Deep Learning-Based Defects Detection in Keyhole TIG Welding with Enhanced Vision

Keyhole tungsten inert gas (keyhole TIG) welding is renowned for its advanced efficiency, necessitating a real-time defect detection method that integrates deep learning and enhanced vision techniques. This study employs a multi-layer deep neural network trained on an extensive welding image dataset. Neural networks can capture complex nonlinear relationships through multi-layer transformations without manual feature selection. Conversely, the nonlinear modeling ability of support vector machines (SVM) is limited by manually selected kernel functions and parameters, resulting in poor performance for recognizing burn-through and good welds images. SVMs handle only lower-level features such as porosity and excel only in detecting simple edges and shapes. However, neural networks excel in processing deep feature maps of "molten pools" and can encode deep defects that are often confused in keyhole TIG. Applying a four-class classification task to weld pool images, the neural network adeptly distinguishes various weld states, including good welds, burn-through, partial penetration, and undercut. Experimental results demonstrate high accuracy and real-time performance. A comprehensive dataset, prepared through meticulous preprocessing and augmentation, ensures reliable results. This method provides an effective solution for quality control and defect prevention in keyhole TIG welding process.