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Proceedings Paper

Optical sensor for real-time weld defect detection
Author(s): Antonio Ancona; Tommaso Maggipinto; Vincenzo Spagnolo; Michele Ferrara; Pietro Mario Lugara
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Paper Abstract

In this work we present an innovative optical sensor for on- line and non-intrusive welding process monitoring. It is based on the spectroscopic analysis of the optical VIS emission of the welding plasma plume generated in the laser- metal interaction zone. Plasma electron temperature has been measured for different chemical species composing the plume. Temperature signal evolution has been recorded and analyzed during several CO2-laser welding processes, under variable operating conditions. We have developed a suitable software able to real time detect a wide range of weld defects like crater formation, lack of fusion, excessive penetration, seam oxidation. The same spectroscopic approach has been applied for electric arc welding process monitoring. We assembled our optical sensor in a torch for manual Gas Tungsten Arc Welding procedures and tested the prototype in a manufacturing industry production line. Even in this case we found a clear correlation between the signal behavior and the welded joint quality.

Paper Details

Date Published: 24 April 2002
PDF: 10 pages
Proc. SPIE 4669, Sensors and Camera Systems for Scientific, Industrial, and Digital Photography Applications III, (24 April 2002); doi: 10.1117/12.463427
Show Author Affiliations
Antonio Ancona, INFM (Italy)
Tommaso Maggipinto, INFM (Italy)
Vincenzo Spagnolo, INFM (Italy)
Michele Ferrara, INFM (Italy)
Pietro Mario Lugara, INFM (Italy)

Published in SPIE Proceedings Vol. 4669:
Sensors and Camera Systems for Scientific, Industrial, and Digital Photography Applications III
Nitin Sampat; Morley M. Blouke; John Canosa; John Canosa; Nitin Sampat, Editor(s)

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