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In this Letter, a vision-based remote sensing methodology is proposed to measure the topography of weld pool surfaces from one single view. Thermal radiations emitted by the hot liquid metal at a wavelength within the arc plasma blind spectral window are acquired by a wavefront division polarimetric system. The refractive index of the liquid metal and the topography of the weld pool surface are inferred from the polarimetric state of the thermal radiations.
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http://dx.doi.org/10.1364/OL.38.002086 | DOI Listing |
Sensors (Basel)
August 2025
Department of Mechanical Engineering, Hanyang University, 55, Hanyangdaehak-ro, Sangnok-gu, Ansan-si 15588, Gyeonggi-do, Republic of Korea.
Multi-layer multi-pass welding plays an important role in manufacturing industries such as nuclear power plants, pressure vessel manufacturing, and ship building. However, distortion or welding defects are still challenges; therefore, welding monitoring and quality control are essential tasks for the dynamic adjustment of execution during welding. The aim was to propose a machine vision system for monitoring and surface quality evaluation during multi-pass welding using a line scanner and infrared camera sensors.
View Article and Find Full Text PDFSensors (Basel)
July 2025
Beijing Botsing Technology Co., Ltd., Beijing 100176, China.
Real-time quality monitoring using molten pool images is a critical focus in researching high-quality, intelligent automated welding. To address interference problems in molten pool images under complex welding scenarios (e.g.
View Article and Find Full Text PDFSensors (Basel)
July 2025
Welding and Additive Manufacturing Centre, School of Aerospace, Transport and Manufacturing, Cranfield University, Bedford MK40 3AA, UK.
Process control and quality assurance of wire + arc additive manufacturing (WAAM) and automated welding rely heavily on in-process monitoring videos to quantify variables such as melt pool geometry, location and size of droplet transfer, arc characteristics, etc. To enable feedback control based upon this information, an automatic and robust segmentation method for monitoring of videos and images is required. However, video segmentation in WAAM and welding is challenging due to constantly fluctuating arc brightness, which varies with deposition and welding configurations.
View Article and Find Full Text PDFMaterials (Basel)
June 2025
School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China.
Traditional narrow gap welding of thick titanium alloy plates easily produces dynamic molten pool flow instability, poor sidewall fusion, and excessive residual stress after welding, which leads to defects such as pores, cracks, and large welding deformations. In view of the above problems, this study takes 16-mm-thick TC4 titanium alloy as the research object, uses low-power pulsed laser-GTA flexible heat source welding technology, and uses the flexible regulation of space between the laser, arc, and wire to promote good fusion of the molten pool and side wall metal. By implementing instant ultrasonic impact treatment on the weld surface, the residual stress of the welded specimen is controlled within a certain range to reduce deformation after welding.
View Article and Find Full Text PDFSci Rep
July 2025
Luoyang Institute of Science and Technology, Luoyang, 471023, China.
This paper primarily addresses the challenges posed by the difficulties in directly measuring the fusion width at the bottom of the weld and in real-time monitoring of the penetration state during the groove welding process. It focuses on the research of online penetration state monitoring technology, which utilizes multi-modal signals such as sound and image during the welding process. The multimodal network proposed in this paper, SIMNet, first employs the short-time Fourier transform (STFT) to convert the original sound signal into the time-frequency domain for preliminary feature extraction.
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