RESEARCH ON THE CORRELATION BETWEEN THE STATUS OF THREE-DIMENSIONAL WELD POOL SURFACE AND WELD PENETRATION IN TIG WELDING

doi:10.11900/0412.1961.2013.00819

Acta Metall Sin

2014, Vol. 50

Issue (8): 995-1002 DOI: 10.11900/0412.1961.2013.00819

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RESEARCH ON THE CORRELATION BETWEEN THE STATUS OF THREE-DIMENSIONAL WELD POOL SURFACE AND WELD PENETRATION IN TIG WELDING

ZHANG Gang, SHI Yu(

), LI Chunkai, HUANG Jiankang, FAN Ding

State Key Laboratory of Advanced Processing and Recycling of Nonferrous Metals, Lanzhou University of Technology, Lanzhou 730050

Cite this article:

ZHANG Gang, SHI Yu, LI Chunkai, HUANG Jiankang, FAN Ding. RESEARCH ON THE CORRELATION BETWEEN THE STATUS OF THREE-DIMENSIONAL WELD POOL SURFACE AND WELD PENETRATION IN TIG WELDING. Acta Metall Sin, 2014, 50(8): 995-1002.

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Abstract

Measurement of the weld pool surface is a difficult but urgent task in the welding community. It plays an important role in developing the next generation intelligent welding machines, in particular, controlling the weld joint penetration in automatic welding. In this work, the images of front-side free surface and back-side width of the weld pool are synchronously captured with two CCD cameras in tungsten inert gas (TIG) arc welding process based on laser vision, and the three dimensional weld pool surface is reconstructed using designed algorithm. Then, the correlation between the weld pool surface under different weld joint penetration and its back-side width is analyzed qualitatively. The variation of reflected laser dots shape is reversely simulated under different depths of weld pool surface, which represents the different weld joint penetration, after established the standard model of weld pool, incident, reflected ray and imaging plan's mathematical model. It is found that the change of weld pool surface obtained by this method has an intimate immanent correlation with the weld joint penetration. When the weld joint penetration changes from partial penetration to complete joint penetration, the weld pool surface's shape changes from convexity to concave, and its depth is increasing with the increased back-side width. The row curvature of reflected laser dots is diminishing. When the penetration achieves excessive penetration, the depth of the weld pool surface is more rapidly increased, and the row curvature is also increased. The gathered laser dots is drawn back again at parallel direction. The simulated results associate with the measurement very well. The variations of reflected laser dots shape can represent the degree of weld joint penetration. This research lays a good foundation for the control of weld joint penetration using the characteristics of weld pool surface.

Key words: TIG welding laser vision weld pool free surface weld joint penetration control

Received: 16 December 2013

ZTFLH:

TG409

Fund: Supported by National Natural Science Foundation of China (No.61365011), Young Creative Talent Support Program of Long Yuan of China, Specialized Basic Scientific Research Program of University of Gansu Province and Hong Liu Outstanding Talent Training Plan of Lanzhou University of Technology (No.J201201)

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	Gang ZHANG
	Yu SHI
	Chunkai LI
	Jiankang HUANG
	Ding FAN

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https://www.ams.org.cn/EN/10.11900/0412.1961.2013.00819 OR https://www.ams.org.cn/EN/Y2014/V50/I8/995

Fig.1 Principle of synchronous measurement using laser vision

Fig.2 Experimental measurement system

Fig.3 Typical reflected laser dot images (a1~j1) and back-side images of weld pool (a2~j2) under welding speeds of 1.3 mm/s (a1~c1, a2~c2), 1.1 mm/s (d1, e1, d2, e2) and 1.0 mm/s (f1~j1, f2~j2)

Fig.4 Welding speed waveform

Fig.5 Preprocessed images of Fig.3e2

(a) enhanced image

(b) median filtered image

Fig.6 Three dimensional reconstructed shapes of weld pool surfaces corresponding to Fig.3c1 (a), Fig.3d1 (b), Fig.3e1 (c) and Fig.3f1 (d)

Fig.7 Processed backside images of weld pools corresponding to Fig.3c2 (a), Fig.3d2 (b), Fig.3e2 (c) and Fig.3f2 (d)

Fig.8 Front-side (a) and back-side (b) weld bead morphologies (c1~f1 in Fig.8a represent the selected positions of typical reflected laser dots images of Fig.3, c2~f2 in Fig.8b represent the selected positions of typical backside weld pool images of Fig.3)

Fig.9 Variation of the weld pool surface height and the back width of weld pool

Fig.10 Calculated model of reflected ray

Fig.11 Simulated convex weld pool (a), incident laser ray and weld pool (b), reflected ray (c)

Fig.12 Simulated results of 0.5 mm convex weld pool (a), concave pool results of 0.1mm (b) and 0.35 mm (c)

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