Development of a melt pool characteristics detection platform based on multi-information fusion of temperature fields and photodiode signals in plasma arc welding

Zhuangzhuang Mao, Wei Feng, Xiao Han, Heng Ma, Ce Hao, Changmeng Liu () and Zhanwei Liu ()
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Zhuangzhuang Mao: Beijing Institute of Technology
Wei Feng: Beijing Institute of Technology
Xiao Han: Beijing Institute of Technology
Heng Ma: AVIC Xi’an Aircraft Industry (Group) Co., Ltd.
Ce Hao: AECC Commercial Aircraft Engine Co. Ltd.
Changmeng Liu: Beijing Institute of Technology
Zhanwei Liu: Beijing Institute of Technology

Journal of Intelligent Manufacturing, 2025, vol. 36, issue 3, No 26, 2017-2037

Abstract: Abstract Melt pool characteristics reflect the formation mechanisms and potential issues of flaws. Long-term, high-precision, and real-time detection of melt pool characteristics is one of the major challenges in the industrial application of additive manufacturing technology. This work proposes, for the first time, the melt pool characteristics detection platform based on multi-information fusion in the plasma arc welding (PAW) process, which fully utilizes real-time photodiode signals and high-precision, information-rich melt pool temperature fields. By optimizing the detection area and wavelength selection of the platform, particularly through the unique photodiode signal acquisition system capable of detecting the high-sensitivity area of the melt pool, we effectively mitigate the influences of intense arc light and welding wire obstruction on the temperature signals and photodiode signals. Through applying machine learning, the trained model integrates photodiode signals with temperature signals from the high-sensitivity area, thereby achieving real-time acquisition of high-precision average temperature. By combining the fused signals collected from the platform and the scanning results from micro-computed tomography (CT), we evaluate and verify the influence of flaws and droplets on the melt pool characteristics, realizing the determination of flaw occurrence based on the abnormal variations of average temperature. The experimental results demonstrated that the platform fully utilized the advantages of long-term and real-time acquisition of the photodiode signal and the high-precision and information-rich of the melt pool temperature field, achieving long-term, high-precision, and real-time detection of melt pool characteristics.

Keywords: Plasma arc welding; Melt pool; Photodiode signal; Real-time detection; Melt pool temperature field; Oscillation frequency (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1007/s10845-024-02342-1

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