EMC 5227 (Elective) - Welding Process Automation

To provide students with knowledge about classic welding processes and their modern versions, arising from electromechanical implementations (including software), and about technologies and monitoring and control methods for mechanized (automated) welding systems, involving not only online trajectory correction but also the autonomous adaptation of parameters to the weld conditions. To present students with industrial applications of these systems, equipment, and devices, involving monitoring instruments and sensors in addition to the welding machines. It also aims to present advanced inspection/monitoring techniques (phased array ultrasound, radiography and video-thermography, high-speed filming) of welding parameters, equipment, and movement. Practical activity in the aforementioned technologies is part of the objective, to enrich and consolidate the theoretical content.

Fundamentals of welding processes and their modern variants, with an emphasis on electric arc processes: review of classic welding processes; constructive, electronic, and electromechanical innovations of the processes; applications of modern processes and their limitations; hybrid processes.
Mechanization / automation systems for welding and monitoring: welding power sources and accessories for material feeding, overview of welding automation systems, programming and special features of welding manipulators, integration/synchronization of power source and manipulators, applications and limitations of different manipulators and robots for welding, sensor systems for adaptive welding.
Monitoring / inspection techniques for the weld, the welding system, and movement: ultrasound, radiography, and video-thermography, tactile sensor, and high-speed filming.

Introductory class: course overview, course objectives, content to be taught,
Review of classic arc welding processes - 1 - MIG/MAG
Review of classic arc welding processes - 2 - TIG and Plasma
Modern variants of the MIG/MAG process
Systems for MIG/MAG Welding
Modern variants of the TIG and Plasma (PTA-P) process
Systems for TIG Welding
Hybrid Processes
Monitoring of Welding Processes
Types of welding automation systems (robots, manipulators, orbital heads)
Programming, basic functions, and special functions of welding automation systems
Sensor systems for adaptive welding (LASER, arc as a sensor, inductive sensors)
Inspection techniques: phased array ultrasound, radiography and video-thermography, high-speed filming, tactile sensors

1. Lectures and technical videos
2. Experimental activities in welding benches / cells
3. Preparation of reports on the practical activities to be presented, discussed, and improved
4. Student seminars

• Intermediate Tests and Final Exam
• Theoretical assignments and reports on practical activities

• Selected technical-scientific papers
• Class presentations
• LABSOLDA Handout
• Manuals of the covered equipment
• Machado, I. G.. Soldagem e Técnicas Conexas: Processos, 1st ed., published by the author, 1996
• Direne Filho, H. MIG/MAG CCC - Avanços na Tecnologia de Controle da Transferencia Metalica como Solução Industrial para o Passe de Raiz, Master's Dissertation, UFSC - 127 f. 2014. 106 f.
• Marques, C. Prospecções da Natureza Física da Soldagem MIG Automática de Ligas de Alumínio, Master's Dissertation, UFSC - 127 f. 2013. 101 f.
• Dilthey, U. Schweisstechnische Fertigungsverfahren 1, 3rd ed., 2005
• MARQUES, Paulo Villani; MODENESI, Paulo José; BRACARENSE, Alexandre Queiroz. Soldagem : fundamentos e tecnologia. Belo Horizonte: Ed. da UFMG, 2005. 362p.
• SCOTTI, Américo; PONOMAREV, Vladimir. Soldagem MIG/MAG: melhor entendimento melhor desempenho. São Paulo: Artliber, 2008. 284 p. ISBN 9788588098428
• GAREIS, Bernardo. A soldagem, simples como ela e. Recife: SACTES, 1994. 221p. (Manuais tecnicos, 9)
• MARQUES, Paulo Villani. Tecnologia da soldagem. Belo Horizonte: ESAB, 1991. 352p.
• QUITES, Almir Monteiro; DUTRA, Jair Carlos. Tecnologia da soldagem a arco voltaico. Florianópolis, SC: EDEME, 1979. 250p.
• SILVA, R. H. G. Inovações em Equipamentos e em Parametrização no Processo de Revestimento por Plasma-Pó (PTA-P). 2010. 265 f. Doctoral Thesis (Mechanical Engineering) - Graduate Program in Mechanical Engineering, Federal University of Santa Catarina, Florianópolis, 2010.
• SILVA, R. H. G. E.; DUTRA, J. C.. Processo PTA-P – Uma Revisão da Literatura como Base para Inovações. Parte 1 de 2: Elementos Construtivos. Soldagem e Inspeção, v. 17, No. 1, Jan/Mar 2012.