This proposal involves the
integration of the pre-weld sensor output, during welding output, post welding
quality surface measurements and NDE results in a way that will enable better
quality welds on a first pass basis, eliminating the creation of welds that
require repair. For example:
that detect pre-welding conditions such as joint fit-up and profile, and
preheat measurement can create “no-go” conditions that preclude welding until
the conditions are corrected.
that measure arc instability can be used to shut down welding operations until
that detect weld surface profiles a foot or two behind a completed weld can
stop welding operations if the output characteristics are non-conforming. For
long welds, such as web-to-flange fillet welds, production can be stopped
instead of the continued creation of less than ideal welds.
of NDE results to the production conditions (pre-weld, during weld and post
welding sensor outputs) can help identify the conditions under which weld
discontinuities are created, enabling adjustments to the acceptable pre-weld
and during welding outputs.
welding process controls described above can be used to identify portions of
welds that are most likely to contain weld discontinuities, and therefore
constitute the best use of our NDE resources. The output of sensor has the
potential of “pointing fingers” to suspect welds.
data is collected, it is probable that the need for new sensors will be
identified that would further reduce the need for after-the-fact NDE.
7) Closed loop system could be developed to adjust
welding output real time so as to eliminate conditions that result in weld
flaws. Currently, seam tracking and joint volume measurement tool are being
used to adjust robotic welding conditions to eliminate underfill and incomplete