Quality Control Of Aluminium Laser-welded Assemblies QCOALA PowerPoint... · • Integrated non-destructive testing – Eddy-current ... • A digital radiography and eddy current
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To develop a new laser processing systemfor the welding of thin-gauge aluminium and copper, 0.1mm to 1.0mm in thickness, with integrated process monitoring and in-line
non-destructive inspection, and
to establish its capability to provide a reliable, high-speed, low-cost and high-quality joining solution for electric car battery and thin-film
– QA through real-time process monitoring and NDT inspection– Weld fingerprint: measure compare action– Integrated ICT and SPC: 100% non-destructive inspection to
reduce scrap to <1% and pseudo-errors<1%
• Productivity:– Tailored energy strategies for aluminium and copper (⇩>20%)– Optimum weld quality reliability / durality productivity (⇧
– Review of commercial sources and delivery options suitable for welding 0.1-1.0mm Al and Cu
– Development of green (532nm λ) laser test platform by M12. Effect of λ on welding performance*.
– Development of on-line temporal pulse control (closed-loop control of the monitored process).
– Development of a dual-wavelength scanning system, capable of emitting both the 532nm and the 1064nm. To be integrated into QCOALA laser demonstration platform by M24.
* Welding performance = absorption, welding speed and weld quality
– Empirical evaluation of the effect of spot size, beam quality. pulse length, average and peak power, and repetition rate, on welding performance* of 0.1-1.0mm Al and Cu for 1064nm λ.
– Empirical evaluation of the effect of the 532nm λ on welding performance*
– Develop tailored energy strategies to control HI and keyhole/weld pools stability
* Welding performance = absorption, welding speed and weld quality
QCOALA technologies• Integrated Process Monitoring
– Development of a CMOS camera-based WMS that can handle both 532nm and 1064nm, capable of assessing weld pool stability and identifying likelihood of imperfections occurring, through fast-rate image acquisition (>1000fps). The imperfection-recognition software will comprise image processing algorithms.
– Development of an interactive WMS graphical user-interface
– Integration of the WMS into the QCOALA laser demonstration platform
– Development of Eddy Current (EC) weld inspection probes with very small sensing area (estimated <0.5mm) and very high frequency (estimated >1MHz), with suitable instrumentation. Modelling and experimental validation
– Development of digital radiography (DR) weld inspection system with contrast sensitivity <2% and spatial resolution better than 10µm will be developed, with incorporated Automatic Defect Recognition (ADR)
Project Steering Committee (PSC)• Project Coordinator• Exploitation Manager• One (senior) representative from each Beneficiary• Six-monthly meetings, chaired by Project Coordinator• Responsible for the overall project control and delivery
– Monitoring of project progress: proper integration of activities, link between Work Packages (WPs) and clear consideration of exploitation
– Approval of changes to technical work programme, project finances and exploitation of results
– Timely submission of deliverables (incl. progress reports and cost statements)
Work PackagesWP 3 – Intelligent laser welding (TWI)• To assess the effect of spot size, beam quality, laser
wavelength (in particular ~1064nm and ~532nm), pulse duration, pulse repetition rate, average and peak power, on the welding performance of Al and Cu interconnections in terms of absorption efficiency, welding speed and weld quality (process stability).
• To develop a tailored energy strategy to allow the development of on-line temporal pulse capability of the QCOALA laser demonstration platform (WP2).
• To develop the optimum process parameter window and establish welding strategy for high-quality welding of thin-film PV cell interconnections and electric battery Al and Cu interconnections.
Work PackagesWP 6 – System integration and demonstration (RUB)• To integrate the WMS, the DR and the EC inspection systems
into the QCOALA laser demonstration platform• To evaluate the performance of the fully integrated QCOALA
system in a real production environment for the high-quality welding of electric car battery and thin-film PV cell interconnections, and compare with current conventional joining technology.
WP 7 – Project Management (TWI)• To ensure that the QCOALA project is well managed, the
objectives met in the agreed timescales, the results are effectively exploited, the deliverables and milestones are achieved, and the financial and contractual aspects adhered to.
Work PackagesWP 8 – Exploitation & dissemination (PRE)• To generate information and technology from the results of the
project and disseminate these by means of conferences, publications, and other means and to develop and implement exploitation plans (including training) for each project Beneficiary. Special attention will be taken on IPR issues.
Progress monitoring and reporting• Project Coordinator
– 12-month and 24-month periodic review• Activity report and Management report• Technical progress: collectively and individually• Review of finances and exploitation plan• Involving all Beneficiaries and Scientific Officer
– End review at month M36– Report on progress and redefine, if necessary, the
remainder of the project programme • EC reviews against milestones, deliverables and
exploitation to decide on continuation of Grant Agreement