scholarly journals Sensors for quality control in welding

2012 ◽  
Vol 17 (3) ◽  
pp. 192-200 ◽  
Author(s):  
Sadek Crisóstomo Absi Alfaro
Keyword(s):  
Sensor Fusion ◽  
Welding Process ◽  
Heat Content ◽  
Welding Current ◽  
Feed Speed ◽  
Weld Quality ◽  
Statistical Control ◽  
Radiation Emission ◽  
Inspection Method ◽  
Wire Feed Speed

The classical inspection methods used for detecting and finding disturbances in welding process are based on direct measurement of its parameters as arc voltage, welding current, wire feed speed, etc. Using these inspection methods implies sensors insertion around the welding process and its presence could alter the metallic transference behavior and consequently an uneven quality as well as it can increase the production cost. For reducing these implications is necessary using a non intrusive inspection method. In this paper we will show nonintrusive methods to the weld quality inspection. These methods are based on sensor fusion, the extraction of global information coming from the interrelation data given by each sensor that, for example, sensing the spectroscopy radiation emission, the acoustic sensing of the electrical arc, the infrared emissions indicating the heat content of the weld. Finally, the fusion data will be applied to a statistical control for detecting and finding welding disturbances. The results will show that sensor fusion could be used as a tool to measure indirectly the weld quality in the GMAW process.

Correlation between wire feed speed and external mechanical constraint for enhanced process stability in underwater wet flux-cored arc welding

2018 ◽  
Vol 233 (10) ◽  
pp. 2061-2073 ◽  
Author(s):  
Jianfeng Wang ◽  
Qingjie Sun ◽  
Jiangkun Ma ◽  
Peng Jin ◽  
Tianzhu Sun ◽  
...  
Keyword(s):  
Welding Process ◽  
Electrical Signal ◽  
Feed Speed ◽  
Process Stability ◽  
Underwater Wet Welding ◽  
Extinction Process ◽  
Flux Cored Arc Welding ◽  
Wire Feed Speed ◽  
Wire Feed ◽  
Mechanical Constraint

It is a great challenge to improve the process stability in conventional underwater wet welding due to the formation of unstable bubble. In this study, mechanical constraint method was employed to interfere the bubble generated by underwater wet welding, and the new method was named as mechanical constraint assisted underwater wet welding. The aim of the study was to quantify the combined effect of wire feed speed and condition of mechanical constraint on the process stability in mechanical constraint assisted underwater wet welding. Experimental results demonstrated that the introduction of mechanical constraint not only suppressed the bubble without floating but also stabilized the arc burning process. The degree of influence of mechanical constraint, which changed with wire feed speed, played an important role during the mechanical constraint assisted underwater wet welding process. For all wire feed speeds, the fluctuations of welding electrical signal were decreased through introduction of mechanical constraint. The difference in the proportion of arc extinction process between underwater wet welding and mechanical constraint assisted underwater wet welding became less with increasing wire feed speed. At wire feed speed lower than 7.5 m/min, the improvement of process stability was very significant by mechanical constraint. However, the further improvement produced limited effect when the wire feed speed was greater than 7.5 m/min. The observation results showed that a better weld appearance was afforded at a large wire feed speed, corresponding to a lower variation coefficient.

TIG Auto Welding Process Using Adaptive Wavelet Neural Network Controller

2015 ◽  
Vol 764-765 ◽  
pp. 634-639
Author(s):  
Yen Bin Chen ◽  
Yung Lung Lee ◽  
Shou Jen Hsu ◽  
Chin Chun Chang ◽  
Yi Wei Chen
Keyword(s):  
Neural Network ◽  
Vacuum Chamber ◽  
Welding Current ◽  
Wavelet Neural Network ◽  
Feed Speed ◽  
Automatic Welding ◽  
Adaptive Wavelet ◽  
Neural Network Controller ◽  
Network Controller ◽  
Wire Feed Speed

The study proposed adaptive wavelet neural network controller can achieve good and precise welding control performance and use synchrotron radiation research center developed multi-gun group automatic welding system to verify the validity of the research method. Multi-gun group welding system is applied in Taiwan Photon Source (TPS). Storage ring aluminum alloy vacuum chamber of Taiwan Photon Source .In the past aluminum alloy vacuum chamber welding, it all depends on the empirical welding rule of operator to give appropriate welding current, argon flow, wire feed speed and welding speed for control. Therefore, the paper uses automatic welding skill, which takes National Instruments PXI-8180 system as basic structure, and adaptive wavelet neural network controlled four optimized parameters, I.E. welding current, wire feed speed, flow rate of argon gas and welding speed, The vacuum chamber pressure value is also up to 6.2X10-10Torr/mA. It is successfully applied to the TPS system. Therefore, it can prove the effectiveness and practicality of the method proposed in this study.

Laser-MIG Hybrid Keyhole Welded 6mm Steel/Aluminum Butt Joints

2019 ◽  
Vol 944 ◽  
pp. 581-592
Author(s):  
Dong Qi Lu ◽  
Li Cui ◽  
Hong Xi Chen ◽  
Yao Qing Chang ◽  
Zhi Bo Peng ◽  
...  
Keyword(s):  
Laser Welding ◽  
Welding Process ◽  
Butt Joint ◽  
Feed Speed ◽  
Welded Steel ◽  
Single Beam ◽  
Beam Laser ◽  
Wire Feed Speed ◽  
Wire Feed ◽  
Laser Welding Process

At present, the connection of steel/aluminum joints has been widely used in industrial fields such as aerospace, marine and automotive.Although the joints with excellent performance can be obtained by the solid phase welding methods such as explosion welding and friction welding, the production process is complicated and the efficiency is low, and the practical application is limited.Laser welding has attracted a lot of attention from researchers because of its advantages of high energy density, small welding deformation and fast welding speed.However, in the single-beam laser welding process, there are problems such as high joint assembly precision, excessive energy density, and easy formation of depressions in the weld.The newly developed laser-MIG (Metal Inert Gas) hybrid welding not only retains the advantages of laser welding, but also fully exploits the advantages of MIG welding, improves weld formation, improves the stability of the welding process, and helps solve the single-beam laser welding problems.In this paper, the laser deep penetration welding process of 5.5 mm thick E36 steel and 6 mm thick 5083 aluminum alloy butt joint was studied by laser-MIG composite welding heat source. Compared with the single laser welding process, the influence of wire feed speed on the welded steel/aluminum joint, joint interface structure and joint mechanical properties was studied.The results show that the laser-MIG composite deep-melt welding can obtain good steel/aluminum butt joint performance. At a laser power of 3.25 kW, a wire feed speed of 1.5 m / min, a laser offset of 0.5 mm and a defocus of 0 mm, the tensile strength of the steel/aluminum butt joint is as high as 85.0 MPa.Laser-MIG hybrid welding can improve the dent defects of a single laser welded steel/aluminum butt joint. The amount of acicular Fe4Al13 phase in the intermetallic compound was significantly reduced, and the resistance of the steel/aluminum joint was increased from 8.6 kN to 12.7 kN.

scholarly journals Digitalized Evaluation of Welder Skill by using Cyclogram Characteristics

2019 ◽  
Vol 269 ◽  
pp. 07004
Author(s):  
Seamkong Kuoch ◽  
Eakkachai Warinsiriruk ◽  
Sutep Joy-A-Ka
Keyword(s):  
Signal Processing ◽  
Evaluation Method ◽  
Physical Simulation ◽  
Gas Metal Arc Welding ◽  
Hand Movement ◽  
Welding Process ◽  
Welding Current ◽  
High Sensitivity ◽  
Weld Quality ◽  
Robot Welding

This paper proposes a new evaluation method for welder skill in Gas Metal Arc Welding (GMAW) process in term of studying the natural hand-movement that affect the signal processing. Weld quality of GMAW generally depends on welder skill to maintain the uniform of hand movement. Therefore, the welder skill is considered as the critical point to maintain the weld quality. Hence, welding current and voltage signal could be an alternative way for monitoring and assessing the skill of welder based on the signal variation of the welding process. This research defines in two stages, first is the physical-simulation using robot welding Fanuc Arc Mate 100iB and monitoring the signal using Cyclogram technique. Second is comparing the Cyclogram characteristic of robot welding and manual welder. By using the data acquired, the characteristic of Cyclogram was analyzed by varying Torch angle change (W1) and Torch-height change (W2) to investigate the signal processing. Furthermore, the data of current and voltage were generated as a quantitative method to determine the size of Cyclogram. The results show that the method capable of differentiating the two beginner welders compare to the robot welding performance based area of Cyclogram characteristic. Finally, the Cyclogram could be a novel tool for monitoring and evaluating the welder skill with high sensitivity to detect hand motion.

Investigation on CO and Microparticles Concentrations Produced in MAG-M Welding Process

2015 ◽  
Vol 809-810 ◽  
pp. 455-460 ◽  
Author(s):  
Danuţ Mihailescu ◽  
Marius Corneliu Gheonea ◽  
Elena Scutelnicu
Keyword(s):  
Metal Powder ◽  
Welding Process ◽  
Fusion Welding ◽  
Feed Speed ◽  
Shielding Gas ◽  
Cored Wire ◽  
Environment Quality ◽  
Basic Flux ◽  
Wire Feed Speed ◽  
Welding Processes

It is well known that CO and microparticles generated during GMAW welding processes can affect the welder's health and the environment quality and should be avoided. The main goal of the research was to quantitatively assess the concentrations of CO and microparticules resulting through melted wire - shielding gas - welding pool interaction, specific to fusion welding process, in particular MAG-M (Metal Active Gas with Corgon shielding gas)) process. The concentrations of microparticles and emission of CO developed by several combinations of filler metal and shielding gas, such as ordinary solid wire, basic flux-cored wire, rutile flux-cored wire, metal powder cored wire, low fume metal powder cored wire and Corgon 18, as shielding gas mixture, have been monitored and investigated in detail. The experimental data, achieved for different wire feed speed values, were collected by using special devices as Multilyzer NG and MicroDust Pro and further processed, plotted and comparatively analysed. The analysis revealed that the low fume rutile flux-cored wire significantly developed lower concentrations of microparticles and CO, in comparison with the other types of wires used in MAG-M welding process, and a better protection of the environment would be achieved. Important conclusions related to the influence of the wire type on the concentrations of CO and microparticles produced during MAG-M welding process have been drawn and some recommendations useful for the producers of welded structures are provided at the end of the paper.

Application of MIG Welding Process of Mild Steel Wire in Additive Manufacturing

2021 ◽  
Vol 877 ◽  
pp. 73-79
Author(s):  
Pattarawadee Poolperm ◽  
Wasawat Nakkiew ◽  
Nirut Naksuk
Keyword(s):  
Additive Manufacturing ◽  
Steel Wire ◽  
Welding Process ◽  
Feed Speed ◽  
Mig Welding ◽  
Microhardness Testing ◽  
Wire Feed Speed ◽  
Forming Characteristics ◽  
Arc Current ◽  
Wire Feed

The purpose of this study is to investigate the forming characteristics of single-pass Metal Inert Gas (MIG) welding wire for multi-layer additive manufacturing parts. Influences of arc current, arc voltage, arc distances, welding speed, wire feed speed, temperatures and heat input on layer formation were analyzed. The deposition of material by MIG process is controlled by a robot (ABB) controller for constructing walls of rectangular box shape. The samples were measured with a microhardness testing and tensile testing onto the welded bead created by the additive manufacturing technique. It was found that the mechanical properties of microhardness values are between 151.70 to 155.80 HV and the tensile strength values are between 472.71 to 491.12 MPa according to transverse and longitudinal sections of the specimens.

scholarly journals Development of mathematical model and optimization of GMA welding parameters of IS 2062 grade A steel weldments

2021 ◽  
Vol 15 (56) ◽  
pp. 84-93
Author(s):  
Saadat Ali Rizvi ◽  
Wajahat Ali
Keyword(s):  
Mathematical Model ◽  
Gas Flow ◽  
Gma Welding ◽  
Welding Parameters ◽  
Feed Speed ◽  
Weld Quality ◽  
Gas Flow Rate ◽  
Arc Voltage ◽  
Wire Feed Speed ◽  
Wire Feed

In this experimental works, the effect of GMA welding process parameters, such as arc voltage, wire feed speed, and gas flow rate on the mechanical quality of IS 2062 structural steel of grade A has been studied. Process parameters play an important role in determining the weld quality. In this research work response surface methodology (RSM) technique via design expert (DOE) 12 version software was applied to determining the weld quality and also to develop a mathematical model that can predict the main effect of the above said parameters on weld quality i.e. toughness and hardness. A set of experiments has been conducted to collect the data using a central composite design and ANOVA was used to predict the impact of welding parameters on toughness and hardness and Comparison also made between the actual result and predicted value and from the result that is clear that toughness and hardness of weldment is significantly affected by arc voltage, wire feed speed, and follow by gas flow rate.

scholarly journals Multi-Objective Optimization of Resistance Welding Process of GF/PP Composites

Polymers ◽  
2021 ◽  
Vol 13 (15) ◽  
pp. 2560
Author(s):  
Guowei Zhang ◽  
Ting Lin ◽  
Ling Luo ◽  
Boming Zhang ◽  
Yuao Qu ◽  
...  
Keyword(s):  
Signal To Noise Ratio ◽  
Welding Process ◽  
Welding Current ◽  
Resistance Welding ◽  
Thermoplastic Composites ◽  
Current Time ◽  
Process Factor ◽  
Welding Equipment ◽  
Lap Shear ◽  
Adhesive Connections

Thermoplastic composites (TPCs) are promising materials for aerospace, transportation, shipbuilding, and civil use owing to their lightweight, rapid prototyping, reprocessing, and environmental recycling advantages. The connection assemblies of TPCs components are crucial to their application; compared with traditional mechanical joints and adhesive connections, fusion connections are more promising, particularly resistance welding. This study aims to investigate the effects of process control parameters, including welding current, time, and pressure, for optimization of resistance welding based on glass fiber-reinforced polypropylene (GF/PP) TPCs and a stainless-steel mesh heating element. A self-designed resistance-welding equipment suitable for the resistance welding process of GF/PP TPCs was manufactured. GF/PP laminates are fabricated using a hot press, and their mechanical properties were evaluated. The resistance distribution of the heating elements was assessed to conform with a normal distribution. Tensile shear experiments were designed and conducted using the Taguchi method to evaluate and predict process factor effects on the lap shear strength (LSS) of GF/PP based on signal-to-noise ratio (S/N) and analysis of variance. The results show that current is the main factor affecting resistance welding quality. The optimal process parameters are a current of 12.5 A, pressure of 2.5 MPa, and time of 540 s. The experimental LSS under the optimized parameters is 12.186 MPa, which has a 6.76% error compared with the result predicted based on the S/N.

scholarly journals The effects of welding current and purging gas on mechanical properties and microstructure of tungsten inert gas welded aluminum alloy 5083 H116

2018 ◽  
Vol 197 ◽  
pp. 12007 ◽  
Author(s):  
Ekak Novianto ◽  
Priyo Tri Iswanto ◽  
Mudjijana Mudjijana
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Salt Water ◽  
Surface Hardness ◽  
Welding Process ◽  
Welding Current ◽  
Inert Gas ◽  
Aluminum Alloy 5083 ◽  
Welding Sequence ◽  
Weld Current

Aluminum alloy 5083 H116 has an exceptional performance in extreme environments, moderately high strength, outstanding corrosion resistance in salt water and high impact strength at cryogenic temperature. In the present study, Aluminum alloy AA 5083 H116 plates were joined by tungsten inert gas (TIG) process by single and double sided welding. Welding current used was 53 A and 80 A with the addition of purging gas during welding process. The effects on micro structure and mechanical properties like surface hardness and tensile strength of the welded region were studied. The results have shown that optimum current out of the two weld current used is 53 A. Better microstructures, tensile and hardness were found in the welded joint for the weld current 53 A where the tensile obtained in the softened zone was approximately 87% than that of the base metal (BM). With increasing of TIG current, the width of PMZ increased. In addition, the doubled sided welding sequence also produced broader PMZ area.

An Investigation of Dissimilar Welding Aluminum Alloys to Stainless Steel by the Tungsten Inert Gas (TIG) Welding Process

2017 ◽  
Vol 904 ◽  
pp. 19-23
Author(s):  
Van Nhat Nguyen ◽  
Quoc Manh Nguyen ◽  
Dang Thi Huong Thao ◽  
Shyh Chour Huang
Keyword(s):  
Stainless Steel ◽  
Aluminum Alloy ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Welding Current ◽  
Tig Welding ◽  
Inert Gas ◽  
Dissimilar Welding ◽  
Adjacent Area ◽  
Welding Seam

Welding dissimilar materials has been widely applied in industries. Some of them are considered this as a strategy to develop their future technology products. Aluminum alloy and stainless steel have differences in physical, thermal, mechanical and metallurgic properties. However, selecting a suitable welding process and welding rods can solve this problem. This research aimed to investigate the T-joint welding between A6061 aluminum alloy and SUS304 stainless steel using new welding rods, Aluma-Steel by the Tungsten Inert Gas (TIG) welding process. The mechanical properties, the characteristics of microstructure, and component analysis of the welds have been investigated by the mechanical testing, scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). As a result, the fracture occurred at the adjacent area between welding seam and A6061 alloys plate. The thermal cracking appeared at central welding-seam along the base metals if high welding current. A large amount of copper elements found in the welds due to using the new welding rod, Aluma-Steel rod.

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