Real-Time Weld Process Monitoring

Welding is a complex process, is increasingly automated, and operates at higher speeds in more difficult environments. Defects also need to be detected as they arise to ensure efficient, high-quality production. All these needs have led to a growing interest in the use of sensors to provide accurate, robust, real-time monitoring where this cannot be achieved by more traditional testing and inspection techniques. This important book reviews the range of monitoring techniques available and their applications. After an introductory chapter, the first part of the book reviews the range of sensor technologies in welding, from arc and optical sensors to infrared and ultrasonic techniques. Part two discusses the monitoring of particular aspects of welding such as weld seams and profiles, the analysis of weld penetration and weld pool surface, as well as monitoring of resistance and laser welding. With its distinguished editor and international team of contributors, Real-time weld process monitoring will be a valuable reference to all those concerned with improving the quality of welding and welded components.

Table of Contents:
An Analysis of Welding Process Monitoring and Control Y-M Zhang, University of Kentucky, USA - Introduction - Welding process as a system - Welding process as a complex system - Welding process as an uncertain process - Monitoring of welding processes - Overview of the book - References PART 1 MONITORING TECHNOLOGIES Arc Sensors in Weld Monitoring G E Cook, A M Strauss, D H Lammlein and P A Fleming, Vanderbilt University, USA - Introduction - Background - Non-consumable electrode processes - Consumable electrode processes - Power supply considerations - Signal processing and control approaches - Future trends - Sources of further information and advice - Appendix: List of symbols - References Optical Sensors in Welding G Saeed, Schlumberger and H Song, University of Kentucky, USA - Introduction - Knowledge of optics - Optical sensor component - Optical sensing system - Application of optical sensor - References Infrared Sensors in Welding H Yang, H C Wikle, S Nagarajan, M Johnson, P Banerjee and B A Chin, Auburn University, USA - Introduction - Theory of infrared sensors - Measurement of weld temperature distribution - Infrared sensors for real-time weld quality control - Weld position control - Cooling rate - Summary - References Ultrasonic Sensors in Welding J Shao and Y Yan, University of Kent, UK - Introduction - Principles of ultrasonic sensing - Ultrasonic techniques and their applications - Future trends - Summary - Sources of further information and advice - References PART 2 MONITORING OF WELDING PROCESSES Weld Seam Monitoring S-J Na, Korea Advanced Institute of Science and Technology, Korea - Introduction - Methods of weld seam monitoring - Through-arc monitoring of weld seams in gas metal arc welding - Electromagnetic monitoring of weld seams in gas metal arc welding - Laser visual monitoring of weld seams in gas metal arc welding - References Weld Profile Monitoring L Wu and G Zhang, Harbin Institute of Technology, China - Necessity for weld profile measurement - Outline of weld profile - Surface shaping defects - Automatic detection of weld profile - References Weld Penetration Monitoring W Lu and Y-M Zhang, University of Kentucky, USA - Introduction - Weld pool oscillation sensor - Infrared sensor - Ultrasonic sensor - Vision based sensor - Weld pool sag depression - Plasma charge based sensors - Weld penetration control using sensor feedback - Summary - References Weld Pool Surface Monitoring C S Wu, Institute for Materials Joining, Shandong University, China - Vision-based sensing 2-D surface geometry of weld pool in GTAW - Sensing 2-D weld pool boundary in GMAW - Modeling and simulation of weld pool surface - Sensing 3-D weld pool surface using specular reflection - Improvement on observation of dynamic 3-D weld pool surface - References Monitoring Resistance Welding D Farson, The Ohio State University, USA - Introduction - Resistance spot welding (RSW) systems, weld formation and signals - Real-time process monitoring and control - Future trends - Sources of further information and advice - References Monitoring Laser Welding A Ancona and T Sibillano, CNR-INFM, Italy - Introduction - Principles of laser welding - Optical sensing - Frequency analyses of acoustic and optical emissions - Smart systems - Other systems and future trends - References