Detection and characterization of metal transfer in GMAW using computational vision algorithms

Solano, Jorge Luis Ortiz; Moreno-Uribe, Andrés Mauricio; Jaimes, Brayan Rene Acevedo; Okuyama, Marcelo Pompermaier; Arias, Ariel Rodríguez; Silva, Régis Henrique Gonçalves e

doi:10.1007/s00170-023-12180-9

Cited by 5 publications

(2 citation statements)

References 24 publications

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“…PLA can decompose under specific circumstances, aiding in curbing plasti waste and reducing reliance on fossil fuels. In general, the FRW exhibits lower energ consumption than conventional gas arc welding [37]. Consequently, the outcomes of thi study bear practical significance for industrial applications and align with Sustainable De velopment Goals 7, 9, 10, and 12 [38].…”

Section: Resultsmentioning

confidence: 67%

Enhancing the Weld Quality of Polylactic Acid Biomedical Materials Using Rotary Friction Welding

Kuo,

Liang,

Huang

et al. 2024

Polymers

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Polylactic acid (PLA) stands out as a biomaterial with immense potential, primarily owing to its innate biodegradability. Conventional methods for manufacturing PLA encompass injection molding or additive manufacturing (AM). Yet, the fabrication of sizable medical devices often necessitates fragmenting them into multiple components for printing, subsequently requiring reassembly to accommodate the constraints posed by the dimensions of the AM platform. Typically, laboratories resort to employing nuts and bolts for the assembly of printed components into expansive medical devices. Nonetheless, this conventional approach of jointing is susceptible to the inherent risk of bolts and nuts loosening or dislodging amid the reciprocating movements inherent to sizable medical apparatus. Hence, investigation into the joining techniques for integrating printed components into expansive medical devices has emerged as a critical focal point within the realm of research. The main objective is to enhance the joint strength of PLA polymer rods using rotary friction welding (RFW). The mean bending strength of welded components, fabricated under seven distinct rotational speeds, surpasses that of the underlying PLA substrate material. The average bending strength improvement rate of welding parts fabricated by RFW with three-stage transformation to 4000 rpm is about 41.94% compared with the average bending strength of PLA base material. The average surface hardness of the weld interface is about 1.25 to 3.80% higher than the average surface hardness of the PLA base material. The average surface hardness of the weld interface performed by RFW with variable rotational speed is higher than the average surface hardness of the weld interface performed at a fixed rotating friction speed. The temperature rise rate and maximum temperature recorded during RFW in the X-axis of the CNC turning machine at the outer edge of the welding part surpassed those observed in the internal temperature of the welding part. Remarkably, the proposed method in this study complies with the Sustainable Development Goals due to its high energy efficiency and low environmental pollution.

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Section: Resultsmentioning

confidence: 67%

Enhancing the Weld Quality of Polylactic Acid Biomedical Materials Using Rotary Friction Welding

Kuo,

Liang,

Huang

et al. 2024

Polymers

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“…Chang et al [ 19 ] proposed a real-time monitoring method based on machine vision for droplet transfer distance and achieved a stable liquid bridge process by adjusting the height of the base in real time. Solano et al [ 20 ] developed an algorithm that can recognize droplets accurately and they achieved the recognition of droplet shapes and the extraction of droplet sizes from photos captured by a high-speed camera. Wang et al [ 21 ] developed a laser back-lighting-based monitoring system to obtain photos of the droplet transfer process and proposed a double-threshold method to segment the image robustly so that they could extract the droplet transfer information smoothly.…”

Section: Introductionmentioning

confidence: 99%

A Real-Time Monitoring Method for Droplet Transfer Frequency in Wire-Filled GTAW Based on Arc Sensing

Jia,

Luo,

Hong

et al. 2024

Sensors

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Droplet transfer frequency is a decisive factor in welding quality and efficiency in gas tungsten arc welding (GTAW). However, there still needs to be a monitoring method for droplet transfer frequency with high precision and good real-time performance. Therefore, a real-time monitoring method for droplet transfer frequency in wire-filled GTAW using arc sensing is proposed in this paper. An arc signal acquisition system is developed, and the wavelet filtering method filters out noise from the arc signal. An arc signal segmentation method—based on the OTSU algorithm and a feature extraction method for droplet transition based on density-based spatial clustering of applications with noise (DBSCAN)—is proposed to extract the feature signal of the droplet transition. A new conception of droplet transition uniformity is proposed, and it can be used to monitor the weld bead width uniformity. Numerous experiments for monitoring droplet transfer frequency in real time are conducted with typical welding parameters. This method enables the real-time observation of droplet transfer frequency, and the result shows that the average monitoring error is less than 0.05 Hz.

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Operational performance and metal droplet formation in pulsed-shielded metal arc underwater welding

Moreno-Uribe,

Vaccari,

Bracarense

et al. 2024

Archiv.Civ.Mech.Eng

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Underwater Shielded Metal Arc Welding (SMAW) is highly affected by the welding depth. The arc and molten metal in contact with the surrounding environment cause operational and metallurgical challenges regarding arc stability, metal transfer, gas formation, high-cooling rates, and diffusible hydrogen uptake. The hydrostatic pressure causes losses in consumable fusion efficiency, constricts the arc, increases the number of short-circuit events, and consequently decreases the welded joint’s process quality. In the present study, the novel approach of pulsed welding current is applied to wet shielded metal arc welding and is operational characteristics are evaluated in detail. Automated welding using an arc-voltage control system was used to obtain reproducible results. For the pulse conditions, two values of pulse current combinations, taking 140 A as the mean value, were set (ΔI of 40 A and 80 A). The same pulse and base duration were chosen, giving pulsing frequencies of 2.5 Hz and 25 Hz. The voltage and current signals were acquired and the short-circuit numbers and melting rates were calculated by processing the data stability factors. As a result, it was possible to weld with lower average welding currents through pulsed-current technology. This new approach can improve the stability of the wet SMAW process and contribute to obtaining better-quality welds without any changes for the underwater welder.

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Detection and characterization of metal transfer in GMAW using computational vision algorithms

Cited by 5 publications

References 24 publications

Enhancing the Weld Quality of Polylactic Acid Biomedical Materials Using Rotary Friction Welding

Enhancing the Weld Quality of Polylactic Acid Biomedical Materials Using Rotary Friction Welding

A Real-Time Monitoring Method for Droplet Transfer Frequency in Wire-Filled GTAW Based on Arc Sensing

Operational performance and metal droplet formation in pulsed-shielded metal arc underwater welding

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