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    Real-Time Weld Process Monitoring

    ISBN-10: 1420077872
    ISBN-13: 9781420077872
    Author(s): Y. M. Zhang
    Description: Welding is a complex process, is increasingly automated, and operates at higher speeds in more difficult environments. Defects also need to be detected as they arise to ensure efficient, high-quality production. All these needs have led to a growing  More...
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    Publisher: CRC Press LLC
    Binding: Hardcover
    Size: 6.25" wide x 9.25" long x 0.75" tall
    Weight: 1.298
    Language: English

    Welding is a complex process, is increasingly automated, and operates at higher speeds in more difficult environments. Defects also need to be detected as they arise to ensure efficient, high-quality production. All these needs have led to a growing interest in the use of sensors to provide accurate, robust, real-time monitoring where this cannot be achieved by more traditional testing and inspection techniques. This important book reviews the range of monitoring techniques available and their applications. After an introductory chapter, the first part of the book reviews the range of sensor technologies in welding, from arc and optical sensors to infrared and ultrasonic techniques. Part two discusses the monitoring of particular aspects of welding such as weld seams and profiles, the analysis of weld penetration and weld pool surface, as well as monitoring of resistance and laser welding. With its distinguished editor and international team of contributors, Real-timeweld process monitoringwill be a valuable reference to all those concerned with improving the quality of welding and welded components.

    Contributor contact detailsp. ix
    An analysis of welding process monitoring and controlp. 1
    Introductionp. 1
    Welding process as a systemp. 1
    Welding process as a complex systemp. 4
    Welding process as an uncertain systemp. 6
    Monitoring of welding processesp. 7
    Overview of the bookp. 10
    Referencesp. 11
    Monitoring technologiesp. 13
    Arc sensors in weld monitoringp. 15
    Introductionp. 15
    Backgroundp. 15
    Non-consumable electrode processesp. 20
    Consumable electrode processesp. 25
    Power supply considerationsp. 31
    Signal processing and control approachesp. 36
    Future trendsp. 39
    Sources of further information and advicep. 41
    List of symbols and abbreviationsp. 41
    Referencesp. 43
    Optical sensors in weldingp. 45
    Introductionp. 45
    Knowledge of opticsp. 46
    Optical sensor componentp. 52
    Optical sensing systemp. 62
    Application of optical sensorsp. 69
    Referencesp. 72
    Infrared sensors in weldingp. 74
    Introductionp. 74
    Theory of infrared sensorsp. 74
    Measurement of weld temperature distributionp. 80
    Infrared sensors for real-time weld quality controlp. 82
    Summaryp. 99
    Referencesp. 99
    Ultrasonic sensors in weldingp. 104
    Introductionp. 104
    Principles of ultrasonic sensingp. 105
    Ultrasonic techniques and their applicationsp. 110
    Future trendsp. 122
    Summaryp. 123
    Sources of further information and advicep. 124
    Referencesp. 124
    Monitoring of welding processesp. 129
    Weld seam monitoringp. 131
    Introductionp. 131
    Methods of weld seam monitoringp. 131
    Through-arc monitoring of weld seams in gas metal arc weldingp. 132
    Electromagnetic monitoring of weld seams in gas metal arc weldingp. 150
    Laser visual monitoring of weld seams in gas metal arc weldingp. 152
    Referencesp. 162
    Weld profile monitoringp. 164
    Necessity for weld profile measurementp. 164
    Outline of weld profilep. 165
    Surface shaping defectsp. 170
    Automatic detection of weld profilep. 172
    Referencesp. 184
    Weld penetration monitoringp. 186
    Introductionp. 186
    Weld pool oscillation sensorp. 187
    Infrared sensorp. 191
    Ultrasonic sensorp. 193
    Vision-based sensorp. 195
    Weld pool sag depressionp. 196
    Plasma charge-based sensorsp. 199
    Weld penetration control using sensor feedbackp. 205
    Summaryp. 209
    Referencesp. 211
    Weld pool surface monitoringp. 213
    Vision-based sensing 2D surface geometry of weld pool in gas tungsten arc weldingp. 213
    Sensing 2D weld pool boundary in gas metal arc weldingp. 217
    Modeling and simulation of weld pool surfacep. 220
    Sensing 3D weld pool surface using specular reflectionp. 229
    Improvement on observation of dynamic 3D weld pool surfacep. 232
    Referencesp. 236
    Monitoring resistance weldingp. 238
    Introductionp. 238
    Resistance spot welding systems, weld formation and signalsp. 239
    Real-time process monitoring and controlp. 245
    Future trendsp. 255
    Sources of further information and advicep. 258
    Acknowledgmentp. 258
    Referencesp. 258
    Monitoring laser weldingp. 260
    Introductionp. 260
    Principles of laser weldingp. 260
    Optical sensingp. 263
    Frequency analyses of acoustic and optical emissionsp. 274
    Smart systemsp. 278
    Other systems and future trendsp. 280
    Referencesp. 284
    Indexp. 289
    Table of Contents provided by Ingram. All Rights Reserved.

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