Development of Robotized Laser Welding Applications for Joining Thin Sheets

Laser Welding (LW) is more often used in manufacturing due to its advantages, such as accurate control, good repeatability, less heat input, opportunities for joining of special materials, high speed, capability to join small dimension parts etc. LW is dedicated to robotized manufacturing, and the fabrication cells are using various level of flexibility, from specialized robots to very flexible setups. This paper features several LW applications using two industrially-scaled manufacturing cells at UPM Laser Centre (CLUPM) of Polytechnical University of Madrid (Universidad Politécnica de Madrid). The one dedicated to Remote Laser Welding (RLW) of thin sheets for automotive and other sectors uses a CO2 laser of 3500 W. The second has a high flexibility, is based on a 6-axis ABB robot and a Nd:YAG laser of 3300 W, and is meant for various laser processing methods, including welding. After a short description of each cell, several LW applications experimented at CLUPM and recently implemented in industry are briefly presented: RLW of automotive coated sheets, LW of high strength automotive sheets, LW vs. laser hybrid welding (LHW) of Double Phase steel thin sheets, and LHW of thin sheets of stainless steel and carbon steel (dissimilar joints). The main technological issues overcame and the critical process parameters are pointed out. Conclusions about achievements and trends are provided.

Characterization Of Friction Stir Welded Joints Of Aa 2024-T351 - Native Vs. Treated By Laser Shock Processing

The paper presents a consistent set of results showing the ability of Laser Shock Processing (LSP) in modifying the overall properties of the Friction Stir Welded (FSW) joints made of AA 2024-T351. Based on laser beam intensities above 109 W/cm2 with pulse energies of several Joules and pulses durations of nanoseconds, LSP is able of inducing a compression residual stress field, improving the wear and fatigue resistance by slowing crack propagation and stress corrosion cracking, but also improving the overall behaviour of the structure. After the FSW and LSP procedures are briefly presented, the results of micro-hardness measurements and of transverse tensile tests, together with the corrosion resistance of the native joints vs. LSP treated are discussed. The ability of LSP to generate compressive residual stresses and to improve the behaviour of the FSW joints is underscored.

Estudios de confort de vehículos ferroviarios mediante técnicas combinadas de simulación FEM y MBS

La elasticidad de la caja de viajeros de los vehículos ferroviarios tiene una gran influencia sobre el confort. Por esta razón, cuando se desea simular el comportamiento dinámico del vehículo para estudios de confort, resulta conveniente construir un modelo elástico de caja, a fin de obtener resultados más precisos. La construcción de este tipo de modelos pasa por el desarrollo de dos etapas fundamentales, que comprenden la generación de un modelo de caja mediante la técnica de los elementos finitos (FEM) para su caracterización dinámica como cuerpo elástico y la definición de un modelo de sistema multicuerpo (MBS) que englobe los restantes componentes del vehículo. En este artículo se presentan los resultados obtenidos en un estudio comparativo llevado a cabo con modelos de caja rígida y elástica, en los que se ha valorado el nivel de confort obtenido con ambas configuraciones. Para ello, se ha simulado el comportamiento del vehículo a dos velocidades distintas, de 70 y 110km/h, y con dos niveles de irregularidades. Se han analizado las aceleraciones de la caja, que se han procesado de acuerdo a las especificaciones de la norma EN12299, a fin de obtener el índice de comodidad. Este parámetro se ha utilizado para comparar el nivel de confort obtenido con ambos modelos, habiéndose encontrado una gran diferencia en los índices calculados con caja rígida y con caja elástica, lo que confirma la gran influencia de la elasticidad de la caja en los estudios de confort llevados a cabo mediante técnicas de simulación dinámica.

Control rod drop surveillance using two friction coefficients

In the case of large burnup, a control rod (CR) guide tube in the pressurized water reactor of a commercial nuclear power plant might bend. As a consequence, a CR drop experiment may indicate an event of a CR partially inserted and whether the CR should be deemed inoperable. Early prevention of such an event can be achieved by measuring two friction coefficients: the hydraulic coefficient and the sliding coefficient. The hydraulic coefficient hardly changes, so that the curvature of the guide tube can only be detected thanks to a variation of the sliding coefficient. A simple model for the CR drop is established and validated with CR drop experiments. If tmx denotes the instant of CR maximum velocity, a linear relationship between (tmx)_2 and the sliding coefficient is found.

Asymptotic Description of Flutter Amplitude Saturation by Nonlinear Friction Forces

The computation of the non-linear vibration dynamics of an aerodynamically unstable bladed-disk is a formidable numerical task, even for the simplified case of aerodynamic forces assumed to be linear. The nonlinear friction forces effectively couple dif- ferent travelling waves modes and, in order to properly elucidate the dynamics of the system, large time simulations are typically required to reach a final, saturated state. Despite of all the above complications, the output of the system (in the friction microslip regime) is basically a superposition of the linear aeroelastic un- stable travelling waves, which exhibit a slow time modulation that is much longer than the elastic oscillation period. This slow time modulation is due to both, the small aerodynamic effects and the small nonlinear friction forces, and it is crucial to deter- mine the final amplitude of the flutter vibration. In this presenta- tion we apply asymptotic techniques to obtain a new simplified model that captures the slow time dynamics of the amplitudes of the travelling waves. The resulting asymptotic model is very re- duced and extremely cheap to simulate, and it has the advantage that it gives precise information about the characteristics of the nonlinear friction models that actually play a role in the satura- tion of the vibration amplitude.

Asymptotic Description of Flutter Amplitude Saturation by Nonlinear Friction Forces

The computation of the non-linear vibration dynamics of an aerodynamically unstable bladed-disk is a formidable numerical task, even for the simplified case of aerodynamic forces assumed to be linear. The nonlinear friction forces effectively couple dif- ferent travelling waves modes and, in order to properly elucidate the dynamics of the system, large time simulations are typically required to reach a final, saturated state. Despite of all the above complications, the output of the system (in the friction microslip regime) is basically a superposition of the linear aeroelastic un- stable travelling waves, which exhibit a slow time modulation that is much longer than the elastic oscillation period. This slow time modulation is due to both, the small aerodynamic effects and the small nonlinear friction forces, and it is crucial to deter- mine the final amplitude of the flutter vibration. In this presenta- tion we apply asymptotic techniques to obtain a new simplified model that captures the slow time dynamics of the amplitudes of the travelling waves. The resulting asymptotic model is very re- duced and extremely cheap to simulate, and it has the advantage that it gives precise information about the characteristics of the nonlinear friction models that actually play a role in the satura- tion of the vibration amplitude.

Laser Shock Processing influence on local properties and overall tensile behavior of friction stir welded joints

Based on laser beam intensities above 109 W/cm2 with pulse energy of several Joules and duration of nanoseconds, Laser Shock Processing (LSP) is capable of inducing a surface compressive residual stress field. The paper presents experimental results showing the ability of LSP to improve the mechanical strength and cracking resistance of AA2024-T351 friction stir welded (FSW) joints. After introducing the FSW and LSP procedures, the results of microstructural analysis and micro-hardness are discussed. Video Image Correlation was used to measure the displacement and strain fields produced during tensile testing of flat specimens; the local and overall tensile behavior of native FSW joints vs. LSP treated were analyzed. Further, results of slow strain rate tensile testing of the FSW joints, native and LSP treated, performed in 3.5% NaCl solution are presented. The ability of LSP to improve the structural behavior of the FSW joints is underscored.

Development of FEM/BEM and SEA models from experimental results for structural elements with attached equipment

This work focuses on the analysis of a structural element of MetOP-A satellite. Given the special interest in the influence of equipment installed on structural elements, the paper studies one of the lateral faces on which the Advanced SCATterometer (ASCAT) is installed. The work is oriented towards the modal characterization of the specimen, describing the experimental set-up and the application of results to the development of a Finite Element Method (FEM) model to study the vibro-acoustic response. For the high frequency range, characterized by a high modal density, a Statistical Energy Analysis (SEA) model is considered, and the FEM model is used when modal density is low. The methodology for developing the SEA model and a compound FEM and Boundary Element Method (BEM) model to provide continuity in the medium frequency range is presented, as well as the necessary updating, characterization and coupling between models required to achieve numerical models that match experimental results.

A FEM-BEM coupling procedure through the Steklov-Poincarè operator

Many advantages can be got in combining finite and boundary elements.It is the case, for example, of unbounded field problems where boundary elements can provide the appropriate conditions to represent the infinite domain while finite elements are suitable for more complex properties in the near domain. However, in spite of it, other disadvantages can appear. It would be, for instance, the loss of symmetry in the finite elements stiffness matrix, when the combination is made. On the other hand, in our days, with the strong irruption of the parallel proccessing the techniques of decomposition of domains are getting the interest of numerous scientists. With their application it is possible to separate the resolution of a problem into several subproblems. That would be beneficial in the combinations BEM-FEM as the loss of symmetry would be avoided and every technique would be applicated separately. Evidently for the correct application of these techniques it is necessary to establish the suitable transmission conditions in the interface between BEM domain and FEM domain. In this paper, one parallel method is presented which is based in the interface operator of Steklov Poincarè.

Discrimination of AE Signals From Friction and Concrete Cracking in a Reinforced Concrete Frame Subjected to Seismic Trainings

This paper shows the preliminary results of the development and application of a procedure to filter the Acoustic Emission (AE) signals to distinguish between AE signals coming from friction and AE signals coming from concrete cracking. These signals were recorded during the trainings of an experiment carried out on a reinforced concrete frame subjected to dynamic loadings with the shaking table of the University of Granada (Spain). Discrimination between friction and cracking AE signals is the base to develop a successful procedure and damage index based on AE testing for health monitoring of RC structures subjected to earthquakes.

Residual stress distribution in ferritic-austenitic steel joints made by laser welding

The present investigation addresse the influence of laser welding process-ing parameters used for joining dis-similar metals (ferritic to austenitic steel), on the induced residual stress field. Welding was performed on a Nd:YAG laser DY033 (3300 W) in a continuous wave (CW), keyhole mode. The base metals (BM) employed in this study are AISI 1010 carbon steel (CS) and AISI 304L austenitic stainless steel (SS). Pairs of dissimilar plates of 200 mm x 45 mm x 3 mm were butt joined by laser welding. Different sets of parameters were used to engineer the base metals apportionment at joint formation, namely distinct dilution rates. Residual strain scanning, carried out by neutron diffraction was used to assess the joints. Through-thickness residual stress maps were determined for the laser welded samples of dis-similar steels using high spatial reso-lution. As a result, an appropriate set of processing parameters, able to mi-nimize the local tensile residual stress associated to the welding process, was found.

Residual stress distribution in ferritic to austenitic steel joints made by laser welding,

In this study, autogenous laser welding was used to join thin plates of low carbon ferritic and austenitic stainless steel. Due to the differences in the thermo-physical properties of base metals, this kind of weld exhibits a complex microstructure, which frequently leads to an overall loss of joint quality. Four welded samples were prepared by using different sets of processing parameters, with the aim of minimizing the induced residual stress field. The dissimilar austenitic-ferritic joints obtained under all welding conditions were uniform and free of defects. Variations in beam position did not influence the weld geometiy, which is a typical keyhole welding. Microstructural characterization and residual strain scanning (by neutron diffraction) were used to assess the features of the joints. By varying laser beam power density and by displacing the laser beam towards the carbon steel side, an optimum combination of processing parameters was found.

Effect of LSP treatment on the surface topography, friction and wear of Al2024 alloy

OUTLINE: •Introduction •Experimental Setup • Experimental Procedure • Experimental Results - Surface Roughness - Residual Stresses - Friction - Wear - EDX •Conclusions

A comparative analysis between FEM and Boundary Methods in bending of Plates

Two different methods of analysis of plate bending, FEM and BM are discussed in this paper. The plate behaviour is assumed to be represented by using the linear thin plate theory where the Poisson-Kirchoff assumption holds. The BM based in a weighted mean square error technique produced good results for the problem of plate bending. The computational effort demanded in the BM is smaller than the one needed in a FEM analysis for the same level of accuracy. The general application of the FEM cannot be matched by the BM. Particularly, different types of geometry (plates of arbitrary geometry) need a similar but not identical treatment in the BM. However, this loss of generality is counterbalanced by the computational efficiency gained in the BM in the solution achievement

Overall vs. local mechanical behaviour of ferritic austenitic steel joints made by laser welding

The present investigation addresses the overall and local mechanical performance of dissimilar joints of low carbon steel (CS) and stainless Steel (SS) thin sheets achieved by laser welding in case of heat source displacement from the weld gap centreline towards CS. Welding was performed on a Nd:YAG laser DY033 (3300 W) in a continuos wave (CW), keyhole mode. The tensile behavior of the joint different zones assessed by using a video-image based system (VIC-2D) reveals that the residual stress field, together with the positive difference in yield between the weld metal and the base materials protects the joint from being plastically deformed. The tensile loadings of flat transverse specimens generate the strain localization and failure in CS, far away from the weld.