Barriers for industrial implementation of in-process monitoring of weld penetration for quality control
- 338 Downloads
The research conducted sheds a light on the question why robust in-process monitoring and adaptive control are not fully implemented in the welding industry. In the research project FaRoMonitA, the possibilities to monitor the weld quality during welding have been investigated. Research conducted in this area has merely focused on technical issues investigated in a laboratory environment. To advance the research front and release some barriers related to industrial acceptance, the studies conducted in this paper have been both quantitative and qualitative in form of experiments combined with an interview study. The quality property weld penetration depth was chosen for in-process monitoring to evaluate the industrial relevance and applicability. A guaranteed weld penetration depth is critical for companies producing parts influenced by fatigue. The parts studied were fillet welds produced by gas metal arc welding. The experiments show that there is a relationship between final penetration depth and monitored arc voltage signals and images captured by CMOS vision and infrared cameras during welding. There are still technical issues to be solved to reach a robust solution. The interview study indicates that soft issues, like competence and financial aspects, are just as critical.
KeywordsProcess monitoring Gas metal arc welding Fillet weld Weld penetration Quality assurance Manufacturing Non-destructive testing
- 4.Dahle T, Olsson KE, Samuelsson J (1999) Fatigue design optimisation of welded box beams subjected to combined bending and torsion. In: Solin GmaJ (ed) European Structural Integrity Society, Fatigue Design and Reliability, vol 23. ElsevierGoogle Scholar
- 6.Ericson Öberg A, Johansson M, Holm EJ, Hammersberg P, Svensson LE (2012) The influence of correct transfer of weld information on production costGoogle Scholar
- 8.Hammersberg P, Olsson H (2013) Proactive control of weld dimensions in robotised MAG weldingGoogle Scholar
- 10.Lantz A (2007) Intervjumetodik, 2nd edn. Studentlitteratur, LundGoogle Scholar
- 14.Metwalli MR, Nasr AH, Allah OSF, El-Rabaie S (2009) Image fusion based on principal component analysis and high-pass filter. In: International Conference on Computer Engineering Systems, 2009. ICCES 2009, Cairo, pp 63–70. doi: 10.1109/ICCES.2009.5383308
- 15.Öberg A, Hammersberg P, Svensson LE (2012) Selection of evaluation methods for new weld demands: pitfalls and possible solutions. Durban, South AfricaGoogle Scholar
- 16.Raj B, Subramanian CV, Jayakumar T (2000) Non-destructive testing of welds. Alpha Science International Ltd, IndiaGoogle Scholar
- 23.Swedish Standard (2004) SS-EN ISO 5817 Welding-fusion-welded joints in steel, quality levels for imperfections. Tech. rep.Google Scholar
- 24.Volvo Group (2011) STD 181-0004 fusion welding—weld classes and requirements life optimized welded structures steel, thickness 3mm. Tech. rep., Volvo GroupGoogle Scholar
Open AccessThis article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.