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Related Experiment Video

Updated: Jan 21, 2026

Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing
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Research on the Weld Position Detection Method for Sandwich Structures from Face-Panel Side Based on Backscattered

Angang Wei1,2, Baohua Chang1, Boce Xue1

  • 1Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China.

Sensors (Basel, Switzerland)
|July 24, 2019
PubMed
Summary

This study presents an X-ray based method for detecting weld positions in aluminum web-core sandwich panels. The technique accurately locates joints from the face panel side, crucial for manufacturing aerospace and naval structures.

Keywords:
T-joint from face-panel sideX-ray backscatteraluminum T-jointdenoising methodweb-core sandwich panelsweld position detection

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Area of Science:

  • Materials Science
  • Non-destructive Testing
  • Manufacturing Engineering

Background:

  • Web-core sandwich panels are vital lightweight structures in aerospace and naval applications.
  • Welding is used to join panels, but locating the core panel position from the face panel side is challenging due to shielding.
  • Accurate weld joint detection is essential for high-reliability manufacturing of these structures.

Purpose of the Study:

  • To develop and validate an X-ray based method for detecting weld positions in aluminum web-core sandwich panels.
  • To address the challenge of locating core panel joints obscured by the face panel.
  • To provide a technical basis for automated weld joint tracking in curved sandwich structure manufacturing.

Main Methods:

  • Designed an experimental system for weld position detection using backscattered X-ray intensity signals.
  • Developed a signal processing method to extract characteristic values representing the joint center.
  • Established an analytical model to optimize detection parameters based on system and specimen characteristics.

Main Results:

  • The developed method accurately extracts X-ray intensity signals to identify the weld joint center.
  • An analytical model was created to calculate and optimize detection parameters.
  • Experiments on a 3 mm thick 6061 aluminum alloy specimen achieved a maximum absolute error of 0.340 mm.

Conclusions:

  • The X-ray based method provides sufficient accuracy for locating weld joints in aluminum web-core sandwich panels.
  • The technique is suitable for detecting joints from the face panel side, overcoming shielding issues.
  • This research supports the automated tracking of weld joints for reliable manufacturing of complex sandwich structures.