Microstructural and spectrophotometric analysis system for metal welding processes

We describe an analysis system for some of the most important methods of metal welding, based on the acquisition, study and comparison of the atomic emission spectra (in the range from 250 nm to 830 nm), hyperspectral imaging between 600 nm and 950 nm wavelengths and microstructural analysis. The radiometric measurement system acquires information while the welding process is in progress and acquired data are then compared with those resulting from the subsequent microstructural analysis. It is known that the process parameters like, for example, the source power or its speed over the parts during welding, significantly affect the mechanical properties and quality of the resulting junction like hardness, porosity, presence of cracks or other damages and so on. On the other hand, these properties and, above all, the changes in the joint features due to unwanted variations in the process parameters or in the materials being welded, can be inferred by studying the microstructure. In this sense, a proper correlation between the in situ spectral analysis and the microstructural properties is of paramount importance for controlling and adjusting the parameters during the process. In line with the requirements of Industry 4.0, the system described is a study of the application of metrology in a production line, designed to increase information about the production parameters of mechanical industry without increasing costs and limiting the complexity of additional installations. In this paper we report a series of experiments performed using LASER and TIG welding systems applied to different metals. The comparison between the welding conditions acquired by the optical systems and the methods of structural analysis are the basis of a project to improve production systems and their automation.