QCOALA. Quality Control Of Aluminium Laser-welded Assemblies. An idea from. A collaboration between:

Transcription

1 QCOALA Quality Control Of Aluminium Laser-welded Assemblies An idea from A collaboration between: LASAG, Precitec, CIT and SAFEL, Flisom, SolarPro and VW, Ruhr-Universität Bochum, Fraunhofer ILT and TWI Technology Engineering 1

2 QCOALA Introduction to the project Technology Engineering 2

3 Background to the proposal Rapid advances in laser technology, for both macroand micro-scale materials processing Welding interconnections, aluminium & copper EV and HEV markets expanding rapidly demand for lithium-ion and super-capacitor batteries current manufacturing (RSW, TIG) slow, expensive and inconsistent weld quality Flexible thin-film PV market growing rapidly technical challenges remain, eg shingling current manufacturing (US, adhesives) too slow, expensive and sometimes unreliable need for accurate, local, low heat-input process Technology Engineering 3

4 QCOALA call & consortium FoF.ICT Smart Factories: ICT for agile and environmentally friendly manufacturing 10 participants from 5 countries 40% SME laser manufacture, process monitoring, NDT, end-user 30% RTD 30% LE solar energy, automotive Technology Engineering 4

5 QCOALA overall objective To develop a new laser processing system for the welding of thin-gauge aluminium and copper, 0.1mm to 1.0mm in thickness, with integrated process monitoring and in-line non-destructive inspection, and to establish its capability to provide a reliable, high-speed, low-cost and high-quality joining solution for electric car battery and thin-film photovoltaic (PV) cell interconnections. Technology Engineering 5

6 QCOALA key features Quality: QA through real-time process monitoring and NDT inspection Weld fingerprint: measure compare action Integrated ICT and SPC: 100% non-destructive inspection to reduce scrap to <1% and pseudo-errors<1% Productivity: Tailored energy strategies for aluminium and copper ( >20%) Optimum weld quality reliability / durality productivity ( %) Autonomous operation: Integrated ICT and SPC 100% non-destructive inspection immediate remedial action Technology Engineering 6

7 QCOALA key features mm aluminium and copper welding New laser processing system pulsed platform Near-IR and green wavelength capable Real temporal pulse control (closed-loop control) Integrated process monitoring plasma, back-reflection, temperature Integrated non-destructive testing Eddy-current Digital radiography Technology Engineering 7

8 Solar energy - Automotive Industry focus Technology Engineering 8

9 QCOALA technologies Technology Engineering 9

10 QCOALA technologies Laser System Development Review of commercial sources and delivery options suitable for welding mm Al and Cu Development of green (532nm λ) laser test platform by M12. Effect of λ on welding performance*. Development of on-line temporal pulse control (closed-loop control of the monitored process). Development of a dual-wavelength scanning system, capable of emitting both the 532nm and the 1064nm. To be integrated into QCOALA laser demonstration platform by M24. * Welding performance = absorption, welding speed and weld quality Technology Engineering 10

11 QCOALA technologies Intelligent Laser Welding Empirical evaluation of the effect of spot size, beam quality. pulse length, average and peak power, and repetition rate, on welding performance* of mm Al and Cu for 1064nm λ. Empirical evaluation of the effect of the 532nm λ on welding performance* Develop tailored energy strategies to control HI and keyhole/weld pools stability * Welding performance = absorption, welding speed and weld quality Technology Engineering 11

12 QCOALA technologies Integrated Process Monitoring Development of a CMOS camera-based WMS that can handle both 532nm and 1064nm, capable of assessing weld pool stability and identifying likelihood of imperfections occurring, through fast-rate image acquisition (>1000fps). The imperfection-recognition software will comprise image processing algorithms. Development of an interactive WMS graphical userinterface Integration of the WMS into the QCOALA laser demonstration platform Technology Engineering 12

13 QCOALA technologies In-line Weld Inspection Development of Eddy Current (EC) weld inspection probes with very small sensing area (estimated <0.5mm) and very high frequency (estimated >1MHz), with suitable instrumentation. Modelling and experimental validation Development of digital radiography (DR) weld inspection system with contrast sensitivity <2% and spatial resolution better than 10µm will be developed, with incorporated Automatic Defect Recognition (ADR) Technology Engineering 13

14 Summary of deliverables New laser processing system with pulsing capabilities (µs to ms pulse duration, up to 30J pulse energy) Dual-wavelength beam scanner Real-time temporal pulse control allowing thermal management and closed-loop control of the process Weld quality improvement strategies (wavelength, spot size, beam quality, pulse length, average and peak power, and repetition rate) A weld monitoring system comprising fast-rate image acquisition and processing algorithms for imperfection recognition. A digital radiography and eddy current weld inspection system with Automatic Defect Recognition (ADR) Technology Engineering 14

15 QCOALA Project Management and Structure Technology Engineering 15

16 Management structure Technology Engineering 16

17 Project Steering Committee (PSC) Project Coordinator Exploitation Manager One (senior) representative from each Beneficiary Six-monthly meetings, chaired by Project Coordinator Responsible for the overall project control and delivery Monitoring of project progress: proper integration of activities, link between Work Packages (WPs) and clear consideration of exploitation Approval of changes to technical work programme, project finances and exploitation of results Timely submission of deliverables (incl. progress reports and cost statements) Technology Engineering 17

18 Project Coordinator Paola De Bono (TWI Ltd) Liaison between the Consortium and the EC Overall management, coordination and delivery of the project Consolidation of planning, progress reports, delivery reports, cost statements Coordinate technical progress through Project Steering Committee and Work Package Leaders Effective communication to and between Beneficiaries Assisted by TWI Administrator and Contracts Officer Assisted by Exploitation Manager Technology Engineering 18

19 Exploitation Manager Markus Kogel-Hollacher (Precitec KG) Responsible for the development and management of an overall Exploitation Plan Arrangements between Beneficiaries Dissemination of project results outside consortium Through the PSC and liaison with each Beneficiary individually Cost-benefit analysis demonstrating the impact of the project deliverables on current and future market position Technology Engineering 19

20 QCOALA structure Technology Engineering 20

21 Work Packages WP 1 QCOALA system specification (TWI) To finalise the specification of the QCOALA system to be developed. To finalise the methodology to be followed for the development of the QCOALA technologies WP 2 Laser system development (LAS) To carry out a laser system technology assessment To demonstrate the efficient generation of the 532nm (green) wavelength with standard pulse shaping capabilities. To design and manufacture a QCOALA laser demonstration platform with on-line temporal pulse capability and dual-scanner for welding thin-gauge Al and Cu interconnections. Technology Engineering 21

22 Work Packages WP 3 Intelligent laser welding (TWI) To assess the effect of spot size, beam quality, laser wavelength (in particular ~1064nm and ~532nm), pulse duration, pulse repetition rate, average and peak power, on the welding performance of Al and Cu interconnections in terms of absorption efficiency, welding speed and weld quality (process stability). To develop a tailored energy strategy to allow the development of on-line temporal pulse capability of the QCOALA laser demonstration platform (WP2). To develop the optimum process parameter window and establish welding strategy for high-quality welding of thin-film PV cell interconnections and electric battery Al and Cu interconnections. Technology Engineering 22

23 Work Packages WP 4 Process monitoring and quality assurance (ILT) To develop and evaluate a Weld (process) Monitoring System with imperfection-recognition software to assure high quality laser welding of thin-gauge aluminium and copper interconnections. To develop an operator-friendly user interface for the WMS. WP 5 In-line weld inspection (CIT) To develop a Digital Radiography (DR) weld inspection system for high-quality laser welding of aluminium and copper interconnections. To develop an Eddy Current (EC) weld inspection system for high-quality laser welding of aluminium and copper interconnections. Technology Engineering 23

24 Work Packages WP 6 System integration and demonstration (RUB) To integrate the WMS, the DR and the EC inspection systems into the QCOALA laser demonstration platform To evaluate the performance of the fully integrated QCOALA system in a real production environment for the high-quality welding of electric car battery and thin-film PV cell interconnections, and compare with current conventional joining technology. WP 7 Project Management (TWI) To ensure that the QCOALA project is well managed, the objectives met in the agreed timescales, the results are effectively exploited, the deliverables and milestones are achieved, and the financial and contractual aspects adhered to. Technology Engineering 24

25 Work Packages WP 8 Exploitation & dissemination (PRE) To generate information and technology from the results of the project and disseminate these by means of conferences, publications, and other means and to develop and implement exploitation plans (including training) for each project Beneficiary. Special attention will be taken on IPR issues. Technology Engineering 25

26 WP Leaders Responsible for the successful performance, delivery and reporting of individual work packages Reporting to the Project Coordinator Technical meetings at discretion of WP leaders (guideline: 3-monthly) Assisted by Task Leaders, if needed. Technology Engineering 26

27 Communication strategy Responsibility of Project Coordinator Responsibility of all Beneficiaries Formal (and informal) communication encouraged Please inform the Project Coordinator immediately of any significant actions, conclusions and/or problems that may affect the outcome of (part of) the project Website: restricted and public , phone, teleconference Technology Engineering 27

28 Progress monitoring and reporting Beneficiary Short 6-weekly progress statement per work package involved to WP leader and Project Coordinator Reporting on: work completed, problems encountered, solutions suggested, percentage completion, time-to-completion, deliverable / milestone achieved Financial reporting (presentation by A Surowiec) WP leader 3-monthly WP progress statement summarised from 6-weekly Beneficiary statements Reporting on: as above Focus on summarising progress, identification of delays (if any) or variance from project plans, suggestion of corrective actions Technology Engineering 28

29 Progress monitoring and reporting Project Coordinator 12-month and 24-month periodic review Activity report and Management report Technical progress: collectively and individually Review of finances and exploitation plan Involving all Beneficiaries and Scientific Officer End review at month M36 Report on progress and redefine, if necessary, the remainder of the project programme EC reviews against milestones, deliverables and exploitation to decide on continuation of Grant Agreement Technology Engineering 29