Development of a Collaborative Robot (COBOT) for Increased Welding Productivity and Quality in the Shipyard

2015 ◽  
Author(s):  
Jerald E. Jones ◽  
Valerie L. Rhoades ◽  
Jamie Beard ◽  
Radford M. Arner ◽  
James R. Dydo ◽  
...  
Keyword(s):  
Automobile Industry ◽  
Welding Speed ◽  
Welding Process ◽  
Robot Programming ◽  
Automated Systems ◽  
Shipbuilding Industry ◽  
New Approach ◽  
Human In The Loop ◽  
Collaborative Robot ◽  
Welding Productivity

The future of welding for shipbuilding is increasing automation. As quality and productivity requirements continue to increase, automated systems will be required to meet those demands. What processes cannot be automated will require more highly skilled welders. Today, the shipbuilding industry depends heavily on manual welders. The nature of shipbuilding is that much of the welding, is done to produce relatively small number of ships – compared to, for example, the automobile industry. Robot programming is difficult and expensive, particularly for the welding process. By amortizing that cost over tens of thousands of automobiles, that industry can afford to use welding robots. Recently, a new approach to robotics is being developed – Collaborative Robots, also known as COBOT’s which are designed to work alongside humans. A feasibility study has been completed to develop a welding COBOT, specifically for shipbuilding. The study has shown that this human-in-the-loop mobile welding COBOT can be successful in remotely producing welds, increasing the welding speed of a skilled welder, and not requiring scaffolding to produce the weld.

scholarly journals Prediction of Bead Geometry with Changing Welding Speed Using Artificial Neural Network

Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1494
Author(s):  
Ran Li ◽  
Manshu Dong ◽  
Hongming Gao
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Welding Speed ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Training Dataset ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Bead Width ◽  
Artificial Neural

Bead size and shape are important considerations for industry design and quality detection. It is hard to deduce an appropriate mathematical model for predicting the bead geometry in a continually changing welding process due to the complex interrelationship between different welding parameters and the actual bead. In this paper, an artificial neural network model for predicting the bead geometry with changing welding speed was developed. The experiment was performed by a welding robot in gas metal arc welding process. The welding speed was stochastically changed during the welding process. By transient response tests, it was indicated that the changing welding speed had a spatial influence on bead geometry, which ranged from 10 mm backward to 22 mm forward with certain welding parameters. For this study, the input parameters of model were the spatial welding speed sequence, and the output parameters were bead width and reinforcement. The bead geometry was recognized by polynomial fitting of the profile coordinates, as measured by a structured laser light sensor. The results showed that the model with the structure of 33-6-2 had achieved high accuracy in both the training dataset and test dataset, which were 99% and 96%, respectively.

Fatigue Behaviour of Friction Stir Welded Steel Joints

2014 ◽  
Vol 891-892 ◽  
pp. 1488-1493 ◽  
Author(s):  
José Azevedo ◽  
Virgínia Infante ◽  
Luisa Quintino ◽  
Jorge dos Santos
Keyword(s):  
Base Material ◽  
Welding Process ◽  
Steel Structures ◽  
Fatigue Behaviour ◽  
Fatigue Tests ◽  
Fatigue Properties ◽  
Welded Steel ◽  
Shipbuilding Industry ◽  
Friction Stir ◽  
Steel Joints

The development and application of friction stir welding (FSW) technology in steel structures in the shipbuilding industry provide an effective tool of achieving superior joint integrity especially where reliability and damage tolerance are of major concerns. Since the shipbuilding components are inevitably subjected to dynamic or cyclic stresses in services, the fatigue properties of the friction stir welded joints must be properly evaluated to ensure the safety and longevity. This research intends to fulfill a clear knowledge gap that exists nowadays and, as such, it is dedicated to the study of welded steel shipbuilding joints in GL-A36 steel, with 4 mm thick. The fatigue resistance of base material and four plates in as-welded condition (using several different parameters, tools and pre-welding conditions) were investigated. The joints culminate globally with defect-free welds, from which tensile, microhardness, and fatigue analyses were performed. The fatigue tests were carried out with a constant amplitude loading, a stress ratio of R=0.1 and frequency between 100 and 120 Hz. The experimental results show the quality of the welding process applied to steel GL-A36 which is reflected in the mechanical properties of joints tested.

scholarly journals Investigations on force generation and joint properties of dissimilar thickness friction stir corner welded AA 5086 alloy

2020 ◽  
Vol 40 (1) ◽  
pp. 67-74
Author(s):  
Manigandan Krishnan ◽  
Senthilkumar Subramaniam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Welding Process ◽  
Spindle Motor ◽  
Parent Material ◽  
Force Generation ◽  
Friction Stir ◽  
Current Consumption ◽  
Spindle Motor Current

The force generation, joint mechanical and metallurgical properties of friction stir corner welded non-heat treatable AA 5086 aluminum alloy are investigated in this paper. The friction stir welding process is carried out with the plate thicknesses of 6 mm and 4 mm. The welding speed, tool rotational speed and tool plunge depth were considered as the process parameters to conduct the welding experiments. The machine spindle motor current consumption and tool down force generation during friction stir welding were analyzed. The microstructures of various joint regions were observed. The tensile samples revealed the tensile strength of 197 MPa with tool rotational and welding speeds of 1,000 rev/min and 150 mm/min respectively, which is 78 % of parent material tensile strength. A maximum micro hardness of 98 HV was observed at thermomechanically joint affected zone, which was welded with tool rotation of 1,000 rev/min and welding speed of 190 mm/min.

scholarly journals Welding Process Optimization of WELDOX960 High Strength Steel

2018 ◽  
Vol 207 ◽  
pp. 04005
Author(s):  
Min Hu
Keyword(s):  
Penetration Depth ◽  
Process Optimization ◽  
Process Parameters ◽  
Welding Speed ◽  
High Strength Steel ◽  
Welding Process ◽  
Welding Current ◽  
High Strength ◽  
Influence Of Process Parameters ◽  
Steel Analysis

This paper studies WELDOX960 high strength steel, analysis of the welding ability of WELDOX960 high strength steel. Analyze the weld ability of WELDOX960 high-strength steel materials, and study the influence of process parameters such as welding current, welding voltage, and welding speed on penetration depth and weld width in the automated welding process. Through this test, the welding process is optimized to ensure the weld quality. The results show that WELDOX960 high-strength steel adopts multi-layer and multi-pass welding to form better welds.

Study on Electron Beam Welding of AZ61 Magnesium Alloy

2010 ◽  
Vol 34-35 ◽  
pp. 1516-1520
Author(s):  
Hong Ye ◽  
Han Li Yang ◽  
Zhong Lin Yan
Keyword(s):  
Electron Beam ◽  
Magnesium Alloys ◽  
Welding Speed ◽  
Electron Beam Welding ◽  
Weld Zone ◽  
Welding Process ◽  
Processing Parameters ◽  
Beam Current ◽  
Fine Grained ◽  
Section Shape

Electron beam welding process of AZ61 with 10mm thickness magnesium alloys was investigated. The influence of processing parameters including focusing current, welding beam current and welding speed was researched. The results show that an ideal weld bead can be formed by choosing processing parameters properly. Focusing current is main parameter that determines cross section shape. The beam current and welding speed are main parameters that determine the weld width and dimensions. The test results for typical welds indicate that the microhardness of the weld zone is better than that of the base meta1. A fine-grained weld region has been observed and no obvious heat-affected zone is found. The fusion zone mainly consists of small α-Mg phase and β-Mg17A112. The small grains and β phases in the joint are believed to play an important role in the increase of the strength of weld for AZ61 magnesium alloys.

scholarly journals Experimental and Numerical Analysis on TIG Arc Welding of Stainless Steel Using RSM Approach

Metals ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1659
Author(s):  
Sasan Sattarpanah Karganroudi ◽  
Mahmoud Moradi ◽  
Milad Aghaee Attar ◽  
Seyed Alireza Rasouli ◽  
Majid Ghoreishi ◽  
...  
Keyword(s):  
Heat Flux ◽  
Stainless Steel ◽  
Welding Speed ◽  
Arc Welding ◽  
Welding Process ◽  
Weld Bead ◽  
Bead Geometry ◽  
Depth Of Penetration ◽  
Weld Bead Geometry ◽  
Bead Width

This study involves the validating of thermal analysis during TIG Arc welding of 1.4418 steel using finite element analyses (FEA) with experimental approaches. 3D heat transfer simulation of 1.4418 stainless steel TIG arc welding is implemented using ABAQUS software (6.14, ABAQUS Inc., Johnston, RI, USA), based on non-uniform Goldak’s Gaussian heat flux distribution, using additional DFLUX subroutine written in the FORTRAN (Formula Translation). The influences of the arc current and welding speed on the heat flux density, weld bead geometry, and temperature distribution at the transverse direction are analyzed by response surface methodology (RSM). Validating numerical simulation with experimental dimensions of weld bead geometry consists of width and depth of penetration with an average of 10% deviation has been performed. Results reveal that the suggested numerical model would be appropriate for the TIG arc welding process. According to the results, as the welding speed increases, the residence time of arc shortens correspondingly, bead width and depth of penetration decrease subsequently, whilst simultaneously, the current has the reverse effect. Finally, multi-objective optimization of the process is applied by Derringer’s desirability technique to achieve the proper weld. The optimum condition is obtained with 2.7 mm/s scanning speed and 120 A current to achieve full penetration weld with minimum fusion zone (FZ) and heat-affected zone (HAZ) width.

scholarly journals Study of Laser Welding of HCT600X Dual Phase Steels

2014 ◽  
Vol 22 (1) ◽  
pp. 93-98
Author(s):  
Pavol Švec ◽  
Viliam Hrnčiar ◽  
Alexander Schrek
Keyword(s):  
Tensile Strength ◽  
Base Metal ◽  
Heat Affected Zone ◽  
Welding Speed ◽  
Welding Process ◽  
Beam Power ◽  
Welding Parameters ◽  
Dual Phase ◽  
Welded Steel ◽  
Steel Sheets

AbstractThe effects of beam power and welding speed on microstructure, microhardnes and tensile strength of HCT600X laser welded steel sheets were evaluated. The welding parameters influenced both the width and the microstructure of the fusion zone and heat affected zone. The welding process has no effect on tensile strength of joints which achieved the strength of base metal and all joints fractured in the base metal.

Enhancements on dissimilar friction stir welding between AZ31 and SPHC mild steel with Al-Mg as powder additives

2021 ◽  
pp. 1-22
Author(s):  
Mohd Ridha Muhamad ◽  
Sufian Raja ◽  
Mohd Fadzil Jamaludin ◽  
Farazila Yusof ◽  
Yoshiaki Morisada ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Welding Speed ◽  
Welded Joint ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Interface

Abstract Dissimilar materials joining between AZ31 magnesium alloy and SPHC mild steel with Al-Mg powder additives were successfully produced by friction stir welding process. Al-Mg powder additives were set in a gap between AZ31 and SPHC specimen's butt prior to welding. The experiments were performed for different weight percentages of Al-Mg powder additives at welding speeds of 25 mm/min, 50 mm/min and 100 mm/min with a constant tool rotational speed of 500 rpm. The effect of powder additives and welding speed on tensile strength, microhardness, characterization across welding interface and fracture morphology were investigated. Tensile test results showed significant enhancement of tensile strength of 150 MPa for 10% Al and Mg (balance) powder additives welded joint as compared to the tensile strength of 125 MPa obtained for welded joint without powder additives. The loss of aluminium in the alloy is compensated by Al-Mg powder addition during welding under a suitable heat input condition identified by varying welding speeds. Microstructural analysis revealed that the Al-Mg powder was well mixed and dispersed at the interface of the joint at a welding speed of 50 mm/min. Intermetallic compound detected in the welding interface contributed to the welding strength.

Experimental Analysis of Repair Welding Alternatives for Shipbuilding DH36 Plates

2020 ◽  
Vol 64 (04) ◽  
pp. 384-391
Author(s):  
Tetyana Gurova ◽  
Segen F. Estefen ◽  
Anatoli Leontiev ◽  
Plinio T. Barbosa ◽  
Valentin Zhukov ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Best Practice ◽  
Welding Process ◽  
Offshore Structures ◽  
Residual Stress Distribution ◽  
Shipbuilding Industry ◽  
Repair Welding ◽  
Ship Construction ◽  
Repair Techniques

Repair by welding is widely used in the shipbuilding industry during ship construction. The effect of the residual stress distribution induced by the welding process on the ship structure is important for the repair effectiveness. This article presents an experimental study of the residual stress distribution induced by repair welding in the plates that are typically used in ships and offshore structures. Different repair techniques are evaluated to identify the best practice associated with residual stress values. Recommendations for repair welding are discussed, and modifications to the present practice are proposed.

Experimental Investigation on Laser Transmission Welding of Polycarbonate and Acrylic

2021 ◽  
pp. 160-180
Author(s):  
Dhiraj Kumar ◽  
Sudipta Paitandi ◽  
Arunanshu Shekhar Kuar ◽  
Dipankar Bose
Keyword(s):  
Mathematical Model ◽  
Process Parameters ◽  
Welding Speed ◽  
Laser Power ◽  
Optimum Parameter ◽  
Optimization Technique ◽  
Welding Process ◽  
Parameter Setting ◽  
Laser Transmission Welding ◽  
Weld Width

This chapter presents the effect of various process parameters, namely laser power, pulse frequency, and welding speed, on the weld shear strength and weld width using a diode laser system. Here, laser transmission welding of transparent polycarbonate and black carbon filled acrylic each of 2.8 mm thickness have been performed to create lap joint by using low power laser. Response surface methodology is applied to develop the mathematical model between the laser welding process parameters and the responses of weld joint. The developed mathematical model is tested for its adequacy using analysis of variance and other adequacy measures. It has been observed that laser power and welding speed are the dominant factor followed by frequency. A confirmation test has also been conducted to validate the experimental results at optimum parameter setting. Results show that weld strength of 34.3173 N/mm and weld width of 2.61547 mm have been achieved at optimum parameter setting using desirability function-based optimization technique.

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