Friction stir welding (FSW) is an advantageous solid-state joining process, suitable for many materials in the energy, aerospace, naval and automotive industries. Like all other welding processes, friction stir welding requires non-destructive evaluation (NDE). The time and resources to preform NDE is expensive. To reduce these costs, nontraditional NDE methods are being developed for FSW. Spectral based defect recognition uses the forces during the welding process to validate weld quality. Although spectral NDE methods have shown promise as an alternative NDE processes, many research welding speeds do not correspond to manufacturing speeds, nor do they explain the relationship between the spectral data and the process. The purpose of this work is to explore the possibility of acquiring additional information about the defect. Namely the defect’s type, location, and magnitude. In this study, welds with “wormhole” defects were produced at 2000, 2500 and 3000 mmpm in 5754 aluminum. The welding process forces and torque were measured and analyzed spectrally. The welded plates were then imaged with x-ray photography, a validated NDE method. It was found that low frequencies (0 – 4 Hz) in the y & z force signals correlate with defect presence in high speed FSW. In addition, the strong correlation between the spectral data and the presence of a defect allowed for defect magnitude predictions. Linear fits were applied to the defect measurements and the spectral data. Large error inhibits the wide use of this prediction method.

Friction stir welding (FSW) is an advantageous solid-state joining process, suitable for many materials in the energy, aerospace, naval and automotive industries. Like all other welding processes, friction stir welding requires non-destructive evaluation (NDE). The time and resources to preform NDE is expensive. To reduce these costs, nontraditional NDE methods are being developed for FSW. Spectral based defect recognition uses the forces during the welding process to validate weld quality. Although spectral NDE methods have shown promise as an alternative NDE processes, many research welding speeds do not correspond to manufacturing speeds, nor do they explain the relationship between the spectral data and the process. The purpose of this work is to explore the possibility of acquiring additional information about the defect. Namely the defect’s type, location, and magnitude. In this study, welds with “wormhole” defects were produced at 2000, 2500 and 3000 mmpm in 5754 aluminum. The welding process forces and torque were measured and analyzed spectrally. The welded plates were then imaged with x-ray photography, a validated NDE method. It was found that low frequencies (0 – 4 Hz) in the y & z force signals correlate with defect presence in high speed FSW. In addition, the strong correlation between the spectral data and the presence of a defect allowed for defect magnitude predictions. Linear fits were applied to the defect measurements and the spectral data. Large error inhibits the wide use of this prediction method.

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In this thesis project, an underwater 3D scanner based on structured light has been constructed and developed. Two other scanners, based on stereoscopy and a line-swept laser, were also tested. The target application is to examine objects inside the water filled reactor vessel of nuclear power plants. Structured light systems (SLS) use a projector to illuminate the surface of the scanned object, and a camera to capture the surfaces' reflection. By projecting a series of specific line-patterns, the pixel columns of the digital projector can be identified off the scanned surface. 3D points can then be triangulated using ray-plane intersection. These points form the basis the final 3D model. To construct an accurate 3D model of the scanned surface, both the projector and the camera need to be calibrated. In the implemented 3D scanner, this was done using the Camera Calibration Toolbox for Matlab. The codebase of this scanner comes from the Matlab implementation by Lanman & Taubin at Brown University. The code has been modified and extended to meet the needs of this project. An examination of the effects of the underwater environment has been performed, both theoretically and experimentally. The performance of the scanner has been analyzed, and different 3D model visualization methods have been tested. In the constructed scanner, a small pico projector was used together with a high pixel count DSLR camera. Because these are both consumer level products, the cost of this system is just a fraction of commercial counterparts, which uses professional components. Yet, thanks to the use of a high pixel count camera, the measurement resolution of the scanner is comparable to the high-end of industrial structured light scanners.