Quality assessment of friction-stir-welded aluminum alloy welds via three-dimensional force signals

doi:10.1007/s40436-023-00452-2

Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (1): 61-75.doi: 10.1007/s40436-023-00452-2

• • 上一篇

Quality assessment of friction-stir-welded aluminum alloy welds via three-dimensional force signals

Ji-Hong Dong^1,2,3, Yi-Ming Huang⁴, Jia-Lei Zhu¹, Wei Guan⁴, Xu-Kai Ren⁵, Huan-Wei Yu⁵, Lei Cui⁴

1. Beijing Institute of Petrochemical Technology, Beijing, 102617, People's Republic of China;
2. Beijing Academy of Safety Engineering and Technology, Beijing, 102617, People's Republic of China;
3. AVIC Manufacturing Technology Institute, Beijing, 100024, People's Republic of China;
4. Tianjin Key Laboratory of Advanced Joining Technology, School of Materials Science and Engineering, Tianjin University, Tianjin, 300350, People's Republic of China;
5. Shaoxing Special Equipment Testing Institute, Shaoxing Key Laboratory of Special Equipment Intelligent Testing and Evaluation, Shaoxing, 312071, Zhejiang, People's Republic of China

收稿日期:2022-09-13 修回日期:2023-03-22 发布日期:2024-03-14
通讯作者: Yi-Ming Huang,E-mail:ymhuang26@tju.edu.cn;Lei Cui,E-mail:leicui@tju.edu.cn E-mail:ymhuang26@tju.edu.cn;leicui@tju.edu.cn;leicui@tju.edu.cn
作者简介:Ji-Hong Dong received his M.S. degree and Ph.D. degree in Materials Processing Engineering from Beijing University of Chemical Technology in 2009 and 2017, respectively. He has been with Beijing Academy of Safety Engineering and Technology from 2020 and currently as a professor level senior engineer. His research interests focus on friction stir welding process and additive manufacturing. He has undertaken several projects supported by National Defense Science and Industry Bureau of China;
Yi-Ming Huang received his B.S. degree and Ph.D. degree in Materials Processing Engineering from Jilin University and Shanghai Jiao Tong University, in 2011 and 2017, respectively. He has been with School of Materials Science and Engineering, Tianjin University since 2018, and currently as a associate professor. His research interests focus on welding process modeling, machine learning and defect detection. In addition, he commits to exploring the quality monitoring based on sensing signals in the welding process. So far, he has published more than forty research papers in international conferences and reputed journals as well as an academic monograph;
Jia-Lei Zhu received his Ph.D. degree in Materials Processing Engineering from Beijing University of Chemical Technology in 2010. He has been with Beijing Institute of Petrochemical Technology since 2005 and currently as a professor. His research interests focus on underwater welding process and additive manufacturing. He has undertaken several projects supported by National Science Foundation of China;
Wei Guan received his M.S. degree in Materials Processing Engineering from Nanjing University of Aeronautics and Astronautics in 2018. He is now working on his Ph.D. in Tianjin University. His research interests focus on friction stir welding process measurement and control;
Xu-Kai Ren received his M.S. degree and Ph.D. degree from Northeastern University and Shanghai Jiao Tong University, in 2017 and 2021, respectively. He has been working in Shaoxing Special Equipment Testing Institute. His main research fields are robotic intelligent grinding, welding quality control and intelligent welding equipment. So far, he has published several papers in reputed journals and fve patents;
Huan-Wei Yu received his Ph.D. degree from Shanghai Jiao Tong University in 2013. He is a senior engineer of Shaoxing Special Equipment Testing Institute. His main research fields are robotic intelligent welding, welding quality control. So far, he has published several papers in reputed journals and five patents;
Lei Cui received his Ph.D. degree in Materials Processing Engineering from Tianjin University in 2014. He has been with School of Materials Science and Engineering, Tianjin University since 2015, and currently as an associate professor. His research interests focus on advanced friction welding technology and equipment, welding structure performance and reliability. He has undertaken several projects supported by National Science Foundation of China.
基金资助:
This work was supported by the National Natural Science Foundation of China (Grant No. 52201048), the China Postdoctoral Science Foundation (Grant No. 2020M670651), and the National Natural Science Foundation of China (Grant No. 52075376).

Quality assessment of friction-stir-welded aluminum alloy welds via three-dimensional force signals

Ji-Hong Dong^1,2,3, Yi-Ming Huang⁴, Jia-Lei Zhu¹, Wei Guan⁴, Xu-Kai Ren⁵, Huan-Wei Yu⁵, Lei Cui⁴

1. Beijing Institute of Petrochemical Technology, Beijing, 102617, People's Republic of China;
2. Beijing Academy of Safety Engineering and Technology, Beijing, 102617, People's Republic of China;
3. AVIC Manufacturing Technology Institute, Beijing, 100024, People's Republic of China;
4. Tianjin Key Laboratory of Advanced Joining Technology, School of Materials Science and Engineering, Tianjin University, Tianjin, 300350, People's Republic of China;
5. Shaoxing Special Equipment Testing Institute, Shaoxing Key Laboratory of Special Equipment Intelligent Testing and Evaluation, Shaoxing, 312071, Zhejiang, People's Republic of China

Received:2022-09-13 Revised:2023-03-22 Published:2024-03-14
Contact: Yi-Ming Huang,E-mail:ymhuang26@tju.edu.cn;Lei Cui,E-mail:leicui@tju.edu.cn E-mail:ymhuang26@tju.edu.cn;leicui@tju.edu.cn;leicui@tju.edu.cn
Supported by:
This work was supported by the National Natural Science Foundation of China (Grant No. 52201048), the China Postdoctoral Science Foundation (Grant No. 2020M670651), and the National Natural Science Foundation of China (Grant No. 52075376).

摘要/Abstract

摘要： An online detection technology must be developed for realizing the real-time control of friction stir welding. In this study, the three-dimensional force exerted on a material during friction stir welding was collected synchronously and the relationship between the forces and welding quality was investigated. The results indicated that the fluctuation period of the traverse force was equal to that of the lateral force during the stable welding stage. The phase difference between two horizontal forces was π/2. The values of the horizontal forces increased with welding speed, whereas their amplitudes remained the same. The proposed force model showed that the traverse and lateral forces conformed to an elliptical curve, and this result was consistent with the behavior of the measured data. The variational mode decomposition was used to process the plunge force. The intrinsic mode function that represented the real fluctuation in the plunge force varied at the same frequency as the spindle rotational speed. When tunnel defects occurred, the fluctuation period features were consistent with those obtained during normal welding, whereas the ratio parameter defined in this study increased significantly.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00452-2

关键词: Friction stir welding (FSW), Three-dimensional force model, Variational mode decomposition, Tunnel defect

Abstract: An online detection technology must be developed for realizing the real-time control of friction stir welding. In this study, the three-dimensional force exerted on a material during friction stir welding was collected synchronously and the relationship between the forces and welding quality was investigated. The results indicated that the fluctuation period of the traverse force was equal to that of the lateral force during the stable welding stage. The phase difference between two horizontal forces was π/2. The values of the horizontal forces increased with welding speed, whereas their amplitudes remained the same. The proposed force model showed that the traverse and lateral forces conformed to an elliptical curve, and this result was consistent with the behavior of the measured data. The variational mode decomposition was used to process the plunge force. The intrinsic mode function that represented the real fluctuation in the plunge force varied at the same frequency as the spindle rotational speed. When tunnel defects occurred, the fluctuation period features were consistent with those obtained during normal welding, whereas the ratio parameter defined in this study increased significantly.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00452-2

Key words: Friction stir welding (FSW), Three-dimensional force model, Variational mode decomposition, Tunnel defect

Ji-Hong Dong, Yi-Ming Huang, Jia-Lei Zhu, Wei Guan, Xu-Kai Ren, Huan-Wei Yu, Lei Cui. Quality assessment of friction-stir-welded aluminum alloy welds via three-dimensional force signals[J]. Advances in Manufacturing, 2024, 12(1): 61-75.

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[1]	Hao Su, Chuan-Song Wu. Numerical simulation for the comparison of thermal and plastic material flow behavior between symmetrical and asymmetrical boundary conditions during friction stir welding[J]. Advances in Manufacturing, 2023, 11(1): 143-157.
[2]	M. Wasif Safeen, P. Russo Spena, G. Buffa, D. Campanella, A. Masnata, L. Fratini. Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications[J]. Advances in Manufacturing, 2020, 8(1): 59-71.

Quality assessment of friction-stir-welded aluminum alloy welds via three-dimensional force signals

Quality assessment of friction-stir-welded aluminum alloy welds via three-dimensional force signals

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