A Comprehensive overview of the theory and applications of laser welding

This complete and up-to-date overview examines both the state of the art and likely future directions of laser welding technology. Paying particular attention to manufacturing, where applications of laser welding range from vehicle assembly to the joining of microelectric components, this comprehensive volume reviews the fundamentals, examines the latest research data, and offers detailed coverage of practical applications. The emphasis is on optimizing laser welding techniques to achieve defect-free results at high speed and under reproducible conditions. Author Walter W. Duley also discusses design issues, material properties, and the efficient delivery of laser radiation in welding applications, as well as the practical aspects of joint design. Other important features of this book include:

• Comprehensive data on real-world laser welding applications, including the new application of tailor blanking
• Performance criteria for numerous laser welding systems
• A review of available welding data for various metals and other materials
• A section on laser welding diagnostics and monitoring techniques
• Over 160 illustrations
• Extensive references and a bibliography for specific industrial applications.

Laser Welding is an indispensable resource for engineers and scientists using laser welding technology and a useful text for students in physics, material science, and mechanical engineering. It is also a valuable reference for researchers and designers developing new laser welding systems and studying the laser welding process. Walter W. Duley is a professor at the University of Waterloo in Ontario, Canada, and is the founder and former chairman of Powerlasers Limited. His previous books include UV Lasers: Effects and Applications in Materials Science, Laser Processing and Analysis of Materials, and CO2 Lasers: Effects and Applications.

This volume presents selected papers from the 2nd International Conference on Mechanical, Manufacturing and Process Plant Engineering (ICMMPE 2016) which was held from 23rd to 24th November, 2016 in Kuala Lumpur, Malaysia. The proceedings discuss genuine problems of joining technologies that are heart of manufacturing sectors. It discusses the findings of experimental and numerical works from soldering, arc welding to solid state joining technology that faced by current industry.

However well equipped the workshop may be there seems to be an incessant need to make up special gadgets of one sort or another. These may range from mutilating a clothes peg to act as a 'third hand' up to major modifications to an existing machine tool. The making of such devices can be fun (indeed, some may appear to do nothing else!) but nevertheless the time taken up in 'devising the device' can often delay the completion of an important project. Shared experience is a most potent tool in reducing such delays, and can, moreover, often provide solutions to problems hitherto believed to be intractable. Tubal Cain has enjoyed more than sixty years' experience in designing and building engines and machines (in both full size and model dimensions) and over this time has made many ancillary devices. In this book he shares 52 of them with you. A number of these had been published in magazines from time to time and some were assembled in volume form about thirty years ago. The opportunity was later taken not only to reprint that book but to revise some of the entries to take advantage of user experience, to add new material and to introduce it into the popular Workshop Practice Series.

Join the thousands of professionals who have already gotten Inside the Technical Consulting Business — and discover how to channel your technical know-how into an exciting career as an independent consultant. This Third Edition of Harvey Kaye's bestselling guide gives you the focused, no-nonsense help you need to start and run your own consulting practice in today's ultracompetitive environment. What's inside: Setting up your consulting business. The lowdown on finances, record-keeping, office space, taxes, and choosing the form of business organization that's right for you.

Insider's guide to proposals and contracts. Gives plenty of examples to use in your own consulting practice.

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The changing manufacturing environment requires more responsive and adaptable manufacturing systems. The theme of the 5th International Conference on Changeable, Agile, Reconfigurable and Virtual production (CARV2013) is "Enabling Manufacturing Competitiveness and Economic Sustainability. Leading edge research and best implementation practices and experiences, which address these important issues and challenges, are presented. The proceedings include advances in manufacturing systems design, planning, evaluation, control and evolving paradigms such as mass customization, personalization, changeability, re-configurability and flexibility. New and important concepts such as the dynamic product families and platforms, co-evolution of products and systems, and methods for enhancing manufacturing systems' economic sustainability and prolonging their life to produce more than one product generation are treated. Enablers of change in manufacturing systems, production volume and capability, scalability and managing the volatility of markets, competition among global enterprises and the increasing complexity of products, manufacturing systems and management strategies are discussed. Industry challenges and future directions for research and development needed to help both practitioners and academicians are presented. About the Editor Prof. Dr.-Ing. Michael F. Zaeh, born in 1963, has been and is Professor for and Manufacturing Technology since 2002 and, together with Prof. Dr.-Ing. Gunther Reinhart, Head of the Institute for Machine Tools and Industrial Management (iwb) at the Technische Universitaet Muenchen (TUM). After studying general mechanical engineering, he was doctoral candidate under Prof. Dr.-Ing. Joachim Milberg at TUM from 1990 until 1993 and received his doctorate in 1993. From 1994 to 1995, he was department leader under Prof. Dr.-Ing. Gunther Reinhart. From 1996 to 2002, he worked for a machine tool manufacturer in several positions, most recently as a member of the extended management. Prof. Dr.-Ing. Michael F. Zaeh is an associated member of the CIRP and member of acatech, WGP and WLP. His current researches include among others Joining and Cutting Technologies like Laser Cutting and Welding as well as Friction Stir Welding, Structural Behaviour and Energy Efficiency of Machine Tools and Manufacturing Processes like Additive Manufacturing.

This book provides fundamental understanding and practical application of characteristics of flexural motion in the assessment of the weld size and coating thickness. Some formulations of heat transfer and flexural motion are introduced while displacement and load correlation are used to estimate elastic modules and the size of the heat affected zone as well as the coating thickness. The case studies presented give a practical understanding of weld size and coating thickness characterizations.

This book presents a complete and updated overview of Flame Spray process, from its History to the Apparatus necessary for the synthesis of nanostructures. It addresses not only the materials produced by this technique, but also their properties, such as crystallinity and crystallite size, specific surface area, particle size and morphology. Also, the principles of nanoparticle formation are described. It is a useful read to all those interested in low cost synthesis of nanostructured powders and coatings.

This book discusses the latest advances in people-centered design, operation, and management of broadly defined advanced manufacturing systems and processes. It reports on human factors issues related to various research areas such as intelligent manufacturing technologies, web-based manufacturing services, digital manufacturing worlds, and manufacturing knowledge support systems, as well as other contemporary manufacturing environments. The book covers an extensive range of applications of human factors in the manufacturing industry: from work design, supply chains, evaluation of work systems, and social and organization design, to manufacturing systems, simulation and visualization, automation in manufacturing, and many others. Special emphasis is given to computer aided manufacturing technologies supporting enterprises, both in general and in the manufacturing industry in particular, such as knowledge-based systems, virtual reality, artificial intelligence methods, and many more. Based on the AHFE 2016 International Conference on Human Aspects of Advanced Manufacturing, held on July 27-31, 2016, in Walt Disney World (R), Florida, USA, the book provides readers with a timely snapshot of the enterprises of the future and a set of cutting-edge technologies and methods for building innovative, human-centered, and computer-integrated manufacturing systems.

This book provides an overview of metal casting technologies starting from its historical evolution to casting design strategies that are being followed today in foundries and other metal casting industries. The details of most of the casting processes and their applications are also included for completeness. Foundry practices such as mold materials and molding techniques, pattern making and cores, furnaces, pouring, cleaning and heat treatment etc. are discussed in detail. Finally, current practices in casting design are demonstrated. Further developments in the field through computational methods and virtual reality are also described.

This book focuses on emerging issues in ergonomics, with a special emphasis on modeling, usability engineering, human computer interaction and innovative design concepts. It presents advanced theories in human factors, cutting-edge applications aimed at understanding and improving human interaction with products and systems, and discusses important usability issues. The book covers a wealth of topics, including devices and user interfaces, virtual reality and digital environments, user and product evaluation, and limits and capabilities of special populations, particularly the elderly population. It presents both new research methods and user-centered evaluation approaches. Based on the AHFE 2016 International Conference on Ergonomics Modeling, Usability and Special Populations, held on July 27-31, 2016, in Walt Disney World (R), Florida, USA, the book addresses professionals, researchers, and students dealing with visual and haptic interfaces, user-centered design, and design for special populations, particularly the elderly.

The approach to the solution within the CRC/TR 96 financed by the German Research Foundation DFG aims at measures that will allow manufacturing accuracy to be maintained under thermally unstable conditions with increased productivity, without an additional demand for energy for tempering. The challenge of research in the CRC/TR 96 derives from the attempt to satisfy the conflicting goals of reducing energy consumption and increasing accuracy and productivity in machining. In the current research performed in 19 subprojects within the scope of the CRC/TR 96, correction and compensation solutions that influence the thermo-elastic machine tool behaviour efficiently and are oriented along the thermo-elastic functional chain are explored and implemented. As part of this general objective, the following issues must be researched and engineered in an interdisciplinary setting and brought together into useful overall solutions:   1.  Providing the modelling fundamentals to calculate the heat fluxes and the resulting thermo-elastic deformations in a comprehensive manner, 2.  Mapping of the structural variability as a result of the relative movement inside the machine tool, 3.  Providing the tools for an efficient adjustment of parameters that vary greatly in time and space by means of parameter identification methods as a prerequisite for correction and compensation solutions, 4.  Engineering and demonstrating solutions to control-integrated correction of thermo-elastic errors by an inverse position setpoint compensation of the error at the TCP, 5.  Engineering and demonstrating solutions based on the material properties to compensate for thermo-elastic effects through a homogeneous propagation of the temperature field, as well as reducing and smoothing the distribution of heat dissipated in supporting structures, 6.  Developing metrological fundamentals to record the thermo-elastic errors in special structural areas of machine tools, 7.  Engineering a methodological approach to simultaneous and complex evaluation of the CRC/TR 96 solutions, referring to their impact on product quality, production rate, energy consumption and machine tool costs    

Computational kinematics is an enthralling area of science with a rich spectrum of problems at the junction of mechanics, robotics, computer science, mathematics, and computer graphics. The covered topics include design and optimization of cable-driven robots, analysis of parallel manipulators, motion planning, numerical methods for mechanism calibration and optimization, geometric approaches to mechanism analysis and design, synthesis of mechanisms, kinematical issues in biomechanics, construction of novel mechanical devices, as well as detection and treatment of singularities. The results should be of interest for practicing and research engineers as well as Ph.D. students from the fields of mechanical and electrical engineering, computer science, and computer graphics.

The fuel consumption of a modern combustion engine is one of the most important purchase criteria in contemporary society. Increasing oil prices and exhaust emissions taxes force the automotive industry to continuously improve the vehicle engines. The fuel consumption is closely related to the frictional losses of an engine. New material pairings or constructive modifications of the piston group can reduce such losses. Another innovative concept to lower the frictional forces is the micro-structuring of thermo-mechanically highly stressed surfaces. Within an interdisciplinary research group sponsored by the German Research Foundation, scientists at the Leibniz Universität Hannover and Universität Kassel have been working together to investigate this research topic. This final report presents their findings and offers scope for further discussion.

This book presents a complete, in-depth analysis for on the impact of liquid sulfur dioxide and liquid sulfur trioxide to carry out complex and difficult sulfonations, as well as manufacture of sulfuric acid with a CAPEX requirement of less than half, an area requirement less than one-third, and no emission of sulfur dioxide. The processes described in this volume represents an innovative approach relevant to the current manufacturing processes of sulfuric acid, sulfamic acid, para toluene sulfonic acid and other sulfonated product.

This book contains papers on a wide range of topics in the area of kinematics, mechanisms, robotics, and design, addressing new research advances and innovations in design education. The content is divided into five main categories headed 'Historical Perspectives', 'Kinematics and Mechanisms', 'Robotic Systems', 'Legged Locomotion', and 'Design Engineering Education'. Contributions take the form of survey articles, historical perspectives, commentaries on trends on education or research, original research contributions, and papers on design education. This volume celebrates the achievements of Professor Kenneth Waldron who has made innumerable and invaluable contributions to these fields in the last fifty years. His leadership and his pioneering work have influenced thousands of people in this discipline.

Designing Weldments An important tool for professionals wishing to enhance their understanding or those who are new to the subject, Designing Weldments bridges that gap between structural engineers and a deeper understanding of the welding engineering within the structures. In modern-day construction, welding is the primary method to join various members of any structure. Welds are required to meet various types of load in tension, compression, torsion, and perform in static or cyclic loading conditions. The weld has to be at least as strong as the parent metal to meet the demands of various stress working on the structure. It should meet the structural requirement, add value to the integrity of the structure, and prevent failures. However, many design engineers lack even a fundamental insight or a basic understanding of essential welding processes and design requirements. Simply copying a few joint configurations in a drawing will not suffice. All-embracing and readable, Designing Weldments delivers a deeper understanding of many design factors that play a critical role in the design. The book clarifies welding design principles and applications. With this reference in hand, designers will have expert knowledge to consider very early on in the project, the implications of the choice of what type of weld to use for joining structural members, and how the component is made. The author explains the many welding techniques developed over the years, as well as some of which are still evolving. The reader will also find in this book: Rules of thumb for saving time and money in the design phase of a project. An insider's view for choosing the proper welding approach to ensure the overall strength of a structure. Offers structural engineers a deeper understanding of the weld within their structures. Clarifies welding design principles and applications, limiting the necessity to redesign the structure. Audience The intended market for this book is professionals working on the infrastructural projects in shipbuilding, construction of buildings, bridges, offshore platforms, wind towers for renewable energy, and other structures that join plates, pipes, and pipelines in power plants, manufacturing, and repair.

Energy efficiency represents a cost-effective and immediate strategy of a sustainable development. Due to substantial environmental and economic implications, a strong emphasis is put on the electrical energy requirements of machine tools for metalworking processes. The improvement of energy efficiency is however confronted with diverse barriers, which sustain an energy efficiency gap of unexploited potential. The deficiencies lie in the lack of information about the actual energy requirements of machine tools, a minimum energy reference to quantify improvement potential and the possible actions to improve the energy demand. Therefore, a comprehensive concept for energy performance management of machine tools is developed which guides the transition towards energy efficient machine tools. It is structured in four innovative concept modules, which are embedded into step-by-step workflow models. The capability of the performance management concept is demonstrated in an automotive manufacturing environment. The target audience primarily comprises researchers and practitioners challenged to enhance energy efficiency in manufacturing. The book may also be beneficial for graduate students who want to specialize in this field.

This Brief presents a new method that is based on the author and his students' shared experience in applying a structured procedure that has as its main goal the creation of a material selection technique that uses language and employs a platform that is not restricted to engineers. Based on a hybrid approach that exploits both traditional and semi-quantitative concepts, it moves forward step-by step, and uses a platform based on a Quality Function Deployment matrix framework. Candidate materials are screened out and finally assessed by two user-friendly graphic analysis tools, one based on the value curve of the product and the other on an original Bubble Maps tool. The Brief is written for all those whose aim is for a better understanding of how to integrate and speed up the entire product development process from the initial product concept and engineering design phases to design specs, manufacturability and product marketing with optimal choice of materials.

Dimensional metrology is an essential part of modern manufacturing technologies, but the basic theories and measurement methods are no longer sufficient for today's digitized systems. The information exchange between the software components of a dimensional metrology system not only costs a great deal of money, but also causes the entire system to lose data integrity. Information Modeling for Interoperable Dimensional Metrology analyzes interoperability issues in dimensional metrology systems and describes information modeling techniques. It discusses new approaches and data models for solving interoperability problems, as well as introducing process activities, existing and emerging data models, and the key technologies of dimensional metrology systems. Written for researchers in industry and academia, as well as advanced undergraduate and postgraduate students, this book gives both an overview and an in-depth understanding of complete dimensional metrology systems. By covering in detail the theory and main content, techniques, and methods used in dimensional metrology systems, Information Modeling for Interoperable Dimensional Metrology enables readers to solve real-world dimensional measurement problems in modern dimensional metrology practices.

This book analyzes the wrapping and packaging machinery sector in the Emilia/Bologna district in Italy and compares the most recent trends with those in the industry in Schwabisch Hall and Waiblingen, Baden-Wurttemberg, Germany, which represents a direct rival. In a detailed and original study, the authors trace the evolution of manufacturing in Bologna during a period that witnessed extraordinary growth in automatic wrapping and packaging machines, leading the sector to become a central pillar of Italian mechanical engineering. Similarly, the history of the industry in the Emilia district is described, highlighting the factors that led to its success. A comprehensive comparative analysis of the German and Italian sectors is then performed. Export figures and the trade balance for the sector are examined based on Eurostat data, and the significance of the two districts in terms of global trade is identified with reference to UN data. In addition, the number of companies, sales, and the size of the workforces are thoroughly compared. The book will be of interest to economists and others with an interest in the development and importance of the automatic packaging machinery sector.

This book aims to show how tribological concepts can be applied in order to improve manufacturing technology in modern industry. It can be used as a guide book for engineering students or a reference useful for academics in the fields of tribology, manufacturing, materials and mechanical engineering.

Readers of System Design Optimization for Product Manufacturing will learn about detailed concepts and practical technologies that enable successful product design and manufacture. These concepts and technologies are based on system optimization methodologies that consider a broad range of mechanical, as well as human, factors. System Design Optimization for Product Manufacturing explains the methodologies behind current and future product manufacture. Its detailed explanations of key concepts are relevant not only for product design and manufacture, but also for other business fields. These core concepts and methodologies can be applied to practically any field where informed decision-making is important, and where a range of often conflicting factors must be carefully weighed and considered. System Design Optimization for Product Manufacturing can be used as a fundamental reference book by both engineers and students in the fields of manufacturing, design engineering, and product development.

In this book, advanced steel technologies mainly developed at the National Institute for Materials Science (NIMS), Japan, for structure control, mechanical properties, and the related mechanisms are introduced and discussed. NIMS has long worked on developing advanced steel techniques, namely, producing advanced steels by using only simple alloying elements such as carbon, manganese, and silicon, and also by utilizing steel scrap. The hope is that this approach will lead to a technology of a so-called steel-to-steel recycling process, with the ultimate goal of a recycling process such as an automotive-steel-to-automotive-steel recycling process to take the place of the current cascade-type recycling system. The main idea is to utilize ultra-grain refining structures and hetero structures as well as martensite structures. In particular, the focus of this book is on tensile strength and toughness of advanced steels from both the fundamental and engineering points of view. Fundamentally, a unique approach to analysis is taken, based on fracture surface energy as effective grain size is employed to better understand the mechanism of property improvement. From the engineering point of view, in fracture toughness such factors as crack tip opening displacement (CTOD) of advanced steels are evaluated in comparison with those of conventional steels.

Workshop Processes, Practices and Materials is an ideal introduction for entry level engineers and workshop technicians, as well as engineering university students with little or no practical experience. With detailed illustrations throughout and simple, clear language, this is a practical introduction to what can be a very complex subject. It has been significantly updated and revised to include new material on current Health and Safety legislation, gauging and digital measuring instruments, as well as modern measuring techniques such as laser scan micrometer, co-ordinate and visual measuring systems. A new chapter on an introduction to CNC milling and turning has been added. This book covers all standard workshop topics, including safe practices, measuring equipment, hand and machine tools, metal and plastics materials, joining methods including welding, presswork, primary forming, casting and moving loads, making it an indispensable handbook for use both in class and the workshop. Its broad coverage makes it a useful reference book for many different courses worldwide. Health and Safety chapter covers current best practice and has been checked by a certified health and safety examiner. Addition of modern measuring techniques using laser scan micrometer, co-ordinate and visual measuring systems. Addition of an introduction to CNC milling and turning.

The book offers a snapshot of the state-of-art in the field of model-based mechatronic system design. It covers topics including machine design and optimization, predictive systems in manufacturing networks, and the development of software for modeling and simulation of processes, which are supplemented by practical case studies. The book is a collection of fifteen selected contributions presented during the Workshop on Mechatronic Systems, held on March 17-19, 2014, in Mahdia, Tunisia. The workshop was jointly organized by the Laboratory of Mechanics Modeling and Production (LA2MP) of the National School of Engineers Sfax, Tunisia, and the Laboratory for Mechanical Systems and Materials Engineering (LISMMA) of Higher Institute of Mechanics (SUPMECA), Paris, France.