The Xiris Blog

DED Additive Manufacturing: 5 Things You Can Monitor With A Weld Camera

Posted by Cameron Serles on Thursday, July 05, 2018 @ 12:00 PM

Of greatest interest to most users of Additive Manufacturing using Direct Energy Depostion (DED) processes is the ability to constantly monitor the deposition process and to stop the process if the deposition goes awry. DED power sources generate a lot of light which is difficult to properly image using a traditional camera.  By using a Xiris Weld Camera placed around the DED head to monitor the DED process, an operator can stop the deposition process and repair the defective region then resume the deposition without adding additional material on top of the defective area. 

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 A detailed image of the Additive Manufacturing process, captured by a Xiris Weld Camera.

With a Xiris Weld Camera, the bright light arc from the DED power source can be clearly seen as well as the detail of its immediate surrounding environment.  Here are 5 areas where the operator is able to see more details of the additive process with such a camera:

  1. Amount of shielding gas being used (Plasma or TIG)

With a clear view of the arc used to melt the fed powder or wire, operators can monitor how much shielding gas is being used and whether adjustments are needed

  1. Alignment of weld torch to previous layer

With a clear view of the previous pass of material, the operator can make sure that the DED head is tracking the layer properly.

  1. Keyhole spot size, location and shape (Laser)

All features of the molten material being deposited can be better monitored with a clearer view of the weld environment.

  1. The powder or wire being deposited,

With a clear view of the arc used to melt the fed powder or wire, operators can monitor how much shielding gas is being used and whether adjustments are needed

  1. The quality of the resulting melt pool and formed final bead.

Looking for dross, good quality melting and proper wetting in the melt pool and proper final bead shape one the bead has cooled is possible with a weld camera as the operator can see enough detail for these features to be visible.

 

Summary

By adding a Xiris weld camera to a DED process, operators can ensure that their parts quality is optimized during production and expensive rework is avoided.

 

Topics: color weld camera, additive manufacturing, weld camera system

Tracking Tube Production Using the WI2000 and WI3000 systems

Posted by Cornelius Sawatzky on Thursday, June 21, 2018 @ 09:00 AM

Xiris' WeldInspection System Helps Identify the Root Cause of Variations in Tube Production

Many applications require tube producers to identify and document their tubes by batch, date and sometimes even time stamp for trace-ability. If a tube segment fails at a sub process or worse at the end user, a detailed analysis and root cause investigation follows.

 

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Audit Log Files from Xiris' WeldInspection System

When the original tube production date and time information is available, a helpful tool to identify anomalies is to review the audit log files generated on Xiris’ WeldInspection system.The audit log files are date and time stamped and easily accessible to look for any weld related geometries that may have deviated for a time period during the production run.

Variations may be a change in bead shape/size that can be an indicator of squeeze pressure or weld heat change. With the WeldInspection system monitoring multiple geometrical conditions such as mismatch, bead height, width and potential freeze line, much information can be gained by reviewing the log files and identifying a potential root cause. Additionally if a particular condition has been identified as the potential cause, the audit logs can be utilized to determine for how long that condition existed therefore helping reduce the volume of product that might be quarantined for further evaluation.

 

If you are interested in learning more about how our WeldInspection system can benefit you and your company, please contact us here.

 

Topics: Tube and Pipe welding, pipe, tube, defects, WI-2000p, tubedefects

Xiris at the 2018 Beijing Essen Welding and Cutting Show

Posted by Dean Zhao on Thursday, June 07, 2018 @ 12:00 PM

Discovering New Opportunities Alongside our Chinese Distributors

The Beijing Essen Welding & Cutting Fair is among the leading welding exhibitions, attracting many professionals in different sectors of the welding industry. It was an excellent opportunity for us to work alongside our Chinese distributors Harbin Jinlifeng Science and Technology Development Co. Ltd and Belwin Intelligent Technology Co. They continue to help us expand our presence in the area, and have our products applied in new ways.

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Representatives from Harbin Jinlifeng Science and Technology Development Co. and Belwin Intelligent Technology Co. with Xiris President Cameron Serles

Our cameras were on display for visitors, along with footage from our XVC product line. If you wish to have our cameras on display at your booth to highlight your products and equipment in live demonstrations, or are interested in learning more about our company and products, please contact us here.

Topics: Trade Show, weld camera system, Beijing Essen 2018

Weld Safety: Before and After

Posted by Margaret Montgomery on Friday, May 18, 2018 @ 01:37 PM

According to the Bureau of Labor Statistics, welders and cutters "have one of the highest rates of injuries of all occupations." [1] 

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Before installing a weld camera, welders are often perched at unsafe heights, giving them a poor view of their welding activities. 

Welders Work in Precarious Positions

Many welding activities are done at unsafe heights, while the welder attempts to monitor and control the welding process. The moving machinery around them forces them to work in small, constrained working areas- which is often dangerous and uncomfortable for the operator. In these conditions- behind a helmet and perched above the welding process- welders miss important details in the welding arc, which can lead to mistakes and inaccuracies that are costly and timely to fix. Not only are these conditions a safety risk, but they make it harder for welders to ensure that they execute a high quality weld.

Weld Cameras Give Welders an Eye Into Detail

Xiris Automation weld cameras enable workers to perform a weld without leaving the ground. Our solutions give welders a consistent image quality regardless of the angle of the weld. They can view multiple images of the weld from leading, trailing or side views of the weld process. 

 

Don't pay for accidents, prevent them using machine vision technology. 

 

If you are interested in learning more about our company and products, please contact us here.

 

[1]“Welders, Cutters, Solderers, and Brazers.” U.S. Bureau of Labor Statistics, U.S. Bureau of Labor Statistics, 13 Apr. 2018, www.bls.gov/ooh/production/welders-cutters-solderers-and-brazers.htm#tab-3.

Topics: weld camera, weld safety, arc welding, mig welding, weld camera system

April 2018: Looking Back

Posted by Margaret Montgomery on Friday, May 04, 2018 @ 04:24 PM

April was an extremely successful month for Xiris Automation! Read below for a recap of the month's events. 

Tube Dusseldorf 2018

Xiris exhibited at Tube Dusseldorf 2018 in Dusseldorf, Germany, from April 16-20. This was an important opportunity for those in the tube and tube processing industry to witness new technology and innovation in the field. We were thrilled to be an exhibitor at such a pre-eminent event! 

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Our team demonstrated how our innovative quality control solutions add value to tube and pipe welding activities, especially for detecting problems sooner in the tube manufacturing process using our WI2000 inspection system.Overall, it was an extremely successful event for Xiris and an excellent opportunity to engage with leaders in the tube processing and fabrication industries.

 

 

Rapid + TCT

Xiris exhibited at the Rapid + TCT conference in Forth Worth, Texas, USA from April 24-26. Rapid is a significant event for innovation in the additive manufacturing industry, and attracted leaders in 3D Manufacturing from around the world. 

rapid booth

Through demonstrations and interactions with these companies, the Xiris team showed how our HDR weld cameras can decrease building times, reduce operating and engineering costs, and lower materials costs in research and development for Metal Additive Manufacturing. When our High Dynamic Range (HDR) weld cameras are added into an Additive Manufacturing machine, operators can monitor every step of the welding process in real time to ensure quality outputs, detecting any material placement issues such as warping without having to stop the machine.

Japan International Welding Show

Xiris attended the 2018 Japan International Welding Show in Tokyo from April 25- 28, displaying our cameras in the Matsumoto Group booth. This was Japan's largest exhibition of welding technology, and was thus an extremely significant opportunity for Xiris. 

Our extremely durable, industrialized weld camera was on display at the show, as seen below. 

Japan Welding show

 

If you are interested in learning about or displaying one of our cameras, please contact us here.

 

 

Topics: Tube and Pipe welding, weld, Tube Dusseldorf, conference, weld monitoring, XVC Weld Camera, color weld camera

Rugged Cameras for Tough Weld Environments

Posted by Dean Zhao on Tuesday, April 24, 2018 @ 11:16 AM

Tandem MIG Welding - Environmental Concerns?  Not everyone was as confident as we were that our XVC-1000e weld cameras would last in this welding environment.

But they did. 

In fact, installed over three years ago, two Xiris XVC-1000e weld cameras were installed in a tandem MIG welding operation.  Over the past two years, they have been operating 24 hours per day, 7 days per week in some of the harshest MIG welding conditions amidst extensive smoke, fumes and weld spatter.

We are happy to say that the cameras are still going strong!

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The cameras as they were when they were first installed

 

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The cameras after one month

 

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The cameras 2 years later – still running, still going strong!

 

The Xiris XVC-1000e cameras are equipped with a rugged industrial housing that allows the camera to be protected from ambient dirt, smoke and fumes.  Equipped with optics with motorized focus, integrated LED lighting, replaceable spatter window and cooling chamber, the Xiris cameras can withstand some of the most rugged welding environments!

Topics: weld camera

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