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Inspection of welding pool height from shading in pulsed GTAW with wire filler

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Purpose ‐ The control of weld penetration in gas tungsten-arc welding (GTAW) is required for fully automated systems to overcome variations in the welding process. The surface depression of weld pool, or weld pool height, has a close relationship with width of the backside bead in the full-penetrated weld. The purpose of this paper is to inspect the pool height. Design/methodology/approach ‐ A fast linear approach, based on shape from shading (SFS) algorithm, was employed to reconstruct a 3D shape of welding pool from a 2D image, which was obtained from a real welding pool. Then the pool height can be extracted. Furthermore, three methods were introduced to improve the above algorithm. Findings ‐ The reconstructed pool height was in good agreement with the real height of weld pool from experiments. Research limitations/implications ‐ The algorithm requires a uniform reflection on the pool surface. Practical implications ‐ This method is applicable to inspect weld pool height in GTAW. It is a basis for future work on control of weld penetration. Originality/value ‐ A faster SFS algorithm has been introduced to extract weld pool height in real-time. Moreover, the algorithm was improved to fit for extracting the surface shape of weld pool.
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Keywords: Gas tungsten-arc welding; Programming and algorithm theory; Welding

Document Type: Research Article

Publication date: May 1, 2009

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