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  • 1.
    Asala, G.
    et al.
    University of Manitoba, Winnipeg, R3T 5V6, Canada .
    Andersson, Joel
    University West, Department of Engineering Science, Division of Mechanical Engineering.
    Ojo, Olanrewaj A.
    University of Manitoba, Winnipeg, R3T 5V6, Canada .
    Precipitation behavior of gamma′ precipitates in the fusion zone of TIG welded ATI 718Plus®2016In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 87, no 9-12, p. 2721-2729Article in journal (Refereed)
    Abstract [en]

    The precipitation behavior of the main strengthening phase, γ′ precipitates, in ATI 718Plus® superalloy after Tungsten Inert Gas (TIG) welding and postweld heat treatments has been studied. In contrast to electron beam welding, where no γ′ precipitates are reported to form in the as-welded condition, analytical transmission electron microscopy study in this work revealed the formation of γ′ precipitates after the TIG welding, albeit in a non-uniform distribution manner. This is attributable to a more extensive elemental microsegregation that occurred into the interdendritic liquid and slower cooling rate during the TIG welding, which also induced the formation of interdendritic Nb-rich Laves phase particles and MC-type carbides. Theoretical calculations were performed to study the influence of Nb microsegregation, on both the kinetics and extent of γ′ precipitation, and the results agree with experimental observations. It is found that the precipitation kinetics, and not the extent of γ′ precipitate formation in the fusion zone, during postweld heat treatments is affected by the micro-segregation of Nb that produced Laves phase particles during the weld solidification.

  • 2.
    Asala, Gbenga
    et al.
    University of Manitoba, Department of Mechanical Engineering, Winnipeg, R3T 5V6, Canada.
    Andersson, Joel
    University West, Department of Engineering Science, Division of Welding Technology.
    Ojo, Olanrewaj A.
    University of Manitoba, Department of Mechanical Engineering, Winnipeg, R3T 5V6, Canada.
    Analysis and constitutive modelling of high strain rate deformation behaviour of wire-arc additive-manufactured ATI 718Plus superalloy2019In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 103, no 1-4, p. 1419-1431Article in journal (Refereed)
    Abstract [en]

    A fundamental prerequisite for obtaining realistic finite element simulation of machining processes, which has become a key machinability assessment for metals and alloys, is the establishment of a reliable material model. To obtain the constitutive model for wire-arc additive-manufactured ATI 718Plus, Hopkinson pressure bar is used to characterise the flow stress of the alloy over a wide range of temperatures and strain rates. Experiment results show that the deformation behaviours of as-deposited ATI 718Plus superalloy are influenced by the applied strain rate, test temperature and strain. Post-deformation microstructures show localised deformation within the deposit, which is attributable to the heterogeneous distribution of the strengthening precipitates in as-deposited ATI 718Plus. Furthermore, cracks are observed to be preferentially initiated at the brittle eutectic solidification constituents within the localised band. Constitutive models, based on the strain-compensated Arrhenius-type model and the modified Johnson-Cook model, are developed for the deposit based on experimental data. Standard statistical parameters, correlation coefficient (R), root-mean-square error (RMSE) and average absolute relative error (AARE) are used to assess the reliability of the models. The results show that the modified Johnson-Cook model has better reliability in predicting the dynamic flow stress of wire-arc-deposited ATI 718Plus superalloy. © 2019, Springer-Verlag London Ltd., part of Springer Nature.

  • 3.
    da Silva, Leandro João
    et al.
    SENAI Innovation Institute for Manufacturing Systems and Laser Processing, Joinville, SC, Brazil (BRA); Federal University of Uberlândia (UFU), Laprosolda – Center for Research and Development of Welding,Processes, Uberlandia, MG, Brazil (BRA).
    Souza, Danielle Monteiro
    Federal University of Uberlândia (UFU), Laprosolda – Center for Research and Development of Welding,Processes, Uberlandia, MG, Brazil (BRA).
    de Araújo, Douglas Bezerra
    Federal University of Uberlândia (UFU), Laprosolda – Center for Research and Development of Welding,Processes, Uberlandia, MG, Brazil (BRA).
    Reis, Ruham Pablo
    Federal University of Uberlândia (UFU), Laprosolda – Center for Research and Development of Welding,Processes, Uberlandia, MG, Brazil (BRA).
    Scotti, Americo
    University West, Department of Engineering Science, Division of Welding Technology. Federal University of Uberlândia (UFU), Laprosolda – Center for Research and Development of Welding,Processes, Uberlandia, MG, Brazil (BRA).
    Concept and validation of an active cooling technique to mitigate heat accumulation in WAAM2020In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 107, no 5-6, p. 2513-2523Article in journal (Refereed)
    Abstract [en]

    This work aimed at introducing and exploring the potential of a thermal management technique, named as near-immersion active cooling (NIAC), to mitigate heat accumulation in Wire + Arc Additive Manufacturing (WAAM). According to this technique concept, the preform is deposited inside a work tank that is filled with water, whose level rises while the metal layers are deposited. For validation of the NIAC technique, Al5Mg single-pass multi-layer linear walls were deposited by the CMT® process under different thermal management approaches. During depositions, the temperature history of the preforms was measured. Porosity was assessed as a means of analyzing the potential negative effect of the water cooling in the NIAC technique. The preform geometry and mechanical properties were also assessed. The results showed that the NIAC technique was efficient to mitigate heat accumulation in WAAM of aluminum. The temperature of the preforms was kept low independently of its height. There was no measurable increase in porosity with the water cooling. In addition, the wall width was virtually constant, and the anisotropy of mechanical properties tends to be reduced, characterizing a preform quality improvement. Thus, the NIAC technique offers an efficient and low-cost thermal management approach to mitigate heat accumulation in WAAM and, consequently, also to cope with the deleterious issues related to such emerging alternative of additive manufacturing.

  • 4.
    De Backer, Jeroen
    et al.
    University West, Department of Engineering Science, Division of Automation and Computer Engineering.
    Bolmsjö, Gunnar
    University West, Department of Engineering Science, Division of Automation and Computer Engineering.
    Christiansson, Anna-Karin
    University West, Department of Engineering Science, Division of Automation and Computer Engineering.
    Temperature control of robotic friction stir welding using the thermoelectric effect2014In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 70, no 1-4, p. 375-383Article in journal (Refereed)
    Abstract [en]

    Friction stir welding (FSW) of non-linear joints receives an increasing interest from several industrial sectors like automotive, urban transport and aerospace. A force-controlled robot is particularly suitable for welding complex geometries in lightweight alloys. However, complex geometries including three-dimensional joints, non-constant thicknesses and heat sinks such as clamps cause varying heat dissipation in the welded product. This will lead to changes in the process temperature and hence an unstable FSW process with varying mechanical properties. Furthermore, overheating can lead to a meltdown, causing the tool to sink down into the workpiece. This paper describes a temperature controller that modifies the spindle speed to maintain a constant welding temperature. A newly developed temperature measurement method is used which is able to measure the average tool temperature without the need for thermocouples inside the tool. The method is used to control both the plunging and welding operation. The developments presented here are applied to a robotic FSW system and can be directly implemented in a production setting.

  • 5.
    dos Santos Paes, Luiz Eduardo
    et al.
    Federal University of Santa Catarina, Department of Mechanical Engineering, Laboratory of Precision Engineering, Laser Division (LMP-Laser), Florianópolis, Brazil (BRA).
    Pereira, Milton
    Federal University of Santa Catarina, Department of Mechanical Engineering, Laboratory of Precision Engineering, Laser Division (LMP-Laser), Florianópolis, Brazil (BRA).
    Weingaertner, Walter Lindolfo
    Federal University of Santa Catarina, Department of Mechanical Engineering, Laboratory of Precision Engineering, Laser Division (LMP-Laser), Florianópolis, Brazil (BRA).
    Scotti, Americo
    University West, Department of Engineering Science, Division of Welding Technology. Federal University of Uberlandia, Center for Research and Development of Welding Processes (Laprosolda), Uberlândia Brazil (BRA).
    Souza, Tiago
    Federal University of Santa Catarina, Department of Mechanical Engineering, Laboratory of Precision Engineering, Laser Division (LMP-Laser), Florianópolis, Brazil (BRA).
    Comparison of methods to correlate input parameters with depth of penetration in LASER welding2019In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 101, no 5-8, p. 1157-1169Article in journal (Refereed)
    Abstract [en]

    Despite the industrial relevance of LASER welding, determination of sustainable parameterization is still a challenge. Trial and error, or even not totally justified methodologies, are frequently applied on LASER welding parametrization. This approach potentially leads to a decrease of the process tolerance and, consequently, increasing the likelihood of imperfections, which means extra operational time and raising of the final cost. The present paper addresses a comparative discussion about five factors experimentally determined and frequently used to predict depth of penetration in LASER welding. The experiments were performed with a 10-kW fiber LASER. In a first batch, power was varied while welding speed was fixed at 1 m/min. In a second batch, welding speed was varied and power was kept at 10 kW. The first demonstrated concern on using these popular factors is the definition and quantification of LASER energy. For evidencing this aspect, two samples were processed with the same welding energy of 120 kJ/m, yet resulting in completely different penetrations. Eventually, an empirical model based on power as a factor allowed a more reliable prediction of the depth of penetration.

  • 6.
    Ericson Öberg, Anna
    et al.
    Chalmers, Gothenburg, Sweden.
    Åstrand, Erik
    University West, Department of Engineering Science, Research Enviroment Production Technology West. Volvo Construct Equipment, Braås, Sweden.
    Improved productivity by reduced variation in gas metal arc welding (GMAW)2017In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 92, no 1-4, p. 1027-1038Article in journal (Refereed)
    Abstract [en]

    The purpose of the research conducted is to describe the consequences of variation in the welding industry and the effect it has on manufacturing productivity. The potential has shown to be hidden in unnecessarily stringent requirements and over-processing. This has been studied in steps: customer requirements, design and analysis, preparation, welding, and assessment. The effect of variation in each step has been analyzed including estimations of its productivity improvement potential. Theoretically, in a perfect situation, with customized requirements and eliminated variation, more than half of all welding could be removed. Such a reduction is certainly neither practical nor possible. However, a sensible, controlled reduction could still have a very high impact. The financial implications are therefore substantial. The improved productivity of the manufacturing resources could be used for business development and increased production. To be able to realize the potential, interdisciplinary efforts are necessary. Management across different functions need to agree on the intended product life and make decisions thereafter.

  • 7.
    Eriksson, Kristina M.
    et al.
    University West, Department of Engineering Science, Division of Production Systems.
    Carlsson, Linnea
    University West, School of Business, Economics and IT, Divison of Informatics.
    Olsson, Anna Karin
    University West, School of Business, Economics and IT, Division of Business Administration.
    To digitalize or not? Navigating and merging human: and technology perspectives in production planning and control2022In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015Article in journal (Refereed)
    Abstract [en]

    Contemporary manufacturing companies are navigating industrial digitalization anticipating increased production efciency and competitiveness in a volatile environment. This study focuses on the implementation processes of digital tools for production planning and control (PPC), i.e., advanced planning and scheduling (APS) software, in relation to the application of analog planning with physical fow boards. Digital tools can support understanding the consequences of production changes and variations, hence facilitating adaptable and resilient manufacturing. However, technological changes can be daunting, and efective implementations require dynamic capabilities to remain competitive in elusive environments. The aim is to study the implementation processes of an APS software to understand the requirements of fruitfully moving from analog planning to next-generation digital tools for decision support in PPC. The paper presents an explorative case study, at a manufacturing company within the energy sector. The interview study took place over 9 months during 2020–2021, investigating current and retrospective aspects of the case across 2019–2021. The case study comprises 17 in-depth interviews with a range of company employees, e.g., logistics managers and functions responsible for digitalization development. The results highlight the challenges of implementing and especially trusting digital tools for PPC. To realize the value of digital tools for PPC, it is argued that it is imperative to simultaneously apply a human-centric perspective in decision making to ensure trustworthy, sustainable, and resilient human-data-technology nexus implementations towards smart manufacturing

  • 8.
    Glorieux, Emile
    et al.
    University West, Department of Engineering Science, Division of Automation Systems.
    Danielsson, Fredrik
    University West, Department of Engineering Science, Division of Automation Systems.
    Svensson, Bo
    University West, Department of Engineering Science, Division of Automation Systems.
    Lennartson, Bengt
    University West, Department of Engineering Science, Division of Automation Systems. University West, Department of Engineering Science, Division of Production Systems. Chalmers University of Technology, Department of Signals and Systems, Gothenburg, Sweden.
    Constructive cooperative coevolutionary optimisation for interacting production stations2015In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 78, no 1-4, p. 673-688Article in journal (Refereed)
    Abstract [en]

    Optimisation of the control function for multiple automated interacting production stations is a complex problem, even for skilled and experienced operators or process planners. When using mathematical optimisation techniques, it often becomes necessary to use simulation models to represent the problem because of the high complexity (i.e. simulation-based optimisation). Standard optimisation techniques are likely to either exceed the practical time frame or under-perform compared to the manual tuning by the operators or process planners. This paper presents the Constructive cooperative coevolutionary (C3) algorithm, which objective is to enable effective simulation-based optimisation for the control of automated interacting production stations within a practical time frame. C3 is inspired by an existing cooperative coevolutionary algorithm. Thereby, it embeds an algorithm that optimises subproblems separately. C3 also incorporates a novel constructive heuristic to find good initial solutions and thereby expedite the optimisation. In this work, two industrial optimisation problems, involving interaction production stations, with different sizes are used to evaluate C3. The results illustrate that with C3, it is possible to optimise these problems within a practical time frame and obtain a better solution compared to manual tuning.

  • 9.
    Holmberg, Jonas
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. Swerea-IVF AB, 431 22, Mölndal, Sweden.
    Wretland, Anders
    GKN Aerospace Engine Systems AB, Trollhättan, Sweden.
    Berglund, Johan
    Swerea IVF AB, Argongatan 30, 431 22 Mölndal, Sweden.
    Beno, Tomas
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Evaluation of surface integrity after high energy machining with EDM, Laser Beam Machining and Abrasive Water Jet Machining of Alloy 7182019In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 100, no 5-8, p. 1575-1591Article in journal (Refereed)
    Abstract [en]

    Development of future aero engine components based on new design strategies utilising topological optimisation and additive manufacturing has in the past years become a reality. This allows for designs that involve geometries of "free form" surfaces and material combinations that could be difficult to machine using conventional milling. Hence, alternative manufacturing routes using non-conventional high energy methods are interesting to explore. In this investigation, the three high energy machining methods abrasive water jet machining (AWJM), electrical discharge machining (EDM) and laser beam machining (LBM) have been compared in terms of surface integrity to the reference, a ball nosed end milled surface. The results showed great influence on the surface integrity from the different machining methods. It was concluded that AWJM resulted in the highest quality regarding surface integrity properties with compressive residual stresses in the surface region and a low surface roughness with texture from the abrasive erosion. Further, it was shown that EDM resulted in shallow tensile residual stresses in the surface and an isotropic surface texture with higher surface roughness. However, even though both methods could be considered as possible alternatives to conventional milling they require post processing. The reason is that the surfaces need to be cleaned from either abrasive medium from AWJM or recast layer from EDM. It was further concluded that LBM should not be considered as an alternative in this case due to the deep detrimental impact from the machining process.Keywords

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  • 10.
    Holmberg, Jonas
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. Manufacturing Swerea IVF AB Mölndal Sweden.
    Wretland, Anders
    GKN Aerospace Sweden AB Trollhättan Sweden.
    Berglund, Johan
    Manufacturing Swerea IVF AB Mölndal Sweden.
    Beno, Tomas
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Surface integrity after post processing of EDM processed Inconel 718 shaft2018In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 95, no 5-8, p. 2325-2337Article in journal (Refereed)
    Abstract [en]

    Electrical discharge machining (EDM) is considered as an efficient alternative to conventional material removal concepts that allows for much higher material removal rates. However, EDM generates unwanted features such as re-cast layer (RCL), tensile residual stresses and a rough surface. In order to recover the surface integrity, different post processes has been compared: high-pressure water jet (HPWJ), grit blasting (GB) and shot peening (SP). Surface integrity has been evaluated regarding microstructure, residual stresses, chemical content and surface roughness. The results showed that a combination of two post processes is required in order to restore an EDM processed surface of discontinuous islands of RCL. HPWJ was superior for removing RCL closely followed by grit blasting. However, grit blasting showed embedded grit blasting abrasive into the surface. Regarding surface roughness, it was shown that both grit blasting and HPWJ caused a roughening of the surface topography while shot peening generates a comparably smoother surface. All three post processes showed compressive residual stresses in the surface where shot peening generated the highest amplitude and penetration depths. However, the microstructure close to the surface revealed that shot peening had generated cracks parallel to the surface. The results strongly state how important it is to evaluate the surface at each of the different subsequent process steps in order to avoid initiation of cracks.

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  • 11.
    Jadidi, Aydin
    et al.
    University West, Department of Engineering Science, Division of Production Systems.
    Azhiri, R. B.
    Department of Mechanical Engineering, University of Texas at Dallas, Richardson (USA).
    Baghdadchi, Amir
    University West, Department of Engineering Science, Division of Welding Technology.
    Salmanibideskan, A.
    Department of Mechanical Engineering, University of Tabriz, Tabriz (IRN).
    Lap joining of aluminum 5052 to copper by optimum friction stir spot welding process2022In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015Article in journal (Refereed)
    Abstract [en]

    In the present study, lap joints of dissimilar 5052 aluminum alloy and pure copper were fabricated by friction stir spot welding process. The work was aimed to find simultaneous effect of parameters such as tool rotary speed (1000, 1500, and 2000 rpm) and dwell time (5, 10, and 15 s) on lap shear force (LSF), hardness, and microstructure evolution. Also, statistical models of the quality characteristics were developed to understand which parameter has dominant effect on quality characteristics. Research findings showed that to obtain sound joints with high lap shear strength, tool rotary speed of 1500 rpm and dwell time of 15 s should be selected. It provides sufficient heat input for mechanical interlocking and prevents the formation of coarse and thick intermetallic compounds (IMCs) in the stir zone. On the other hand, to achieve maximum hardness, 2000 rpm tool rotary speed should be chosen to provide enough heat for formation of intermetallic compound and 10Â s dwell time should be used to prevent enough time for microstructure refining. Moreover, from the statistical analyses, it was found that dwell time and tool speed are the significant factors for lap shear strength and hardness, respectively. In order to attain simultaneous maximum strength and hardness, tool speed of 1630 rpm and dwell time of 14 s should be used. In such condition, lap shear strength of 1980 N and hardness of 78 V are achieved with desirability of 86%. 

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    Springer
  • 12.
    Jorge, Vinicius Lemes
    et al.
    Federal University of Uberlandia (UFU), Center for Research and Development of Welding Processes (Laprosolda), Uberlândia, MG, Brazil (BRA).
    Scotti, Fernando Matos
    Federal University of Uberlandia (UFU), Center for Research and Development of Welding Processes (Laprosolda),Uberlândia, MG, Brazil (BRA).
    Reis, Ruham Pablo
    Federal University of Uberlandia (UFU), Center for Research and Development of Welding Processes (Laprosolda),Uberlândia, MG, Brazil (BRA).
    Scotti, Americo
    University West, Department of Engineering Science, Division of Welding Technology. Federal University of Uberlandia (UFU), Center for Research and Development of Welding Processes (Laprosolda),Uberlândia, MG, Brazil (BRA); Federal University of Parana (UFPR), Graduate Program in Materials Science and Engineering, Curitiba, PR, Brazil (BRA).
    The potential of wire feed pulsation to influence factors that govern weld penetration in GMA welding2020In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 110, p. 2685-2701Article in journal (Refereed)
    Abstract [en]

    Derivative welding processes are in many cases capable of altering phenomena that determine fundamental aspects of weld bead formation. Some of these evolutions act over the wire feed dynamics. However, in this scenario, the effects of the wire feed pulsation on the weld bead formation governing factors have not been fully explored yet. Therefore, this work aimed at examining how a wire feed pulsation approach affects the droplet transfer in gas metal arc welding and how its interaction with the molten pool defines the weld bead penetration. Bead-on-plate weldments were produced by varying the wire feed pulsation frequency, yet keeping the same levels of arc energy and wire feed speed, with the power source operating in constant voltage and current modes. To assess the droplet transfer behavior, high-speed imaging was used. The geometry of the weld beads was compared in terms of fusion penetration. The results showed that an increase in the wire feed pulsation frequency intensifies the detachment frequency of the droplets, being possible to accomplish a stable metal transfer with them straightly projected toward the weld pool, which contributed to a centralized-increased penetration profile. Based on a descriptive model, it was demonstrated that the increase in droplet momentum or kinetic energy, due to the wire feed pulsation, was not enough to justify the penetration enhancement. It was concluded that the wire feed dynamics can also stimulate surface tension variations in the weld pool and therefore disrupt the behavior of its mass and heat convection, supporting fusion penetration.

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  • 13.
    Jorge, Vinius Lemes
    et al.
    Federal University of Uberlandia, Uberlândia, MG, Brazil (BRA).
    Scotti, Fernando Matos
    Federal University of Uberlandia, Uberlândia, MG, Brazil (BRA).
    Reis, Ruham Pablo
    Federal University of Uberlandia, Uberlândia, MG, Brazil (BRA).
    Scotti, Américo
    University West, Department of Engineering Science, Division of Welding Technology.
    The effect of pulsed cold-wire feeding on the performanceof spray GMAW2020In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 107, p. 3485-3498Article in journal (Refereed)
    Abstract [en]

    The application of pulsed cold-wire (P-CW) feeding has been one of the new approaches for arc welding over the past years. Such technique applied to GTAW shows that it can influence the process performance. However, P-CW feeding in GMAW has not been explored yet. Thus, the current work aimed at introducing and evaluating the effects of P-CW on the performance of GMAW, particularly with the spray metal transfer. The P-CW pulsing frequency and the angle between the cold-wire and the plate were varied in bead-on-plate and V-groove weldments. The effects of the P-CW on the weld bead geometry and metallurgical texture were, then, examined through cross-sections. The metal transfer from the wire tip to the weld pool and the arc behavior during wire feeding were analyzed backed by high-speed imaging. A thermal camera was used to monitor the back of the plates to examine the heat behavior with both the P-CW and non-pulsed feeding conditions. On the one hand, the results revealed that, although the pulsation affects the arc and the electric signal behavior and the metal transfer, no sensitive influence could be noticed regarding the weld bead geometries. On the other hand, the pulsed cold-wire feeding interfered in the thermal profile outside the weld pool. For the highest frequency explored, regardless the feeding angle, less heat was transferred to the plate. The smaller heat input in these cases limited grain growth, reducing the coarse grain HAZ area and resulting in a more refined microstructure. Therefore, P-CW showed to interfere in the GMAW process performance.

  • 14.
    Karimi Neghlani, Paria
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Raza, Tahira
    University West, Department of Engineering Science, Division of Welding Technology.
    Andersson, Joel
    University West, Department of Engineering Science, Division of Welding Technology.
    Svensson, Lars-Erik
    University West, Department of Engineering Science, Division of Welding Technology.
    Influence of laser exposure time and point distance on 75-μm-thick layer of selective laser melted Alloy 7182018In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 94, no 5-8, p. 2199-2207Article in journal (Refereed)
    Abstract [en]

    A systematic matrix with 25 samples, using five different point distances and five laser exposure times, depositing 75-μm-thick layers of Alloy 718 has been studied. The work has concentrated on defects formed, hardness of the deposits, and the microstructure. Relatively large amount of defects, both lack of fusion and porosity, was found in several of the specimens in the deposits. The defects were never possible to fully eliminate, but a significant decrease, mainly in the lack of fusion, was seen with increasing laser exposure time. The gas porosity on the other hand was not affected to any larger degree, except for the lowest laser energy input, where a slight increase in porosity was seen. A small increase in hardness was noted with increasing laser energy input. The width of the deposited beads increased with increasing laser energy, while the depth of deposits was more or less constant. However, for the lowest combination of point distance and laser exposure time, quite deep and narrow beads were formed. A comparison was made with deposition of 50-μm-thick layers, with quite similar laser energy input, but with some variation in detailed deposition parameters. It was found that the 75-μm-thick layers contained less lack of fusion, particularly for small point distances. The amount of porosity was also less, but that did not vary with deposition parameters.© 2017 The Author(s)

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  • 15.
    Karimi Neghlani, Paria
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Sadeghi, Esmaeil
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Ålgårdh, Joakim
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. GE Additive | Arcam EBM, Designvägen 2, Mölnlycke, 435 33, Sweden.
    Harlin, P.
    Sandvik Additive Manufacturing, Sandviken, 811 81, Sweden.
    Andersson, Joel
    University West, Department of Engineering Science, Division of Welding Technology.
    Effect of build location on microstructural characteristics and corrosion behavior of EB-PBF built Alloy 7182020In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 106, no 7-8, p. 3597-3607Article in journal (Refereed)
    Abstract [en]

    Electron beam-powder bed fusion (EB-PBF), a high-temperature additive manufacturing (AM) technique, shows great promise in the production of high-quality metallic parts in different applications such as the aerospace industry. To achieve a higher build efficiency, it is ideal to build multiple parts together with as low spacing as possible between the respective parts. In the EB-PBF technique, there are many unknown variations in microstructural characteristics and functional performance that could be induced as a result of the location of the parts on the build plate, gaps between the parts and part geometry, etc. In the present study, the variations in the microstructure and corrosion performance as a function of the parts location on the build plate in the EB-PBF process were investigated. The microstructural features were correlated with the thermal history of the samples built in different locations on the build plate, including exterior (the outermost), middle (between the outermost and innermost), and interior (the innermost) regions. The cubic coupons located in the exterior regions showed increased level (~ 20 %) of defects (mainly in the form of shrinkage pores) and lower level (~ 30-35 %) of Nb-rich phase fraction due to their higher cooling rates compared to the interior and middle samples. Electrochemical investigations showed that the location indirectly had a substantial influence on the corrosion behavior, verified by a significant increase in polarization resistance (Rp) from the exterior (2.1 ± 0.3 kΩ.cm2) to interior regions (39.2 ± 4.1 kΩ.cm2). © 2020, The Author(s).

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  • 16.
    Karimi Neghlani, Paria
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Sadeghimeresht, Esmaeil
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Deng, D.
    Linköping University, Division of Engineering Materials, Department of Management and Engineering, Linköping, 581 83, Sweden.
    Gruber, H.
    University of Chalmers, Division of Materials and Manufacture, Industrial and Materials Science, Gothenburg, 412 96, Sweden.
    Andersson, Joel
    University West, Department of Engineering Science, Division of Welding Technology.
    Nylen, Per
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Influence of build layout and orientation on microstructural characteristics of electron beam melted Alloy 7182018In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 99, no S1, p. 2903-2913Article in journal (Refereed)
    Abstract [en]

    Effects of build layout and orientation consisting of (a) height from the build plate (Z-axis), (b) distance between samples, and (c) location in the build plate (X-Y plane) on porosity, NbC fraction, and hardness in electron beam melted (EBM) Alloy 718 were studied. The as-built samples predominantly showed columnar structure with strong ˂001˃ crystallographic orientation parallel to the build direction, as well as NbC and ÎŽ-phase in inter-dendrites and grain boundaries. These microstructural characteristics were correlated with the thermal history, specifically cooling rate, resulted from the build layout and orientation parameters. The hardness and NbC fraction of the samples increased around 6% and 116%, respectively, as the height increased from 2 to 45 mm. Moreover, by increasing the height, formation of ÎŽ-phase was also enhanced associated with lower cooling rate in the samples built with a greater distance from the build plate. However, the porosity fraction was unaffected. Increasing the sample gap from 2 to 10 mm did not change the NbC fraction and hardness; however, the porosity fraction increased by 94%. The sample location in the build chamber influenced the porosity fraction, particularly in interior and exterior areas of the build plate. The hardness and NbC fraction were not dependent on the sample location in the build chamber. © 2018, The Author(s).

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  • 17.
    Li, Peigang
    et al.
    ESAB AB, Gothenburg, Sweden.
    Hurtig, Kjell
    University West, Department of Engineering Science, Division of Welding Technology.
    Högström, Mats
    University West, Department of Engineering Science, Division of Welding Technology.
    Svensson, Lars-Erik
    University West, Department of Engineering Science, Division of Welding Technology.
    Scotti, Americo
    University West, Department of Engineering Science, Division of Welding Technology.
    A contribution to the study of negative polarity in GMA welding2018In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 95, no 5-8, p. 2543-2553Article in journal (Refereed)
    Abstract [en]

    GMAW using the electrode with negative polarity (DCEN) has been frequently suggested as a potential means of increasing production capacity. The objective of this work was to further study the performance of negative polarity in GMAW of carbon steels. In this project phase, bead-on-plate welds were carried out in flat position to assess the effect of different potential shielding gas compositions on bead geometry, finishing and spattering. The characteristics were compared with DCEP at the same current, but depositing the same volume of material per unit of length (more industrial related comparison). The arc length was kept the same by adjusting voltage to reach shortest arcs, yet with suitable non short-circuiting metal transfer mode. An approach to measure bead convexity was also proposed and assessed. The results showed that DCEN is feasible as a means of increasing GMAW production capacity. However, to become DCEN applicable with GMAW, the results suggest an Ar based blend with around 6.5 % of O2 is the most appropriate shielding gas, as much as that there is a demand for a standard electronic controlled power source able to work in constant current mode. 

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  • 18.
    Nilsen, Morgan
    et al.
    University West, Department of Engineering Science, Division of Production Systems.
    Sikström, Fredrik
    University West, Department of Engineering Science, Division of Production Systems.
    Christiansson, Anna-Karin
    University West, Department of Engineering Science, Division of Production Systems.
    Adaptive control of the filler wire rate during laser beam welding of squared butt joints with varying gap width2019In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 102, no 9-12, p. 3667-3676Article in journal (Refereed)
    Abstract [en]

    Adding filler wire control to autogenous laser beam welding of squared butt joints offers a means to widen up the tight fit-up tolerances associated with this process. When the gap width varies, the filler wire rate should be controlled to assure a constant geometry of the resulting weld seam. A dual mode sensing system is proposed to estimate the joint gap width and thereby control the filler wire rate. A vision camera integrated into the welding tool together with external LED illumination and a laser line projection enables two sensing modes, one surface feature extraction mode and one laser triangulation-based mode. Data from the both modes are fused in a Kalman filter, and comparisons show that the fusing of the data gives more robust estimation than estimates from each single mode. A feed-forward control system adaptively adjusts the filler wire rate based on the estimations ofthe joint gap width in front of the keyhole. The focus is on keeping the data processing simple and affordable, and the real-time performance of the sensor and control system has been evaluated by welding experiments. It is shown that the proposed system can be used for on-line control of the filler wire rate to achieve a constant weld geometry during varying joint gap widths

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  • 19.
    Nilsen, Morgan
    et al.
    University West, Department of Engineering Science, Division of Production Systems.
    Sikström, Fredrik
    University West, Department of Engineering Science, Division of Production Systems.
    Christiansson, Anna-Karin
    University West, Department of Engineering Science, Division of Production Systems.
    Ancona, Antonio
    University West, Department of Engineering Science, Division of Production Systems. Physics Department, IFN-CNR Institute for Photonics and Nanotechnologies, Bari, Italy.
    Robust vision-based joint tracking for laser welding of curved closed-square-butt joints2019In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 101, no 5-8, p. 1967-1978Article in journal (Refereed)
    Abstract [en]

    Robotized laser beam welding of closed-square-butt joints is sensitive to how the focused laser beam is positioned in relation to the joint, and existing joint tracking systems tend to fail in detecting the joint when the gap and misalignment between the work pieces are close to zero. A camera-based system is presented based on a high dynamic range camera operating with LED illumination at a specific wavelength and a matching optical filter. An image processing algorithm based on the Hough transform extracts the joint position from the camera images, and the joint position is then estimated using a Kalman filter. The filter handles situations, when the joint is not detectable in the image, e.g., when tack welds cover the joint. Surface scratches, which can be misinterpreted as being the joint, are handled by a joint curve prediction model based on known information about the nominal path defined by the robot program. The performance of the proposed system has been evaluated off line with image data obtained during several welding experiments.

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  • 20.
    Nilsson, Anders
    et al.
    University West, Department of Engineering Science, Division of Production Systems.
    Danielsson, Fredrik
    University West, Department of Engineering Science, Division of Production Systems.
    Svensson, Bo
    University West, Department of Engineering Science, Division of Production Systems.
    From CAD to Plug & Produce: A generic structure for the integration of standard industrial robots into agents2023In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 128, no 11-12, p. 5249-5260Article in journal (Refereed)
    Abstract [en]

    Industries of low-batches or one-of manufacturing aim for automation that is competitive enough to adapt to new or modifed products daily through in-house knowledge that focuses on manufacturing processes and not on machine function programming. To solve this, a complete set of actions that utilize seamless data transfer from product design in CAD to a Plug & Produce automation concept is proposed together with a generic structure for the integration of standard industrial robots into agents. This structure enables agents to handle their local reference coordinate systems and locations relative to a global perspective. Seamless utilization of data from product designs to Plug & Produce will simplify and shorten the time of digital development through concurrently usable text-based and graphical confguration tools of a confgurable multi-agent system. Needed data extracts directly from the product design as requirements of operational goals. Extraction of data from the product design, sequence of goals, and process plans, which are recipes of how to solve goals, can by this concept be confgured by in-house knowledge that has the process knowledge but not necessarily programming competence.

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  • 21.
    Odenberger, Eva-Lis
    et al.
    Luleå University of Technology, Division of Mechanics of Solid Materials, Luleå, SE-971 87, Sweden; Division Materials and Production, RISE IVF AB, RISE Research Institutes of Sweden, Vällaregatan 30, Olofström, SE-293 38, Sweden.
    Pederson, Robert
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Oldenburg, Mats
    Luleå University of Technology, Division of Mechanics of Solid Materials, Luleå, SE-971 87, Sweden.
    Finite element modeling and validation of springback and stress relaxation in the thermo-mechanical forming of thin Ti-6Al-4V sheets2019In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 104, no 9-12, p. 3429-3455Article in journal (Refereed)
    Abstract [en]

    In this work, a hot forming procedure is developed using computer-aided engineering (CAE) to produce thin Ti-6Al-4V sheet components in an effective way. Traditional forming methods involve time- and cost-consuming furnace heating and subsequent hot sizing steps. A material model for finite element (FE) analyses of sheet metal forming and springback at elevated temperatures in Ti-6Al-4V is calibrated and evaluated. The anisotropic yield criterion proposed by Barlat et al. 2003 is applied, and the time- and temperature-dependent stress relaxation behavior for elastic and inelastic straining are modeled using a Zener–Wert–Avrami formulation. Thermo-mechanical uniaxial tensile tests, a biaxial test, and uniaxial stress relaxation tests are performed and used as experimental reference to identify material model parameters at temperatures up to 700 °C. The hot forming tool setup is manufactured and used to produce double-curved aero engine components at 700 °C with different cycle times for validation purposes. Correlations between the predicted and measured responses such as springback and shape deviation show promising agreement, also when the forming and subsequent holding time was as low as 150 s. The short cycle time resulted in elimination of a detectable alpha case layer. Also, the tool surface coating extends the tool life in combination with a suitable lubricant. © 2019, The Author(s).

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  • 22.
    Parsian, Amir
    et al.
    University West, Department of Engineering Science, Division of Manufacturing Processes. AB Sandvik Coromant, Sandviken (SWE).
    Magnevall, Martin
    AB Sandvik Coromant, SE-811 81 Sandviken (SWE).
    Eynian, Mahdi
    University West, Department of Engineering Science, Division of Manufacturing Processes.
    Beno, Tomas
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Time Domain Simulation of Chatter Vibrations in Indexable Drills2017In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 89, no 1-4, p. 1209-1221Article in journal (Refereed)
    Abstract [en]

    Regenerative chatter vibrations are common in drilling processes. These unwanted vibrations lead to considerable noise levels, damage the quality of the workpiece, and reduce tool life. The aim of this study is to simulate torsional and axial chatter vibrations as they play important roles in dynamic behavior of indexable insert drills with helical chip flutes. While asymmetric indexable drills are not the focal points in most of previous researches, this paper proposes a simulation routine which is adapted for indexable drills. Based on the theory of regenerative chatter vibration, a model is developed to include the asymmetric geometries and loadings that are inherent in the design of many indexable insert drills. Most indexable insert drills have two inserts located at different radial distances, namely central and peripheral inserts. Since the positions of the central and peripheral inserts are different, the displacement and thereby the change in chip thickness differs between the inserts. Additionally, the inserts have different geometries and cutting conditions, e.g., rake angle, coating, and cutting speed, which result in different cutting forces. This paper presents a time-domain simulation of torsional and axial vibrations by considering the differences in dynamics, cutting conditions, and cutting resistance for the central and peripheral inserts on the drill. The time-domain approach is chosen to be able to include nonlinearities in the model arising from the inserts jumping out of cut, multiple delays, backward motions of edges, and variable time delays in the system. The model is used to simulate cutting forces produced by each insert and responses of the system, in the form of displacements, to these forces. It is shown that displacements induced by dynamic torques are larger than those induced by dynamic axial forces. Finally, the vibration of a measurement point is simulated which is favorably comparable to the measurement results.

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  • 23.
    Silva, Ana
    et al.
    University West, Department of Engineering Science, Division of Production Systems.
    De Backer, Jeroen
    University West, Department of Engineering Science, Division of Production Systems.
    Bolmsjö, Gunnar
    University West, Department of Engineering Science, Division of Production Systems.
    Temperature measurements during friction stir welding2017In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 88, no 9-12, p. 2899-2908Article in journal (Refereed)
    Abstract [en]

    The increasing industrial demand for lighter, more complex and multi-material components supports the development of novel joining processes with increased automation and process control. Friction stir welding (FSW) is such a process and has seen a fast development in several industries.This welding technique gives the opportunity of automation and online feedback control, allowing automatic adaptation to environmental and geometrical variations of the component.Weld temperature is related to the weld quality and therefore proposed to be used for feedback control. For this purpose, accurate temperature measurements are required. This paper presents an overview of temperature measurement methods applied to the FSW process. Three methods were evaluated in this work: thermocouples embedded in the tool, thermocouples embedded in the workpiece and the tool-workpiece thermocouple(TWT) method. The results show that TWT is an accurate and fast method suitable for feedback control of FSW.

  • 24.
    Svenman, Edvard
    et al.
    University West, Department of Engineering Science, Research Enviroment Production Technology West. GKN Aerospace.
    Runnemalm, Anna
    University West, Department of Engineering Science, Division of Production Systems.
    A complex response inductive method for improved gap measurement in laser welding2017In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 88, no 1-4, p. 175-184Article in journal (Refereed)
    Abstract [en]

    Laser welding needs precise measurement of weldgap position to avoid weld defects. Most often, optical measurement methods are used, but well-aligned narrow gaps canbe difficult to detect. An improved inductive method capable of detecting zero gaps in square butt joints is proposed. The new method uses two eddy current coils, one on each side of the gap, and measures the complex response of the individual coils, i.e. both the inductive and resistive response. By combining the coil responses, both the position and the geometry of the weld gap can be estimated. The method was experimentally investigated by traversing a single coil over an adjustable gap between two plates and combining the measured coil responses into a simulated two-coil probe. The gap was adjusted in both misalignment and gap width up to 0.4 mm. Comparing the results to known settings and positions shows that gap position is measured to within 0.1 mm, if the probe is within a working area of 1 mm from the gap in both position and height. Results from the new method were compared to simulations, from the same experimental data, of a previously reported method where the coils were electrically combined by wiring them together. The previous method can give accurate results but has a much smaller working area and depends on servo actuation to position the probe above the gap. The improved method gives better tolerance to varying misalignment and gap width, which is an advantage over previous inductive methods.

  • 25.
    Svensson, Bo
    et al.
    University West, Department of Engineering Science, Division of Automation and Computer Engineering.
    Danielsson, Fredrik
    University West, Department of Engineering Science, Division of Automation and Computer Engineering.
    Lennartson, Bengt
    University West, Department of Engineering Science, Division of Automation and Computer Engineering. University West, Department of Engineering Science, Division of Production Systems.
    An efficient algorithm for press line optimisation2013In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 68, no 5, p. 1627-1638Article in journal (Refereed)
    Abstract [en]

    Automated manufacturing processes such as automotive tandem press lines include time dependent complex control functions. All motions and critical interactions between moving parts must be synchronised to avoid collisions and reach high production rate. It is even for a skilled operator hard to optimise these processes on-line. Therefore, a hardware-in-the-loop simulation including real industrial control systems and its control code establish an essential tool for optimisation. Additionally, an efficient optimisation algorithm is required to reach a useful simulation-based optimisation method. This paper proposes a new optimisation algorithm starting with the Lipschitzian algorithm DIRECT as global search and then switches over to the Nelder-Mead simplex algorithm for local convergence. During the switch over, the new algorithm determines all local candidates of the set of points evaluated by DIRECT and starts multiple Nelder-Mead local searches in each of these. An optimisation study for an automotive press line shows that the proposed algorithm combines the benefits of the Lipschitzian and the simplex algorithms in an efficient way. The importance of multiple local searches from all local candidates found is also shown in the study. Based on the same number of function evaluations, it is also shown that this algorithm reaches improved press line performances compared to the stochastic differential evolution algorithm.

  • 26.
    Teixeira, Felipe Ribeiro
    et al.
    Center for Research and Development of Welding Processes, Federal University of Uberlandia, Uberlândia (BRA).
    Scotti, Fernando Matos
    Center for Research and Development of Welding Processes, Federal University of Uberlandia, Uberlândia, MG, (BRA).
    Jorge, Vinicius Lemes
    Center for Research and Development of Welding Processes, Federal University of Uberlandia, Uberlândia, MG (BRA).
    Scotti, Americo
    University West, Department of Engineering Science, Division of Welding Technology. Center for Research and Development of Welding Processes, Federal University of Uberlandia, Uberlândia, MG (BRA).
    Combined effect of the interlayer temperature with travel speed on features of thin wall WAAM under two cooling approaches2023In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 126, p. 273-289Article in journal (Refereed)
    Abstract [en]

    This work presents the evaluation of the interlayer temperature (IT) with travel speed (TS) combined effect for a given wire feed speed (WFS) on operational, geometrical, and metallurgical features of thin walls with the same width deposited by wire arc additive manufacturing (WAAM) with a low alloy steel, using or not active cooling. A preliminary experimental design was carried out to define a range of IT that could prevent the molten pool from running down and, then, be used in the main experimental design. The main tests were planned and performed to find different IT and TS combinations for a given WFS capable of depositing walls with the same target effective wall width. After selecting the parameters, six walls were deposited, three under natural cooling (NC) and three under near immersion active cooling (NIAC). A more significant temperature variability along the layer length (ΔT/ΔLL) is observed in increasing IT-TS combination and under NIAC. Regardless of the cooling approach, a worse surface aspect was observed with lower IT and TS. However, NC or NIAC do not affect the wall width (effective or external) or the layer height. On the other hand, they are affected by the IT with TS combination. A shorter production time was obtained on the walls with NIAC and higher IT-TS. No marked microstructural differences were observed comparing the walls, regardless of the cooling approach. However, microstructure tempering (hardness reduction) was observed in the walls deposited with NC using higher IT levels.  

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  • 27.
    Teixeira, Felipe Ribeiro
    et al.
    Center for Research and Development of Welding Processes, Federal University of Uberlandia, Uberlândia, MG(BRA).
    Scotti, Fernando Matos
    Center for Research and Development of Welding Processes, Federal University of Uberlandia, Uberlândia, MG (BRA).
    Vilarinho, Louriel Oliveira
    Center for Research and Development of Welding Processes, Federal University of Uberlandia, Uberlândia, MG (BRA).
    da Mota, Carlos Alberto Mendes
    Department of Mechanical Engineering, Federal University of Pará, Belém, PA (BRA).
    Scotti, Americo
    University West, Department of Engineering Science, Division of Welding Technology. Center for Research and Development of Welding Processes, Federal University of Uberlandia, Uberlândia, MG (BRA).
    Transferability of the working envelope approach for parameter selection and optimization in thin wall WAAM2021In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 119, no 1-2, p. 969-989Article in journal (Refereed)
    Abstract [en]

    This work aims to propose and assess a methodology for parameterization for WAAM of thin walls based on a previously existing working envelope built for a basic material (parameter transferability). This work also aimed at investigating whether the working envelope approach can be used to optimize the parameterization for a target wall width in terms of arc energy (which governs microstructure and microhardness), surface finish and active deposition time. To reach the main objective, first, a reference working envelope was developed through a series of deposited walls with a plain C-Mn steel wire. Wire feed speed (WFS) and travel speed (TS) were treated as independent variables, while the geometric wall features were considered dependent variables. After validation, three combinations of WFS and TS capable of achieving the same effective wall width were deposited with a 2.25Cr-1Mo steel wire. To evaluate the parameter transferability between the two materials, the geometric features of these walls were measured and compared with the predicted values. The results showed minor deviations between the predicted and measured values. As a result, WAAM parameter selection for another material showed to be feasible after only fewer experiments (shorter time and lower resource consumption) from a working envelope previously developed. The usage of the approach to optimize parameterization was also demonstrated. For this case, lower values of WFS and TS were capable of achieving a better surface finish. However, higher WFS and TS are advantageous in terms of production time. As long as the same wall width is maintained, variations in WFS and TS do not significantly affect microstructure and microhardness.

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  • 28.
    Tricarico, Luigi
    et al.
    DMMM, Politecnico di Bari, Viale Japigia 182, Bari, 70126, Italy; CNR-IFN UOS Bari, Via Amendola 173, Bari, 70126, Italy.
    Ancona, Antonio
    University West, Department of Engineering Science, Division of Production Systems. CNR-IFN UOS Bari, Via Amendola 173, Bari, 70126, Italy.
    Palumbo, Gianfranco
    DMMM, Politecnico di Bari, Viale Japigia 182, Bari, 70126, Italy; CNR-IFN UOS Bari, Via Amendola 173, Bari, 70126, Italy.
    Sorgente, Donato
    NR-IFN UOS Bari, Via Amendola 173, Bari, 70126, Italy; Università degli Studi della Basilicata, School of Engineering, Via Ateneo Lucano, 10, Potenza, 85100, Italy .
    Corizzo, Ottavio
    DMMM, Politecnico di Bari, Viale Japigia 182, Bari, 70126, Italy.
    Spina, Roberto
    DMMM, Politecnico di Bari, Viale Japigia 182, Bari, 70126, Italy; CNR-IFN UOS Bari, Via Amendola 173, Bari, 70126, Italy.
    Lugara, Pietro Mario
    CNR-IFN UOS Bari, Via Amendola 173, Bari, 70126, Italy; Università degli Studi e Politecnico di Bari, Dipartimento di Fisica, Via Amendola 173, Bari, 70126, Italy .
    Numerical and experimental investigation of the discrete spot laser hardening of a graphite-coated hypereutectoid steel using a fibre laser2019In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 104, no 1-4, p. 1393-1402Article in journal (Refereed)
    Abstract [en]

    The single-pulse laser hardening of a hypereutectoid steel coated by a graphite layer was investigated using a numerical/experimental approach. Experimental tests were conducted on coated samples using a fibre laser source and without any gas shielding aiming to explore the effect of laser power, pulse energy and defocusing distance on the dimensions of the hardened region. The process operating window of the discrete spot laser hardening using the graphite layer was determined through a finite element model and compared with previous results obtained on uncoated samples. For the same laser power and interaction times, an enlargement of the hardened region was found when using the graphite coating, especially when operating at the lowest laser energy level. The process operating window remains similar in shape to the one of the uncoated steel but moves towards larger hardened diameters and much larger defocusing distances. Once the maximum temperature has been fixed, a linear relationship between the hardened diameter and the defocusing distance exists. No obvious surface oxidation occurs since the graphite coating acts as a protective layer. © 2019, Springer-Verlag London Ltd., part of Springer Nature.

  • 29.
    Yehorov, Yurii
    et al.
    Federal University of Uberlandia (UFU),Center for Research and Development of Welding Processes, Laprosolda, Uberlândia, MG 38408-100, Brazil.
    da Silva, Leandro João
    Federal University of Uberlandia (UFU),Center for Research and Development of Welding Processes, Laprosolda, Uberlândia, MG 38408-100, Brazil.
    Scotti, Americo
    University West, Department of Engineering Science, Division of Welding Technology. Federal University of Uberlandia (UFU),Center for Research and Development of Welding Processes, Laprosolda, Uberlândia, MG 38408-100, Brazil.
    Exploring the use of switchback for mitigating homoepitaxial unidirectional grain growth and porosity in WAAM of aluminium alloys2019In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 104, no 1-4, p. 1581-1592Article in journal (Refereed)
    Abstract [en]

    In this work, an alternative approach to prevent unidirectional grain growth in wire + arc additive manufacturing (WAAM) is proposed and assessed, by moving cyclically the torch forward and backward, likewise the welding technique known as switchback. A series of tests were planned with CMT (cold metal transfer) process to compare three wall-like build-ups, which uses different deposition patterns, namely, in one-way direction, reverse direction, and switchback. The same equivalent travel speed and number of deposited layers were kept among them. Longitudinal sections were taken to identify the grain growth behaviour. Finally, samples were removed from the walls for porosity evaluation. The results confirmed the characteristics of unidirectional grain growth, when one-way direction condition was employed, and the break of growth direction between layers, when reverse direction was used, yet a zig-zag pattern became present. Differently, the application of switchback showed no preferential or unidirectional grain growth, suggesting less anisotropy of mechanical properties. In addition, switchback reduced porosity. © 2019, The Author(s).

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  • 30.
    Åstrand, Erik
    University West, Department of Engineering Science, Research Environment Production Technology West. University West, Department of Engineering Science, Research Enviroment Production Technology West. Volvo Construction Equipment, Carl Lihnells väg, Braås, Sweden .
    A new innovative toolbox for lean welding of fatigue loaded structures2015In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 81, no 1-4, p. 635-643Article in journal (Refereed)
    Abstract [en]

    Welding is a key manufacturing technology in the production of heavy steel structures, but it is likewise a weak link in the production chain since fatigue fractures in welds is a common cause of failures. This paper proposes several changes in the process to make the manufacturing more efficient and to improve the fatigue properties. The idea is to adopt the weld quality demands for the purpose of the weld and to connect them to the welding procedures. This approach ensures that the primary focus during welding is at the critical characteristics which add value to the welded structure through an enhanced fatigue life. These fatigue life-critical properties have been found to be related to the local weld geometry in the weld toe and at the weld root. Traditional demands related to the good workmanship of welding can often be neglected, due to its limited effect to the fatigue life. The research presented in this paper has contributed to the development of welding procedures for improved fatigue life properties at the critical points of the weld. Results indicate a considerable potential for enhanced fatigue life of fillet welds. The idea is to replace the standard fillet welds with a new toolbox containing three different welds: (i) welds with optimized penetration, (ii) welds with optimized weld toe, and (iii) welds with a low cost. Right usage of these weld types contributes to an efficient production that offer a long fatigue life. This paper describes a holistic view of the subject and highlights issues with the traditional way of working. The challenge and the novelty in the paper are the connection between the welding process, weld demands, and fatigue life properties. This connection is necessary for the development of welding procedures that can contribute to the fabrication of weight optimized welded structures with a predictable life. © 2015 Springer-Verlag London

  • 31.
    Öberg, Anna Ericson
    et al.
    Volvo Construction Equipment, Arvika, Sweden.
    Sikström, Fredrik
    University West, Department of Engineering Science, Division of Production Systems.
    Barriers for industrial implementation of in-process monitoring of weld penetration for quality control2017In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 91, no 5-8, p. 2427-2434Article in journal (Refereed)
    Abstract [en]

    The research conducted sheds a light on the question why robust in-process monitoring and adaptive control are not fully implemented in the welding industry. In the research project FaRoMonitA, the possibilities to monitor the weld quality during welding have been investigated. Research conducted in this area has merely focused on technical issues investigated in a laboratory environment. To advance the research front and release some barriers related to industrial acceptance, the studies conducted in this paper have been both quantitative and qualitative in form of experiments combined with an interview study. The quality property weld penetration depth was chosen for in-process monitoring to evaluate the industrial relevance and applicability. A guaranteed weld penetration depth is critical for companies producing parts influenced by fatigue. The parts studied were fillet welds produced by gas metal arc welding. The experiments show that there is a relationship between final penetration depth and monitored arc voltage signals and images captured by CMOS vision and infrared cameras during welding. There are still technical issues to be solved to reach a robust solution. The interview study indicates that soft issues, like competence and financial aspects, are just as critical.

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