Weld pool and keyhole dynamic analysis based on visual system and neural network during laser keyhole welding

In keyhole fiber laser welding processes, the weld pool behavior and keyhole dynamics are essential to determining welding quality. To observe and control the welding process, the accurate extraction of the weld pool boundary as well as the width is required. In addition, because of the cause-and-effect relationship between the welding defects and stability of the keyhole, which is primarily determined by keyhole geometry during the welding process, the stability of keyhole needs to be considered as well.^ The first part of this thesis presents a weld pool edge detection technique based on an off axial green illumination laser and a coaxial image capturing system that consists of a CMOS camera and optic filters. According to the difference of image quality, a complete developed edge detection algorithm is proposed based on the local maximum gradient of grayness searching approach and linear interpolation. The extracted weld pool geometry and the width are validated by the actual welding width measurement and predictions by a numerical multi-phase model.^ As for the keyhole dynamics, three essential attributes to describe the simplified three-dimensional keyhole shape include keyhole size, penetration depth and keyhole inclination angle. However, when using traditional measurement techniques, it is very challenging to take in-process measurements of penetration depth and inclination angle, even if the keyhole size can be detected by using a visual monitoring system. To realize the on-line estimation of keyhole dynamics and welding defects, a data-based radial basis function neural network state observer is adopted for estimating penetration depth and inclination angle in the transient state when welding parameters change suddenly. First, a static neural network is trained in advance to establish a correlation between the welding parameters and unobservable keyhole geometry. The dynamic state observer is trained based on the transient welding conditions predicted by a numerical model and then used to estimate the time-varying keyhole geometery. Meanwhile, the coaxial monitoring system is used to observe the keyhole shape from the top side in real time, which not only provides input to the neural network but also indicates the potential welding porosities. The predicted results are validated by experimental data performed by welding with stainless steel 304 and magnesium alloy AZ31B

Doctor of Philosophy

dissertation3D reconstruction from image pairs relies on finding corresponding points between images and using the corresponding points to estimate a dense disparity map. Today's correspondence-finding algorithms primarily use image features or pixel intensities common between image pairs. Some 3D computer vision applications, however, don't produce the desired results using correspondences derived from image features or pixel intensities. Two examples are the multimodal camera rig and the center region of a coaxial camera rig. Additionally, traditional stereo correspondence-finding techniques which use image features or pixel intensities sometimes produce inaccurate results. This thesis presents a novel image correspondence-finding technique that aligns pairs of image sequences using the optical flow fields. The optical flow fields provide information about the structure and motion of the scene which is not available in still images, but which can be used to align images taken from different camera positions. The method applies to applications where there is inherent motion between the camera rig and the scene and where the scene has enough visual texture to produce optical flow. We apply the technique to a traditional binocular stereo rig consisting of an RGB/IR camera pair and to a coaxial camera rig. We present results for synthetic flow fields and for real images sequences with accuracy metrics and reconstructed depth maps

Holographic flow visualization

Holographic visualization techniques are presented of the vortex wake of a lifting wing. The motions of tracer particles in vortical flows are described along with the development of a liquid-drop tracer generator. An analysis is presented of the motion of particles of arbitrary density and size in solid body and potential vortex flows

Automated microscopic analysis of optical fibre transmission surfaces

Outlined in this thesis is the design of a prototype device for the inspection of optical fibre endfaces. The device designed uses lenses with different magnification’s to acquire scaled microscopic images of the endfaces for analysis purposes. The design specifications for the device are established based on the optical transmission requirements of the fibres and the impact of defects on transmission losses in various regions of the optical fibre endface. The specifications of this device are as follows: • Optical System o 3 lens automated changeover • Imaging System: o Minimum Resolvable Object Size of 2.43j.im o Maximum Field of View of 0.9mm o Resolution of 740 X 560 pixels • Autofocus System with Focus Resolution of 1.25pm • Coaxial Illumination System • 12Mbits/sec USB video acquisition hardware The device designed realises all the mechanical, optical and electronic functionality required to automate the inspection process of optical fibres. The hardware and software challenges involved in designing and building the prototype are discussed in detail in the thesis. A complete evaluation of the design is also carried out, difficulties and problems that occurred with the project are analysed, and recommendations for the improvement of the design are made

Optical In-Process Measurement Systems

Information is key, which means that measurements are key. For this reason, this book provides unique insight into state-of-the-art research works regarding optical measurement systems. Optical systems are fast and precise, and the ongoing challenge is to enable optical principles for in-process measurements. Presented within this book is a selection of promising optical measurement approaches for real-world applications

Towards absolute calibration of optical tweezers

Aiming at absolute force calibration of optical tweezers, following a critical review of proposed theoretical models, we present and test the results of MDSA (Mie-Debye-Spherical Aberration) theory, an extension of a previous (MD) model, taking account of spherical aberration at the glass/water interface. This first-principles theory is formulated entirely in terms of experimentally accessible parameters (none adjustable). Careful experimental tests of the MDSA theory, undertaken at two laboratories, with very different setups, are described. A detailed description is given of the procedures employed to measure laser beam waist, local beam power at the transparent microspheres trapped by the tweezers, microsphere radius and the trap transverse stiffness, as a function of radius and height in the (inverted microscope) sample chamber. We find generally very good agreement with MDSA theory predictions, for a wide size range, from the Rayleigh domain to large radii, including the values most often employed in practice, and at different chamber heights, both with objective overfilling and underfilling. The results asymptotically approach geometrical optics in the mean over size intervals, as they should, and this already happens for size parameters not much larger than unity. MDSA predictions for the trapping threshold, position of stiffness peak, stiffness variation with height, multiple equilibrium points and `hopping' effects among them are verified. Remaining discrepancies are ascribed to focus degradation, possibly arising from objective aberrations in the infrared, not yet included in MDSA theory.Comment: 15 pages, 20 figure

Interplay between powder catchment efficiency and layer height in self-stabilized laser metal deposition

In laser metal deposition (LMD) the height of the deposited track can vary within and between layers, causing significant deviations during the process evolution. Previous works have shown that in certain conditions a self-stabilizing mechanism occurs, maintaining a regular height growth and a constant standoff distance between the part and the deposition nozzle. Here we analyze the link between the powder catchment efficiency and the deposition height stability. To this purpose, a monitoring system was developed to study the deposition in different process conditions, using inline measurements of the specimen weight in combination with the layer height information obtained with coaxial optical triangulation. An analytical model was used to estimate the deposition efficiency in real-time from the height monitoring and the process parameters, which was verified by the direct mass measurements. The results show that the track height stabilization is associated to a reduction of the powder catchment efficiency, which is governed by the melt pool relative position with respect to the powder cone and the laser beam. For a given set of parameters, the standoff distance can be estimated to achieve the highest powder catchment efficiency and a regular height through the build direction

Modern optical astronomy: technology and impact of interferometry

The present `state of the art' and the path to future progress in high spatial resolution imaging interferometry is reviewed. The review begins with a treatment of the fundamentals of stellar optical interferometry, the origin, properties, optical effects of turbulence in the Earth's atmosphere, the passive methods that are applied on a single telescope to overcome atmospheric image degradation such as speckle interferometry, and various other techniques. These topics include differential speckle interferometry, speckle spectroscopy and polarimetry, phase diversity, wavefront shearing interferometry, phase-closure methods, dark speckle imaging, as well as the limitations imposed by the detectors on the performance of speckle imaging. A brief account is given of the technological innovation of adaptive-optics (AO) to compensate such atmospheric effects on the image in real time. A major advancement involves the transition from single-aperture to the dilute-aperture interferometry using multiple telescopes. Therefore, the review deals with recent developments involving ground-based, and space-based optical arrays. Emphasis is placed on the problems specific to delay-lines, beam recombination, polarization, dispersion, fringe-tracking, bootstrapping, coherencing and cophasing, and recovery of the visibility functions. The role of AO in enhancing visibilities is also discussed. The applications of interferometry, such as imaging, astrometry, and nulling are described. The mathematical intricacies of the various `post-detection' image-processing techniques are examined critically. The review concludes with a discussion of the astrophysical importance and the perspectives of interferometry.Comment: 65 pages LaTeX file including 23 figures. Reviews of Modern Physics, 2002, to appear in April issu

Focus+Context via Snaking Paths

Focus+context visualizations reveal specific structures in high detail while effectively depicting its surroundings, often relying on transitions between the two areas to provide context. We present an approach to generate focus+context visualizations depicting cylindrical structures along snaking paths that enables the structures themselves to become the transitions and focal areas, simultaneously. A method to automatically create a snaking path through space by applying a path finding algorithm is presented. A 3D curve is created based on the 2D snaking path. We describe a process to deform cylindrical structures in segmented volumetric models to match the curve and provide preliminary geometric models as templates for artists to build upon. Structures are discovered using our constrained volumetric sculpting method that enables removal of occluding material while leaving them intact. We find the resulting visualizations effectively mimic a set of motivating illustrations and discuss some limitations of the automatic approach