Abstract
Fillet welds were made using the gas metal arc welding (GMAW) process with various parameter settings while arc voltage, arc current, and wire feed speed signals were recorded. Porosity was induced in some welds by excessive contact tip-to-work distance or low shielding gas flow rate. Welds were visually inspected for porosity and classified as porous or nonporous, and the arc current power spectral density (PSD) was calculated from the recorded values. Arc voltage, the 0 Hz arc current PSD component, arc current PSD components from 20 Hz to 40 Hz, and wire feed speed comprised the predictor group for linear discriminant analysis (LDA). This discriminator was called the “universal predictor” because it was designed to be independent of voltage and wire speed settings within a specified range. Arc current PSD components from 20 Hz to 40 Hz, wire feed speed, and the 0 Hz current PSD component comprised the predictor group for a second series of voltage-specific porosity detectors. It was found that the universal discriminator was about as accurate as discriminators formulated specifically for each voltage level.
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