Robot-assisted non-destructive testing of automotive resistance spot welds

Changwook Ji, Jeong K. Na, Yoon Seok Lee, Yeong Do Park, Menachem Kimchi

Research output: Contribution to journalArticlepeer-review

Abstract

A commercially available matrix phased array (MPA) ultrasonic imaging system was successfully integrated into a robot-assisted automated non-destructive testing (NDT) method for resistance spot weld applications. The NDT system utilizes a dual-time gate feature, where optimized time gate positions and widths were determined for near-normal incidence inspections of spot welds in thin materials. The effects of probe contact pressure and ultrasonic beam incident angle were also studied using the robot arm. Based on the current robot-assisted automated NDT results, an optimized contact pressure of 0.5 lb, and an incidence angle of ± 0.5o relative to the normal direction were determined. Under these optimum probe contact conditions, it was found that a measurement uncertainty of less than 5% can be achieved when the gate position is set to be between one-half and two-third positions of the total part thickness, along with a gate width equals to one-third of the total stack thickness.

Original languageEnglish
Pages (from-to)119-126
Number of pages8
JournalWelding in the World
Volume65
Issue number1
DOIs
Publication statusPublished - Jan 2021

Keywords

  • Advanced high-strength steel
  • Matrix phased array
  • Resistance spot welds
  • Robot assisted inspection
  • Ultrasonic non-destructive testing

ASJC Scopus subject areas

  • Mechanics of Materials
  • Mechanical Engineering
  • Metals and Alloys

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