Search Results (106)

Accurate weld defect detection is critical for ensuring structural safety and evaluating welding quality in industrial applications. Manual inspection methods have inherent limitations, including inefficiency and inadequate sensitivity to subtle defects. Existing detection models, primarily designed for natural images, struggle to adapt to the characteristic challenges of weld X-ray images, such as high noise, low contrast, and inter-defect similarity, particularly leading to missed detections and false positives for small defects. To address these challenges, a multi-dimensional feature fusion model (MADet), which is a multi-branch deep fusion network for weld defect detection, was proposed. The framework incorporates two key innovations: (1) A multi-scale feature fusion network integrated with lightweight attention residual modules to enhance the perception of fine-grained defect features by leveraging low-level texture information. (2) An anchor-based feature-selective detection head was used to improve the discrimination and localization accuracy for five typical defect categories. Extensive experiments on both public and proprietary weld defect datasets demonstrated that MADet achieved significant improvements over the state-of-the-art YOLO variants. Specifically, it surpassed the suboptimal model by 7.41% in mAP@0.5, indicating strong industrial applicability. Full article

This study analyses the application of the Friction Stir Welding (FSW) process on polymeric materials manufactured by additive manufacturing (AM), specifically with polylactic acid (PLA). FSW is a solid-state welding process characterized by its low heat input and minimal distortion, which makes it ideal for the assembly of complex or large components made by additive manufacturing. To evaluate its effectiveness, a portable FSW device was developed for the purpose of joining PLA specimens made by AM using different filler densities (15% and 100%). Two tool geometries (a cylindrical and truncated cone) were utilized by varying the parameters of rotational speed, tilt angle, and feed rate. The results revealed two different process stages, transient and steady-state, and showed differences in weld quality depending on the material density, tool type, and material addition. The study confirms the viability of FSW for joining PLA parts made by AM and suggests potential applications in industries that require robust and precise joints in plastic parts, thereby helping hybrid manufacturing to progress. Full article

Zirconium-89 (⁸⁹Zr) is a widely used radionuclide in immune-PET imaging due to its physical decay characteristics. Despite its importance, the production of ⁸⁹Zr radiopharmaceuticals remains largely manual, with limited cost-effective automation solutions available. To address this, we developed an automated system for the agile and reliable production of radiopharmaceuticals. The system performs transmutations, dissolution, and separation for a range of radioisotopes. Steps in the production of ⁸⁹Zr-oxalate are used as an exemplar to illustrate its use. Three-dimensional (3D) printing was exploited to design and manufacture a target holder able to include solid targets, in this case an ⁸⁹Y foil. Spot welding was used to attach ⁸⁹Y to a refractory tantalum (Ta) substrate. A commercially available CPU chiller was repurposed to efficiently cool the metal target. Furthermore, a commercial resin (ZR Resin) and compact peristaltic pumps were employed in a compact (10 × 10 × 10 cm³) chemical separation unit that operates automatically via computer-controlled software. Additionally, a standalone 3D-printed unit was designed with three automated functionalities: photolabelling, vortex mixing, and controlled heating. All components of the assembly, except for the target holder, are housed inside a commercially available hot cell, ensuring safe and efficient operation in a controlled environment. This paper details the design, construction, and modelling of the entire assembly, emphasising its innovative integration and operational efficiency for widespread radiopharmaceutical automation. Full article

Process control and quality assurance of wire + arc additive manufacturing (WAAM) and automated welding rely heavily on in-process monitoring videos to quantify variables such as melt pool geometry, location and size of droplet transfer, arc characteristics, etc. To enable feedback control based upon this information, an automatic and robust segmentation method for monitoring of videos and images is required. However, video segmentation in WAAM and welding is challenging due to constantly fluctuating arc brightness, which varies with deposition and welding configurations. Additionally, conventional computer vision algorithms based on greyscale value and gradient lack flexibility and robustness in this scenario. Deep learning offers a promising approach to WAAM video segmentation; however, the prohibitive time and cost associated with creating a well-labelled, suitably sized dataset have hindered its widespread adoption. The emergence of large computer vision models, however, has provided new solutions. In this study a semi-automatic annotation tool for WAAM videos was developed based upon the computer vision foundation model SAM and the video object tracking model XMem. The tool can enable annotation of the video frames hundreds of times faster than traditional manual annotation methods, thus making it possible to achieve rapid quantitative analysis of WAAM and welding videos with minimal user intervention. To demonstrate the effectiveness of the tool, three cases are demonstrated: online wire position closed-loop control, droplet transfer behaviour analysis, and assembling a dataset for dedicated deep learning segmentation models. This work provides a broader perspective on how to exploit large models in WAAM and weld deposits. Full article

Defects formed during the thermite welding process of two sections of rails require the welded joints to be inspected for quality, and the most used non-destructive method for inspection is radiography testing. However, the conventional defect investigation process from the obtained radiography images is costly, lengthy, and subjective as it is conducted manually by trained experts. Additionally, it has been shown that most rail breaks occur due to a crack initiated from the weld joint defect that was either misclassified or undetected. To improve the condition monitoring of rails, the railway industry requires an automated defect investigation system capable of detecting and classifying defects automatically. Therefore, this work proposes a method based on image processing and machine learning techniques for the automated investigation of defects. Histogram Equalization methods are first applied to improve image quality. Then, the extraction of the weld joint from the image background is achieved using the Chan–Vese Active Contour Model. A comparative investigation is carried out between Deep Convolution Neural Networks, Local Binary Pattern extractors, and Bag of Visual Words methods (with the Speeded-Up Robust Features extractor) for extracting features in weld joint images. Classification of features extracted by local feature extractors is achieved using Support Vector Machines, K-Nearest Neighbor, and Naive Bayes classifiers. The highest classification accuracy of 95% is achieved by the Deep Convolution Neural Network model. A Graphical User Interface is provided for the onsite investigation of defects. Full article

The mechanical performance of metallic components is intrinsically linked to their microstructural features. However, the manual quantification of microconstituents in metallographic images remains a time-consuming and subjective task, often requiring over 15 min per image by a trained expert. To address this limitation, this study proposes an automated approach for quantifying the microstructural constituents from low-carbon steel welded zone images using convolutional neural networks (CNNs). A dataset of 210 micrographs was expanded to 720 samples through data augmentation to improve model generalization. Two architectures (AlexNet and VGG16) were trained from scratch, while three pre-trained models (VGG19, InceptionV3, and Xception) were fine-tuned. Among these, VGG19 optimized with stochastic gradient descent (SGD) achieved the best predictive performance, with an $R^2$ of 0.838, MAE of 5.01%, and RMSE of 6.88%. The results confirm the effectiveness of CNNs for reliable and efficient microstructure quantification, offering a significant contribution to computational metallography. Full article

Welding defects threaten structural integrity, demanding efficient and accurate detection methods. Traditional radiographic testing defects interpretation is subjective, necessitating automated solutions to improve accuracy and efficiency. This study integrates wavelet transform convolutions (WTConv) into YOLOv11n, creating WT-YOLO, to enhance defect detection in X-ray films. Wavelet transforms enable multi-resolution analysis, extracting both high-frequency and low-frequency features critical for detecting various welding defects. WT-YOLO replaces standard convolutional layers with WTConv, improving multi-scale feature extraction and noise suppression. Trained on 7000 radiographic images, WT-YOLO achieved a 0.0212 increase in mAP75 and a 0.0479 improvement in precision compared to YOLOv11n. On a test set of 200 images per defect category across seven defect types, WT-YOLO showed precision improvements of 0.0515 for cracks, 0.0784 for lack of fusion, 0.0067 for incomplete penetration, 0.1180 for concavity, 0.0516 for undercut, and 0.0204 for porosity, while experiencing a slight 0.0028 decline for slag inclusion. Compared to manual inspection, WT-YOLO achieved higher precision for cracks (0.0037), undercut (0.1747), slag inclusion (0.1129), and porosity (0.1074), with an inference speed 300 times faster than manual inspection. WT-YOLO enhances weld defect detection capabilities, providing the possibility for a robust solution for industrial applications. Full article

Quality assessment of the resistance spot welding process (RSW) is vital during manufacturing. Evaluating the quality without altering the joint material’s physical and mechanical properties has gained interest. This study uses a trained computer vision model to propose a cheap, non-destructive quality-evaluation methodology. The methodology connects the welding input and during-process parameters with the output visual quality information. A manual resistance spot welding machine was used to monitor and record the process input and output parameters to generate the dataset for training. The welding current, welding time, and electrode pressure data were correlated with the welding spot nugget’s quality, mechanical characteristics, and thermal and visible images. Six machine learning models were trained on visible and thermographic images to classify the weld’s quality and connect the quality characteristics (pull force and welding diameter) and the manufacturing process parameters with the visible and thermographic images of the weld. Finally, a cross-validation method validated the robustness of these models. The results indicate that the welding time and the angle between electrodes are highly influential parameters on the mechanical strength of the joint. Additionally, models using visible images of the welding spot exhibited superior performance compared to thermal images. Full article

Automating industrial processes, particularly quality inspection, is a key objective in manufacturing. While welding tasks are frequently automated, inspection processes remain largely manual. Advances in computer vision and AI, especially ViTs, now enable more effective defect detection and classification, offering opportunities to automate these workflows. This study evaluates ViTs for identifying defects in aluminum welding using the Aluminum 5083 TIG dataset. The analysis spans binary classification (detecting defects) and multiclass categorization (Good Weld, Burn Through, Contamination, Lack of Fusion, Misalignment, and Lack of Penetration). ViTs achieved 98% to 99% accuracy across both tasks, significantly outperforming prior models such as dense and CNNs, which struggled to surpass 80% accuracy in binary and 70% in multiclass tasks. These results, achieved with datasets of 2400 to 8000 images, highlight ViTs’ efficiency even with limited data. The findings underline the potential of ViTs to enhance manufacturing inspection processes by enabling faster, more reliable, and cost-effective automated solutions, reducing reliance on manual inspection methods. Full article

Layout design is the process in which industrial robots and other manufacturing components are positioned within a manufacturing system so that the intended operations can be handled appropriately. The traditional layout design process presents several challenges. It involves numerous iterations of testing different manually generated manufacturing layouts, requiring extensive trial and error to achieve an optimal solution. This process is highly time-consuming and demands significant expertise and cognitive effort from the designer. Within this publication, a flexible, scalable, and efficient function-block-based solution is presented for the optimization of manufacturing system layouts, especially in the field of multi-robot cells in two different use cases: one in additive manufacturing and one in jig-less welding. The findings showcase that the methodology followed enabled the efficient allocation of industrial robots in a workspace, minimizing the cognitive effort required in comparison to the traditional manual trial-and-error layout design procedure. Full article

The rapid advancement of industrial automation in the automotive manufacturing sector has heightened demand for welding quality, particularly in critical component welding, where traditional manual inspection methods are inefficient and prone to human error, leading to low defect recognition rates that fail to meet modern manufacturing standards. To address these challenges, an enhanced YOLOv8-based algorithm for steel defect detection, termed YOLOv8-WD (weld detection), was developed to improve accuracy and efficiency in identifying defects in steel. We implemented a novel data augmentation strategy with various image transformation techniques to enhance the model’s generalization across different welding scenarios. The Efficient Vision Transformer (EfficientViT) architecture was adopted to optimize feature representation and contextual understanding, improving detection accuracy. Additionally, we integrated the Convolution and Attention Fusion Module (CAFM) to effectively combine local and global features, enhancing the model’s ability to capture diverse feature scales. Dynamic convolution (DyConv) techniques were also employed to generate convolutional kernels based on input images, increasing model flexibility and efficiency. Through comprehensive optimization and tuning, our research achieved a mean average precision (map) at IoU 0.5 of 90.5% across multiple datasets, contributing to improved weld defect detection and offering a reliable automated inspection solution for the industry. Full article

Steel traditional Chinese buildings (STCBs) are constructed using modern materials, replicating the esthetics of ancient Chinese buildings, but their irregular joints differ significantly from those in conventional steel structures. To investigate the influence of beam section shape and axial compression ratio on the failure mode and shear resistance of all-welded irregular joints (WIJs) in STCBs, the size proportion relationships in the traditional Chinese modular construction system for such joints in existing practical projects are analyzed. Four exterior joint specimens were designed and fabricated for pseudo-static loading tests. The failure mode, hysteresis curve, and skeleton curve of the specimens were obtained. The test results indicate that the failure mode of the specimens involves shear deformation in the lower core area, with final failure due to crack formation in the weld at the junction between the column wall and the beam flange. As the axial compression ratio increases, the bearing capacity of the joint decreases. Based on the test results, the numerical model was established by using finite element software Abaqus2016, and parameter analysis was performed by varying the axial compression ratio of the column. After analyzing the force transfer mechanism of the core area in the WIJs of STCBs, a simplified calculation formula for the shear bearing capacity of the core area was derived based on the proportional relationship outlined in the construction manual from the Song Dynasty. The calculated results show good agreement with the experimental results, providing a basis for the structural design of WIJs in STCBs. Full article

Automated ultrasonic testing (AUT) is a critical tool for infrastructure evaluation in industries such as oil and gas, and, while skilled operators manually analyze complex AUT data, artificial intelligence (AI)-based methods show promise for automating interpretation. However, improving the reliability and effectiveness of these methods remains a significant challenge. This study employs the Segment Anything Model (SAM), a vision foundation model, to design an AI-assisted tool for weld defect detection in real-world ultrasonic B-scan images. It utilizes a proprietary dataset of B-scan images generated from AUT data collected during automated girth weld inspections of oil and gas pipelines, detecting a specific defect type: lack of fusion (LOF). The implementation includes integrating knowledge from the B-scan image context into the natural image-based SAM 1 and SAM 2 through a fully automated, promptable process. As part of designing a practical AI-assistant tool, the experiments involve applying both vanilla and low-rank adaptation (LoRA) fine-tuning techniques to the image encoder and mask decoder of different variants of both models, while keeping the prompt encoder unchanged. The results demonstrate that the utilized method achieves improved performance compared to a previous study on the same dataset. Full article

Gas metal arc welding (GMAW) is widely used for its productivity and ease of automation across various industries. However, certain tasks in shipbuilding and heavy industry still require manual welding, where quality depends heavily on operator skill. Defects in manual welding often necessitate costly rework, reducing productivity. Vision sensing has become essential in automated welding, capturing dynamic changes in the molten pool and arc length for real-time defect insights. Laser vision sensors are particularly valuable for their high-precision bead profile data; however, most current models require offline inspection, limiting real-time application. This study proposes a deep learning-based system for the real-time monitoring of both the molten pool and weld-bead profile during GMAW. The system integrates an optimized optical design to reduce arc light interference, enabling the continuous acquisition of both molten pool images and 3D bead profiles. Experimental results demonstrate that the molten pool classification models achieved accuracies of 99.76% with ResNet50 and 99.02% with MobileNetV4, fulfilling real-time requirements with inference times of 6.53 ms and 9.06 ms, respectively. By combining 2D and 3D data through a semantic segmentation algorithm, the system enables the accurate, real-time extraction of weld-bead geometry, offering comprehensive weld quality monitoring that satisfies the performance demands of real-time industrial applications. Full article

The main directions and fields of the application of metal nanopowders in joining technologies are considered. Based on this analysis, the purpose of this research was to determine the effect of tungsten nanopowder on the structure and properties of the deposited metal. In order to increase the efficiency of using tungsten nanopowder for modification, it is necessary to ensure the introduction of nanopowder into the low-temperature zone of the molten metal during surfacing. To study the metal, microstructural analysis was performed, and the microhardness of the deposited joint was determined. On the basis of the conducted studies, a change in the structure of the deposited metal and an increase in mechanical properties were revealed. A conclusion is made about the effect of tungsten nanopowder on the metal modification process during manual metal arc, metal inert gas, and flux-cored arc welding. Based on the conducted studies, it was found that the introduction of tungsten nanopowder into the low-temperature zone of the molten metal ensures the modification of the surfacing and induces an increase in the microhardness of the deposited metal. At the same time, grains of polyhedral morphology are formed at the surface, and the structure of oriented dendrites at the boundary of fusion with the base metal is also revealed, showing the peculiarities of the distribution of microhardness in various surfacing methods. The minimum and maximum values of microhardness depend not only on the nanopowder but also on the method of its introduction into the molten metal. Full article