Skip to main content
SpringerLink
Log in

Automatic Welding: Infrared Sensors for Process Control

  • Chapter
Computer-Based Automation

Abstract

A feasibility study was performed to determine if infrared thermography could be used to detect perturbations in the arc welding process which result in defects. Data were gathered using an infrared camera with a resolution of.2C which was trained on the molten metal pool during welding. Several defects were then intentionally induced and the resulting thermal images were preserved on film. These images revealed that different types of weld defects induce different characteristic changes in the thermal image by detectably altering the temperature field around the weld. These perturbations in the temperature field can be used to identify and locate defects such as arc misalignment, plate gap, puddle impurities etc. Macrostructural examinations permitted investigations into the relationships between weld puddle penetration depth and the temperature field. Using computer aided processing of these thermal images, it is expected that the welding process can be controlled to a higher degree than is presently possible.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 39.99
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 54.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. A. J. Moorehead and R. W. Reed, “Internal bore welding of 2 1/4 Cr-lMo steel tube to tubesheet joints,” Welding Journal, Jan. 1980.

    Google Scholar 

  2. T. Nozaki and Y. Higo, “The development of an arc welding robot for shipbuilding,” Joint Automatic Control Conference, FA7–7, 1980.

    Google Scholar 

  3. G. E. Cook, “Feedback control of process variables in arc welding,” Joint Automatic Control Conference, FA7-B, 1980.

    Google Scholar 

  4. D. P. Edmonds, G. M. Goodwin, and G. M. Slaughter, “Development of automated pipe and tube welding techniques for aluminum,” Welding Journal, Feb. 1977.

    Google Scholar 

  5. P. T. Houldcraft, “Automation and automatic welding,” British Welding Journal, 13 (4), p. 212, 1966.

    Google Scholar 

  6. J. G. Balliger and H. L. Harrison, “Automated welding using spatial seam tracing,” Welding Journal, p. 787, Nov. 1971.

    Google Scholar 

  7. J. A. Bachelis and I. V. Varlamov, “Movement of the electric arc in a magnetic field,” Automatic Weld, 19 (4), p. 43, 1966.

    Google Scholar 

  8. S. L. Mandelberg, B. G. Sidorenko, and V. E. Lopata, “Control of arc welding with the help of a traveling magnetic field,” Automatic Weld, 29 (9), p. 1, 1976.

    Google Scholar 

  9. G. K. Hicken, N. D. Stucki, and H. W. Randall, “Application of magnetically controlled welding arcs,” Welding Journal, p. 264, April 1976.

    Google Scholar 

  10. T. N. Jayarajan and C. E. Jackson, “Magnetic control of gas tungsten-arc welding process,” Welding Journal, p. 377S, August 1972.

    Google Scholar 

  11. A. E. Guile, “Magnetic fields in arc welding,” IEEE Conference on Gas Discharges, No. 70, p. 489, 1970.

    Google Scholar 

  12. M. S. L’vov and A. P. Igoshin, “A system for the automation of arc welding with self adjustment by depth of penetration,” Automatic Weld, 24 (5), p. 42, 1971.

    Google Scholar 

  13. A. M. Naidenov, “Mechanical control of the transfer of electrode metal,” Automatic Weld, 22 (12), p. 35, 1969.

    Google Scholar 

  14. E. P. Vilkas, “Automation of gas tungsten arc welding process,” Welding Journal, Vol. 45, No. 5, p. 410, May 1966.

    Google Scholar 

  15. W. M. McCampbell, G. E. Cook, L. E. Nordholt, and G. J. Merrick, “Development of weld intelligence system,” Welding Journal, Vol. 45, No. 3, p. 139S, March 1966.

    Google Scholar 

  16. G. J. Vanderbrug, J. S. Albus, and E. Barkmeyer, “A vision system for real time control of robots,” Proceedings 9th International Symposium on Industrial Robots, Washington, DC, March 1979.

    Google Scholar 

  17. R. Eskenazi and J. M. Wilf, “Low level processing for real-time image analysis,” JPL Report 79–79 NSAS Contract NAS7–100.

    Google Scholar 

  18. Ya. S. Vaisband, A. B. Voitsekhovskii, and A. P. Zhurishkin, “A television system for automatically guiding electrodes along butt welds,” Automatic Weld, 24 (7), p. 47, 1971.

    Google Scholar 

  19. N. Yokoshima and H. Takagi, “Online adaptive control of narrow gap CO2 welding with industrial television camera,” Joint Automatic Control Conference, FA7-F, 1980.

    Google Scholar 

  20. B. E. Paton, N. V. Podola, V. G. Kvachev, and A. A. Ursat’ev, “The mathematical modelling of welding processes to create systems for forecasting the quality of joints and for optimum control,” Automatic Weld, 24 (7), p. 1, 1971.

    Google Scholar 

  21. S. J. Mech and T. E. Michaels, “Development of ultrasonic examination methods for austenitic stainless steel weld inspection,” Materials Evaluation, p. 61, July 1977.

    Google Scholar 

  22. L. Alder, K. V. Cook, B. R. Dewey, and R. T. King, “The relationship between ultrasonic rayleight waves and surface residual stress,” Materials Evaluation, p. 93, July 1977.

    Google Scholar 

  23. L. Alder, K. V. Cook, H. L. Whaley, and R. W. McClung, “Flaw size measurement in a weld sample by ultrasonic frequency analysis,” Materials Evaluation, p. 44, March 1977.

    Google Scholar 

  24. W. D. Jolly, “The application of acoustic emission to in-process inspection of welds,” Materials Evaluation, p. 135, June 1970.

    Google Scholar 

  25. D. M. Romrell, “Acoustic emission weld monitoring of nuclear components,” Welding Journal, p. 81S.

    Google Scholar 

  26. F. N. Kiselevskii, N. R. Shvydkii, and Yu. I. Streletskii, “The automatic analysing of radiographic pictures of welded joints,” Automatic Weld, 24 (7), p. 10, 1971.

    Google Scholar 

  27. P. W. Ramsey, J. J. Chyle, J. N. Kuhr, P. S. Myers, M. Weiss, and W. Groth, “Infrared temperature sensing systems for automatic fusion welding,” Welding Journal, p. 337-S, August 1963.

    Google Scholar 

  28. D. R. Green and J. A. Hassberger, “Infrared electro-thermal method for nondestructively testing welds in stainless steel pipes,” Materials Evaluation, Vol. 37, No. 11, p. 54, 1979.

    Google Scholar 

  29. D. R. Green, “Experimental electro-thermal method for nonde- structively testing welds in stainless steel pipes,” Materials Evaluation, Vol. 37, No. 11, p. 54, 1979.

    Google Scholar 

  30. D. R. Green, “Principles and applications of emittanceindependent infrared nondestructive testing,” Applied Optics, Vol. 7, No. 9, p. 1779, Sept. 1968.

    Article  Google Scholar 

  31. L. D. McCullough and D. R. Green, “Electrothermal nondestructive testing of metal structures,” Materials Evaluation, Vol. xxx, No. 4, p. 87, April 1972.

    Google Scholar 

  32. W. E. Lukens and R. A. Morris, “Infrared temperature sensing of cooling rates for arc welding control,” Welding Journal, Vol. 61, No. 1, p. 27, Jan. 1982.

    Google Scholar 

  33. N. D. Malmuth, W. F. Hall, B. I. Davis, and C. D. Rosen, “Transient thermal phenomena and weld geometry in GTAW,” Welding Journal, Vol. 53, No. 9, p. 388-S, Sept. 1974.

    Google Scholar 

  34. B. A. Chin, N. H. Madsen, and J. S. Goodling, “Infrared thermography for sensing the arc welding process,” Welding Journal, Vol. 62, No. 9, p. 227–5, Sept. 1983.

    Google Scholar 

  35. B. A. Chin, J. S. Goodling, and N. H. Madsen, “Infrared thermography shows promise for sensors in robotic welding,” Robotics Today, Vol. 5, No. 1, p. 85, Feb. 1983.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering Auburn University, Auburn University, AL, 36849, USA

    Bryan A. Chin & Nels H. Madsen

Authors
  1. Bryan A. Chin
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Nels H. Madsen
    View author publications

    You can also search for this author in PubMed Google Scholar

Editor information

Editors and Affiliations

  1. Automatic Generation of Knowledge Base from Electronic Diagrams for Computer-Aided Design, Center for Information Research, University of Florida, 32611, Gainesville, Florida, USA

    Julius T. Tou

Rights and permissions

Reprints and permissions

Copyright information

© 1985 Plenum Press, New York

About this chapter

Cite this chapter

Chin, B.A., Madsen, N.H. (1985). Automatic Welding: Infrared Sensors for Process Control. In: Tou, J.T. (eds) Computer-Based Automation. Springer, Boston, MA. https://doi.org/10.1007/978-1-4684-7559-3_19

Download citation

  • DOI: https://doi.org/10.1007/978-1-4684-7559-3_19

  • Publisher Name: Springer, Boston, MA

  • Print ISBN: 978-1-4684-7561-6

  • Online ISBN: 978-1-4684-7559-3

  • eBook Packages: Springer Book Archive

Publish with us

Policies and ethics

Search

Navigation