Infrared sensor for top face monitoring of weld pools

The development of a novel sensor for the measurement of bead size in tungsten inert gas (TIG) welds is described. A passive vision-based sensor combines infrared imaging of the weld pool and selective optical filtering, both to reduce excessive arc glare and improve contrast between weld pool and heat affected zone (HAZ). The arc interruption and external illumination techniques, used by others, are not required. Image quality is shown to be comparable to that obtained with external illumination and superior to that of arc interruption methods. The technique has been successfully applied to both pulsed and continuous TIG welding of stainless steel in order to maintain the bead size during a welding run.