Person: Villanueva Roldán, Pedro
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Villanueva Roldán
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Pedro
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Ingeniería
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0000-0003-0865-3789
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Publication Open Access Benefits of aeronautical preform manufacturing through arc-directed energy deposition manufacturing(MDPI, 2023) Suárez, Alfredo; Ramiro, Pedro; Veiga Suárez, Fernando; Ballesteros Egüés, Tomás; Villanueva Roldán, Pedro; Ingeniería; IngeniaritzaThe paper introduces an innovative aerospace component production approach employing Wire Arc Additive Manufacturing (WAAM) technology to fabricate near-finished preforms from Ti6Al4V titanium. Tensile tests on WAAM Ti6Al4V workpieces demonstrated reliable mechanical properties, albeit with identified anisotropic behavior in horizontal samples, underscoring the need for optimization. This alternative manufacturing strategy addresses the challenges associated with machining forged preforms, marked by a high Buy To Fly (BTF) ratio (>10), leading to material wastage, prolonged machining durations, elevated tool expenses, and heightened waste and energy consumption. Additionally, logistical and storage costs are increased due to extended delivery timelines, exacerbated by supply issues related to the current unstable situation. The utilization of WAAM significantly mitigates initial BTF, preform costs, waste production, machining durations, and associated expenditures, while notably reducing lead times from months to mere hours. The novelty in this study lies in the application of Wire Arc Additive Manufacturing (WAAM) technology for the fabrication of titanium aircraft components. This approach includes a unique height compensation strategy and the implementation of various deposition strategies, such as single-seam, overlapping, and oscillating.Publication Open Access Methodology for the path definition in multi-layer gas metal arc welding (GMAW)(MDPI, 2023) Curiel Braco, David; Veiga Suárez, Fernando; Suárez, Alfredo; Villanueva Roldán, Pedro; Ingeniería; IngeniaritzaThe reconstruction of the geometry of weld-deposited materials plays an important role in the control of the torch path in GMAW. This technique, which is classified as a direct energy deposition technology, is experiencing a new emergence due to its use in welding and additive manufacturing. Usually, the torch path is determined by computerised fabrication tools, but these software tools do not consider the geometrical changes along the case during the process. The aim of this work is to adaptively define the trajectories between layers by analysing the geometry and symmetry of previously deposited layers. The novelty of this work is the integration of a profiling laser coupled to the production system, which scans the deposited layers. Once the layer is scanned, the geometry of the deposited bead can be reconstructed and the symmetry in the geometry and a continuous trajectory can be determined. A wall was fabricated under demanding deposition conditions, and a surface quality of around 100 microns and mechanical properties in line with those previously reported in the literature are observed.Publication Open Access Intelligent and adaptive system for welding process automation in T-shaped joints(MDPI, 2023) Aldalur, Eider; Suárez, Alfredo; Curiel Braco, David; Veiga Suárez, Fernando; Villanueva Roldán, Pedro; Ingeniería; IngeniaritzaThe automation of welding processes requires the use of automated systems and equipment, in many cases industrial robotic systems, to carry out welding processes that previously required human intervention. Automation in the industry offers numerous advantages, such as increased efficiency and productivity, cost reduction, improved product quality, increased flexibility and safety, and greater adaptability of companies to market changes. The field of welding automation is currently undergoing a period of profound change due to a combination of technological, regulatory, and economic factors worldwide. Nowadays, the most relevant aspect of the welding industry is meeting customer requirements by satisfying their needs. To achieve this, the automation of the welding process through sensors and control algorithms ensures the quality of the parts and prevents errors, such as porosity, unfused areas, deformations, and excessive heat. This paper proposes an intelligent and adaptive system based on the measurement of welding joints using laser scanning and the subsequent analysis of the obtained point cloud to adapt welding trajectories. This study focuses on the optimization of T-joints under specific welding conditions and is intended as an initial implementation of the algorithm, thus establishing a basis to be worked on further for a broader welding application.Publication Open Access Automatic trajectory determination in automated robotic welding considering weld joint symmetry(MDPI, 2023) Curiel Braco, David; Veiga Suárez, Fernando; Suárez, Alfredo; Villanueva Roldán, Pedro; Aldalur, Eider; Ingeniería; IngeniaritzaThe field of inspection for welded structures is currently in a state of rapid transformation driven by a convergence of global technological, regulatory, and economic factors. This evolution is propelled by several key drivers, including the introduction of novel materials and welding processes, continuous advancements in inspection technologies, innovative approaches to weld acceptance code philosophy and certification procedures, growing demands for cost-effectiveness and production quality, and the imperative to extend the lifespan of aging structures. Foremost among the challenges faced by producers today is the imperative to meet customer demands, which entails addressing both their explicit and implicit needs. Furthermore, the integration of emerging materials and technologies necessitates the exploration of fresh solutions. These solutions aim to enhance inspection process efficiency while providing precise quantitative insights into defect identification and location. To this end, our project proposes cutting-edge technologies, some of which have yet to gain approval within the sector. Noteworthy among these innovations is the integration of vision systems into welding robots, among other solutions. This paper introduces a groundbreaking algorithm for tool path selection, leveraging profile scanning and the concept of joint symmetry. The application of symmetry principles for trajectory determination represents a pioneering approach within this expansive field.Publication Open Access Advanced welding automation: Intelligent systems for multipass welding in Butt Double V-Groove and Tee Double Bevel configurations(Elsevier, 2024-12-01) Curiel Braco, David; Suárez, Alfredo; Veiga Suárez, Fernando; Aldalur, Eider; Villanueva Roldán, Pedro; Ingeniería; IngeniaritzaThe paper addresses the imperative shift towards automation in welding processes, leveraging advanced technologies such as industrial robotic systems. Focusing on the reconstruction and classification of weld joints, it introduces a methodology for automatic trajectory determination. Utilizing a laser profilometer mounted on the robot, weld joints are reconstructed in three di- mensions, and spurious data is filtered out through signal processing. A classification algorithm, integrating signal processing and artificial intelligence, accurately categorizes joint profiles, in- cluding V-joints and single bevel T-joints. The proposed intelligent and adaptive system enhances welding automation by analyzing point cloud data from laser scanning to optimize welding tra- jectories. This study establishes a foundational framework for further refinement and broader application in welding automation. Key Points - Introduction of a methodology for automated trajectory determination in welding processes. - Utilization of laser scanning and signal processing for reconstruction and classification of weld joints. - Implementation of an intelligent and adaptive system to optimize welding trajectoriesPublication Open Access Weld joint reconstruction and classification algorithm for trajectory generation in robotic welding(Trans Tech Publications, 2023) Curiel Braco, David; Veiga Suárez, Fernando; Suárez, Alfredo; Villanueva Roldán, Pedro; Aldalur, Eider; Ingeniería; IngeniaritzaPublication Open Access Advances in robotic welding for metallic materials: application of inspection, modeling, monitoring and automation techniques(MDPI, 2023) Curiel Braco, David; Veiga Suárez, Fernando; Suárez, Alfredo; Villanueva Roldán, Pedro; Ingeniería; IngeniaritzaThe robotic welding manufacturing of metal parts is a very important process, especially in heavy industries such as shipbuilding, oil and gas, automotive, and aerospace. There is a great variety of different techniques for manufacturing by robotic welding, and the welding operations are always in a constant process of evolution, as any advance can be significant to avoid defects during the welding process. Although a great deal of research work has been carried out in recent years, thanks to which results and reviews have been presented on this subject, the main aim of this publication is to define and review works that show the advances in the main inspection, modeling, monitoring, and automated operations during the welding process to avoid, or predictively identify, any possible defect in order to obtain an optimum degree of quality in the welding.