Automation in the Welding Industry

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.

• Preface xvAcknowledgments xix1 Introduction to Industry 5.0 1Muralimohan Cheepu, Syed Quadir Moinuddin and Ashok Kumar Dewangan1.1 Introduction 21.2 Industry 4.0 81.3 Industry 5.0 92 Advancements in Welding Technologies 13Pavan Meena, Ansari Mohd Farhan, Ramkishor Anant and Shaik Himam Saheb2.1 Introduction 132.2 Quality of Weld Joint 152.3 Pulsed Current GMAW 162.4 P-GMAW Process Stability Factors 182.5 Suitable Pulse Parameters of Selection 182.6 Effect of Pulse Parameters 192.7 Pulsed Current GMAW Advances 222.8 Double-Pulsed GMAW 232.9 Synergic Control 242.10 Self-Regulating Control 252.11 Microcomputer Control 262.12 GMAW Shielding Gas Flow 272.13 Particle Image Velocimetry (PIV) 272.14 The Measurement of Oxygen (O2) Concentration 312.15 Spectroscopic Measurements of Plasma Temperature 312.16 P-GMAW Numeric Simulation 323 Automation in Welding Industries 37Deepak Kumar Naik, Ved Prakash Sharma and Dinesh Kumar R.3.1 Introduction 383.2 Automation Trends 413.3 Plasma Welding 423.4 Laser Welding 443.5 Arc Welding 453.6 MIG Welding 453.7 Resistance Welding 463.8 Conclusions 474 Digitalization of Welding Processes 49Atla Sridhar, K. Prasanna Lakshmi, Shaik Himam Saheb and M. Siva Surya4.1 Introduction 494.2 Techniques for Process Monitoring 514.3 Process Monitoring Applications 614.4 Future Directions 675 AI and ML in Welding Technologies 73Suresh Goka, Gorle Shanmukha Narayana, Divya Jyothi G., Himam Saheb Shaik and Syed Quadir Moinuddin5.1 Introduction 745.2 Enhancing the Welding Industry 765.3 Machine Learning Algorithm Types 805.4 Background of AI and ML 815.5 Weld Defects 825.6 Level of Weld Quality 835.7 Case Studies 865.8 Feasibility of Online Inspection of Ultrasonic Weld Quality 885.9 Conclusions 896 Digital Twin in Welding 91Syam Kumar Chokka, M. Nagaraju and K. Nagabushan Kumar6.1 Introduction 916.2 Friction Stir Welding 926.3 Defects in Friction Stir Welding 966.4 Laser Welding 1026.5 Summary 1067 IoT in Welding Industries 111Harisivasri Phanindra K., S. Venukumar, Muralimohan Cheepu and Venkata Charan Kantumuchu7.1 Introduction 1117.2 Sensing and Analyzing Welding Data via the Internet of Things (IoT) 1137.3 Welding Manufacture Based on IoT 1147.4 Conclusion 1278 VR and AR in Welding Technologies 129Veningston K. and Dinesh Kumar Rajendran8.1 Introduction 1298.2 How Intelligent is AI When Coupled with VR/AR? 1328.3 VR/AR Architecture 1328.4 Welding Processes 1328.5 Intelligent Welding Technology 1338.6 Types of Intelligent Welding Processes 1348.7 Automated Welding Examples 1358.8 Applications of VR and AR in Automated Welding 1368.9 AI and ML for Visual Inspection of Welds 1388.10 Limitations in the Existing State-of-the-Art Welding Techniques 1408.11 Conclusions 1419 Intelligent, Clean Cobot Arc Welding Cell 143E. Schubert, S. Rose, M. Bender, N. Spietz and T. Weber9.1 Chances for SMEs 1439.2 Parameters and Consumption Data 1469.3 CO2 Footprint Methodology 1489.4 Result Presentation 1499.5 Conclusion 15410 Welding-Based 3D, 4D, 5D Printing 157Suresh Goka, Satish Narayana Srirama, Divya Jyothi G., Syed Quadir Moinuddin and Himam Saheb Shaik10.1 Introduction 15810.2 Differences Among 3DP, 4DP and 5DP 16010.3 Materials Used in 3DP, 4DP and 5DP Processes 16210.4 Machinability of Welded Components 16810.5 Concept of 4D and 5D Printing 16910.6 FEM-Based Analysis 17210.7 Applications 17410.8 Conclusions 17711 Welding and Joining of Novel Materials 183Rajendra Goud, Poonam S. Deshmukh, Bhavesh Jain, G. Dan Sathiaraj and Kodli Basanth Kumar11.1 Introduction 18411.2 Core Effects 18411.3 Arc Welding Techniques for HEAs 18611.4 Solid State Welding 19211.5 Explosive Welding 19711.6 EBW and EBC of HEAs 20011.7 Laser Welding of HEAs 20211.8 Laser Cladding of HEAs 20611.9 Conclusion and Summary 20812 Sustainability in Welding Industries 215Y.G. Bala, Santhi B. and Dinesh Kumar R.12.1 Introduction 21512.2 Critical Factors for Sustainability of Welding 21612.3 Adoptability of Sustainable Welding 21812.4 New Welding Standards for Sustainability 21812.5 Resource-Conserving Techniques 21912.6 Sustainability in Welding Training 22012.7 5S Lean Strategy for a Sustainable Welding Process 22112.8 A-TIG Welding: A Small Step Towards Sustainable Manufacturing 22312.9 Sustainability Indices 22712.10 Conclusion 22713 Global Welding Market Growth 229Y.G. Bala and Dinesh Kumar Rajendran13.1 Introduction 22913.2 Patrons of Global Welding Market 23313.3 Welding Technologies in the Global Welding Market 23613.4 Fluxes, Wires, Electrodes, and Fillers 23713.5 Welding Market Dynamics 23813.6 Manpower and Labor Challenges in Global Market 23913.7 COVID-19’s Impact on Global Welding Materials Market 24013.8 New Opportunity in the Welding Market and Advanced Applications 24113.9 Conclusions 24114 Quality Assurance and Control in Welding and Additive Manufacturing 245Venkata Charan Kantumchu, Syed Quadir Moinuddin, Ashok Kumar Dewangan and Muralimohan Cheepu14.1 Introduction 24614.2 Quality Issues in Welding 24714.3 Quality Issues in 3D Printing 25514.4 Conclusion 25915 Welding Practices in Industry 5.0: Opportunities, Challenges, and Applications 263Suresh Goka, Syed Quadir Moinuddin, Muralimohan Cheepu and Ashok Kumar Dewangan15.1 Introduction 26415.2 Manufacturing Trends 26415.3 Welding Technology 26515.4 Variety of Materials Used by Welding for Industry 5.0 26715.5 Virtual Reality (VR) for Welders 27415.6 Challenges and Opportunities in Nuclear Reactor 27515.7 Challenges of AM-Based Functionally Graded Materials Through LDED 27615.8 Conclusion 277References 277Index 281