Deviations during a welding process are detectable via high-frequency impulses. This applies for weak spots like cold cracks, tiny welding pores, burn-through and splashes during the welding. Additionally, it’s possible to evaluate the amount of energy that goes into the process. Even with laser welding. You receive the quality results during the welding process.
In the left region of the image you can see emissions of a varying welding process with multiple micro crack emissions.
At second 16 the cool-down period gets visible; 4 seconds later macro cracks are occurring.
These cracks can be detected and counted automatically. Exceeds this crack count a set threshold level, a signal is emitted, telling the machine that the workpiece is flawed and has to be sorted out.
The picture shows the welding of a metal sheet with a laser welder.
The laser’s power has been adjusted from 0 kW up to 3 kW and back again to 0 kW continuously. In the image produced by the Optimizer4D you can now track the tagging-, melting- and welding periods. There are distinct differences between the emission’s frequencies and intensities.
On the right you see an enlarged process landscape of a welding process. You can easily track variations during a welding pulse (duration of 10ms).
Applying mathematical integration on the signal amplitudes over time and frequency, the welding capacity absorbed by the workpiece can be determined.
The Optiomizer4D allows continuous monitoring of welding quality and detection of welding flaws.
In the test setup standardized holes of 4mm, 3mm and 2mm diameter are being welded shut. In this scenery the acoustic emissions are made visible, the turquoise line shows the welding current. At the flagged positions at second 26 and 32 a hole is being welded shut. Looking at the second hole, the flaws in the current control are perfectly visible after the drop.