Development of a SMART system integrating automatic/robotic hybrid WELDing technologies, digital-twin-assisted quality monitoring, and WPS predictive tool

ongoing

SMARTWELD Project aims to develop new smart, efficient and eco-friendly welding processes. Steel industry emissions must fall by at least 55% within 2030 to contribute to the European Green Deal final goal of making EU carbon neutral by 2050. The most promising mitigation approach to tackle the problem is the combination of material efficiency and hydrogen transition, capable to reduce direct emissions by 48%. In the present scenario, a crucial role in this mitigation approach can be played by new more efficient welding processes. No commercial product is present although the literature points to hybrid PAW+MAG, LBW+MAG as state-of-the-art efficient process for pipeline welding. The SMARTWELD ambition is to fill this gap by developing, validating, and diffusing an integrated welding system expected to save machining time by 15%, save filler metal/flux by 25%, save energy and shielding gas by 15%, improve productivity by 33%, decrease repairing activity by 15%, decreasing residual stresses by 15%. The system will be constituted by (1) new robotised/automated hybrid welding technologies, (2) digital-twin-assisted online quality monitoring systems, and (3) a predictive tool – providing efficient, eco-friendly welding processes. It will be accomplished by validating those integrated technologies at TRL5 within the Project timeframe and planning to reach the market 5 years after the end of the Project. First a specific business case (i.e., [U]HSS pipes) will be considered, then transferability of results will be assessed to other relevant areas where welding is crucial, such as hydrogen steels and structural steels.