Toward an intelligent aluminum laser welded blanks (ALWBs) factory based on industry 4.0; a critical review and novel smart model

The aim of this review paper is a comprehensive investigation of the laser welding and forming process as two critical parts of smart manufacturing and welding intelligent systems in Industry 4.0, especially for forming Aluminum Laser Welded Blanks (ALWB). In the modern era, manufacturing companies and their business models have a major impact on economic development and social relationships. Since Industry 4.0 has become a commonly accepted term for research centers and universities, both businesses and researchers are interested in the initiative. On the other side, aluminum has proven more challenging to weld than the other metals ac-counting for the most part for its tendency to form porosity. In this regard, monitoring using sensor-based approachesarehat centralize the information in real time is gaining ground. In addition, this ensures the accu-racy and quality of the final product. There are several critical factors such as laser power, laser speed, focal point, laser scanning, and frequency that play a key role in laser technology which is important to control them toward the zero-defect manufacturing system. On the other hand, robustness accounting for geometrical defects (ex. underfill amount/angle at the toe as well as the number of admissible porosity defects in the weld about formability) are the critical parameters in the forming process. Here, a comprehensive review paper is conducted insight into the function of different sensors to signals from the welding and forming process. Finally, a novel model has been proposed as a roadmap for applying the idea of Industry 4.0 in forming Aluminum Laser Welded Blanks (ALWB).

Automated summary

The aim of this review paper is to investigate the laser welding and forming process in the context of smart manufacturing and welding intelligent systems in Industry 4.0, focusing on Aluminum Laser Welded Blanks (ALWB) forming. Manufacturing companies and their business models have significant impact on economic development and social relationships. Aluminum welding is challenging due to its tendency to form porosity, thus real-time sensor-based monitoring has gained importance for accuracy and quality. Laser power, speed, focal point, scanning, and frequency are critical factors in laser technology for zero-defect manufacturing. Geometrical defects and porosity defects are critical parameters in the forming process. This review paper provides insights on different sensors and proposes a roadmap for applying Industry 4.0 in ALWB forming.