Automatic detection of welding defects using the convolutional neural network

Quality control of welded joints is an important step before commissioning of various types of metal structures. The main obstacles to the commissioning of such facilities are the areas where the welded joint deviates from acceptable defective standards. The defects of welded joints include non-welded, foreign inclusions, cracks, pores, etc. The article describes an approach to the detection of the main types of defects of welded joints using a combination of convolutional neural networks and support vector machine methods. Convolutional neural networks are used for primary classification. The support vector machine is used to accurately define defect boundaries. As a preprocessing in our work, we use the methods of morphological filtration. A series of experiments confirms the high efficiency of the proposed method in comparison with pure CNN method for detecting defects

In-situ crack and keyhole pore detection in laser directed energy deposition through acoustic signal and deep learning

Cracks and keyhole pores are detrimental defects in alloys produced by laser directed energy deposition (LDED). Laser-material interaction sound may hold information about underlying complex physical events such as crack propagation and pores formation. However, due to the noisy environment and intricate signal content, acoustic-based monitoring in LDED has received little attention. This paper proposes a novel acoustic-based in-situ defect detection strategy in LDED. The key contribution of this study is to develop an in-situ acoustic signal denoising, feature extraction, and sound classification pipeline that incorporates convolutional neural networks (CNN) for online defect prediction. Microscope images are used to identify locations of the cracks and keyhole pores within a part. The defect locations are spatiotemporally registered with acoustic signal. Various acoustic features corresponding to defect-free regions, cracks, and keyhole pores are extracted and analysed in time-domain, frequency-domain, and time-frequency representations. The CNN model is trained to predict defect occurrences using the Mel-Frequency Cepstral Coefficients (MFCCs) of the lasermaterial interaction sound. The CNN model is compared to various classic machine learning models trained on the denoised acoustic dataset and raw acoustic dataset. The validation results shows that the CNN model trained on the denoised dataset outperforms others with the highest overall accuracy (89%), keyhole pore prediction accuracy (93%), and AUC-ROC score (98%). Furthermore, the trained CNN model can be deployed into an in-house developed software platform for online quality monitoring. The proposed strategy is the first study to use acoustic signals with deep learning for insitu defect detection in LDED process.Comment: 36 Pages, 16 Figures, accepted at journal Additive Manufacturin

Advanced Optical Coherence Tomography for Real-Time Detection of Defects in Aluminum Alloy Laser Welding

In order to measure the quality of aluminum alloy laser welding workpiece online, an optical coherence tomography on-line detection system was established. Porosity is one of the most common defects in laser welding of aluminum alloy. The porosity produced during welding will seriously affect the welding quality. Firstly, a test device of laser welding quality detection system is built based on optical coherence tomography algorithm. Then, the theoretical model of the optical coherence tomography detection system is built, and the key parameters affecting the detection device are qualitatively analyzed. Then, deep convolutional neural network algorithm is used to process the image. Finally, the testing equipment is used to test the sample, and the testing results are analyzed. The experimental results show that this method can detect the weld quality of laser welding, and the detection accuracy is 20 μm

TOWARD INTELLIGENT WELDING BY BUILDING ITS DIGITAL TWIN

To meet the increasing requirements for production on individualization, efficiency and quality, traditional manufacturing processes are evolving to smart manufacturing with the support from the information technology advancements including cyber-physical systems (CPS), Internet of Things (IoT), big industrial data, and artificial intelligence (AI). The pre-requirement for integrating with these advanced information technologies is to digitalize manufacturing processes such that they can be analyzed, controlled, and interacted with other digitalized components. Digital twin is developed as a general framework to do that by building the digital replicas for the physical entities. This work takes welding manufacturing as the case study to accelerate its transition to intelligent welding by building its digital twin and contributes to digital twin in the following two aspects (1) increasing the information analysis and reasoning ability by integrating deep learning; (2) enhancing the human user operative ability to physical welding manufacturing via digital twins by integrating human-robot interaction (HRI). Firstly, a digital twin of pulsed gas tungsten arc welding (GTAW-P) is developed by integrating deep learning to offer the strong feature extraction and analysis ability. In such a system, the direct information including weld pool images, arc images, welding current and arc voltage is collected by cameras and arc sensors. The undirect information determining the welding quality, i.e., weld joint top-side bead width (TSBW) and back-side bead width (BSBW), is computed by a traditional image processing method and a deep convolutional neural network (CNN) respectively. Based on that, the weld joint geometrical size is controlled to meet the quality requirement in various welding conditions. In the meantime, this developed digital twin is visualized to offer a graphical user interface (GUI) to human users for their effective and intuitive perception to physical welding processes. Secondly, in order to enhance the human operative ability to the physical welding processes via digital twins, HRI is integrated taking virtual reality (VR) as the interface which could transmit the information bidirectionally i.e., transmitting the human commends to welding robots and visualizing the digital twin to human users. Six welders, skilled and unskilled, tested this system by completing the same welding job but demonstrate different patterns and resulted welding qualities. To differentiate their skill levels (skilled or unskilled) from their demonstrated operations, a data-driven approach, FFT-PCA-SVM as a combination of fast Fourier transform (FFT), principal component analysis (PCA), and support vector machine (SVM) is developed and demonstrates the 94.44% classification accuracy. The robots can also work as an assistant to help the human welders to complete the welding tasks by recognizing and executing the intended welding operations. This is done by a developed human intention recognition algorithm based on hidden Markov model (HMM) and the welding experiments show that developed robot-assisted welding can help to improve welding quality. To further take the advantages of the robots i.e., movement accuracy and stability, the role of the robot upgrades to be a collaborator from an assistant to complete a subtask independently i.e., torch weaving and automatic seam tracking in weaving GTAW. The other subtask i.e., welding torch moving along the weld seam is completed by the human users who can adjust the travel speed to control the heat input and ensure the good welding quality. By doing that, the advantages of humans (intelligence) and robots (accuracy and stability) are combined together under this human-robot collaboration framework. The developed digital twin for welding manufacturing helps to promote the next-generation intelligent welding and can be applied in other similar manufacturing processes easily after small modifications including painting, spraying and additive manufacturing

The application of artificial neural networks to interpret acoustic emissions from submerged arc welding

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Automated fusion welding processes play a fundamental role in modern manufacturing industries. The proliferation of joint geometries together with the large permutation of associated process variable configurations has given rise to research into complex system modelling and control strategies. Many of these techniques have involved monitoring of not only the electrical characteristics of the process but visual and acoustic information. Acoustic information derived from certain welding processes is well documented as it is an established fact that skilled manual welders utilise such information as an aid to creating an optimum weld. The experimental investigation presented in this thesis is dedicated to the feasibility of monitoring airborne acoustic emissions of Submerged Arc Welding (SAW) for diagnostic and real time control purposes. The experimental method adopted for this research takes a cybernetic approach to data processing and interpretation in an attempt to replicate the robustness of human biological functions. A custom designed audio hardware system was used to analyse signals obtained from bead on mild steel plate fusion welds. Time and frequency domains were used in an attempt to establish salient characteristics or identify the signatures associated with changes of the process variables. The featured parameters were voltage / current and weld travel speed, due to their ease of validation. However, consideration has also been given to weld defect prediction due to process instabilities. As the data proved to be highly correlated and erratic when subjected to off line statistical analysis, extensive investigation was given to the application of artificial neural networks to signal processing and real time control scenarios. As a consequence, a dedicated neural based software system was developed, utilising supervised and unsupervised neural techniques to monitor the process. The research was aimed at proving the feasibility of monitoring the electrical process parameters and stability of the welding process in real time. It was shown to be possible, by the exploitation of artificial neural networks, to generate a number of monitoring parameters indicative of the welding process state. The limitations of the present neural method and proposed developments are discussed, together with an overview of applied neural network technology and its impact on artificial intelligence and robotic control. Further developments are considered together with recommendations for future areas of research

Novel Approaches for Nondestructive Testing and Evaluation

Nondestructive testing and evaluation (NDT&E) is one of the most important techniques for determining the quality and safety of materials, components, devices, and structures. NDT&E technologies include ultrasonic testing (UT), magnetic particle testing (MT), magnetic flux leakage testing (MFLT), eddy current testing (ECT), radiation testing (RT), penetrant testing (PT), and visual testing (VT), and these are widely used throughout the modern industry. However, some NDT processes, such as those for cleaning specimens and removing paint, cause environmental pollution and must only be considered in limited environments (time, space, and sensor selection). Thus, NDT&E is classified as a typical 3D (dirty, dangerous, and difficult) job. In addition, NDT operators judge the presence of damage based on experience and subjective judgment, so in some cases, a flaw may not be detected during the test. Therefore, to obtain clearer test results, a means for the operator to determine flaws more easily should be provided. In addition, the test results should be organized systemically in order to identify the cause of the abnormality in the test specimen and to identify the progress of the damage quantitatively

Real-time Automated Weld Quality Analysis From Ultrasonic B-scan Using Deep Learning

Resistance spot welding is a widely used process for joining metals using electrically generated heat or Joule heating. It is one of the most commonly used techniques in automotive industry to weld sheet metals in order to form a car body. Although, industrial robots are used as automated spot welders in massive scale in the industries, the weld quality inspection process still requires human involvement to decide if a weld should be passed as acceptable or not. Not only it is a tedious and error- prone job, but also it costs industries lots of time and money. Therefore, making this process automated and real-time will have high significance in spot welding as well as the field of Non-destructive Testing (NDT). Research team in Institute of Diagnostic Imaging Research (IDIR) have developed technology to obtain grey-scale 2D images called ultrasonic b-scans in real-time during production in order to visualize the weld development with respect to time. They have demonstrated that by extracting and interpreting relevant patterns from these b-scans, weld quality can be determined accurately. However, current works combining conventional image and signal processing techniques are unable to extract those patterns from a wide variety of weld shapes with production-level satisfaction. Therefore, in this thesis, we propose to apply SSD, a single-shot multi-box detection based deep convolutional neural network framework for real-time embedded detection of components of cross-sectional weld shape from ultrasonic b-scans and interpret them to numeric parameters which are used as features to classify welds as good, bad or acceptable in real-time. Our proposed model has showed significant improvement in deciding weld quality compared to existing methods when tested on real industry facility

WELD PENETRATION IDENTIFICATION BASED ON CONVOLUTIONAL NEURAL NETWORK

Weld joint penetration determination is the key factor in welding process control area. Not only has it directly affected the weld joint mechanical properties, like fatigue for example. It also requires much of human intelligence, which either complex modeling or rich of welding experience. Therefore, weld penetration status identification has become the obstacle for intelligent welding system. In this dissertation, an innovative method has been proposed to detect the weld joint penetration status using machine-learning algorithms. A GTAW welding system is firstly built. Project a dot-structured laser pattern onto the weld pool surface during welding process, the reflected laser pattern is captured which contains all the information about the penetration status. An experienced welder is able to determine weld penetration status just based on the reflected laser pattern. However, it is difficult to characterize the images to extract key information that used to determine penetration status. To overcome the challenges in finding right features and accurately processing images to extract key features using conventional machine vision algorithms, we propose using convolutional neural network (CNN) to automatically extract key features and determine penetration status. Data-label pairs are needed to train a CNN. Therefore, an image acquiring system is designed to collect reflected laser pattern and the image of work-piece backside. Data augmentation is performed to enlarge the training data size, which resulting in 270,000 training data, 45,000 validation data and 45,000 test data. A six-layer convolutional neural network (CNN) has been designed and trained using a revised mini-batch gradient descent optimizer. Final test accuracy is 90.7% and using a voting mechanism based on three consequent images further improve the prediction accuracy