Digital Lifecycle Manufacturing / Laser Welding Applications Lab

Project Description: The scope of this iCASE PhD project is to model and simulate the formation and propagation of weld cracks in RLW of 6xxx high strength aluminium extrusions and to integrate those models with readily available sensors in order to enable in-process monitoring of RLW weldments. During this project, we will complement sensor data streams, gathered by in-process detectors and processed via machine learning techniques, with physics-driven CAE simulation. The physics-driven CAE simulation will combine knowledge about the laser-to-material interaction, solidification mechanisms, thermo-dynamics and material microstructure. Besides, the physics-driven simulation approach will also be used as a standalone tool during the early design stages to support the selection of welding parameters and make a more informative decision about the crack sensitivity of specific aluminium alloys. This project will develop new capabilities for modelling and characterising cracking mechanisms in 6xxx high strength aluminium extrusions, and the outcomes of the project will inform: (1) selection and optimisation of welding process parameters; (2) in-process monitoring of weld cracks; (3) adaptive closed-loop process control, with the final aim to achieving defect-free welds.

Project Summary and workplan
Objectives of the iCASE program are as follows:
(1) Review existing models for modelling and prediction of mechanisms of weld cracking
(2) Development of physics-driven CAE simulation
(3) Propose strategy for integrating physics-driven CAE simulation and sensor data streams
(4) Verification and validation of proposed models with relevant materials (alloys and core applications to be selected based on Constellium's input).

Fit to EPSRC Themes: The project directly addresses the ESPRC theme 'Manufacturing the Future'. It also directly contributes to ESPRC research areas such as Manufacturing Technologies and Materials Engineering - Metals and Alloys.