EMC 5797 (Elective) - Metallic Coatings via Automated Welding Processes

To provide students with knowledge about modern arc welding processes, configured by advanced versions of classic processes, as well as by the synergy between different processes, regarding their physical properties, application techniques, industrial applications with an emphasis on metallic coatings, equipment, systems and devices for their control and automation, involving, in addition to welding machines, monitoring instruments and sensors. It also aims to present advanced inspection techniques (phased array ultrasound, radiography, and video-thermography). Practical activity in the aforementioned technologies is part of the objective, to enrich and consolidate the theoretical content. For this purpose, practical demonstrations of these processes are carried out in the Welding Laboratory during classes, and a practical assignment is also carried out, where students are divided into groups to develop and perform tests with a cladding welding procedure and analyze the main aspects of this cladding.

Fundamentals of advanced arc welding processes, with an emphasis on metallic coatings: review of classic arc welding processes; constructive, electronic, and electromechanical innovations of the processes; applications of modern processes and their limitations, application techniques of modern processes; hybrid processes. Notions of welding metallurgy applied to cladding welding.
Welding automation and monitoring systems: overview of welding automation systems, programming and special features of welding manipulators, power source and manipulator integration/synchronization, applications and limitations of different manipulators and robots for welding, sensor systems for adaptive welding.
Advanced inspection techniques: phased array ultrasound, radiography, and video-thermography

Introductory class: course overview, course objectives, content to be taught,
Review of classic arc welding processes - 1
Review of classic arc welding processes - 2
Modern variants of the MIG/MAG process - 1
Modern variants of the MIG/MAG process - 2
Modern variants of the TIG process
PTA-P process
Hybrid Processes
Types of welding automation systems (robots, manipulators)
Programming, basic functions, and special functions of welding automation systems
Sensor systems for adaptive welding
Inspection techniques: phased array ultrasound, radiography, and video-thermography

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

• Exam
• Theoretical assignments and practical activity reports

• Selected technical-scientific papers
• Class presentations
• Manuals of the covered equipment
• Scotti, A., Ponomarev, V. Soldagem MIG/MAG, 1st ed., Artliber Editora, 2008
• Machado, I. G.. Soldagem e Técnicas Conexas: Processos, 1st ed., published by the author, 1996
• Marques, C. Prospecções da Natureza Física da Soldagem MIG Automática de Ligas de Alumínio, Master's Dissertation, UFSC - 127 f. 2013. 101 f.
• MACHADO, Ivan Guerra. Soldagem & tecnicas conexas: processos. Porto Alegre (RS): published by the author, 1996. x, 477p.
• 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
• 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, Régis Henrique Gonçalves e;  DUTRA, Jair Carlos. Processo PTA-P - Uma revisão da literatura como base para inovações: parte 2 de 2: comportamento térmico e cinemático do pó, parâmetros e consumíveis do processo. Soldagem e Inspeção [online]. 2012, vol.17, n.2, pp. 173-183. ISSN 0104-9224.
• 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.