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Title: Monitoring Weld Pool Surface and Penetration Using Reversed Electrode Images

The three­-dimensional weld pool top surface shape provides important informa­tion about the state of weld penetration during welding. In this study, a method was developed to quantitatively relate weld pool surface height to the reversed electrode image (REI) on the weld pool surface. This new feature was extracted from the weld pool image using a passive vision-­based monitoring system during gas tungsten arc welding (GTAW). Due to the specular reflection of the weld pool top surface, the REI is visible on the weld pool surface during GTAW. The position of the REI was determined with a robust image processing algorithm. Based on the principle of light reflection, the distance between the electrode tip and the REI (DERI) was related to the weld pool surface height. By assuming the weld pool surface was a spherical mirror, a reflection model was established to calculate the surface height (SH) index based on the measurement of the DERI, arc length, and weld pool geometry. The pro­posed method was verified with bead­-on­plate welding experiments. The SH was positively related to the face reinforcement or depression of the weld bead. This method was applied to monitor the penetration state during bead­on­plate autoge­nous welding, particularly when amore » complete penetration weld was formed.« less
Authors:
ORCiD logo [1] ; ORCiD logo [1] ;  [1]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Publication Date:
Grant/Contract Number:
AC05-00OR22725
Type:
Accepted Manuscript
Journal Name:
Welding Journal
Additional Journal Information:
Journal Volume: 96; Journal Issue: 10; Journal ID: ISSN 0043-2296
Publisher:
American Welding Society
Research Org:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org:
USDOE
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING
OSTI Identifier:
1407780

Feng, Zhili, Chen, Jian, and Chen, Zongyao. Monitoring Weld Pool Surface and Penetration Using Reversed Electrode Images. United States: N. p., Web.
Feng, Zhili, Chen, Jian, & Chen, Zongyao. Monitoring Weld Pool Surface and Penetration Using Reversed Electrode Images. United States.
Feng, Zhili, Chen, Jian, and Chen, Zongyao. 2017. "Monitoring Weld Pool Surface and Penetration Using Reversed Electrode Images". United States. doi:. https://www.osti.gov/servlets/purl/1407780.
@article{osti_1407780,
title = {Monitoring Weld Pool Surface and Penetration Using Reversed Electrode Images},
author = {Feng, Zhili and Chen, Jian and Chen, Zongyao},
abstractNote = {The three­-dimensional weld pool top surface shape provides important informa­tion about the state of weld penetration during welding. In this study, a method was developed to quantitatively relate weld pool surface height to the reversed electrode image (REI) on the weld pool surface. This new feature was extracted from the weld pool image using a passive vision-­based monitoring system during gas tungsten arc welding (GTAW). Due to the specular reflection of the weld pool top surface, the REI is visible on the weld pool surface during GTAW. The position of the REI was determined with a robust image processing algorithm. Based on the principle of light reflection, the distance between the electrode tip and the REI (DERI) was related to the weld pool surface height. By assuming the weld pool surface was a spherical mirror, a reflection model was established to calculate the surface height (SH) index based on the measurement of the DERI, arc length, and weld pool geometry. The pro­posed method was verified with bead­-on­plate welding experiments. The SH was positively related to the face reinforcement or depression of the weld bead. This method was applied to monitor the penetration state during bead­on­plate autoge­nous welding, particularly when a complete penetration weld was formed.},
doi = {},
journal = {Welding Journal},
number = 10,
volume = 96,
place = {United States},
year = {2017},
month = {10}
}