Temporal Resolution of Acoustic Process Emissions for Monitoring Joint Gap Formation in Laser Beam Butt Welding

Abstract

With the increasing power and speed of laser welding, in-process monitoring has become even more crucial to ensure process stability and weld quality. Due to its low cost and installation flexibility, acoustic process monitoring is a promising method and has demonstrated its effectiveness. Although its feasibility has been the focus of existing studies, the temporal resolution of acoustic emissions (AE) has not yet been addressed despite its utmost importance for realizing real-time systems. Aiming to provide a benchmark for further development, this study investigates the relationship between duration and informativeness of AE signals during high-power (3.5 kW) and high-speed (12 m/min) laser beam butt welding. Specifically, the informativeness of AE signals is evaluated based on the accuracy of detecting and quantifying joint gaps for various time windows of signals, yielding numerical comparison. The obtained results show that signals can be shortened up to a certain point without sacrificing their informativeness, encouraging the optimization of the signal duration. Our results also suggest that large gaps (>0.3mm) induce unique signal characteristics in AE, which are clearly identifiable from 1 ms signal segments, equivalent to 0.2mm weld seam.

Keywords

• laser beam butt welding
• acoustic process monitoring
• nondestructive testing (NDT)
• joint gap detection
• temporal resolution
• clustering