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robotic welding
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Image
Published: 31 October 2011
Fig. 5 Robotic welding. Note wire feed device supplying “cold” wire. Courtesy of The Lincoln Electric Company
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Image
Published: 30 November 2018
Fig. 12 Gas tungsten arc robotic welding head with cold wire-feed device. Courtesy of Lincoln Electric Company
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Image
Published: 31 December 2017
Fig. 7 Robotic systems for friction stir welding/friction stir processing. (a) Articulated arm. (b) Parallel-kinematic arm. Source: Ref 14
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Image
Published: 31 October 2011
Fig. 4 C-frame ultrasonic welder on a robot arm welding a license plate holder to an aluminum automotive trunk lid
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Series: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001470
EISBN: 978-1-62708-173-3
... by several organizations, as of 1993. Less-complex systems should be released in the near future by welding robot vendors. Currently, an intelligent automation system for arc welding, called WELDEXCELL, is being developed for the U.S. Navy at the American Welding Institute (AWI). A graphical overview...
Abstract
Efforts in improving the efficiency of automated equipment lead to combining automatic joining equipment with a modem computer technique eventually known as artificial intelligence (intelligent automation) that usually includes an off-line planning system and a real-time adaptive control system connected through a computer communications interface. This article focuses on the application of intelligent automation system to arc welding, called WELDEXCELL, and other joining processes. An outline of the interface between off-line planners and real-time control systems is also provided.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005590
EISBN: 978-1-62708-174-0
... process: electrical shock, fumes and gases, arc radiation, and fire and explosion. arc radiation automatic welding electrical shock filler metals fire and explosion fumes gas tungsten arc welding power supplies robotic welding safety precautions shielding gas torch construction tungsten...
Abstract
The gas tungsten arc welding (GTAW) process derives the heat for welding from an electric arc established between a tungsten electrode and the part to be welded. This article provides a discussion on the basic operation principles, advantages, disadvantages, limitations, and applications of the process. It describes the equipment used for GTAW, namely, power supplies, torch construction and electrodes, shielding gases, and filler metals as well as the GTAW welding procedures. The article concludes with a review of the safety precautions to avoid possible hazards during the GTAW process: electrical shock, fumes and gases, arc radiation, and fire and explosion.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005635
EISBN: 978-1-62708-174-0
... Abstract This article presents an overview of the rules, regulations, and techniques implemented to minimize the safety hazards associated with welding, cutting, and allied processes. Safety management, protection of the work area, process-specific safety considerations, and robotic...
Abstract
This article presents an overview of the rules, regulations, and techniques implemented to minimize the safety hazards associated with welding, cutting, and allied processes. Safety management, protection of the work area, process-specific safety considerations, and robotic and electrical safety are discussed. The article explains the use of personal protective equipment and provides information on protection against fumes, gases, and electromagnetic radiation. It concludes with a discussion on safe handling of compressed gases as well as the prevention and protection of fire and explosion.
Series: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001363
EISBN: 978-1-62708-173-3
... of RSW. Major advantages of spot welding include high operating speeds and suitability for automation or robotization and inclusion in high-production assembly lines together with other fabricating operations. With automatic control of current, timing, and electrode force, sound spot welds can...
Abstract
Resistance spot welding (RSW) is a process in which faying surfaces are joined in one or more spots by the heat generated by resistance to the flow of electric current through workpieces that are held together under force by electrodes. This article discusses the major advantages of spot welding and the three principal elements, such as electrical circuit, control circuit, and mechanical system, of RSW machines. It reviews the three basic types of RSW machines: pedestal-type welding machines, portable welding guns, and multiple spot welding machines. The article provides information on weldabilily of uncoated steels and zinc-coated steels, as well as aluminum alloys.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005630
EISBN: 978-1-62708-174-0
... will cost less than the CO 2 laser. However, this part volume is not expected until well into the third production year ( Ref 10 ). Case Study—1/M Robotic Metal Inert Gas versus Robotic Laser Welding An automotive parts manufacturer had a contract to supply in excess of 375,000 completed...
Abstract
Properly designed beam-delivery optics is essential to quality of the beam acting on the workpiece and to the economics of the manufacturing process. This article describes the design considerations of laser beam delivery optics. It also reviews the manufacturing economics and presents two case studies of typical economic environments found in laser welding applications.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005607
EISBN: 978-1-62708-174-0
... are available. These include a hand-guided weld gun used for spot welding or for closing and sealing copper tubes for HVAC assembly ( Fig. 3 ) and a robot-controlled C-gun for welding automotive sheet metal assemblies, such as trunk lids or hoods ( Fig. 4 , 5 ). A continuous seam welder for foil welding...
Abstract
Ultrasonic metal welding is a solid-state welding process that produces coalescence through the simultaneous application of localized high-frequency vibratory energy and moderate clamping forces. This article discusses the parameters to be considered when selecting a suitable welder for ultrasonic metal welding. It details the personnel requirements, advantages, limitations, and applications, namely, wire welds, spot welds, continuous seam welds, and microelectronic welds of ultrasonic metal welding.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005594
EISBN: 978-1-62708-174-0
..., or trays is another common application of RSW. Major advantages of spot welding include high operating speeds and suitability for automation and inclusion in high-production assembly lines as well as other manufacturing operations. Repetitive spot welding can be carried out by the use of robots...
Abstract
Resistance spot welding (RSW) is the most widely used joining technique for the assembly of sheet metal products. This article discusses the process description, evaluation methods, and applications of RSW. It describes the equipment needed for RSW and explicates the major functions of electrodes in RSW and effect of surface condition on the technique. The article concludes with information on the safety precautions to be followed during the welding process.
Image
Published: 31 October 2011
Fig. 5 C-frame ultrasonic welder on a robot arm programmed to make successive spot welds on coupons for a tip life study
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Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005553
EISBN: 978-1-62708-174-0
... and partial truths. Fully automated welding robots will require a marriage between mechanistic approaches for phenomena that are physically well understood and mathematically feasible for both sensors and control algorithms and heuristic approaches for phenomena that are otherwise difficult or impractical...
Abstract
This article provides an overview of the methods used to control aspects of the arc welding process and research associated with the development of closed-loop feedback control of the process. Successful implementation of a closed-loop feedback control system requires sensing, modeling, and control. The article describes the commonly applied sensing techniques for arc welding control: arc sensing and nonimaging and imaging optics. It reviews the physics-based, empirically-derived, and neural network models for arc welding control. The article also discusses the research and development activities that attempt to extend the commercial, welding process controllers, namely, adaptive control, intelligent control, multivariable control, and distributed, hierarchical control.
Series: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001465
EISBN: 978-1-62708-173-3
.... The former Soviet Union experimented with a manual electron-beam welding gun for space application. However, x-ray shielding capacity is proportional to the mass of the shield; therefore, shielding of workers may be difficult due to the high cost of payload weight on spacecraft. Automated or robotic welding...
Abstract
Welding as an assembly process has become increasingly more attractive to designers of space structures because of its sufficient strength, endurance, reliability during their service lives, and ease of repair. This article reviews a variety of applications for welding in space and low-gravity environments and describes the unique aspects of the space environment. It compares the applicable welding processes, namely, electron-beam welding, laser-beam welding, and gas-tungsten arc welding and examines the metallurgy of low-gravity welds. Steps taken to ensure the continued development of welding technology in space are also discussed.
Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005849
EISBN: 978-1-62708-167-2
..., discharge chutes, pinch roll extractors, pick-n-place systems, and robots. billet pusher systems continuous conveyor systems dual pinch roll drive assemblies hot billet handling systems induction heating infeed bar handling systems infeed billet handling systems material handling equipment...
Abstract
The handling of billets or bars is an essential part of an induction heating system. This article describes two types of handling systems available for bar heating lines: inclined ramps with escapement, and sling feeder with inclined ramp and escapement. It focuses on the various infeed billet handling systems such as bin tippers, elevator feeders, rotary feeders, vibratory bowl feeders, magazine loaders, and rod feeders. The article provides information on the main categories of billet feeding systems, namely, dual pinch roll drive assemblies, tractor drive assemblies, billet pusher systems, walking beam assemblies, and index/continuous conveyor systems. It also discussed the hot billet handling systems used to deliver heated billets to the forging cell. These methods include billet extractor conveyors, accept/reject systems with pyrometer measurements, extractor rolls, discharge chutes, pinch roll extractors, pick-n-place systems, and robots.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005622
EISBN: 978-1-62708-174-0
... as those for conventional GTAW, especially when mechanized or robotic welding is employed. The only significant difference is a short arc length, preferably with arc voltage control (AVC). The use of AVC makes the technique a little more difficult to achieve when welding manually, and the deeper weld pool...
Abstract
Penetration-enhanced gas tungsten arc welding (GTAW) processes have been referred to variously as flux tungsten inert gas (TIG), A-TIG, and GTAW with a penetration-enhancing compound. This article provides a discussion on the principles of operation, advantages, disadvantages, procedures, and applications of GTAW. It also includes information on the equipment used and health and safety issues associated with GTAW.
Series: ASM Handbook
Volume: 18
Publisher: ASM International
Published: 31 December 2017
DOI: 10.31399/asm.hb.v18.a0006389
EISBN: 978-1-62708-192-4
... for FSW/FSP is commercially available. Figure 6 is an example of a modified milling machine capable of FSW/FSP operation. Fig. 6 Example of modified milling machine for friction stir welding/friction stir processing. Reprinted with permission from Elsevier. Source: Ref 15 Robotic FSW/FSP...
Abstract
This article discusses the application of friction stir processing (FSP) and friction surfacing for tribological components. It describes the three critical aspects involved in the application of FSP for near-surface material modifications intended for tribological applications. These include tools, processing parameters, and machines. The article also discusses the equipment and processing parameters for friction surfacing. It describes various hybrid stir processing techniques that involve preheating of the workpiece material, especially relatively hard and high-strength ones. The article presents a partial list of surface-modification methods based on FSP. The partial list includes surface hardening, surface composites, and additive coating. The article also provides information on generation of residual stresses in metallic materials and alloys form different variants of FSP.
Book Chapter
Book: Thermal Spray Technology
Series: ASM Handbook
Volume: 5A
Publisher: ASM International
Published: 01 August 2013
DOI: 10.31399/asm.hb.v05a.a0005759
EISBN: 978-1-62708-171-9
... or spray box structures and the equipment or systems—internal and external—required to operate the thermal spray processes within these enclosures. This includes the mitigation of sound, dust and fume, ultraviolet light, and mechanical (robotics) hazards that must be contained or controlled by a properly...
Abstract
This article discusses the safety issues associated with the design and operation of thermal spray booths and spray box structures and the equipment or systems required for operating thermal spray processes. It describes the design elements necessary to mitigate sound, dust and fume, ultraviolet light, and mechanical hazards. The means selected for safeguarding personnel must be based on a formal risk assessment that meets ANSI/RIA standards. The safeguards include sensing devices, barriers, awareness signals, procedures, and training. It also provides guidelines that are intended to increase the safety awareness and the use of safety practices for gas and liquid piping and electrical equipment within thermal spray installations.
Series: ASM Handbook
Volume: 24A
Publisher: ASM International
Published: 30 June 2023
DOI: 10.31399/asm.hb.v24A.a0006959
EISBN: 978-1-62708-439-0
... repetitive and laborious construction tasks. These single-task robots are designed to imitate skilled labor in performing a specific task. Examples include robots for concrete finishing, welding, spray painting, rebar placement, tile inspection, and material handling ( Ref 12 , 15 ). The industrial-scale...
Abstract
Construction-scale additive manufacturing, also known as construction three-dimensional printing (C3DP), has received significant attention as a technology that could transform the construction industry by offering a highly automated construction process for various applications. This article presents an overview of the current developments in C3DP as well as future prospects and discusses the technical and regulatory barriers to its widespread adoption by the construction industry. It also presents a detailed discussion on construction-scale additive manufacturing technologies.
Book Chapter
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005355
EISBN: 978-1-62708-187-0
.... These finishing operations include: Shotblasting Grinding (from coarse to fine, depending on the casting finish quality) Trimming Machining (milling, drilling) Quality testing and inspection Depending on the alloy and requirements, the processing of castings may also include repair welding...
Abstract
After solidification and cooling, further processing and finishing of the castings are required. This article describes the general operations of shakeout, grinding, cleaning, and inspection of castings, with particular emphasis on automation technology. It illustrates the vertical core knockout machine and the A-frame core knockout machine and lists the advantages and disadvantages of these machines. The article describes the general factors in automated or manual gate removal process. It concludes with discussion on the various types of inspection, such as the liquid penetrant inspection, pressure testing, radiographic inspection, magnetic particle inspection, and ultrasonic inspection.
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