Abstract
In this study, a low-cost, flexible process monitoring system for focussed arc tungsten inert gas welder tool electrodes is presented. The system is capable of acquiring and processing geometric data that are used to define acceptance criteria. This system is used to characterise tool wear phenomena in repetitive brazing runs ensuring that the tool is operating within its process window. It was found, using this apparatus, that a build-up of zinc oxide, originating from the zinc-coated steel, on the braze tool prohibits arcing and delivery of a good quality joint. The vision system can identify build-up of this layer before failure of ignition. Measurements showed that after 990 s of continuous arcing, the zinc oxide build-up would cause system malfunction. The vision system gave a warning of zinc build-up at 577 s.
Published Version
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