GOALI: Enabling Real-Time Detection and Identification of Friction Stir Welding Defects Through the Use of Physics-Based Process Dynamic Modeling

目标：通过使用基于物理的过程动态建模实现搅拌摩擦焊缺陷的实时检测和识别

• 批准号: 1332738
• 负责人: Michael Zinn
• 金额: $ 37.49万
• 依托单位: University of Wisconsin-Madison
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2013
• 资助国家: 美国
• 起止时间: 2013-08-01 至 2017-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1332738&HistoricalAwards=false
• 关键词: GOALI; Enabling; Real; Time; Detection

This Grant Opportunities for Academic Liaison with Industry (GOALI) award provides funding for the investigation and development of a real-time defect detection approach for the material joining process known as friction stir welding. The defect detection approach will use physics-based process and defect dynamic modeling to filter or condition real-time process measurements to significantly improve the reliability of detection. The research project will develop and validate the physics-based process and defect disturbance models through a combination of process-level system identification, using both computational and experimental data, and system level validation, including verification of real-time in-situ defect detection capabilities. The project will investigate the limitations and applicability of the overall defect detection approach to include the evaluation of the sensitivity to variations in defect size and defect type and the evaluation of the robustness of the approach in the presence of non-defect related process disturbances. If successful, real-time weld defect detection would substantially reduce the total cost of friction stir welding by reducing or eliminating the need for costly post-process inspection work. In addition, the development and validation of process and defect formation models will improve our understanding of the complex solid-state friction stir welding process. The resulting reduction in cost and increase in process understanding would help accelerate its adoption as a joining process - providing the substantial economic, environmental, and energy conservation advantages that wide-spread adoption of friction stir welding and friction stir processing would bring. Finally, the project will have a strong training and mentoring focus by providing an integrated educational and research environment for graduate and undergraduate student researchers - including those in underrepresented groups through established University fellowship programs.

这项与行业联络的赠款机会（GOALI）奖为调查和开发实时缺陷检测方法提供了资金，用于材料连接过程，称为摩擦搅拌焊接。缺陷检测方法将使用基于物理的过程和缺陷动态建模来过滤或条件实时过程测量，以显着提高检测的可靠性。该研究项目将使用计算和实验数据以及系统级验证，包括验证实时现场原位缺陷检测功能，通过过程级系统识别（同时验证过程级系统识别）的组合来开发和验证缺陷干扰模型。该项目将研究总体缺陷检测方法的局限性和适用性，以包括评估对缺陷大小和缺陷类型变化的敏感性，以及在存在非缺陷相关过程障碍的情况下评估该方法的鲁棒性。如果成功，实时焊接缺陷检测将大大减少摩擦搅拌焊接的总成本，以减少或消除昂贵的后进程检查工作的需求。此外，过程和缺陷形成模型的开发和验证将提高我们对复杂的固态摩擦搅拌焊接过程的理解。由此导致的成本降低和过程理解的增加将有助于加速其作为加入过程的采用 - 提供了实质性的经济，环境和节能的优势，即广泛采用摩擦式搅拌焊接和摩擦搅拌的加工。最后，该项目将通过为研究生和本科生的研究人员提供综合的教育和研究环境，包括通过成熟的大学奖学金计划，包括人数不足的团体，包括那些综合的教育和研究环境。