A Weld Pool Morphology Acquisition and Visualization System Based on an In Situ Calibrated Analytical Solution and Virtual Reality
Abstract
:1. Introduction
2. System Design
3. The 3D Reconstruction Process and Model Visualization
3.1. The 3D Reconstruction Process
3.2. The 3D Model Visualization
4. Experiment
5. Discussion
6. Conclusions
- (1)
- The system has successfully applied the existing welding analytical model in practice and optimized the algorithms of the image processing and analytical model calculations in order to achieve the requirements of real-time feedback. In real welding experiments, it has been proved that the error in the welding diameter is 0.8% at the minimum, and the average value is 8.54%. The welding experiments have proven the feasibility of the analytical model and the necessity of calibrating the heat source distribution coefficient.
- (2)
- The hot-update technology is used to transmit the three-dimensional model to the virtual environment, including the conversion of the model format before transmission, the use of the AssetBundle technology to package the resource files during the transmission process, and the instantiation of the model in the virtual environment. Experiments have proved that this process is completely feasible and has no impact on the accuracy of the model. The overall transmission time is 2 s, which is mainly due to the limitations of the hardware devices.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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ID | (W) | (mm) | ||
---|---|---|---|---|
1 | 500 | 0.2 | 0.2 | 2.8 |
2 | 500 | 0.2 | 0.4 | |
… | … | … | … | … |
448 | 700 | 5.0 | 0.8 | 0 |
449 | 700 | 5.0 | 1.2 | 0 |
450 | 700 | 5.0 | 1.2 | 0 |
Input Parameters | Set Values |
---|---|
Initial welding temperature (°C) | 0 |
Density ρ (kg·mm−3) | 8.03 × 10−6 |
Specific heat capacity c (J·kg·K−1) | 500 |
Thermal conductivity λ (W·mm·K−1) | 16.2 × 10−3 |
Thermal diffusivity a (mm2·s−1) | 4.035 |
Volumetric expansion coefficients αv (K−1) | 4.5 × 10−5 |
Melting point (°C) | 1400 |
ID | Time (s) | Welding Current (I) (A) | Welding Heat Input (Q) (W) | Diameter from Calculation () (mm) | Heat Source Parameters () |
---|---|---|---|---|---|
I | 0–30 | 50 | 500 | 2.11 | (2.020, 0.743) |
30–60 | 60 | 600 | 2.70 | (2.008, 0.696) | |
60–90 | 70 | 700 | 3.37 | (2.445, 0.701) | |
II | 0–30 | 50 | 500 | 2.14 | (1.998, 0.693) |
30–60 | 60 | 600 | 2.73 | (1.992, 0.695) | |
60–90 | 50 | 500 | 2.95 | (0.493, 0.200) | |
III | 0–30 | 70 | 700 | 3.63 | (2.224, 0.697) |
30–60 | 60 | 600 | 3.46 | (1.475, 0.69) | |
60–90 | 70 | 700 | 3.93 | (1.873, 0.746) | |
IV | 0–30 | 70 | 700 | 3.49 | (2.350, 0.702) |
30–60 | 50 | 500 | 2.98 | (0.493, 0.200) | |
60–90 | 60 | 600 | 3.40 | (1.535, 0.693) | |
V | 0–30 | 70 | 700 | 3.71 | (2.145, 0.697) |
30–60 | 60 | 600 | 3.46 | (1.535, 0.693) | |
60–90 | 60 | 600 | 3.41 | (1.526, 0.689) |
ID | Diameter from Metallography (d) (mm) | Diameter from Calculation () (mm) | Error of Diameter (%) | Welding Depth from Metallography () (mm) | Welding Depth from Calculation () (mm) | Error of Welding Depth (%) |
---|---|---|---|---|---|---|
I | 3.41 | 4.24 | 24.3 | 1.31 | 1.68 | 28.2 |
II | 3.16 | 2.96 | 6.3 | 1.07 | 1.39 | 30.0 |
III | 3.98 | 4.32 | 7.9 | 1.66 | 1.88 | 13.3 |
IV | 3.48 | 3.60 | 3.4 | 1.25 | 1.59 | 27.2 |
V | 3.63 | 3.60 | 0.8 | 1.38 | 1.68 | 21.7 |
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Share and Cite
Niu, Y.; Wu, S.; Cheng, F.; Wang, Z. A Weld Pool Morphology Acquisition and Visualization System Based on an In Situ Calibrated Analytical Solution and Virtual Reality. Sensors 2025, 25, 2711. https://doi.org/10.3390/s25092711
Niu Y, Wu S, Cheng F, Wang Z. A Weld Pool Morphology Acquisition and Visualization System Based on an In Situ Calibrated Analytical Solution and Virtual Reality. Sensors. 2025; 25(9):2711. https://doi.org/10.3390/s25092711
Chicago/Turabian StyleNiu, Yecun, Shaojie Wu, Fangjie Cheng, and Zhijiang Wang. 2025. "A Weld Pool Morphology Acquisition and Visualization System Based on an In Situ Calibrated Analytical Solution and Virtual Reality" Sensors 25, no. 9: 2711. https://doi.org/10.3390/s25092711
APA StyleNiu, Y., Wu, S., Cheng, F., & Wang, Z. (2025). A Weld Pool Morphology Acquisition and Visualization System Based on an In Situ Calibrated Analytical Solution and Virtual Reality. Sensors, 25(9), 2711. https://doi.org/10.3390/s25092711