Sokolov, Mikhail, Franciosa, Pasquale, Al Botros, Rehab and Ceglarek, Dariusz (2020) Keyhole mapping to enable closed-loop weld penetration depth control for remote laser welding of aluminium components using optical coherence tomography. In: International Congress on Applications of Lasers & Electro–Optics (ICALEO) Conference, Orlando, FL, USA, 7-10 Oct 2019. Published in: Journal of Laser Applications, 32 (3). doi:10.2351/7.0000086 ISSN 1042-346X.

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Abstract

Remote Laser Welding (RLW) combines the positive features of tactile laser welding with additional benefits such as increased processing speed, reduced operational cost and service as well as higher process flexibility. A leading challenge preventing the full uptake of RLW technology in industry is the lack of efficient Closed Loop In-Process (CLIP) monitoring and weld quality control solutions. This underpins the need to fuse multiple sensor technologies, data analytics along with predictive engineering simulations. Although the development and integration of a variety of sensors, covering the radiation spectrum from ultra-violet to farinfrared, the flawless deployment of CLIP solutions is still challenged by the need for: signal de-noising in case of process instability; real-time data analytics; adaptive control engineering architecture to cope with process variations induced by manufacturing tolerances. This paper focuses on the aspect of the Weld Penetration Depth Control (WPDC) using Optical Coherence Tomography (OCT) as necessary step to enable adaptive penetration depth control during RLW of aluminium components in fillet lap joint configuration in consideration of part-to-part gap variation. The approach is decoupling the welding process parameters in two sub-sets: (1) in-plane control of the heat input on the upper part to facilitate the droplet formation; (2) outof-plane heat management to achieve the desired level of penetration control in keyhole mode. The paper presents the results of the keyhole mapping with variable part-to-part gap, that provide the insights for future research to enable the fully automatic closed-loop weld penetration depth control. Current limitations and next phases of research and development are highlighted based on the experimental study.

Item Type:	Conference Item (Paper)
Subjects:	R Medicine > RE Ophthalmology T Technology > TN Mining engineering. Metallurgy T Technology > TS Manufactures
Divisions:	Faculty of Science, Engineering and Medicine > Engineering > WMG (Formerly the Warwick Manufacturing Group)
Library of Congress Subject Headings (LCSH):	Optical coherence tomography, Laser welding, Manufacturing processes -- Research, Aluminum alloys -- Welding
Journal or Publication Title:	Journal of Laser Applications
Publisher:	Laser Institute of America
ISSN:	1042-346X
Official Date:	3 June 2020
Dates:	Date Event 3 June 2020 Published 1 April 2020 Accepted
Volume:	32
Number:	3
Article Number:	032004
DOI:	10.2351/7.0000086
Status:	Peer Reviewed
Publication Status:	Published
Reuse Statement (publisher, data, author rights):	This article may be downloaded for personal use only. Any other use requires prior permission of the author and AIP Publishing. This article appeared in Journal of Laser Applications. 32(3) 032004., and may be found at https://doi.org/10.2351/7.0000086
Access rights to Published version:	Restricted or Subscription Access
Copyright Holders:	© 2020 Author(s). Published under license by Laser Institute of America
Description:	This paper is part of the Special Collection: Proceedings of the International Congress of Applications of Lasers & Electro-Optics (ICALEO® 2019).
Date of first compliant deposit:	22 October 2019
Date of first compliant Open Access:	17 February 2021
RIOXX Funder/Project Grant:	Project/Grant ID RIOXX Funder Name Funder ID UNSPECIFIED Warwick Manufacturing Group https://viaf.org/viaf/123628346/ New lightweight Materials and Processing Technologies for Common Lightweight Architecture of Electric and Hybrid Powertrain Systems Advanced Propulsion Centre, UK https://www.apcuk.co.uk/ EP/K019368/1 [EPSRC] Engineering and Physical Sciences Research Council http://dx.doi.org/10.13039/501100000266
Conference Paper Type:	Paper
Title of Event:	International Congress on Applications of Lasers & Electro–Optics (ICALEO) Conference
Type of Event:	Conference
Location of Event:	Orlando, FL, USA
Date(s) of Event:	7-10 Oct 2019
Related URLs:	Organisation

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