Machine Vision‑Based Spatter Monitoring Method and Spatter Characterization for High Power Laser Welding Process

Wang Cai; Ping Jiang; Leshi Shu; Shaoning Geng; Qi Zhou; Longchao Cao

doi:10.3788/CJL230864

Chinese Journal of Lasers, Volume. 50, Issue 24, 2402106(2023)

Machine Vision‑Based Spatter Monitoring Method and Spatter Characterization for High Power Laser Welding Process

Wang Cai¹, Ping Jiang^2,3, Leshi Shu^2,3, Shaoning Geng^2,3, Qi Zhou⁴, and Longchao Cao^1、*

¹Hubei Key Laboratory of Digital Textile Equipment, School of Mechanical Engineering and Automation, Wuhan Textile University, Wuhan 430073, Hubei , China

²School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, Hubei , China

³State Key Laboratory of Intelligent Manufacturing Equipment and Technology, Wuhan 430074, Hubei , China

⁴School of Aerospace Engineering, Huazhong University of Science and Technology, Wuhan 430074, Hubei , China

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Figures & Tables(18)

Fig. 1. Spatter monitoring platform and equipment for high-power laser welding

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Fig. 2. Schematic of variable power laser welding

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Fig. 3. Monitoring images in high-power laser welding process under different moments

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Fig. 4. Schematics of spatter extraction process

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Fig. 5. Analysis of metal vapor interference distributions in continuous spatter extraction images

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Fig. 6. Schematics of residual metal vapor interference removal process

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Fig. 7. Position of target spatter in different monitoring images

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Fig. 8. Reconstruction method of spatter motion trajectory

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Fig. 9. Spatter size reduction method

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Fig. 10. Spatter motion trajectory reconstruction image and spatter count acquisition image

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Fig. 11. Position changes of target spatters in continuous spatter extraction images

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Fig. 12. Numbers of spatters in sampling intervals under different laser powers

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Fig. 13. Reconstructed images of spatter trajectories and scanned image of weld plate. (a) Reconstructed images; (b) scanned image

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Table 1. Size of each spatter in spatter recognition image
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Table 1. Size of each spatter in spatter recognition image
Spatter No. 1 2 3 4 5 6 7 8
Size /pixel² 1201 439 108 83 446 452 65 16
Spatter No. 9 10 11 12 13 14 15 16
Size /pixel² 296 268 263 987 260 23 380 238

Table 2. Characteristics of target spatter
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Table 2. Characteristics of target spatter
Image No. No.12467 No.12776
Size /pixel² 633 742
Center coordinate （360.6 pixel，347.39 pixel）（453.76 pixel，180.18 pixel）

Table 3. Sizes and velocity features of target spatters in continuous spatter extraction images

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Table 3. Sizes and velocity features of target spatters in continuous spatter extraction images

Image No.	2584	2634	2684	2734	2784	2834	2884	2934	2984	3034	3084
Size /pixel²	754	797	841	834	839	821	841	945	926	980	764
$Δ v_{x}$ /（pixel/ms）	‒	5.93	5.35	5.44	5.05	5.64	4.98	5.69	5.36	5.30	5.46
$Δ v_{y}$ /（pixel/ms）	‒	-4.40	-3.91	-2.58	-2.25	-1.74	-0.78	-0.18	0.99	1.46	2.02

Table 4. Sizes and velocity features of No.2 spatter in continuous spatter extraction images

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Table 4. Sizes and velocity features of No.2 spatter in continuous spatter extraction images

Image No.	2484	2534	2584	2634	2684	2734	2784	2834	2884
Size /pixel²	659	706	762	850	922	905	887	1076	861
$Δ v_{x}$ /（pixel/ms）	‒	-2.45	-2.48	-2.41	-2.39	-2.29	-2.51	-2.47	-2.42
$Δ v_{y}$ /（pixel/ms）	‒	1.87	2.31	3.41	4.25	5.15	6.04	6.95	7.64

Table 5. Sizes and velocity features of No.3 spatter in continuous spatter extraction images

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Table 5. Sizes and velocity features of No.3 spatter in continuous spatter extraction images

Image No.	2684	2784	2834	2884	2934	2984	3034	3084	3134	3184
Size /pixel²	329	325	317	310	264	240	305	330	345	349
$Δ v_{x}$ /（pixel/ms）	‒	3.92	3.91	4.20	3.83	3.98	4.13	3.73	3.93	3.87
$Δ v_{y}$ /（pixel/ms）	‒	-7.47	-6.55	-5.67	-5.08	-4.27	-3.62	-2.74	-2.13	-1.38

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Wang Cai, Ping Jiang, Leshi Shu, Shaoning Geng, Qi Zhou, Longchao Cao. Machine Vision‑Based Spatter Monitoring Method and Spatter Characterization for High Power Laser Welding Process[J]. Chinese Journal of Lasers, 2023, 50(24): 2402106

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Paper Information

Category: Laser Forming Manufacturing

Received: May. 26, 2023

Accepted: Jul. 24, 2023

Published Online: Nov. 27, 2023

The Author Email: Cao Longchao (longchao2017@gmail.com)

DOI:10.3788/CJL230864

Topics

laser devices and laser physics

Lasers and Laser Optics

Laser physics

laser manufacturing

Instrumentation, Measurement and Metrology

Table 1. Size of each spatter in spatter recognition image

Table 1. Size of each spatter in spatter recognition image

Table 2. Characteristics of target spatter

Table 2. Characteristics of target spatter

Table 3. Sizes and velocity features of target spatters in continuous spatter extraction images

Table 3. Sizes and velocity features of target spatters in continuous spatter extraction images

Table 4. Sizes and velocity features of No.2 spatter in continuous spatter extraction images

Table 4. Sizes and velocity features of No.2 spatter in continuous spatter extraction images

Table 5. Sizes and velocity features of No.3 spatter in continuous spatter extraction images

Table 5. Sizes and velocity features of No.3 spatter in continuous spatter extraction images