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Automation in the Welding Industry

Incorporating Artificial Intelligence, Machine Learning and Other Technologies
Edited by Syed Quadir Moinuddin, Shaik Himam Saheb, Ashok Kumar Dewangan, Muralimohan Cheepu and S. Balamurugan
Series: Industry 5.0 Transformation Applications
Copyright: 2024   |   Status: Published
ISBN: 9781394172412  |  Hardcover  |  
304 pages
Price: $195 USD
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One Line Description
This volume serves as a multidimensional perspective of welding practices in Industry 5.0 from the perspective of automation, digitization, digital twins, cobots, virtual reality, augmented reality, machine learning, artificial intelligence, and IoT ranging from rudiments to advanced applications.

Audience
Engineering research scholars, industry welding, and additive manufacturing groups. A diverse group of industries will be interested in this book, such as medical, automotive, construction, pipeline, shipping, aerospace, etc.

Description
This book introduces the concept of Industry 5.0 in welding technologies, where the human brain collaborates with robots to achieve rapid productivity and economic efficiency. It presents the latest information on adapting and integrating Industry 5.0 in welding industries through critical constituents such as artificial intelligence (AI), machine learning (ML), Internet of Things (IoT), digital twin, augmented and virtual reality (AR & VR), and collaborative robots (Cobots), towards intelligent welding systems. The chapter authors have comprehensively addressed the issues related to welding industries such as a shortage of welders, challenges in critical applications, creating defect-free and quality products through real-time monitoring, feedback systems, and in situ adjustments, etc. The utilization of cobots in welding technology is addressed in real-world problems to move towards a green welding environment (i.e., minimal fumes with less shielding gas) and thereby, less energy consumption. Two or more welding processes are combined to form a hybrid process where the compatibility of existing materials and novel materials can be used in 3D, 4D, and 5D printing of complex geometries.

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Author / Editor Details
Syed Quadir Moinuddin, PhD, is an assistant professor in the Department of Mechanical Engineering, College of Engineering, King Faisal University, Al-Houfuf, Kingdom of Saudi Arabia. He has 14 years of research and 5 years of teaching experience in the field of manufacturing science. Through his research work, he has contributed to national and international publications via book chapters, journal articles, and conferences.

Shaik Himam Saheb, PhD, is an assistant professor in the Department of Mechatronics Engineering, at ICFAI Foundation for Higher Education (deemed to be a University), Hyderabad, Telangana, India. He has published many articles in international journals and conferences. The team guided by him has received a national-level Go-Kart Championship award organized by the Indian Society of New Era Engineers.

Ashok Kumar Dewangan, PhD, is an assistant professor in the Department of Mechanical Engineering, National Institute of Technology Delhi, India. He has published 25 research papers in reputed peer-reviewed international journals, conferences, and book chapters. Currently, he is working in a few areas including thermal modeling of selective laser melting, and single/twin wire gas metal arc welding.

Murali Mohan Cheepu, PhD, is a research manager at Starwelds Inc. Busan, Republic of Korea. He has several years of industry experience specializing in the development of wire arc additive manufacturing processes for large-scale components, welding process design, automation, digitalization, and artificial intelligence. He has published numerous papers in scientific and conference proceedings, edited books, and patents.

S. Balamurugan, PhD, is the Director of Research and Development, Intelligent Research Consultancy Services (iRCS), Coimbatore, Tamilnadu, India. He is also Director of the Albert Einstein Engineering and Research Labs (AEER Labs), as well as Vice-Chairman, Renewable Energy Society of India (RESI), India. He has published 45 books, 200+ international journals/ conferences, and 35 patents.

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Table of Contents
Preface
Acknowledgments
1. Introduction to Industry 5.0

Muralimohan Cheepu, Syed Quadir Moinuddin and Ashok Kumar Dewangan
1.1 Introduction
1.2 Industry 4.0
1.3 Industry 5.0
References
2. Advancements in Welding Technologies
Pavan Meena, Ansari Mohd Farhan, Ramkishor Anant and Shaik Himam Saheb
2.1 Introduction
2.2 Quality of Weld Joint
2.3 Pulsed Current GMAW
2.4 P-GMAW Process Stability Factors
2.5 Suitable Pulse Parameters of Selection
2.6 Effect of Pulse Parameters
2.6.1 Weld Bead Geometry
2.6.2 Weld Dilution
2.6.3 Weld Microstructure
2.7 Pulsed Current GMAW Advances
2.8 Double-Pulsed GMAW
2.9 Synergic Control
2.10 Self-Regulating Control
2.11 Microcomputer Control
2.12 GMAW Shielding Gas Flow
2.13 Particle Image Velocimetry (PIV)
2.14 The Measurement of Oxygen (O2) Concentration
2.15 Spectroscopic Measurements of Plasma Temperature
2.16 P-GMAW Numeric Simulation
2.16.1 Approach-1
2.16.2 Approach-II
References
3. Automation in Welding Industries
Deepak Kumar Naik, Ved Prakash Sharma and Dinesh Kumar R.
3.1 Introduction
3.1.1 Types of Automatic Welding
3.1.2 Challenges of Automatic Welding
3.1.3 Benefits of Automatic Welding
3.2 Automation Trends
3.2.1 Production Monitoring
3.2.2 Adaptive Welding Advancements
3.2.3 Upstream Practices
3.2.4 Collaborative Technology
3.2.5 Easier Programming of Automation Systems
3.3 Plasma Welding
3.4 Laser Welding
3.5 Arc Welding
3.6 MIG Welding
3.7 Resistance Welding
3.8 Conclusions
References
4. Digitalization of Welding Processes
Atla Sridhar, K. Prasanna Lakshmi, Shaik Himam Saheb and M. Siva Surya
4.1 Introduction
4.2 Techniques for Process Monitoring
4.2.1 Electrical Process Tests: Voltage and Current for Welding
4.2.2 Thermal Measurement
4.2.3 Optical Measurement
4.2.4 Acoustic Measurement
4.2.5 Measurement of Displacement and Velocity
4.2.6 Measurement of Force
4.3 Process Monitoring Applications
4.3.1 Measurement of Current and Voltage
4.3.2 Thermal Measurement
4.3.3 Optical Measurement
4.3.4 Acoustic Measurement 6
4.3.5 Displacement and Velocity Measurement
4.3.6 Measurement of Force
4.3.7 EMF Measurement
4.4 Future Directions
References
5. AI and ML in Welding Technologies
Suresh Goka, Gorle Shanmukha Narayana, Divya Jyothi G., Himam Saheb Shaik and Syed Quadir Moinuddin
Nomenclature
5.1 Introduction
5.2 Enhancing the Welding Industry
5.3 Machine Learning Algorithm Types
5.4 Background of AI and ML
5.5 Weld Defects
5.6 Level of Weld Quality
5.6.1 Mining Industry
5.6.2 Challenges in ML Practice
5.7 Case Studies
5.7.1 Use of AI Programs to Obtain CCT Welding Diagrams
5.7.2 Use of Algorithms to Predict the Penetration Depth in Friction Stir Spot Welding
5.8 Feasibility of Online Inspection of Ultrasonic Weld Quality
5.9 Conclusions
References
6. Digital Twin in Welding
Syam Kumar Chokka, M. Nagaraju and K. Nagabushan Kumar
6.1 Introduction
6.2 Friction Stir Welding
6.2.1 FSW Parameters
6.3 Defects in Friction Stir Welding
6.3.1 DT for FSW
6.4 Laser Welding
6.4.1 Heat Conduction Welding
6.4.2 Deep Penetration or Keyhole Welding
6.4.3 Weld Process Parameters
6.4.3 DT for Laser Welding
6.5 Summary
References
7. IoT in Welding Industries
Harisivasri Phanindra K., S. Venukumar, Muralimohan Cheepu and Venkata Charan Kantumuchu
7.1 Introduction
7.2 Sensing and Analyzing Welding Data via the Internet of Things (IoT)
7.2.1 Electrical Information
7.2.2 Optical Information
7.3 Welding Manufacture Based on IoT
7.3.1 Example 1: Arc Quality Management with IoT
7.3.2 Example 2: Case Study on IoT-Enabled Molten Metal Temperature Sensing System for Welding
7.3.3 Example 3: IoT-Based Safety Monitoring System During Welding Operations
7.3.4 Example 4: IoT-Based Monitoring of Submerged Arc Welding Process
7.4 Conclusion
References
8. VR and AR in Welding Technologies
Veningston K. and Dinesh Kumar Rajendran
8.1 Introduction
8.1.1 Virtual Reality (VR)
8.1.2 Augmented Reality (AR)
8.1.3 Artificial Intelligence (AI)
8.1.4 Machine Learning (ML)
8.2 How Intelligent is AI When Coupled with VR/AR?
8.3 VR/AR Architecture
8.4 Welding Processes
8.5 Intelligent Welding Technology
8.6 Types of Intelligent Welding Processes
8.6.1 Types of Welding Positions
8.7 Automated Welding Examples
8.7.1 Computer Interface of Automated Welding Processes
8.8 Applications of VR and AR in Automated Welding
8.9 AI and ML for Visual Inspection of Welds
8.9.1 AI in Arc Welding
8.9.2 AI Detection of Welding Defects
8.9.3 VR/AR Welding Simulator
8.10 Limitations in the Existing State-of-the-Art Welding Techniques
8.10.1 Advantages of AR/VR
8.11 Conclusions
References
9. Intelligent, Clean Cobot Arc Welding Cell
E. Schubert, S. Rose, M. Bender, N. Spietz and T. Weber
9.1 Chances for SMEs
9.1.1 Introduction and Goals
9.2 Parameters and Consumption Data
9.3 CO2 Footprint Methodology
9.4 Result Presentation
9.5 Conclusion
Acknowledgments
References
10. Welding-Based 3D, 4D, 5D Printing
Suresh Goka, Satish Narayana Srirama, Divya Jyothi G., Syed Quadir Moinuddin and Himam Saheb Shaik
Nomenclature
10.1 Introduction
10.2 Differences Among 3DP, 4DP and 5DP
10.3 Materials Used in 3DP, 4DP and 5DP Processes
10.3.1 Additive Manufactured Metallic Components
10.4 Machinability of Welded Components
10.5 Concept of 4D and 5D Printing
10.6 FEM-Based Analysis
10.7 Applications
10.7.1 4D Printing Applications
10.7.2 3D Printing in the Aerospace Industry
10.7.3 3D Printing in Electronics
10.7.4 3D Printing in Electrochemical Industries
10.7.5 5D Printing in Dentistry
10.7.6 5D Printing in Orthopedics
10.8 Conclusions
References
11. Welding and Joining of Novel Materials
Rajendra Goud, Poonam S. Deshmukh, Bhavesh Jain, G. Dan Sathiaraj and Kodli Basanth Kumar
11.1 Introduction
11.1.1 Concept of High Entropy Alloys (HEAs)
11.2 Core Effects
11.2.1 High Entropy Effect
11.2.2 Sluggish Diffusion Effect
11.2.3 Severe Lattice Distortion Effect
11.2.4 Cocktail Effect
11.2.5 Current Status of HEAs
11.3 Arc Welding Techniques for HEAs
11.4 Solid State Welding
11.4.1 Friction Stir Welding (FSW)
11.5 Explosive Welding
11.5.1 Soldering and Brazing
11.6 EBW and EBC of HEAs
11.7 Laser Welding of HEAs
11.8 Laser Cladding of HEAs
11.9 Conclusion and Summary
References
12. Sustainability in Welding Industries
Y.G. Bala, Santhi B. and Dinesh Kumar R.
12.1 Introduction
12.2 Critical Factors for Sustainability of Welding
12.3 Adoptability of Sustainable Welding
12.4 New Welding Standards for Sustainability
12.5 Resource-Conserving Techniques
12.5.1 Sustainable Welding in Practice
12.5.2 Boosting Efficiency with Special Welding Processes
12.6 Sustainability in Welding Training
12.6.1 Sustainable Technologies for Thick Metal Plate Welding
12.7 5S Lean Strategy for a Sustainable Welding Process
12.7.1 Sustainability Assessment of Shielded Metal Arc Welding (SMAW) Process
12.8 A-TIG Welding: A Small Step Towards Sustainable Manufacturing
12.8.1 Weight Space Partitions-Based Sustainable Welding
12.8.2 Sustainability Assessment of Welding Processes
12.8.3 Sustainability in Manufacturing
12.9 Sustainability Indices
12.10 Conclusion
References
13. Global Welding Market Growth
Y.G. Bala and Dinesh Kumar Rajendran
13.1 Introduction
13.1.1 Overview of Global Welding Products Market
13.2 Patrons of Global Welding Market
13.3 Welding Technologies in the Global Welding Market
13.4 Fluxes, Wires, Electrodes, and Fillers
13.5 Welding Market Dynamics
13.6 Manpower and Labor Challenges in Global Market
13.7 COVID-19’s Impact on Global Welding Materials Market
13.8 New Opportunity in the Welding Market and Advanced Applications
13.9 Conclusions
References
14. Quality Assurance and Control in Welding and Additive Manufacturing
Venkata Charan Kantumchu, Syed Quadir Moinuddin, Ashok Kumar Dewangan and Muralimohan Cheepu
14.1 Introduction
14.2 Quality Issues in Welding
14.3 Quality Issues in 3D Printing
14.4 Conclusion
References
15. Welding Practices in Industry 5.0: Opportunities, Challenges, and Applications
Suresh Goka, Syed Quadir Moinuddin, Muralimohan Cheepu and Ashok Kumar Dewangan
15.1 Introduction
15.2 Manufacturing Trends
15.3 Welding Technology
15.3.1 Classification of Welding
15.4 Variety of Materials Used by Welding for Industry 5.0
15.4.1 Advantages of Welding
15.4.2 Applications
15.4.3 Automation
15.4.4 Welding-Based AM
15.4.5 Welding Trends in Aeronautic Industry
15.4.6 Robotic and Automated Welding
15.5 Virtual Reality (VR) for Welders
15.6 Challenges and Opportunities in Nuclear Reactor
15.7 Challenges of AM-Based Functionally Graded Materials Through LDED
15.8 Conclusion
References
Index

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