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Desenvolvimento de sistema de inspeção não destrutiva para juntas brasadas a laser
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Resumo(s)
A Soldadura por Brasagem a Laser é uma tecnologia crucial na indústria automóvel,
utilizada para unir chapas metálicas com elevada precisão e eficiência. No entanto, a deteção de
defeitos nos cordões de soldadura, especialmente nas suas extremidades, representa um desafio
significativo, uma vez que defeitos não detetados podem comprometer a integridade estrutural e
a segurança dos veículos. Esta dissertação foca-se na aplicação de métodos de Ensaios Não
Destrutivos para melhorar a deteção de defeitos em cordões de Soldadura por Brasagem a Laser,
propondo soluções inovadoras para superar as limitações dos métodos tradicionais.
Para atingir este objetivo, foram exploradas duas abordagens principais: a monitorização
de pressão e a utilização de Correntes Induzidas. A monitorização de pressão envolveu o
desenvolvimento de um protótipo que permite a deteção de defeitos passantes ao longo dos
cordões de soldadura e nas suas extremidades. Os ensaios realizados com este protótipo
mostraram resultados promissores, conseguindo identificar com precisão a presença de defeitos
passantes. Contudo, é importante notar que os testes foram realizados apenas para um exemplar,
o que limita um pouco a sua viabilidade.
Foi ainda avaliada a eficácia de sondas de Correntes Induzidas na deteção de defeitos
superficiais e em profundidade nos cordões de Soldadura por Brasagem a Laser através de uma
tecnologia emergente denominada de indutores de montagem superficial. Vários ensaios foram
conduzidos para validar o desempenho dessas sondas, fazendo-se variar as frequências e a sua
posição, destacando-se uma das sondas pela sua capacidade de identificar defeitos com uma
precisão razoável. Para a avaliação de extremidades de cordões de soldadura, foi testado um novo
método de leitura pontual da impedância para que depois fosse adaptado para extremidades, no
entanto, os resultados mostraram-se inconsistentes.
Em conclusão, esta dissertação contribuiu para a compreensão e desenvolvimento de
métodos avançados de Ensaios Não Destrutivos para a inspeção de cordões de Soldadura por
Brasagem a Laser. Apesar dos avanços alcançados, identificaram-se áreas que requerem
melhorias, como a automatização do processo de monitorização de pressão e a otimização das
sondas de Correntes Induzidas. A continuidade desta pesquisa poderá viabilizar a aplicação
industrial dos métodos propostos, oferecendo uma solução mais robusta e eficiente para a deteção
de defeitos em cordões deste tipo, crucial para a indústria automóvel.
Laser Brazing Welding is a crucial technology in the automotive industry, used to join metal sheets with high precision and efficiency. However, the detection of defects in the weld beads, especially at their ends, presents a significant challenge, as undetected defects can compromise the structural integrity and safety of vehicles. This dissertation focuses on the application of Non-Destructive Testing methods to improve defect detection in Laser Brazing Welds, proposing innovative solutions to overcome the limitations of traditional methods. To achieve this goal, two main approaches were explored: pressure monitoring and the use of Eddy Currents. Pressure monitoring involved the development of a prototype that enables the detection of passing defects along the weld beads and at their ends. The tests carried out with this prototype showed promising results, managing to accurately identify the presence of defects. However, it is important to note that the tests were only carried out on one sample, which limits their viability somewhat. In addition, the effectiveness of Eddy Current probes in detecting surface and depth defects in Laser Brazing Welding beads was evaluated through an emerging technology called surface mounted inductors. Several tests were conducted to validate the performance of these probes, by varying the frequencies and their position, with one of the probes standing out for its ability to identify defects with reasonable precision. In order to evaluate the ends of weld beads, a new method of point impedance reading was tested and then adapted for ends, but the results were inconsistent. In conclusion, this dissertation has contributed to the understanding and development of advanced Non-Destructive Testing methods for the inspection of Laser Brazing Weld beads. Despite the progress made, areas requiring improvement were identified, such as the automation of the pressure monitoring process and the optimization of Eddy Current probes. Continuing this research could enable the industrial application of the proposed methods, offering a more robust and efficient solution for defect detection in this type of weld, which is crucial for the automotive industry.
Laser Brazing Welding is a crucial technology in the automotive industry, used to join metal sheets with high precision and efficiency. However, the detection of defects in the weld beads, especially at their ends, presents a significant challenge, as undetected defects can compromise the structural integrity and safety of vehicles. This dissertation focuses on the application of Non-Destructive Testing methods to improve defect detection in Laser Brazing Welds, proposing innovative solutions to overcome the limitations of traditional methods. To achieve this goal, two main approaches were explored: pressure monitoring and the use of Eddy Currents. Pressure monitoring involved the development of a prototype that enables the detection of passing defects along the weld beads and at their ends. The tests carried out with this prototype showed promising results, managing to accurately identify the presence of defects. However, it is important to note that the tests were only carried out on one sample, which limits their viability somewhat. In addition, the effectiveness of Eddy Current probes in detecting surface and depth defects in Laser Brazing Welding beads was evaluated through an emerging technology called surface mounted inductors. Several tests were conducted to validate the performance of these probes, by varying the frequencies and their position, with one of the probes standing out for its ability to identify defects with reasonable precision. In order to evaluate the ends of weld beads, a new method of point impedance reading was tested and then adapted for ends, but the results were inconsistent. In conclusion, this dissertation has contributed to the understanding and development of advanced Non-Destructive Testing methods for the inspection of Laser Brazing Weld beads. Despite the progress made, areas requiring improvement were identified, such as the automation of the pressure monitoring process and the optimization of Eddy Current probes. Continuing this research could enable the industrial application of the proposed methods, offering a more robust and efficient solution for defect detection in this type of weld, which is crucial for the automotive industry.
Descrição
Palavras-chave
Soldadura por Brasagem a Laser Ensaios Não Destrutivos Monitorização de Pressão Correntes Induzidas