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Keyhole mapping to enable closed-loop weld penetration depth control for remote laser welding of aluminium components using optical coherence tomography
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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). ISSN 1042-346X. doi:10.2351/7.0000086
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Official URL: https://doi.org/10.2351/7.0000086
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) | ||||||||||||
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| Subjects: | R Medicine > RE Ophthalmology T Technology > TN Mining engineering. Metallurgy T Technology > TS Manufactures |
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| 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: |
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| 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). |
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| RIOXX Funder/Project Grant: |
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| 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 | ||||||||||||
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