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3D Weld Pool Surface Geometry Measurement with Adaptive Passive Vision Images

Monitoring weld pool geometry without the appropriate auxiliary light source remains challenging due to the interference from the intense arc light. In this work, a new software framework was developed to measure the key features related to welding pool three-dimensional (3D) geometry based on the two-dimensional (2D) passive vision images. It was found that the interference of the arc light on the weld pool image can be effectively controlled by adjusting the camera exposure time based on the decision made from machine learning classifier. Weld pool width, trailing length, and surface height (SH) were calculated in real time, and the result agreed with the measurement of the weld bead geometry. The method presented here established the foundation for real-time penetration monitoring and control.