Spot Weld Inspections Using Active Thermography

Spot welds have a significant part in the creation of automotive vehicles. Since the integrity of, for example, a car, is dependent on the performance of multiple welds, it is important to ensure the quality of each spot weld. Several attempts have been made in order to determine the quality of spot welds, but most of them do not focus on the applicability in the manufacturing process. Spot weld inspections are often performed using back heating. However, during manufacturing, robotic inspections are desired, and since the bodywork of a car is a complex shape, the accessibility from the inside of the vehicle is minor. Therefore, inspections using front heating are more suitable. In this manuscript, multiple excitation methods are compared as well as different post-processing techniques. The used excitation techniques can be divided into light heating and inductive heating. Light heating is further divided in lock-in thermography and pulse thermography. The used post-processing techniques are principle component analysis and fast Fourier transform. Inductive heating turns out to be the most suitable measurement technique since it is fast and can be performed as front and back heating. Both investigated post-processing techniques deliver suitable information, such as relief images and information of the internal structure of the spot weld.

Automated summary

Spot welds are crucial in automotive manufacturing, and ensuring their quality is of great importance. Current spot weld inspection methods often lack applicability in the manufacturing process, and robotic inspections with front heating are desired. This study compares different excitation methods and post-processing techniques, and finds that inductive heating is the most suitable measurement technique. Both principal component analysis and fast Fourier transform deliver valuable information about spot welds' relief images and internal structure.