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学者姓名：肖珺
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Abstract ：
The quality of the welding or defect repair of metals using refill friction stir spot welding (RFSSW) is fundamentally influenced by material flow. The welding community is still lack of comprehensive understanding of the flow pattern during the RFSSW process since numerical modeling usually has its own compromises, while current experimental observations of such solid-phase material-flow are lack of precision and suffer from limited visualization. A novel experimental material-flow observation method is proposed to chareactrize the dynamic flow behavior by mixing a few another alloy with the same matrix into the welding zone as a tracing of the flow pattern. Further, the process was combined with the emergent stops at different stages of the RFSSW for ease of analysing the dynamic vertial flow pattern. Meanwhile the deviation angles of the shear textures formed in the welding process were measured and calculated for determing the flow orintation in the horizental planes. During the plunging stage, the flow-climbing zone and flow-expansion zone were observed, with the initial joint connection occurring at their intersections. The threaded sleeve formed an outer stirring zone. A fan-shaped expansion zone developed between the flow-climbing zone and flow-expansion zone during tool dwelling, which reduced the width of the bonding ligament. When the threaded sleeve rotated in a beneficial direction, the generated axial thrust mitigated the incomplete-refill defects. The horizontal material flow in the plunging stage gradually aligned with the ideal shear direction from top to bottom, and in the refilling stage, the flow aligned more closely from bottom to top. Overall, the RFSSW material-flow patterns at different stages were revealed, which could provide explanations for formations and fracture mechanisms of three distinct hook defects. The proposed experimental approach for analyzing the solid-state material flow in this study can be applied to investigations of similar solid-phase processes and help to optimize the tool design.
Keyword ：
Experimental observation Experimental observation Tracing of mixed dissimilar material Tracing of mixed dissimilar material Material flow pattern Material flow pattern Emergent stop Emergent stop Refill friction stir spot welding Refill friction stir spot welding
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| GB/T 7714 | Chen, Shujun , Li, Zhipeng , Xiao, Jun et al. Experimental investigation of material flow behavior during refill friction stir spot welding [J]. | JOURNAL OF MATERIALS PROCESSING TECHNOLOGY , 2025 , 337 . |
| MLA | Chen, Shujun et al. "Experimental investigation of material flow behavior during refill friction stir spot welding" . | JOURNAL OF MATERIALS PROCESSING TECHNOLOGY 337 (2025) . |
| APA | Chen, Shujun , Li, Zhipeng , Xiao, Jun , Pu, Juan , Han, Yang , Gai, Shengnan et al. Experimental investigation of material flow behavior during refill friction stir spot welding . | JOURNAL OF MATERIALS PROCESSING TECHNOLOGY , 2025 , 337 . |
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Abstract ：
PurposeThe purpose of this study is to improve the accuracy of industrial robot kinematic parameter identification and position accuracy by solving the problem of insufficient consideration of error sources in the kinematic parameter identification model and optimizing the selection of measurement pose set.Design/methodology/approachIn this study, a kinematic calibration method for industrial robots considering multiple error sources is proposed. Based on the Modified Denavit Hartenberg (MD-H) model, a robot kinematics identification model including joint reduction ratio error, target ball installation error and coordinate system transformation error is established. Taking the optimal observability index O1 and the minimum flexible deformation as the optimization objectives, a measurement pose set optimization method based on Non-dominated Sorting Genetic Algorithm II (NSGA-II) is proposed to obtain a measurement pose set with higher identification accuracy.FindingsThrough experiments conducted with the Nantong Zhenkang ZK1400-6 robot as the test subject, the kinematic parameters identified by the optimized measurement pose set are more accurate than the randomly selected measurement pose set, and the positioning accuracy of the robot is improved from 2.11 to 0.31 mm, an increase of 85.3%.Originality/valueThis study introduces a position error model that comprehensively accounts for the error sources causing positioning inaccuracies. Building on this foundation, a novel flexible deformation index is proposed to quantify the flexible deformation in the measurement pose set, thereby reducing the impact of such deformation on the position error in the model. To the best of the authors' knowledge, for the first time, this study presents an optimization method for the measurement pose set based on NSGA-II, using the flexible deformation index and observability index as objectives for multi-objective optimization, simultaneously optimizing the pose error and Jacobian matrix in the error model.
Keyword ：
Kinematic calibration Kinematic calibration Error model Error model Pose optimization Pose optimization Positioning accuracy Positioning accuracy Industrial robot Industrial robot
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| GB/T 7714 | Cheng, Bo , Wang, Bo , Chen, Shujun et al. A method for calibrating robotic kinematic parameters based on a multi-error source model and an optimized measurement pose set [J]. | INDUSTRIAL ROBOT-THE INTERNATIONAL JOURNAL OF ROBOTICS RESEARCH AND APPLICATION , 2025 . |
| MLA | Cheng, Bo et al. "A method for calibrating robotic kinematic parameters based on a multi-error source model and an optimized measurement pose set" . | INDUSTRIAL ROBOT-THE INTERNATIONAL JOURNAL OF ROBOTICS RESEARCH AND APPLICATION (2025) . |
| APA | Cheng, Bo , Wang, Bo , Chen, Shujun , Zhang, Ziqiang , Xiao, Jun . A method for calibrating robotic kinematic parameters based on a multi-error source model and an optimized measurement pose set . | INDUSTRIAL ROBOT-THE INTERNATIONAL JOURNAL OF ROBOTICS RESEARCH AND APPLICATION , 2025 . |
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Abstract ：
In complex welding tasks, skilled manual welders often outperform welding robots, primarily due to their expertise in torch manipulation. To address this, a robotic welding teaching system was developed to assist welders in controlling the torch. This system utilizes human-robot interaction to track the welder's movements, significantly enhancing the welding robot's ability to handle intricate weld seams. A virtual welding robot module, created in Unity3D with virtual reality (VR) technology, closely replicates the real robot. This module is integrated with a human-robot interaction interface and a welder operation module. Motion mapping strategies were devised to transfer the welder's movements from the handle to the welding torch, including "static", "dynamic", "velocity" and "acceleration" strategies. These strategies were tested across four trajectories: linear, arc, sinusoidal, and spatial intersection curves. The results revealed the superiority of the "dynamic" strategy. Further evaluations of the teaching system's performance-specifically its "trajectory accuracy", "trajectory delay" and "time delay"-were conducted for straight lines, arcs, and flip motions. The test results showed that, within the operating speed range of 1 to 40 mm/s and 10 to 40 degrees/s, the system's time delay is less than 0.12 s, with actual trajectory errors remaining below 0.06 mm and 0.1 degrees. These performance metrics demonstrate that the system effectively meets the requirements for precise tracking of both the weld seam and torch manipulation.
Keyword ：
Motion mapping Motion mapping Human-like teaching Human-like teaching Virtual reality Virtual reality Robot welding Robot welding
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| GB/T 7714 | Hu, Yijie , Xiao, Jun , Chen, Shujun et al. Virtual reality based programming of human-like torch operation for robotic welding [J]. | WELDING IN THE WORLD , 2025 , 69 (5) : 1447-1458 . |
| MLA | Hu, Yijie et al. "Virtual reality based programming of human-like torch operation for robotic welding" . | WELDING IN THE WORLD 69 . 5 (2025) : 1447-1458 . |
| APA | Hu, Yijie , Xiao, Jun , Chen, Shujun , Gai, Shengnan . Virtual reality based programming of human-like torch operation for robotic welding . | WELDING IN THE WORLD , 2025 , 69 (5) , 1447-1458 . |
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Abstract ：
In this article, Al-Cu-Mg-Ag specimens were successfully wire-arc-additive-manufactured based on by gas metal arc process to investigate the evolution of microstructure and mechanical properties. The results showed that the grain morphology and pore size in the printed specimens varied in height direction. Under the influence of repeated thermal cycling, which affected the solid-state diffusion of the deviated elements at the grain boundaries, the distribution of the nanoscale second phase appeared significantly different in the height direction. The precipitation phase changes caused the microhardness of the printed specimens to decrease gradually from a peak of 125 HV and stabilise at around 100 HV. The changes in the printed specimens' horizontal mechanical properties were insignificant mainly due to interlayer porosity.
Keyword ：
microstructure microstructure properties properties Al-Cu-Mg-Ag Al-Cu-Mg-Ag wire-arc-additive manufacturing wire-arc-additive manufacturing
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| GB/T 7714 | Chen, Shujun , He, Zhi , Xiao, Jun et al. Microstructure evolution and mechanical properties of wire-arc-additively manufactured Al-Cu-Mg-Ag alloy [J]. | SCIENCE AND TECHNOLOGY OF WELDING AND JOINING , 2024 , 29 (2) : 116-123 . |
| MLA | Chen, Shujun et al. "Microstructure evolution and mechanical properties of wire-arc-additively manufactured Al-Cu-Mg-Ag alloy" . | SCIENCE AND TECHNOLOGY OF WELDING AND JOINING 29 . 2 (2024) : 116-123 . |
| APA | Chen, Shujun , He, Zhi , Xiao, Jun , Liu, Liang , Gai, Shengnan , Zhang, Long . Microstructure evolution and mechanical properties of wire-arc-additively manufactured Al-Cu-Mg-Ag alloy . | SCIENCE AND TECHNOLOGY OF WELDING AND JOINING , 2024 , 29 (2) , 116-123 . |
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Abstract ：
At present, Al-Cu-Mg-Ag heat-resistant alloys have become suitable materials for lightweight heat-resistant structures of high-speed crafts. Wire arc direct energy deposition (WA-DED) technology offers a suitable solution to the great challenge of integrated rapid manufacturing of large-complex Al-Cu-Mg-Ag alloy components. Unfortunately, there are few reports on the use of WA-DED technology for the fabrication of Al-Cu-Mg-Ag alloys, and the arc-deposition characteristics of Al-Cu-Mg-Ag alloys are not yet clear. In this work, the droplet transition features and arc characteristics of Al-Cu-Mg-Ag alloy during different Cold Metal Transfer (CMT) modes were investigated to illustrate the special deposit characteristics induced by its unique material properties. The surface tension coefficient of Al-Cu-Mg-Ag alloys at certain high temperatures was quantitatively calculated. The common 2319 alloy with similar Al-Cu content was specifically used as a reference to better reflect the deposit characteristics of Al-Cu-Mg-Ag alloy. The results show that the surface tension coefficient of the Al-Cu-Mg-Ag alloy is 5.6 % lower than that of 2319 alloy in the temperature interval from 1400 to 1650 degrees C. Al-Cu-Mg-Ag alloy is more prone to produce more Mg and Ag vapors with low ionization energies during WA-DED, which promotes stable burning of the arc and improves the electrical conductivity of the arc atmosphere, with a slight decrease in voltage during deposition, despite the increase in arc length. The more stable arc atmosphere enables the more uniform droplet transition period and the more stable and smooth transition process of droplets, while the lower surface tension coefficient facilitates the flow of the molten pool to promote the formation of a smoother deposited layer surface. These promising results will contribute to the application of WA-DED for the efficient manufacturing of Al-Cu-Mg-Ag aerostructural components.
Keyword ：
Deposit characteristics Deposit characteristics Droplet transition Droplet transition Wire arc direct energy deposition (WA-DED) Wire arc direct energy deposition (WA-DED) Al-Cu-Mg-Ag heat-resistant alloys Al-Cu-Mg-Ag heat-resistant alloys Surface tension coefficient Surface tension coefficient
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| GB/T 7714 | Xu, Zhifei , Jun, Xiao , Sheng, Weixing et al. Deposit characteristics of Al-Cu-Mg-Ag heat-resistant alloy during wire arc direct energy deposition [J]. | JOURNAL OF MANUFACTURING PROCESSES , 2024 , 131 : 1514-1530 . |
| MLA | Xu, Zhifei et al. "Deposit characteristics of Al-Cu-Mg-Ag heat-resistant alloy during wire arc direct energy deposition" . | JOURNAL OF MANUFACTURING PROCESSES 131 (2024) : 1514-1530 . |
| APA | Xu, Zhifei , Jun, Xiao , Sheng, Weixing , He, Zhi , Chen, Shujun , Zhao, Hongyan . Deposit characteristics of Al-Cu-Mg-Ag heat-resistant alloy during wire arc direct energy deposition . | JOURNAL OF MANUFACTURING PROCESSES , 2024 , 131 , 1514-1530 . |
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Abstract ：
GH4169 Ni-based superalloy was prepared by wire arc additive manufacturing (WAAM) in this study. Similar to the microstructure of other additive manufactured superalloys, the additively manufactured GH4169 alloy suffered from a high-volume fraction of Laves phase, which is detrimental to the alloy's mechanical properties. To solve this problem, two different post heat-treatment approaches were selected to improve the tensile properties at both room and elevated temperatures, which are the one with solution treatment temperature at 950 degrees C and the modified one with solution treatment at 1150 degrees C, respectively. Detailed phase analysis during different heat treatment processes was conducted using both scanning and transmission electron microscopes. Comparative tensile tests were also conducted at both room tem-perature and 650 degrees C to analyze the role of the different microstructures on the deformation responses of the prepared samples. By increasing the solution treatment temperature from 950 degrees to 1150 degrees C, the volume fraction of Nb-rich Laves phase dramatically decreased, and the previously Laves-phase-trapped Nb con-tributed to the formation of the strengthening gamma '' phase. As a result, the tensile strength of this modified treated alloy is significantly improved at both room and elevated temperatures. Additionally, due to lower volume fraction of the Laves phase, the elongation of the modified treated alloy at room temperature is improved by similar to 35%. These findings provided new insights into the post-heat treatment approaches of the WAAM Ni-based superalloy.(c) 2023 Published by Elsevier B.V.
Keyword ：
Heat-treatment Heat-treatment Wire arc additive manufacturing (WAAM) Wire arc additive manufacturing (WAAM) Laves phase Laves phase Microstructure evolution Microstructure evolution Strengthening phase Strengthening phase Nickel-based superalloy Nickel-based superalloy
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| GB/T 7714 | Chen, Shujun , He, Zhi , Xiao, Jun et al. Modified heat treatment and related microstructure-mechanical property evolution of arc melting additively manufactured GH4169 Ni- based superalloy [J]. | JOURNAL OF ALLOYS AND COMPOUNDS , 2023 , 947 . |
| MLA | Chen, Shujun et al. "Modified heat treatment and related microstructure-mechanical property evolution of arc melting additively manufactured GH4169 Ni- based superalloy" . | JOURNAL OF ALLOYS AND COMPOUNDS 947 (2023) . |
| APA | Chen, Shujun , He, Zhi , Xiao, Jun , Gai, Shengnan , Wang, Zhimin , Li, Jianwei . Modified heat treatment and related microstructure-mechanical property evolution of arc melting additively manufactured GH4169 Ni- based superalloy . | JOURNAL OF ALLOYS AND COMPOUNDS , 2023 , 947 . |
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Abstract ：
High-speed GMAW tends to be accompanied by periodic humping defects, thereby reducing the weld bead quality. A new method was proposed to actively control the weld pool flow for eliminating humping defects. A high-melting point solid pin was designed and inserted into the weld pool to stir the liquid metal during the welding process. The characteristics of the backward molten metal flow were extracted and compared by a high-speed camera. Combined with particle tracing technology, the momentum of the backward metal flow was calculated and analyzed, and the mechanism of hump suppression in high speed GMAW was further revealed. The stirring pin interacted with the liquid molten pool, resulting in a vortex zone behind the stirring pin, which significantly reduced the momentum of the backward molten metal flow, and thus it inhibited the formation of humping beads.
Keyword ：
high-speed GMAW high-speed GMAW humping bead humping bead mechanical stirring mechanical stirring weld pool flow weld pool flow
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| GB/T 7714 | Xiao, Jun , Wang, Xiaolei , Gai, Shengnan et al. Effect of Mechanical Stirring on High-Speed GMAW Hump Bead [J]. | MATERIALS , 2023 , 16 (12) . |
| MLA | Xiao, Jun et al. "Effect of Mechanical Stirring on High-Speed GMAW Hump Bead" . | MATERIALS 16 . 12 (2023) . |
| APA | Xiao, Jun , Wang, Xiaolei , Gai, Shengnan , Chen, Shujun , Huang, Wenhao . Effect of Mechanical Stirring on High-Speed GMAW Hump Bead . | MATERIALS , 2023 , 16 (12) . |
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Abstract ：
As a method of work hardening, the technology of in-situ forging was introduced to solve the problem of poor mechanical properties in the fabrication of large-structural aluminum alloys components using wire arc additive manufacturing (WAAM) technology. Unfortunately, at present, the in-situ forging devices reported could not provide the ability to flexibly adjust output forces over a wide range of frequencies and change the output mode of forces. In this work, a novel method of high-dynamic actuator based in-situ micro-forging process for WAAM was proposed. The system is of compact design and has the characteristics of high dynamic response. The terminal hammering head could automatically fits the surface of the deposited layer successfully, enabling the stable control of the real-time hammering force, meaning that it offers a solution for processing deposited layers with complex paths. In addition, the terminal hammering head could be sufficiently close to the molten pool to enable the cumulative rapid micro-deformation of the as-solidified metal. This new method significantly promotes the reduction of shrinking holes and the closure of spherical pores of the components. The microhardness and the compressive yield strength of the components increased by 12% and 13% respectively. A gradient microstructure was obtained due to the transfer of strain. The mechanism of hybrid dynamic recrystallisation induced by cumulative rapid micro-deformation is investigated. These promising results promote the possibility of applying in-situ micro-forging technology in the field of flexible and intelligent manufacturing in aerospace.
Keyword ：
Gradient microstructure Gradient microstructure Dynamic recrystallisation Dynamic recrystallisation In -situ micro -forging In -situ micro -forging Hybrid manufacturing Hybrid manufacturing Wire arc additive manufacturing Wire arc additive manufacturing
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| GB/T 7714 | Xu, Zhifei , Xiao, Jun , Chen, Shujun . A novel high-dynamic actuator based in-situ micro-forging process for wire arc additive manufacturing of aluminum alloy [J]. | JOURNAL OF MATERIALS PROCESSING TECHNOLOGY , 2023 , 324 . |
| MLA | Xu, Zhifei et al. "A novel high-dynamic actuator based in-situ micro-forging process for wire arc additive manufacturing of aluminum alloy" . | JOURNAL OF MATERIALS PROCESSING TECHNOLOGY 324 (2023) . |
| APA | Xu, Zhifei , Xiao, Jun , Chen, Shujun . A novel high-dynamic actuator based in-situ micro-forging process for wire arc additive manufacturing of aluminum alloy . | JOURNAL OF MATERIALS PROCESSING TECHNOLOGY , 2023 , 324 . |
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Abstract ：
Laser wire deposition (LWD) is a promising method with a great potential for the fabrication of large open-frame components. Using hot wire in such a process, referred to as laser hot wire deposition (LHWD) would improve the laser absorption and deposition rate. In this work, the LHWD process of aluminum-alloy wire was studied with particular attention to the wire transfer behaviors. The results show that the wire melting rate could still be effectively increased even for the low-resistivity aluminum wire. The preheating current has a great influence on the wire transfer dynamics. Analysis demonstrates that the key to maintaining stable wire melting and transfer is to control the wire tip temperature by matching the wire feed speed and preheating current under certain laser power. A model computing the dynamic preheating process was established to predict the wire tip temperature with or without resistance preheating. A criterion based on the predictions was proposed to determine the optimal match of wire feed speed and wire preheating current, and thereby provided a deeper understanding of LHWD process.
Keyword ：
Parameter optimization Parameter optimization Laser hot-wire deposition (LHWD) Laser hot-wire deposition (LHWD) Wire transfer mode Wire transfer mode Wire preheating Wire preheating
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| GB/T 7714 | Huang, Wenhao , Xiao, Jun , Chen, Shujun et al. Control of wire melting behavior during laser hot wire deposition of aluminum alloy [J]. | OPTICS AND LASER TECHNOLOGY , 2022 , 150 . |
| MLA | Huang, Wenhao et al. "Control of wire melting behavior during laser hot wire deposition of aluminum alloy" . | OPTICS AND LASER TECHNOLOGY 150 (2022) . |
| APA | Huang, Wenhao , Xiao, Jun , Chen, Shujun , Jiang, Xiaoqing . Control of wire melting behavior during laser hot wire deposition of aluminum alloy . | OPTICS AND LASER TECHNOLOGY , 2022 , 150 . |
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Abstract ：
While penetration occurs underneath the workpiece, the raw information used to detect it during welding must be measurable to a sensor attached to the torch. Challenges are apparent because it is difficult to find such measurable raw information that fundamentally correlates with the phenomena occurring underneath. Additional challenges arise because the welding process is extremely complex such that analytically correlating any raw information to the underneath phenomena is practically impossible; therefore, handcrafted methods to propose features from raw information are human dependent and labor extensive. In this paper, the profile of the weld pool surface was proposed as the raw information. An innovative method was proposed to acquire it by projecting a single laser stripe on the weld pool surface transversely and intercepting its reflection from the mirror-like weld pool surface. To minimize human intervention, which can affect success, a deep-learning-based method was proposed to automatically recognize features from the single-stripe active vision images by fitting a convolutional neural network (CNN). To train the CNN, spot gas tungsten arc welding experiments were designed and conducted to collect the active vision images in pairs with their actual penetration states measured by a camera that views the backside surface of the workpiece. The CNN architecture was optimized by trying different hyperparameters, including kernel number, kernel size, and node number. The accuracy of the optimized model is about 98% and the cycle time in the personal computer is similar to 0.1 s, which fully meets the required engineering application.
Keyword ：
Weld Pool Image Weld Pool Image Gas Tungsten Arc Welding (GTAW) Gas Tungsten Arc Welding (GTAW) Convolutional Neural Network (CNN) Convolutional Neural Network (CNN) Deep Learning Deep Learning Weld Penetration Weld Penetration
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| GB/T 7714 | Cheng, Y. C. , Wang, Q. Y. , Jiao, W. H. et al. Automated Recognition of Weld Pool Characteristics from Active Vision Sensing [J]. | WELDING JOURNAL , 2021 , 100 (5) : 183S-192S . |
| MLA | Cheng, Y. C. et al. "Automated Recognition of Weld Pool Characteristics from Active Vision Sensing" . | WELDING JOURNAL 100 . 5 (2021) : 183S-192S . |
| APA | Cheng, Y. C. , Wang, Q. Y. , Jiao, W. H. , Xiao, J. , Chen, S. J. , Zhang, Y. M. . Automated Recognition of Weld Pool Characteristics from Active Vision Sensing . | WELDING JOURNAL , 2021 , 100 (5) , 183S-192S . |
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