A residual stress distribution measuring method of the present invention is characterized by comprising: by using an analytical model in which a cut-surface is interpolated to a cross section of a metal member, the step of calculating a residual force vector that is a sum of a load vector acting on a first metal piece at the cut-surface and a load vector acting on a second metal piece at the cut-surface; the step of calculating, as a modified displacement vector, an amount of movement at the cross section by interpolating the residual force vector as a forced load to the cross section of an analytical model of the metal member; by using an analytical model having the shape of a cut-surface of a measured first or second metal piece, the step of modifying the shape of the cut-surface of the first or the second metal piece on the basis of the calculated modified displacement vector; and by using the analytical model in which the shape of the cut-surface of the first or the second metal piece is modified, the step of calculating a residual stress distribution at the cross section by interpolating a forced displacement to the analytical model.

A system for evaluating a bond includes first and second electrodes. A dielectric material layer is positioned at least partially between the first and second electrodes. A power source is connected to the first and second electrodes. The power source is configured to cause the first and second electrodes to generate an electrical arc. The electrical arc is configured to at least partially ablate a sacrificial material layer to generate a plasma.

A system for evaluating a bond includes first and second electrodes. A dielectric material layer is positioned at least partially between the first and second electrodes. A power source is connected to the first and second electrodes. The power source is configured to cause the first and second electrodes to generate an electrical arc. The electrical arc is configured to at least partially ablate a sacrificial material layer to generate a plasma.

A reflection-diffraction-deformation flaw detection method employs a transverse wave oblique probe. When an ultrasonic transverse wave encounters a defect during propagation, a reflected wave, a diffracted wave, and a deformed wave are generated. Through a comprehensive analysis of these waves, the presence or absence of the defect is determined by the reflected wave having reflection characteristics and the diffracted wave having the diffraction characteristics. The shape and size of the defect are determined by the deformed wave having deformation characteristics, namely the deformed surface wave generated at the endpoints of the defect which propagates on the defect surface. Furthermore, by the combination of paths trailed by the deformed surface wave, the deformed transverse wave, and the deformed longitudinal wave that are generated by the defect as well as that trailed by the transmit transverse wave, causes of all those waves in the screen can be revealed.

A reflection-diffraction-deformation flaw detection method employs a transverse wave oblique probe. When an ultrasonic transverse wave encounters a defect during propagation, a reflected wave, a diffracted wave, and a deformed wave are generated. Through a comprehensive analysis of these waves, the presence or absence of the defect is determined by the reflected wave having reflection characteristics and the diffracted wave having the diffraction characteristics. The shape and size of the defect are determined by the deformed wave having deformation characteristics, namely the deformed surface wave generated at the endpoints of the defect which propagates on the defect surface. Furthermore, by the combination of paths trailed by the deformed surface wave, the deformed transverse wave, and the deformed longitudinal wave that are generated by the defect as well as that trailed by the transmit transverse wave, causes of all those waves in the screen can be revealed.

A handheld quality inspection tool for projection welded components and method for utilizing the same is disclosed. The handheld quality inspection tool includes an elongated hollow tube, a spring support, a spring member, a plunger, and a handle. The elongated hollow tube defines a slot. The spring support is connected to an end portion of the elongated tube. The spring member is disposed within the elongated hollow tube and connected to the spring support. The plunger is disposed in the elongated hollow tube and connected to the spring member opposite the spring support. The handle is connected to the plunger and protrudes from the elongated hollow tube through the slot and is translatable along the slot to move the plunger and compress the spring member. Upon release of the handle, the compressed spring member propels the plunger to apply an impact force to a projection welded component.

A handheld quality inspection tool for projection welded components and method for utilizing the same is disclosed. The handheld quality inspection tool includes an elongated hollow tube, a spring support, a spring member, a plunger, and a handle. The elongated hollow tube defines a slot. The spring support is connected to an end portion of the elongated tube. The spring member is disposed within the elongated hollow tube and connected to the spring support. The plunger is disposed in the elongated hollow tube and connected to the spring member opposite the spring support. The handle is connected to the plunger and protrudes from the elongated hollow tube through the slot and is translatable along the slot to move the plunger and compress the spring member. Upon release of the handle, the compressed spring member propels the plunger to apply an impact force to a projection welded component.

A method for monitoring and identifying the quality of a welding performed by a welding machinery on a metallic component; the method for monitoring and identifying comprises the steps of: establishing a plurality of classes that describe possible weld defects on the metallic component; identifying a plurality of features that are relative to the functioning of the welding machinery; acquiring the values assumed by the plurality of features during the execution of a current welding on a metallic component; and processing the values assumed by the plurality of features during the execution of the current welding by means of a system for monitoring and identifying the quality to establish the probabilities of the future outcome of the welding of belonging to each of the classes of the plurality of classes.

A method for monitoring and identifying the quality of a welding performed by a welding machinery on a metallic component; the method for monitoring and identifying comprises the steps of: establishing a plurality of classes that describe possible weld defects on the metallic component; identifying a plurality of features that are relative to the functioning of the welding machinery; acquiring the values assumed by the plurality of features during the execution of a current welding on a metallic component; and processing the values assumed by the plurality of features during the execution of the current welding by means of a system for monitoring and identifying the quality to establish the probabilities of the future outcome of the welding of belonging to each of the classes of the plurality of classes.

Examples described herein provide a method that includes receiving weld data about a weld. The method further includes analyzing, using a physics-based model, the weld data to predict a formation of a defect in the weld. The method further includes providing feedback to enable process optimization during a design stage or active control during welding to control a welding machine to correct for and eliminate the formation of the defect in the weld.