DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE

DEVELOPMENT OF A WELDING MONITORING

SYSTEM FOR IN-PROCESS QUALITY
CONTROL OF THICK WALLED PIPE
Y. Fujita, T. Ogawa, S. Asai, S. Yamamoto, T. Ohdake
and M. Ochiai

The authors have developed a systematized in-process quality control system for arc welding of thick walled
ABSTRACT

pipe utilizing visual sensors and computers. This system consisted of four main subsystems that monitor the
welding conditions, monitor the weld pool shape, visualize the weld bead shape, and visualize inner defects,
respectively. The welding condition monitoring system detects abnormal welding conditions using an electric
signal. The weld pool shape monitoring system assesses the position among weld pool, the electrode, wire,
and groove using a charge coupled device (CCD) camera and filters. The weld bead shape visualization sys-
tem detects abnormal bead surface conditions using a three-dimensional (3D) visual technique. The inner
defect visualization system was achieved using a laser-ultrasonic in-process testing (LUT) technique and
synthesis aperture focus technique (SAFT). Each subsystem informs workers of unsuitable welding condi-
tions to allow them to reestablish the suitable conditions. Furthermore, the in-process quality control system
was applied to thick walled pipe welding to verify the practicality of this system for improving the quality and
efficiency of welding operations.

IIW-Thesaurus keywords: Quality control system; Sensors; Monitoring systems; Laser; Ultrasonic testing; Pipe;
Imaging.

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1 Introduction 2 Material and experimental

Generally, weld quality is assured by welders and by post- procedures
welding nondestructive testing (NDT). The quality during
welding is controlled by the welder’s visual monitoring 150 mm thick walled pipe of Cr-steel was used for the
and managed based on his or her skill, knowledge, and base metal. The wire composition was similar to that of
experience. The quality after welding is certified by visual the base metal. The wire diameter was 1.0 mm. The hot
testing (VT), penetrant testing (PT), magnetic-particle wire TIG method was selected as the welding process.
testing (MT), ultrasonic testing (UT), radio graphic test- Welding was conducted for flat position welding and the
ing (RT), and other methods. Repair welding is conducted pipe was rotated during welding as shown in Figure 1.
when a defect is found using these tests. The welding of
thick walled pipe, however, requires much welding time
and cost. Conducting weld repairs after finding defects
using NDT is expensive because of the exceedingly long
arc time. Therefore, if unsuitable welding conditions and
defects could be found during welding, the welding could
be effectively controlled to maintain suitable conditions,
and the defects should be repaired promptly. Recent
developments in visual sensors and computers, and tech-
niques that utilize them, can be used for such a monitoring
system [1-13]. This research covers a welding monitor-
ing system for in-process quality control utilizing a charge
coupled device (CCD) camera and a laser-ultrasonic
technique (LUT). Finally, we applied this system to thick
walled pipe welding. This thesis reports the basic concept
and features of this system and its application to thick
Figure 1 – Schematic diagram of pipe welding process
walled pipe welding.

IIW-2195, recommended for publication by Commission XII “Arc Welding Processes and Production Systems.”

12 2012 Vol. 56 WELDING IN THE WORLD

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 DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE

Figure 2 shows a schematic diagram of the edge shape.

The bevel angle is 0.5 degrees and the groove width is
from 8 mm to 10.5 mm. Finally, the preheated condition is
at least 473 K.

3 Basic concept and constitution

of welding monitoring system
for in-process quality control
This in-process quality control system has been system-
atized to detect abnormal conditions and defects utilizing
visual sensors and computers. The system consists of
four main subsystems, i.e. the welding conditions moni-
toring system, weld pool shape monitoring system, weld
bead shape visualization system, and inner defect visual-
ization system.
Generally, if suitable welding conditions are selected dur-
ing the preliminary experiment, a sound bead should be
obtained during automatic welding. Actually, however, the
welding conditions are affected by disturbance factors, for
example, figure error and heat deformation of the welded
object, source voltage fluctuation, curved wire, the wind,
and so on. Therefore, sensors that detect the influence
16 of these disturbance factors are needed. In consideration
of this, four systems were used for this research. Table 1
shows the measurement items and sensors of each sys-
tem. The monitoring system of welding conditions detects
abnormal welding conditions using an electric signal. The
weld pool shape monitoring system can inspect the cor-
rect relative positions among the weld pool, electrode,
wire, and groove using a CCD camera and filters. The weld
bead shape visualization system detects surface defects
and abnormal conditions using a three-dimensional (3D)
visual technique [14]. Each system notifies workers when
welding conditions are unsuitable to allow workers to
restore the suitable conditions.
NDT are generally conducted on the welded region after
welding to assure the weld quality. Thus, the results of the
NDT are only known after welding. This creates a delay
before repairs can be made. In particular, when defects
are found in the first pipe weld layer, much time and cost
Figure 2 – Schematic diagram of edge shape
are required to cut the welded region again to reform the
groove. This creates the need for a defect detection sys-
tem. During this research, an inner defect visualization
system was created using a laser-ultrasonic in-process
testing (LUT) technique and synthesis aperture focus
technique (SAFT) [15]. Defects detected by this system
can be promptly repaired because they are located in the
vicinity of the surface.
4 Welding conditions monitoring
system using electric signals
The welding condition electric signals are generally used
to provide indirect information regarding abnormal condi-
tions. The selected signals were welding current, weld-
ing voltage, welding speed, wire current, wire speed, and
wire feeding speed. In this system, these electric signals
were measured by voltage measurement apparatus etc.
and collected through a data logger. The data is analyzed
by software created as shown in Figure 3. The software
judges the deviation from the suitable range which was
given in advance and notifies the welders about the abnor-
mal condition. And in this experiment, pulse condition was
used for welding. This software divides the electric signals
into the pulse peak and base conditions, and detects the
unsuitable welding condition in each pulse condition.

Table 1 – Directly monitored object and measured item for each system
 DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE
Figure 3 – Software screen for the welding condition monitoring system
5 Monitoring system for weld pool
shape by using image processing
Proficient welders could prevent defects by adjusting
welding conditions in response to changes in the weld
pool, etc. Thus, there are many advantages to monitoring
the weld pool directly.
As shown in Figure 4, images of the weld pool were taken
using an IR-CCD camera, special ND filter, and 1064 nm
narrow band pass filter. An IR-CCD camera has a highly
sensitivity of near infrared region and a special ND filter
can partially change transmittance distribution to reduce
Figure 4 – Monitoring camera configuration
17
the transmittance of arc-light region. This method could
recognize the weld pool shape, electrode, wire, and edge
shape from the same image as shown in Figure 5. The
images were analyzed as vector images in a computer and
the position information can be obtained by calculation of
luminance difference. Figure 6 shows the measurement
items, which are length, width, and wetting angle of the
weld pool; electrode position; and wire position. The soft-
ware shown in Figure 7 uses this measurement information
by converting it to numerical values. For example, as shown
in Figure 8, an abnormal condition can be recognized by
the change of wetting angle and distance between wire tip
and torch tip. If the software detects an abnormal value, it
notifies the welders. Back bead monitoring was conducted
in the same way using prisms and mirrors.
Figure 5 – Weld pool monitoring image obtained
using a multiple filtering system
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 DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE

Figure 6 – Measurement items of weld pool monitoring

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Figure 7 – Software screen for the weld pool monitoring system

6 Weld bead shape monitoring

system using a 3d-visual technique
When the welded region quality is confirmed during pro-
cessing, it is important to monitor the bead appearance of
not only the last layer but also the interlayers. Laser sen-
sors were generally to measure the bead shape. However,
a CCD camera can detect not only bead surfaces defects,
such as porosity, undercut, and overlap, but also perform
a quantitative evaluation of the appearance, such as color
and texture. Therefore, a CCD camera is the most appro-
priate sensor for evaluating bead appearance. In particular,
 DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE

Figure 8 – Results of wetting angle and distance between wire tip and torch tip

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a) Monitoring of bead surface b) Monitoring of back bead surface

Figure 9 – Configuration of bead shape visualization system

Figure 10 – Camera image and 3-D measurement results for bead surface

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 DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE

a three dimensional shape can be measured using two of the bead shape right and left side camera images and
CCD cameras and stereo method. Figure 9 shows the the three dimensional image. Figure 11 shows an exam-
configuration the camera used to monitor the bead sur- ple three dimensional image of a normal bead surface
face and back bead surface. Figure 10 shows an example and porosities on the bead surface as defects. Figure 12

Figure 11 – Texture mapping and wire frame

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a) Curvature radius of bead surface

b) Curvature radius of back bead surface

Figure 12 – Bead shape measurement results
 DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE

shows the calculated results for the curvature radius of
the normal bead and back bead. The curvature radius of
the normal bead is a minus value. That means the bead
shape is concave and the wettability around the groove
face is in good condition. Similarly, the curvature radius of
the back bead is a plus value. That means the bead shape
is convex and the weld penetration of the first layer is in
good condition. Figure 7 shows the software screen. Thus,
this system could detect abnormal change and defects in
the bead surface and provide feedback to the welders.
detection laser were arranged in the same way of Time-
of-flight-diffraction (TOFD) method [16]. A Nd:YAG laser
(1064 nm) was used in this experiment. The laser fre-
quency is 60 Hz and the power is at least 400 mJ/pulse.
A few atomic layers of the metal surface became plasma
when a laser beam of a few nanosecond pulse width irra-
diates the subject, and a volume wave is produced from
the reaction force of this plasma. The wave transmits
through the welded region and is reflected and scattered
by the defects. These waves are received by a laser that
is irradiated on the opposite side over the groove. The
defects could be measured without contact under high

7 Inner defect visualization system

using laser-ultrasonic testing
Laser-ultrasonic testing was used as the method to
confirm inner defects during welding. Figure 13 shows
a schematic illustration of the concept. Generator and
temperature conditions. Since it is no-contact sensing,
however, this method does not have as high sensitiv-
ity as TOFD-UT. Therefore, SAFT was used to compen-
sate for the low sensitivity. A detection laser is scanned
perpendicular to the welding direction and receives the
ultrasonic wave at multiple points. Figure 14 shows the
monitor screen of the LUT results as an example. The
positions of defects are shown three-dimensionally using

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Figure 13 – Configuration of laser-ultrasonic testing

Figure 14 – Software screen showing the laser-ultrasonic testing results

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 DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE
depth direction, axis direction, and circumferential direc-
tion. In Figure 15, the length of ‘A’ shows the distance
between the groove and the defect. The length of ‘A’ was
changed in order to survey the detection range under
the groove. When the length of ‘A’ is smaller than 10 mm,
the S/N ratio is small and it is difficult to recognize the
defects due to the noise. Therefore, the detection range
of defects is 10 mm shorter than for the bead surface
in depth direction as shown in Figure 15 because there
is a groove above the bead surface and the pathway of
the ultrasonic wave is limited. Figure 16 shows that the
LUT could detect defects that are larger than at least
FBH Φ 1.6 by comparison with the TOFD-UT results after
welding. Therefore, it is possible to detect defects during
welding and the defects can be repaired promptly.
8 Application of monitoring systems
for thick walled pipe welding
The in-process quality control system was applied to
thick walled pipe welding to confirm the availability of this
system for practical purposes. The temperature of thick
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Figure 15 – The detection range of the laser-ultrasonic testing
walled pipe is over 473 K. Figure 17 shows the consti-
tution of this system. Weld pool shape is monitored by
using the coaxially-arranged IR-CCD camera with torch.
Bead appearance is visualized by using two CCD cam-
eras just after welding. Additionally, laser-ultrasonic test-
ing equipment is located as shown the left lower of Figure
17 a) to detect defects. The backing bead of root pass
is observed by CCD cameras from the center of pipe.
Table 2 shows the criteria to detect abnormal condition.
Figure 18 shows the screen which welders monitor dur-
ing welding. The screen is divided into four parts and bead
appearance, weld pool and welding condition by electric
signal could be monitored. The alarm is indicated on the
screen when the abnormal values are detected and fed
back to a welder.
The welded region is detected using LUT during weld-
ing and TOFD-UT after welding. It was confirmed that
the size of defects in Figure 19 were not over FBH Φ
1.6. This result shows that the monitoring systems could
control the welding condition not to produce defects, and
LUT system could ensure that there is no defect during
welding. Thus we concluded that our objectives for this
system of improving the quality and efficiency of the weld-
ing operation were realized.
 DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE

Figure 16 – Comparison of the results between laser-ultrasonic testing and TOFD UT

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a) Schematic illustration b) Configuration of system for thick walled pipe welding

Figure 17 – Configuration of system for thick walled pipe welding

Table 2 – Criteria for detecting abnormal conditions

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 DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE

Figure 18 – Monitoring screen

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Figure 19 – The results of laser-ultrasonic testing and TOFD UT

9 Conclusions
monitor the weld pool shape, visualize the weld bead
shape, and visualize inner defects, respectively.

The present study aimed to construct a welding monitor-
ing system for in-process quality control of thick walled
pipe welding, and improve the weld quality and efficiency
of the welding operation. The obtained results are sum-
marized below:
(1) The in-process quality control system for arc welding
of thick walled pipe has been systematized utilizing visual
sensors and computers. This system consisted of four
main subsystems that monitor the welding conditions,
(2) The welding condition monitoring system uses soft-
ware to analyze the electric signals of the welding condi-
tions. The software judged the deviation from the suitable
conditions and notifies the welders of abnormal conditions.
(3) The weld pool shape monitoring system takes images
of the weld pool using an IR-CCD camera and special ND
filters. This system could recognize the weld pool shape,
electrode, wire, and edge shape from the same image.
The software analyzes the image and indicates the correct
 DEVELOPMENT OF A WELDING MONITORING SYSTEM FOR IN-PROCESS QUALITY CONTROL OF THICK WALLED PIPE
positions as numerical values. If the software detects an
abnormal value, it notifies the welders.
(4) The weld bead shape visualization system visualizes
the bead appearance using two CCD cameras and a
three dimensional technique, and bead shape is evaluated
using the curvature radius value. This system could detect
the abnormal changes and defects in the bead surface
and provided feedback to the welders.
(5) The inner defect visualization system was created using
a laser-ultrasonic in-process testing (LUT) technique and
synthesis aperture focus technique (SAFT). The defects
could be measured without contact under high tempera-
ture conditions. The positions of defects are shown three-
dimensionally by depth direction, axis direction, and cir-
cumferential direction. The laser ultrasonic testing could
detect defects that are larger than FBH Φ 1.6 by compari-
son of the TOFD-UT results after welding. The detection
range of defects is 10mm lower than the bead surface in
the depth direction because of the existence of the groove.
(6) The in-process quality control system was applied to
thick walled pipe welding to verify the suitability of this
system for practical applications. The weld pool shape was
monitored using a coaxially arranged IR-CCD camera with
a torch. The bead appearance was visualized using two
CCD cameras just behind the welding bead. Additionally,
laser-ultrasonic testing equipment was located to detect
defects. The backing bead of the root pass was observed
by CCD cameras from the center of the pipe. It was con-
firmed that the size of defects is not over FBH Φ 1.6.
Thus, we concluded that this system improves the weld
quality and efficiency welding operations.
Acknowledgements
The authors appreciate Syozo Hirano, Tetsuro Aikawa,
Takahiro Miura, and Takeshi Hoshi of Toshiba Corporation
for their cooperation to constructing the welding monitor-
ing system for in-process quality control.
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About the authors
Dr. Yoshihiro Fujita (yoshihiro3.fujita@toshiba.co.jp), Mr. Tsuyoshi Ogawa
(tsuyoshi.ogawa@toshiba.co.jp), Mr. Satoru Asai (satoru.asai@toshiba.co.jp),
Mr. Setsu Yamamoto (setsu.yamamoto@toshiba.co.jp), Dr. Tatsuya Ohdake
(tatsuya.oodake@toshiba.co.jp), and Dr. Makoto Ochiai (mak.ochiai@toshiba.co.jp)
are with Toshiba Corporation, Power Systems Company, Yokohama, Japan.
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