In this paper a system is presented that combines a robot off-line programming software with a finite element model that predicts temperature-time histories and residual stress distributions. The objective is to develop a tool for the engineer where robot trajectories and welding process parameters can be optimized on parts with complex geometry. The system was evaluated on a stainless steel gas turbine component. Robot weld paths were defined off-line and automatically downloaded to the finite element program, where transient temperatures and residual stresses were predicted. Temperature dependent properties and phase change, were included in the analysis. Assumptions and principles behind the modeling techniques are presented together with predicted temperature histories, residual stresses, and fixture forces.

The application of commercial software (OLP) packages for robot simulation, and programming, use interactive computer graphics, provide powerful tools for creating welding paths off-line. By the use of such software, problems of robot reach, accessibility, collision and timing can be eliminated during the planning stage. This paper describes how such software can be integrated with a numerical model that predicts temperature-time histories in the solid material. The objective of this integration is to develop a tool for the engineer where robot trajectories and process parameters can be optimized on parts with complex geometry. Such a tool would decrease the number of weld trials, increase productivity and reduce costs. Assumptions and principles behind the modeling techniques are presented together with experimental evaluation of the correlation between modeled and measured temperatures.

This paper describes the application of infrared (IR) thermal imaging and temperature measurements in welding applications, both on single plane plates and on an aero engine turbine component with complex geometry. Temperature profiles were measured on the plates using thermocouples (T/C) in combination with an IR camera system, and the results were compared. The IR camera was used both in line scan mode (270 Hz scan frequency) and in full frame mode (1 Hz frame rate). Different methods of surface treatments have been tested to handle the problem of the surface emissivity variations due to oxidation during welding. Results from measurements using thermocouples and IR camera is presented in the paper as well as temperature measurements using the IR camera on an turbine exhaust case (TEC) engine component.