Real time GMAW weld bead profile mapping using acoustic sensing

Abstract

Monitoring the penetration profile of Gas Metal Arc Welding (GMAW) is critical in determining the overall quality and structural integrity of the produced weld bead. However, due to the instability and complexity of the GMAW process, it can be difficult to accurately monitor the weld bead formation and penetration profile. Due to this complexity, traditional methods for modeling the welding process, such as CFD analysis, are unable to be computed in real time. In this work, a new analytical method of estimating the weld bead penetration profile in real time using the sound signal is proposed. This method monitors the sound signal generated during the droplet transfer process to estimate both the heat input and material deposition into the weld pool. Using this estimation, a digital twin of the welding process is produced, allowing for the operator to monitor the weld bead formation in real time, guaranteeing the structural integrity of the final weld bead.