Hand-Held Laser Welding of AISI301LN for components with aesthetic requirements: Toward the integration of machine and human intelligence

The use of Hand-Held Laser Welding (HHLW) systems in the industry has been rapidly growing in recent years as an alternative solution to conventional manual arc-based welding systems. The decreasing cost of fiber laser sources and optics has been a driving factor in enabling a wider use of HHLW systems, beyond the established advantages of laser technology with respect to arc-based systems. While the industrial use of HHLW increases, the subject matter has been studied sparingly in the scientific literature. Due to the intrinsic flexibility of the technology, HHLW systems are highly appealing for joining relatively low thickness metals (≤2 mm) in autogenous configuration in sectors where production lots present low batch and high variability. However, a critical aspect of HHLW is correlated to the operator skill, where welding velocities can vary within and between the welds affecting both their aesthetic and mechanical properties. Hence, the development of combined digital and physical approaches to support manual operations may be highly beneficial. The current study presents an open laboratory HHLW system designed for process development purposes. Beyond conventional manual welding operations, the welding torch could be arranged in different configurations. The system could be combined with a linear axis (enabling welding with stable velocity and inclination) or manually with the aid of a newly developed roller device designed to provide constant speed and inclination. First, the process was benchmarked by joining in butt weld configuration 2 mm thick AISI301LN stainless steel sheets with the linear axis. Successively, four operators with different levels of training (rookie and professional) realized welds with the system in hand-held configuration and with the mechanical roller. The weld width variability was assessed as a direct indicator for aesthetic compliance while tensile tests were allowed to determine the mechanical properties of the joint obtained with different configurations

Automating human skills : preliminary development of a human factors methodology to capture tacit cognitive skills

Despite technological advances in intelligent automation, it remains difficult for engineers to discern which manual tasks, or task components, would be most suitable for transfer to automated alternatives. This research aimed to develop an accurate methodology for the measurement of both observable and unobservable physical and cognitive activities used in manual tasks for the capture of tacit skill. Experienced operators were observed and interviewed in detail, following which, hierarchical task analysis and task decomposition methods were used to systematically explore and classify the qualitative data. Results showed that a task analysis / decomposition methodology identified different types of skill (e.g. procedural or declarative) and knowledge (explicit or tacit) indicating this methodology could be used for further human skill capture studies. The benefit of this research will be to provide a methodology to capture human skill so that complex manual tasks can be more efficiently transferred into automated processes

Feasibility of remotely manipulated welding in space. A step in the development of novel joining technologies

In order to establish permanent human presence in space technologies of constructing and repairing space stations and other space structures must be developed. Most construction jobs are performed on earth and the fabricated modules will then be delivered to space by the Space Shuttle. Only limited final assembly jobs, which are primarily mechanical fastening, will be performed on site in space. Such fabrication plans, however, limit the designs of these structures, because each module must fit inside the transport vehicle and must withstand launching stresses which are considerably high. Large-scale utilization of space necessitates more extensive construction work on site. Furthermore, continuous operations of space stations and other structures require maintenance and repairs of structural components as well as of tools and equipment on these space structures. Metal joining technologies, and especially high-quality welding, in space need developing

Feasibility of remotely manipulated welding in space: A step in the development of novel joining technologies

A six month research program entitled Feasibility of Remotely Manipulated Welding in Space - A Step in the Development of Novel Joining Technologies is performed at the Massachusetts Institute of Technology for the Office of Space Science and Applications, NASA, under Contract No. NASW-3740. The work is performed as a part of the Innovative Utilization of the Space Station Program. The final report from M.I.T. was issued in September 1983. This paper presents a summary of the work performed under this contract. The objective of this research program is to initiate research for the development of packaged, remotely controlled welding systems for space construction and repair. The research effort includes the following tasks: (1) identification of probable joining tasks in space; (2) identification of required levels of automation in space welding tasks; (3) development of novel space welding concepts; (4) development of recommended future studies; and (5) preparation of the final report

Identifying the effects of human factors and training methods on a weld training program

The purpose of this research was to enhance the welding training programs in technical colleges, post-secondary institutions, and industry to prepare certified welders. This dissertation contains three papers: (1) a study describing the ability of dexterity to predict future performance in beginning welders, (2) a study identifying the ability of virtual reality welding simulation to reduce the amount of anxiety experienced by beginning welders when completing test welds, and (3) a descriptive study assessing the ability of virtual reality welding simulations to evaluate seasoned welders. With a high demand for certified welders, training programs need efficient methods of preparing certified welders. It was concluded that all welding training participants experienced anxiety during test welds. In addition, the more a participant used the virtual reality welding simulator, the more the participant experienced anxiety during completion of test welds. This implies that a virtual reality integrated welding training program will reduce anxiety better than a 100% virtual reality training program. The use of virtual reality welding simulations may lead to heightened interest in welding among members of the gaming generation, which could lead to influx of individuals wanting to become welders. With increased numbers of potential welding trainees also comes an increase in cost of training (Mavrikios, Karabatsou, Fragos, & Chryssolouris, 2006). This increase in training cost has led welding training programs to look for criteria by which to select trainees. Dexterity has been documented as a needed skill among certified welders (Giachino & Weeks, 1985). Using the Complete Minnesota Dexterity Test, dexterity could predict future performance for simple welds (2F - horizontal fillet weld and 1G - flat groove weld). This implies that training programs that prepare trainees to become certified in the 2F and 1G weld types can use dexterity as a criterion for selecting potential trainees. Industry must also create a more efficient method of evaluating seasoned welders. The third article of the dissertation concluded that virtual reality welding simulations can distinguish between novice and seasoned welders. The conclusions from the three articles can be used to modify and improve welding training programs in technical colleges, four-year institutions, and industry to prepare certified welders

TOWARD INTELLIGENT WELDING BY BUILDING ITS DIGITAL TWIN

To meet the increasing requirements for production on individualization, efficiency and quality, traditional manufacturing processes are evolving to smart manufacturing with the support from the information technology advancements including cyber-physical systems (CPS), Internet of Things (IoT), big industrial data, and artificial intelligence (AI). The pre-requirement for integrating with these advanced information technologies is to digitalize manufacturing processes such that they can be analyzed, controlled, and interacted with other digitalized components. Digital twin is developed as a general framework to do that by building the digital replicas for the physical entities. This work takes welding manufacturing as the case study to accelerate its transition to intelligent welding by building its digital twin and contributes to digital twin in the following two aspects (1) increasing the information analysis and reasoning ability by integrating deep learning; (2) enhancing the human user operative ability to physical welding manufacturing via digital twins by integrating human-robot interaction (HRI). Firstly, a digital twin of pulsed gas tungsten arc welding (GTAW-P) is developed by integrating deep learning to offer the strong feature extraction and analysis ability. In such a system, the direct information including weld pool images, arc images, welding current and arc voltage is collected by cameras and arc sensors. The undirect information determining the welding quality, i.e., weld joint top-side bead width (TSBW) and back-side bead width (BSBW), is computed by a traditional image processing method and a deep convolutional neural network (CNN) respectively. Based on that, the weld joint geometrical size is controlled to meet the quality requirement in various welding conditions. In the meantime, this developed digital twin is visualized to offer a graphical user interface (GUI) to human users for their effective and intuitive perception to physical welding processes. Secondly, in order to enhance the human operative ability to the physical welding processes via digital twins, HRI is integrated taking virtual reality (VR) as the interface which could transmit the information bidirectionally i.e., transmitting the human commends to welding robots and visualizing the digital twin to human users. Six welders, skilled and unskilled, tested this system by completing the same welding job but demonstrate different patterns and resulted welding qualities. To differentiate their skill levels (skilled or unskilled) from their demonstrated operations, a data-driven approach, FFT-PCA-SVM as a combination of fast Fourier transform (FFT), principal component analysis (PCA), and support vector machine (SVM) is developed and demonstrates the 94.44% classification accuracy. The robots can also work as an assistant to help the human welders to complete the welding tasks by recognizing and executing the intended welding operations. This is done by a developed human intention recognition algorithm based on hidden Markov model (HMM) and the welding experiments show that developed robot-assisted welding can help to improve welding quality. To further take the advantages of the robots i.e., movement accuracy and stability, the role of the robot upgrades to be a collaborator from an assistant to complete a subtask independently i.e., torch weaving and automatic seam tracking in weaving GTAW. The other subtask i.e., welding torch moving along the weld seam is completed by the human users who can adjust the travel speed to control the heat input and ensure the good welding quality. By doing that, the advantages of humans (intelligence) and robots (accuracy and stability) are combined together under this human-robot collaboration framework. The developed digital twin for welding manufacturing helps to promote the next-generation intelligent welding and can be applied in other similar manufacturing processes easily after small modifications including painting, spraying and additive manufacturing

The Variable Polarity Plasma Arc Welding Process: Its Application to the Space Shuttle External Tank

This report describes progress in the implementation of the Variable Polarity Plasma Arc Welding (VPPAW) process at the External Tank (ET) assembly facility. Design allowable data has been developed for thicknesses up to 1.00 in. More than 24,000 in. of welding on liquid oxygen and liquid hydrogen cylinders has been made without an internal defect