In the design of offshore jacket foundations, fatigue life is crucial. Post-weld treatment has been proposed to enhance the fatigue performance of welded joints, where particularly high-frequency mechanical impact (HFMI) treatment has been shown to improve fatigue performance significantly. Automated HFMI treatment has improved quality assurance and can lead to cost-effective design when combined with accurate fatigue life prediction. However, the finite element method (FEM), commonly used for predicting fatigue life in complex or multi-axial joints, relies on a basic CAD depiction of the weld, failing to consider the actual weld geometry and defects. Including the actual weld geometry in the FE model improves fatigue life prediction and possible crack location prediction but requires a digital reconstruction of the weld. Current digital reconstruction methods are time-consuming or require specialised scanning equipment and potential component relocation. The proposed framework instead uses an industrial manipulator combined with a line scanner to integrate digital reconstruction as part of the automated HFMI treatment setup. This approach applies standard image processing, simple filtering techniques, and non-linear optimisation for aligning and merging overlapping scans. A screened Poisson surface reconstruction finalises the 3D model to create a meshed surface. The outcome is a generic, cost-effective, flexible, and rapid method that enables generic digital reconstruction of welded parts, aiding in component design, overall quality assurance, and documentation of the HFMI treatment.

翻译：在海上导管架基础设计中，疲劳寿命至关重要。为提升焊接接头疲劳性能，人们提出了焊后处理技术，其中高频机械冲击（HFMI）处理已被证实能显著改善疲劳性能。自动化HFMI处理提高了质量保障水平，结合精确的疲劳寿命预测可实现经济性设计。然而，常用于复杂或多轴接头疲劳寿命预测的有限元方法（FEM）仅依赖焊缝的基本CAD描述，未能考虑实际焊缝几何形状与缺陷。将实际焊缝几何纳入有限元模型可改善疲劳寿命预测及潜在裂纹位置预测，但需要焊缝的数字重构。现有数字重构方法耗时、需专用扫描设备或需移动部件。本研究提出一种框架，采用工业机械臂配合线扫描仪，将数字重构集成至自动化HFMI处理系统中。该方法运用标准图像处理、简易滤波技术及非线性优化实现重叠扫描的对齐与融合，最后通过筛选泊松表面重构生成网格化三维模型。最终形成一种通用、经济、灵活且快速的方法，可对焊接部件进行通用化数字重构，有助于构件设计、整体质量保障及HFMI处理文档编制。