints with high mechanical strengths were produced. It was also shown that large stacks with foil numbers of 100 can be joined in only a few tenths of a second. The process is therefore especially of interest for the fast production of large-scale battery cells or other new types of high-energy-dense battery cells.

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Torque-Based Temperature Control in Friction Stir Welding by Using a Digital Twin

Cited by 9 publications

References 31 publications

Efficient Build-Up of High-Strength Aluminum Structures Using Friction Stir Additive Manufacturing

Efficient Build-Up of High-Strength Aluminum Structures Using Friction Stir Additive Manufacturing

Digital Twin Virtual Welding Approach of Robotic Friction Stir Welding Based on Co-Simulation of FEA Model and Robotic Model

Cell-Internal Contacting of Prismatic Lithium-Ion Batteries Using Micro-Friction Stir Spot Welding

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