The Xiris Blog

How to Reduce Quality Lab Time Associated with a Tube Mill

Posted by Cameron Serles on Wednesday, October 26, 2016 @ 10:04 AM

Lab time is a precious commodity.  As part of the changeover process on a tube mill, the tube to be produced must first be qualified to a desired level of quality in the lab. This line qualification process often includes cutting as many as three separate cross sections of a tube and sending them to the lab for processing where they get polished and photographed as micrographs. Once created, the micrographs can be measured or analyzed to verify that the weld structure of the tube meets the specifications required by the customer.  By using a weld inspection system that can accurately measure weld bead geometry and tube profiles, it may be possible to reduce the number of micrographs taken for each line qualification from a sample made for 100% of every change over to a lower, statistically relevant percentage.  The net result is that fewer line qualifications are required, leading to fewer tests (e.g., micrograph samples) performed in the lab, saving both lab time and lab personnel costs.

ROI 2 image.png

Image of a Sample Micrograph



Want to reduce your lab times?  Investigate how to justify an automatic weld inspection system using a ROI worksheet where you can enter your own mill data. 


   Download your FREE ROI Calculator Now!

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit or sign up to receive the Weld Video of the Month 

Topics: quality control, Xiris, welding, ROI, return on investment, productivity tools

Xiris Attends CanWeld 2016

Posted by Catherine Cline on Wednesday, October 12, 2016 @ 09:14 AM

Xiris had the pleasure of co-exhibiting with Maverick Testing and TIP TIG USA at the CanWeld Tradeshow and Conference, held at the Expo Centre in Edmonton Alberta, Oct. 5-6, 2016.   The conference was well attended and drew from a wide range of industry, including mining, oil and gas, pipelines, power generation, petrochemical, fabrication and construction, manufacturing, steel and shipbuilding and pulp and paper.  Educators were also out in full force including attendees from Red Deer College, Thompson River University, Southern Alberta Institute of Technology (SAIT) and Northern Alberta Institute of Technology (NAIT).   All were very enthusiastic about the Xiris weld videos on display at the booth citing the unbelievable image clarity Xiris is able to achieve with its high dynamic range weld cameras.Blog_Oct_12_Image_1.jpg

The Maverick and TipTig Booths at CanWeld with “TEX” Front and Centre.

Maverick Testing, with locations in La Porte, Texas and Corpus Christi, Texas, is a full spectrum, state-of-the-art testing laboratory providing a comprehensive range of metallurgical and mechanical testing services as well as Welding Procedure Specification development.  Maverick was exhibiting its welder test coupons which are used in house for its Welding Process Qualifications but are also available to be purchased and shipped to other facilities or jobsites.  Visit

TIP TIG offers a very unique hotwire GTAW welding process that uses patented wire feed technology to provide the highest quality, highest deposition rates with the lowest possible heat input values, while consistently delivering the greatest metallurgical results on all alloys.  The process has also been proven to provide the lowest possible hexavalent chrome weld fume emissions which have been measured as “undetectable”.  The TIP TIG technology can be used successfully on a number of alloys including; Carbon, Duplex and Super Duplex Stainless Steels, Inconel, Stellite, Titanium, Aluminum, Hastelloy and many others.  Visit for more information.

Xiris was also fortunate to be able to integrate our cameras into the orbital welding system at the Lincoln Electric booth.   The welders were extremely impressed by the camera system and found it far easier to weld looking at a clear picture on the computer screen versus the view through a weld helmet!


The Xiris XVC-1000 integrated into the Lincoln Orbital Welder.


Next, Xiris looks forward to Fabtech 2016 in Las Vegas, November 16-18 where both Lincoln and TIP TIG (as well as many others) will be welding with Xiris Cameras.  Check future blogs for details.  We look forward to seeing you there!


Join us at Fabtech Booth N6036Blog_Oct_12_Image_3.jpg

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit 

Topics: weld camera, Xiris, welding, High Dynamic Range, fabtech, Maverick Testing, CanWeld 2016, Tip Tig, Lincoln Electric

How to Reduce Set-Up Time on a Tube Mill

Posted by Cameron Serles on Tuesday, September 27, 2016 @ 02:30 AM


Every time a tube mill is changed over to run a new product, a set-up process must be performed to adjust the mill accordingly.  This process can be quite time consuming as a number of variables, input materials and equipment need to be adjusted to allow the mill to run the best quality product possible.  Reducing  the set-up process time and complexity is welcome news to all mill operators.  One approach is to add an automatic weld inspection system right after the weld box on the tube mill.  By adding such a system, immediate feedback of the weld geometry of the tube being produced can be provided to the mill operators as set-up adjustments are being made.  The result is a faster set-up process, less mill downtime and a more efficient tube mill.


Now, there's a powerful way to justify your productivity investment.  Use your own mill parameters to make an informed decision about buying a post weld inspection system.


  Download your FREE ROI Calculator Now!


For more information on how Xiris Weld Cameras can help monitor your weld processes, visit 

Topics: quality control, Xiris, welding, ROI, return on investment, productivity tools

Monitoring Welding Processes in Color

Posted by Justin Grahn on Tuesday, September 13, 2016 @ 12:52 PM

In most situations, a high dynamic range (HDR) image that provides a clear view of the weld arc and immediate work environment is enough to provide operators everything they need to control or adjust their welding process.  Typically, such images are provided in monochrome because, in certain circumstances, it provides better image saturation and fidelity. Monochrome images can accentuate the light and shadows of a welding scene, making the texture of the welding surfaces, torch tip, wire and melt pool easier to see.  Images with a wide range of tonal values, such as what might exist in a high dynamic range image of a welding scene, tend to work well in monochrome.  This is especially the case when the tones in the image range all the way from the blackest blacks of the background to the whitest whites of the welding arc, with lots of varying grey tones in between.

However, for some welding situations, color imaging that delivers high dynamic range imaging has particular value.  The presence of color allows the boundary of aspects of the weld process to be easily detected by the operator.  Bright hues that highlight an element, such as the melt pool, shielding gas or torch tip can improve the visibility of that object to the operator.


Color Image of a Manual TIG Process

Of all the types of welding, perhaps the most suitable for color imaging is GTAW (TIG).  Some of the features that are better seen with color in a TIG process include:

  • Melt Pool: Better edge definition and detection of flow of molten material.
  • Shielding Gas: Operators are able to see if there is any shielding gas present.  Also, each shielding gas mixture typically has its own signature certain color.  If the gas chemistry in the welding environment changes, then so does its color. 
  • Oxidation: Very easy to detect the presence of flames resulting from the burn-off of any oils or impurities.
  • Heat Affected Zone (HAZ): The leading edge of the heat affected zone can be detected in the parent material as it typically colorizes at elevated temperatures.  This can indicate the amount of heat penetration and energy transfer.
  • Temperature Indicator: Operators can clearly see discoloration of metal due to excess heat in the welding process.
  • Torch Tip: Easier to see the definition of the torch tip and cup relative to the weld arc.  Allows the operator to monitor the impurity build up on the torch tip and spatter presence on the cup.


Narrow Gap TIG Welding – Color Exposes Different Details


Ultimately, the choice of whether to use color or black and white camera technology depends on what feels right for the operator.  Nevertheless, for certain welding operations such as TIG, the use of color imaging can significantly enhance the clarity and detail of the image, thereby improving the operator’s ability to detect even small changes in the weld scene.

For more information on how Xiris Color Weld Cameras can help monitor your weld processes, visit 

Topics: quality control, Xiris, welding, High Dynamic Range, TIG, productivity tools, color imaging

Free ROI Calculator for Tube Weld Inspection Systems

Posted by Karen Serles on Tuesday, August 30, 2016 @ 02:30 AM

Two of the most important competitive advantages in tube production are the quality of the weld and the quality of the formed profile of the tube.  How can you improve your quality while also driving down costs and delivery times?



The Xiris WI2000 Weld Inspection System helps Tube fabricators improve quality and save costs by reducing:

  • Mill Set Up Time
  • Lab Time
  • Mill Downtime
  • Scrap
  • Customer Returns


Now, there's a powerful way to justify your productivity investment.  Use your own cold, hard figures to calculate Return on Investment (ROI). 


 Download your FREE ROI Calculator Now!

Make an informed decision about a XIRIS WI2000 Weld Inspection System purchase and see how you can achieve consistently higher quality while reducing costs and increasing customer satisfaction.

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit 

Topics: quality control, Xiris, welding, ROI, return on investment, productivity tools

Using Weld Cameras For Torch Alignment

Posted by Catherine Cline on Tuesday, August 16, 2016 @ 11:09 AM

When Xiris demonstrates its weld camera systems, one of the unexpected benefits an operator notices right away is the ability to quickly align the torch and seam.   Xiris weld cameras have integrated LED’s that provide a nice bright image of the seam and torch prior to starting the weld process.  Before we begin our demonstration, we ask the operator to align the torch and the seam which is usually done manually with a visual check.  Once we are told the system is aligned, we ask the operator to look at the computer screen and, 90% of the time, the torch and seam are misaligned.  The operator then begins to use the weld camera system right away to achieve perfect alignment on a consistent basis.

Here are three videos that demonstrate the alignment process.  In these examples the manufacturer has installed a positioning sensor on the robotic arm which is meant to ensure perfect torch alignment during each weld and the operator simply verifies the alignment prior to welding.

Operator Alignment:

The positioning sensor and the operator have misaligned the torch, resulting in a bad weld.



Weld Camera Assisted Alignment:

The operator has used the weld camera system to verify the alignment and you will see the adjustments that were made after the robot had been aligned.  Not only do the cameras ensure accuracy, the operator can perform the alignment quickly, right from the console rather than bending, stretching or climbing up on to the equipment to achieve proper alignment.












For more information on how Xiris Weld Cameras can ensure accurate alignment of your torch and weld seam, visit

Topics: quality control, weld camera, welding, High Dynamic Range, productivity, color weld camera, weld seam, weld seam alignment