The Xiris Blog

Xiris Seam Tracking for Laser Welding on Tube Mills

Posted by Greg Cooke on Tuesday, July 09, 2019 @ 01:00 PM

Laser welding offers several advantages over conventional TIG or Plasma welding processes especially for difficult to weld materials where lightweight, high strength and corrosion resistance is needed.

Advantages include:

  • High welding speed (up to 60 m / min), especially for thin walled material
  • Produces a small Heat Affected Zone (HAZ) with less joint distortion
  • Favourable fine grain structure of the weld bead with excellent material properties
  • Very clean welding process with minimal spatter, small weld beads and high precision
  • Well suited for welding exotic alloys of stainless steel, titanium and aluminum

Since laser welding is fast and generates a small melt pool, it requires precise positioning (typically within a few tenths of a mm) relative to the weld seam. Even small misalignments in the fit-up can lead to weld defects in the tube such as lack of sidewall fusion or porosity.  

The Xiris SeamMonitor™ for laser welding has been specifically developed for seam tracking of laser welded seams. The SeamMonitor™ software in combination with a Xiris High Dynamic Range (HDR) weld camera enables real-time monitoring of the melt pool size and shape, and the relative location of the weld seam to the laser keyhole spot using machine vision technology.   

Demo-A

Video of the User Interface of the SeamMonitorTM for a Laser Welding Process

The SeamMonitor™ system includes a Xiris open arc weld camera, industrial HMI controller, SeamMonitor™ software, optics and interfaces to integrate with other automation devices. It can be added to any laser welding process, either mounted off-axis to the laser beam, or on-axis through a suitable laser beam delivery camera port. Regardless as to how the camera is mounted, the SeamMonitor™ can help align the laser before welding, and monitor the laser welding process and track the seam during the welding process. All parameters and images can be recorded for process monitoring and quality assurance based on the set-up parameters and defined warning limits.

The SeamMonitor™ provides a powerful way to manually monitor the laser welding process while automatically measuring the laser keyhole-to-seam alignment and perform spot size. 

Contact Xiris sales to see how our products can enhance your unique process.

Topics: Laser welding, Tube and Pipe welding, tubedefects, tube mill, mill

Seam Monitoring for Coil Joining

Posted by Cornelius Sawatzky on Tuesday, September 04, 2018 @ 10:00 AM

Monitoring the welding process during coil joining at the front end of a tube mill is crucial to the integrity of the weld as it moves through the tube mill.  Coil joint failure can be costly in terms of both time and efficiency of production on the mill. Operator safety must also be maintained by removing them from the direct welding area as much as possible while enabling them to monitor the coil joining process.

Continuous welding processes used in coil joining require real time operator monitoring to ensure that the process continues smoothly and efficiently. The Xiris XVC-1100e50 camera provides a way to do just that.

A recent Xiris customer manufactures thick walled steel pipe in a continuous high frequency welding process at 70 feet (20 m) per minute.  The customer had implemented a semi-automatic coil end joining system on the infeed buffer of the pipe mill, giving the operator about 10 minutes to end sheer, mate and weld a new coil. This is sometimes referred to as end joining.

The welding process used a MIG welding torch mounted onto a linear track with dual axis torch position adjustment via a remote control pendant. With the Xiris XVC-1100e50 camera mounted to the traveling torch assembly, the operator was able to close the curtain, providing greater weld arc shielding while maintaining a clear view of the weld torch-to-seam alignment on a display screen.

The camera provided the operator with a clear, close up view of the weld process, which allowed the operator be remote from the direct welding area.  By providing a clearer image of the weld process, the operator was able to make more consistent welds, reducing the potential for a joint failure as the strip is driven through the pipe making process.

For a video of the coil joining process taken by the XVC-1100e50 camera, please view the video below. 

coil joining

This is just one example of how Xiris products can enhance your manufacturing process. Contact Xiris sales to see how our products can enhance your unique process.

 

Topics: Tube and Pipe welding, tubedefects, coil joining, tube mill, mill

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