Improving Global Quality of Life

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5.5 NDT and structural health monitoring (SHM) of welded and composite structures The trend of introducing light-weight structures in applications such as aviation, railway cars and the automotive industry has involved new joining technology (Laser welding, friction stir welding, adhesive joints) and new materials (high strength steels, Al-, Mg- and Ti-alloys, fibre reinforced composites). The classical NDT technology for maintenance will be replaced by structural health monitoring where in a short term strategy over the next few years, the aviation industry will monitor the fatigue experience of components such as a wing as a first step. These experiments have to be performed according to the damage tolerance concept in order to detect the early development of fatigue flaws and the speed of the damage accumulation. Possible sensor types for continuous monitoring will be tested in reliability tests. In a second step, the optimised sensors will be applied in the structure to monitor critical places where according to the design, fatigue damage can occur. The last step of the SHM strategy is the integration into the structure of reliable lifetime online integrity monitoring of 40 years. The added value by SHM is given by an extension of the maintenance intervals or - if these intervals will not be changed – by reducing the weight of the structure. Some sensors under development are based on fibre technology. Piezoelectric fibres can be embedded in the fibre composites. The fibre is a local transducer which can passively detect acoustic emission propagating from local damage but can also actively emit ultrasound interacting with flaws and producing reflected or scattered waves for detection. Other sensors under development are based on the use of guided waves and can be set at the surface of the composite structure to be monitored. These new type of sensors could be set on composite pressure vessels aiming to store hydrogen for fuel cell development. Figure 5.21 Simulation of propagation and interaction of an ultrasonic guided wave with a defect within a composite medium (reproduced courtesy Institut de Soudure/Georgia Tech university) (a) (b) (c) 5.6 Developments with “local engineering” & SHM towards “Intelligent welded structures” Materials engineers have the vision to further develop the SHM concept in combination with adaptive features. One idea is to utilise the SHM sensors to determine the actual state of a component, for instance the local mechanical stress state in an aircraft wing or the local dynamic pressure on the leading edge. By embedding piezoelectric actuators in the structure, the wing profile can be locally adapted in order to enhance the air gliding and to reduce fuel consumption or to damp vibrations. The wing of the plane is becoming intelligent, the structure is smart. In the case of railway cars, development projects in Europe aim for noise reduction by embedding piezoelectric sensors and actuators. A dream is that materials can be developed with a self-healing or self- repair function. In this case, the SHM sensors give early detection of the beginning of damage and the intelligent processing of the structure, initiates the repair by a local engineer. 50 Improving Global Quality of Life Through Optimum Use and Innovation of Welding and Joining Technologies
5.7 Strategies to face technological challenges in welding and joining technologies There are numerous IT programmes that have been developed and used for design, simulations and off-line programming and expert systems. These can drastically reduce the testing costs and time in the development of new products and check different design alternatives. There are several numerical programmes in the market for such calculations. With the Schaeffler /Delong programme for the calculation of an appropriate weld metal, it can save a lot of work effort compared to manual calculation. The required Heat Treatment of a welded product can easily be calculated with a computer programme. Welding cost calculation is another application suitable for computer calculation. Other examples include: Major cost savings can be realised e.g. by using the ABB software programmes. RobotStudio for simulation and optimising of the movement of the robot arm/wrist for off-line programming and as well welding cycle times. VirtualArc® for optimising of the welding parameters for optimising of welding parameters (Figure 5.15). These programmes are powerful tools to calculate the economical feasibility of planned investments. Figure 5.15 Comparison between calculated penetration with VirtualArc® and real penetration (Reproduced courtesy: ABB Robotics) a) Calculated penetration b) Real penetration SMEs have a huge challenge to introduce such IT-means. Many of the technicians in SMEs must be better educated and the programmes easier to use, which a survey in Sweden has shown. Welding companies can only be competitive by having the personnels with the right education and experience. IIW offers training courses and qualification through its members such as: IIW IWE – International Welding Engineer IIW IWT – International Welding Technologist IIW IWS – International Welding Specialist IIW IWP – International Welding Practitioner IIW IWSD – International Welded Structures Designer IIW IWI P – International Welding Inspection Personnel IIW IW – International Welder Competitive companies are likely to need to have certified welding personnel, with which IIW can assist. Certification of a company’s quality system is another way of getting appropriate procedures applied in order to get the right output quality in products, systems and services the company is delivering. Even in this case Through Optimum Use and Innovation of Welding and Joining Technologies Improving Global Quality of Life 51
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Improving Global Quality of Life Th
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Foreword Dr Baldev Raj Mr Chris Sma
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In alphabetical order (Continued) D
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6.3 Job, skill, career and competen
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9.6.3 Welding processes and challen
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Executive summary “ Welding is an
Page 14 and 15: Editors’ Preface Improving Global
Page 16 and 17: Scope and objectives 1 an important
Page 18 and 19: Welding industry 2.in the world 2.1
Page 20 and 21: 2.2 Today’s welding industry and
Page 22 and 23: 2 Welding industry in the world IIW
Page 24 and 25: 3.welding Signifi cance of and join
Page 26 and 27: 3.3 Welding and joining in sustaina
Page 28 and 29: An example of the value of welding
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Page 32 and 33: 4. Needs and challenges in welding
Page 34 and 35: Welding thick walled steel componen
Page 36 and 37: The trend towards light-weight desi
Page 38 and 39: Up-to-date, titanium alloys have be
Page 40 and 41: Needs for weight reduction in aircr
Page 42 and 43: Finally, testing of welds will be e
Page 44 and 45: As another most important item, the
Page 46 and 47: In order to make the developments i
Page 48 and 49: Reduction and/or elimination of dis
Page 50 and 51: 5. Needs and challenges in welding
Page 52 and 53: The productivity in EB welding has
Page 54 and 55: The potential applications are for
Page 56 and 57: 5.2 Higher automation, productivity
Page 58 and 59: In submerged arc welding one can re
Page 60 and 61: From a practical perspective, the n
Page 62 and 63: Acceptance levels are not included
Page 66 and 67: IIW can help companies to get their
Page 68 and 69: 6. Needs and challenges in health,
Page 70 and 71: welder against Cr6 is a very import
Page 72 and 73: is considerable national concern fo
Page 74 and 75: important in meeting needs with res
Page 76 and 77: 7. Legal codes, rules and standardi
Page 78 and 79: In national or regional legal codes
Page 80 and 81: 7.4.2 Optimum laws Laws applying in
Page 82 and 83: IIW needs to help ISO and others cl
Page 84 and 85: structures. It is unlikely in the s
Page 88 and 89: 8. Needs and challenges for global
Page 90 and 91: infrastructure to develop multiple
Page 92 and 93: Table 8.1 Key actions and key activ
Page 96 and 97: 9.7.1 Hot topics ..................
Page 98 and 99: New discoveries tend to be in deepw
Page 100 and 101: Proved reserves at end 2004 Trillio
Page 102 and 103: easily weldable, the life expectanc
Page 104 and 105: 9.1.3 Hot topics Reducing negative
Page 106 and 107: Following these codes assures initi
Page 108 and 109: 9.1.5 Hot topics Development and up
Page 110 and 111: 9.1.8 Power - Renewable Rising fuel
Page 112 and 113: 9.2.2 Production using joining tech
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still sometimes an unanswered quest
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2. To an increasing extent, joining
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nature and not specifically related
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9.3.2 Hot Topics The following issu
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industry have resulted in the need
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technology based on the existing pi
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general investment climate, includi
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10 000 Eq. SS range, MPa 1000 100 1
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Globalisation: PEI is operating in
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At the same time as automakers are
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On the other hand, when looking at
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9.7.2 Welding in the minerals proce
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Finland Poland Rest of the world Cr
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This situation is unsatisfactory an
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implementation of smart systems. In
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9.9.2 Hot topics Raising and enforc
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9.10.2 Welding industry role As des
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While items and directions may vary
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9.11.2 Hot topics In spite of these
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9.13.2 Preheat Preheating is carrie
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The electronic products industry se
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Portable power: In the Portable Pow
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the HRI report which accounted for
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9.16.2 Joining live tissues and coa
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(material removal, welding, surface
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Furthermore, in the field of dissim
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9.20 Small and medium enterprises
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and assessment. Multi-material desi
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0. Short, medium and long-term stra
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10.3.2 Typical hot topics In the me
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10.4 Long-term strategic agenda IIW
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162 Improving Global Quality of Lif
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[16] Mayr P et al., “Long-term cr
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IIW White Paper - Edition 2012 ISBN
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