Optical sensor for real-time weld defect detection

Antonio Ancona; Tommaso Maggipinto; Vincenzo Spagnolo; Michele Ferrara; Pietro Mario Lugara

doi:10.1117/12.463427

24 April 2002 Optical sensor for real-time weld defect detection

Antonio Ancona, Tommaso Maggipinto, Vincenzo Spagnolo, Michele Ferrara, Pietro Mario Lugara

Proceedings Volume 4669, Sensors and Camera Systems for Scientific, Industrial, and Digital Photography Applications III; (2002) https://doi.org/10.1117/12.463427
Event: Electronic Imaging, 2002, San Jose, California, United States

Abstract

In this work we present an innovative optical sensor for on- line and non-intrusive welding process monitoring. It is based on the spectroscopic analysis of the optical VIS emission of the welding plasma plume generated in the laser- metal interaction zone. Plasma electron temperature has been measured for different chemical species composing the plume. Temperature signal evolution has been recorded and analyzed during several CO₂-laser welding processes, under variable operating conditions. We have developed a suitable software able to real time detect a wide range of weld defects like crater formation, lack of fusion, excessive penetration, seam oxidation. The same spectroscopic approach has been applied for electric arc welding process monitoring. We assembled our optical sensor in a torch for manual Gas Tungsten Arc Welding procedures and tested the prototype in a manufacturing industry production line. Even in this case we found a clear correlation between the signal behavior and the welded joint quality.

Citation Download Citation

Antonio Ancona, Tommaso Maggipinto, Vincenzo Spagnolo, Michele Ferrara, and Pietro Mario Lugara "Optical sensor for real-time weld defect detection", Proc. SPIE 4669, Sensors and Camera Systems for Scientific, Industrial, and Digital Photography Applications III, (24 April 2002); https://doi.org/10.1117/12.463427

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