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A Weld Pool Morphology Acquisition and Visualization System Based on an In Situ Calibrated Analytical Solution and

Yecun Niu1, Shaojie Wu1,2, Fangjie Cheng1,2

  • 1School of Materials Science and Engineering, Tianjin University, Tianjin 300072, China.

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|May 14, 2025
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Summary

A new system provides real-time 3D weld pool visualization for welders. This technology enhances teleoperation welding precision by offering instant weld pool morphology insights.

Keywords:
analytical modeldigital twingas tungsten arc weldingimage processingvirtual reality

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Area of Science:

  • Welding Engineering
  • Materials Science
  • Robotics

Background:

  • Accurate monitoring of weld pool morphology is crucial for precise welding operations.
  • Existing methods often lack real-time feedback, hindering effective control during welding.
  • Advanced visualization techniques are needed to improve welder perception and skill in complex welding tasks.

Purpose of the Study:

  • To develop and validate a system for real-time acquisition and visualization of three-dimensional (3D) weld pool morphologies.
  • To enhance welder understanding and control of the welding process through immediate visual feedback.
  • To investigate the feasibility of integrating virtual reality (VR) for immersive weld pool observation.

Main Methods:

  • Designed a system utilizing an in situ calibrated analytical solution based on real-time welding voltage and current data.
  • Calculated the weld pool's underside by analyzing the surface boundary and employing calibrated heat source distribution coefficients.
  • Integrated the 3D weld pool model with virtual reality (VR) devices using hot-update technology for visualization.

Main Results:

  • The system achieves real-time 3D weld pool updates with minimal error (average 8.54%, minimum 0.8%) in weld diameter.
  • A virtual environment was successfully constructed, enabling visualization of the 3D weld pool model.
  • Experimental results confirmed the system's basic feasibility, though update rates require further optimization.

Conclusions:

  • The developed system offers a feasible approach for real-time 3D weld pool morphology observation.
  • This technology significantly aids in enhancing welder teleoperation skills, particularly for precise remote welding.
  • Further optimization of update rates is recommended for broader practical application.