Process physics understanding, real time monitoring, and control of various manufacturing processes, such as battery manufacturing, are crucial for product quality assurance. While ultrasonic welding has been used for joining batteries in electric vehicles (EVs), the welding physics, and process attributes, such as the heat generation and heat flow during the joining process, is still not well ...

Double-Electrode Gas Metal Arc Welding, referred to as DE-GMAW, is a novel process which decouples the melting current into base metal current and bypass current by adding a bypass torch to a conventional GMAW system to establish a bypass arc. This makes it possible to increase the melting current while the base metal current still be controlled at a desired level. Experiments have been done to...

Quasi-keyhole is a novel approach proposed to operate the keyhole arc welding process. Because the method’s effectiveness depends on the amperage of the peak current used to establish the keyhole, this paper proposes adjusting the amperage based on the duration of the peak current, which equals the keyhole establishment time. A nominal model structure has been selected from those identified usi...

The friction welding of Zr55Al10Ni5Cu30 bulk metallic glasses (BMG) has been tried. An apparatus for the friction welding of BMGs adopting a pneumatic cylinder and gripper based on a conventional lathe, and a welding process which provides a sufficient cooling rate after welding were devised. Friction time and friction pressure were chosen as the control parameters in the friction welding proce...

Laser welding is a widely used but complex industrial process. In this work, we propose the use of an integrated machine intelligence architecture to help address the significant control difficulties that prevent laser welding from seeing its full potential in process engineering and production. This architecture combines three contemporary machine learning techniques to allow a laser welding c...

During arc welding, the arc heats and melts the workpiece as heat flux. When the welding current is given, the distribution and the intensity of the heat flux are determined by the length of the arc. The measurement and control of the arc length are fundamental in robotic and automated welding operations. Length of welding arc determines the distribution of the arc energy and thus the heat inpu...

Purpose: This study aims to examine the interaction between process parameters and bead geometry, to perform the research to predict optimal bead geometry (bead width, reinforcement height, left leg length, right leg length) through the analysis of experimental data. For this, not only linear and the curvilinear equations were developed to predict bead geometry, but also interactions between pr...

It is important to adjust the welding gun's inclination during automatic curved-joint tracking of arc welding. In this paper, a novel method is proposed to detect the deviation and inclination of the welding gun based on the arc currents acquired by a high-speed rotational arc sensor. It uses a least-squares method to fit the arc currents to a plane in three dimensions. The deviation and inclin...

Submerged arc welding also known as sub arc welding has become a chief welding process because of its ability to deposit large amounts of metal with high penetration. The quality of weld depends on bead geometry of the weld which in turn depends on the process variables. This paper deals with the application of factorial design approach for optimising four submerged arc welding parameters viz. ...

An adaptive control based on fuzzy logic has been implemented for Gas Tungsten Arc Welding (GTAW). This adaptive controller eliminates the problems frequently experienced with traditional Automatic Voltage Control (AVC) systems, which do not adequately perform for all operational conditions because of the non-linear relationship between the arc voltage, current and arc length. This paper examin...