Monitoring Gas Metal Arc Welding Process by Using Audible Sound Signal

The most frequently used arc welding process is gas metal arc welding (GMAW). Different methods are in use for monitoring the quality of a welding process. In this paper sound generated during the GMAW process is used for assessing and monitoring of the welding process and for prediction of welding process stability and quality. Theoretical and experimental analyses of the acoustic signals have shown that there are two main noise-generating mechanisms: the first is arc extinction wad arc ignition having impulse character; the second is the arc itself acting as an ionization sound source. A new algorithm based on the measured welding current was established for the calculation of emitted sound during the welding process. The algorithm was verified for different welding condition, different welding materials and different specimen. The comparisons have shown that the calculated values are in good agreement with the measured values of sound signal. (C)2011 Journal of Mechanical Engineering. All rights reserved.