Online Path Recognition for Additive Manufacturing and Arc Welding with Filler Wire Based on Multi-vision Information Fusion

doi:10.3901/JME.2019.17.001

Abstract

Abstract: In the manufacturing process of multi-layer/multi-pass weld of large-scale components in the field of energy equipment and electron beam freeform fabrication in the field of aerospace manufacturing, there is an urgent need for online recognition and real-time automatic guidance technology. But the geometrical differences is very small between adjacent weld passes which makes it difficult to detect the weld position using traditional methods such as structured light. A method of real-time fusion processing of directional and structured light information is developed to solve this problem, which can be used in multi-layer/multi-pass weld and electron beam freeform fabrication. Corresponding visual detection devices are also designed. The result shows that there is a "High-Low-High" distribution of brightness between adjacent passes when using differential image. The act of fusing adjacent images greatly reduces the influence of the spatters and arc light. Compared with the existing weld path recognition and automatic tracking system based on structured light method, it has stronger adaptability to ensure the processing quality. This method also provides a new technical approach to improve the productivity.

Key words: multi-layer/multi pass arc welding, wire feed additive manufacturing, in-situ seam tracking, information fusion, visual detection

CLC Number:

TG156

CHANG Shuhe, ZHANG Haoyu, XU Haiying, HONG Yuxiang, WANG Li, DU Dong. Online Path Recognition for Additive Manufacturing and Arc Welding with Filler Wire Based on Multi-vision Information Fusion[J]. Journal of Mechanical Engineering, 2019, 55(17): 1-7.

References

[1] DING Donghong,PAN Zengxi,CUIURI D,et al. Wire-feed additive manufacturing of metal components:Technologies,developments and future interests[J]. The International Journal of Advanced Manufacturing Technology,2015,81:465-481.
[2] TAMINGER K M,HARFLEY R A. Electron beam freeform fabrication:A rapid metal deposition process[C/CD]//Society of Plastics Engineers. Proceedings of the 3rd Annual Automotive Composites Conference,Sep. 9-10,2003,NASA Technical Reports Server,2003.
[3] GOCKEL J,BEUTH J,TAMINGER K M. Integrated control of solidification microstructure and melt pool dimensions in electron beam wire feed additive manufacturing of Ti-6Al-4V[J]. Additive Manufacturing,2014,1:119-126.
[4] ZHANG Binggang,ZHAO Jian,LI Xiaopeng,et al. Effects of filler wire on residual stress in electron beam welded QCr0.8 copper alloy to 304 stainless steel joints[J]. Applied Thermal Engineering,2015,80:261-268.
[5] WANG T,ZHANG Y,LI X,et al. Influence of beam current on microstructures and mechanical properties of electron beam welding-brazed aluminum-steel joints with an Al5Si filler wire[J]. Vacuum,2017,141:281-287.
[6] NIE Z,WANG G,MCGUFFIN-CAWLEY J D,et al. Experimental study and modeling of H13 steel deposition using laser hot-wire additive manufacturing[J]. Journal of Materials Processing Technology,2016,235:171-186.
[7] DEMIR A G. Micro laser metal wire deposition for additive manufacturing of thin-walled structures[J]. Optics and Lasers in Engineering,2018,100:9-17.
[8] LIU W,LIU S,MA J,et al. Real-time monitoring of the laser hot-wire welding process[J]. Optics & Laser Technology,2014,57:66-76.
[9] WANG F,WILLIAMS S,COLEGROVE P,et al. Microstructure and mechanical properties of wire and arc additive manufactured Ti-6Al-4V[J]. Metallurgical and Materials Transactions A,2013,44(2):968-977.
[10] 都东,邹怡蓉,常保华. 焊接视觉传感及自动跟踪技术的现状与发展[J]. 航空制造技术,2010(9):40-42. DU Dong,ZOU Yirong,CHANG Baohua. Current status and development of welding vision sensing and automatic tracking technology[J]. Aviation Manufacturing Technology,2010(9):40-42.
[11] 邹怡蓉,曾锦乐,都东. 可视化焊接的发展[J]. 电焊机,2013(5):17-19. ZOU Yirong,ZENG Jinle,DU Dong. Development of visual welding[J]. Electric Welder,2013(5):17-19.
[12] 蒋凡,李元锋,陈树君. 焊接电弧监测技术研究现状及展望[J]. 机械工程学报,2018,54(2):16-26. JIANG Fan,LI Yuanfeng,CHEN Shujun. Review of welding arc monitoring technology[J]. Journal of Mechanical Engineering,2018,54(2):16-26.
[13] 邹焱飚,周卫林,王研博. 基于概率连续模型的激光视觉焊缝自动跟踪[J]. 机械工程学报,2017,53(10):70-78. ZOU Yanbiao,ZHOU Weilin,WANG Yanbo. Automatic laser visual seam tracking based on probabilistic continuous model[J]. Journal of Mechanical Engineering,2017,53(10):70-78.
[14] ZENG J,CHANG B,DU D,et al. A precise visual method for narrow butt detection in specular reflection workpiece welding[J]. Sensors,2016,16(9):1480.
[15] ZENG J,CHANG B,DU D,et al. A vision-aided 3D path teaching method before narrow butt joint welding[J]. Sensors,2017,17(5):1099.
[16] ZENG J,CHANG B,DU D,et al. A visual weld edge recognition method based on light and shadow feature construction using directional lighting[J]. Journal of Manufacturing Processes,2016,24:19-30.
[17] ZENG J,CHANG B,DU D,et al. A weld position recognition method based on directional and structured light information fusion in multi-Layer/multi-pass welding[J]. Sensors,2018,18(1):129.
[18] SHAO J,DU D,CHANG B,et al. Automatic weld defect detection based on potential defect tracking in real-time radiographic image sequence[J]. NDT & E International,2012,46:14-21.
[19] SHAO J,DU D,SHI H,et al. Automatic weld recognition and extraction from real-time X-ray images using quadratic curve fitting and multi-order differences analysis of intensity profile[J]. Insight-Non-Destructive Testing and Condition Monitoring,2011,53(10):562-569.
[20] DU D,HOU R,SHAO J,et al. Registration of real-time X-ray image sequences for weld inspection[J]. Nondestructive Testing and Evaluation,2010,25(2):153-159.
[21] ZOU Y,DU D,CHANG B,et al. Automatic weld defect detection method based on Kalman filtering for real-time radiographic inspection of spiral pipe[J]. NDT & E International,2015,72:1-9.
[22] 都东,王胜华,王力,等. 基于对象特征分析的焊缝识别视觉传感技术[J]. 焊接学报,2008,29(10):108-112. DU Dong,WANG Shenghua,WANG Li,et al. Vision-sensing technology for weld seam recognition based on object feature analysis[J]. Journal of Welding,2008,29(10):108-112.
[23] 邹怡蓉,都东,曾锦乐,等. 基于多视觉特征获取与信息融合的焊道识别方法[J]. 焊接学报,2013,34(5):33-36. ZOU Yirong,DU Dong,ZENG Jinle,et al. A method of bead identification based on multi-visual feature acquisition and information fusion[J]. Journal of Welding,2013,34(5):33-36.
[24] 邹怡蓉,吴哲明,曾凯,等. 基于焊缝纹理特征的视觉识别方法[J]. 焊接学报,2009,30(5):13-16. ZOU Yirong,WU Zheming,ZENG Kai,et al. A visual recognition method based on weld texture features[J]. Journal of Welding,2009,30(5):13-16.
[25] 邹怡蓉,吴哲明,郭桂林,等. 基于图像色彩信息的焊缝识别算法[J]. 焊接学报,2009,30(10):37-40. ZOU Yirong,WU Zheming,GUO Guilin,et al. Weld seam recognition algorithm based on image color information[J]. Journal of Welding,2009,30(10):37-40.