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Open AccessArticle

In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision

Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China
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Sensors 2018, 18(8), 2411; https://doi.org/10.3390/s18082411
Received: 12 June 2018 / Revised: 10 July 2018 / Accepted: 23 July 2018 / Published: 25 July 2018
(This article belongs to the Special Issue Sensors Signal Processing and Visual Computing)
Lack of fusion can often occur during ultra-thin sheets edge welding process, severely destroying joint quality and leading to seal failure. This paper presents a vision-based weld pool monitoring method for detecting a lack of fusion during micro plasma arc welding (MPAW) of ultra-thin sheets edge welds. A passive micro-vision sensor is developed to acquire clear images of the mesoscale weld pool under MPAW conditions, continuously and stably. Then, an image processing algorithm has been proposed to extract the characteristics of weld pool geometry from the acquired images in real time. The relations between the presence of a lack of fusion in edge weld and dynamic changes in weld pool characteristic parameters are investigated. The experimental results indicate that the abrupt changes of extracted weld pool centroid position along the weld length are highly correlated with the occurrences of lack of fusion. By using such weld pool characteristic information, the lack of fusion in MPAW of ultra-thin sheets edge welds can be detected in real time. The proposed in-process monitoring method makes the early warning possible. It also can provide feedback for real-time control and can serve as a basis for intelligent defect identification. View Full-Text
Keywords: micro plasma arc welding; edge joint weld; defects detection; weld pool monitoring; lack of fusion; micro vision sensing micro plasma arc welding; edge joint weld; defects detection; weld pool monitoring; lack of fusion; micro vision sensing
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Hong, Y.; Chang, B.; Peng, G.; Yuan, Z.; Hou, X.; Xue, B.; Du, D. In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision. Sensors 2018, 18, 2411.

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