Feasibility study of acoustic sensing for the welding pool mode in variable-polarity plasma arc welding

Abstract The relationships between the acoustic signal and the modes of the welding pool, such as no-keyhole (melt-in), keyhole and cutting, in variable-polarity plasma arc welding are investigated. The Welch power spectral density (PSD) estimate and short-time Fourier transformation are implemented to analyse and identify the different modes of the welding pool. The results show that the no-keyhole mode (melt-in welding process) can be clearly distinguished from the keyhole and the cutting modes. The keyhole size is inversely proportional to the Welch PSD estimate of the acoustic signal.