Visualization of hump formation in high-speed gas metal arc welding

The hump bead is a typical weld defect observed in high-speed welding. Its occurrence limits the improvement of welding productivity. Visualization of hump formation during high-speed gas metal arc welding (GMAW) is helpful in the better understanding of the humping phenomena so that effective measures can be taken to suppress or decrease the tendency of hump formation and achieve higher productivity welding. In this study, an experimental system was developed to implement vision-based observation of the weld pool behavior during high-speed GMAW. Considering the weld pool characteristics in high-speed welding, a narrow band-pass and neutral density filter was equipped for the CCD camera, the suitable exposure time was selected and side view orientation of the CCD camera was employed. The events that took place at the rear portion of the weld pools were imaged during the welding processes with and without hump bead formation, respectively. It was found that the variation of the weld pool surface height and the solid–liquid interface at the pool trailing with time shows some useful information to judge whether the humping phenomenon occurs or not