The Xiris Blog

Xiris Automation: More Than Just an Innovative Product

Posted by Rachel Dalton on Wednesday, March 25, 2020 @ 10:38 AM

In the September issue (page 38) of Australian Welding, Weld Australia highlighted the progress Xiris has made in engineering high-dynamic-range (HDR) cameras that improve weld quality and efficiency.

We’re proud and gratified that Weld Australia recognized us. The organization has been a tireless proponent of the importance of welding, spreading the word that many industries wouldn’t be the same (or even exist) without welding.

All companies in those industries can benefit by using HDR cameras to monitor welding processes in real-time. Visual monitoring with eyes simply can’t match the clarity and certainty of a video record of the welding as it’s happening.

Enviro Blog XVC

Australian Welding explains: “It is an enabling technology used across a wide range of industries and applications, from micro-joining of medical devices, electronics, and photonics to larger-scale applications such as mining equipment, pressure vessels, ships, rail transport, water pipelines, and components.

 “Recent advances in advanced CMOS image-sensor design and supporting electronics allow best­in-class cameras to provide high-contrast images without  saturation of the brightest portion of the image, exposing the details of the electrode, melt pool, seam, and surroundings.”

The article also details how remote camera monitoring benefits employees’ health and safety. Using weld cameras helps operators ergonomically because they’re not continually contouring their bodies to see the weld. They are also safer because they don’t have to be near the flame.

Another plus:  videos of in-process welding can be highly useful in training and continuous improvement.  It’s a technology that will attract and retain welding apprentices.

You can read the full article here.


Topics: quality control, weld camera, weld inspection

Monitoring the Melt Pool from the Backside in Root Pass TIG Welding

Posted by David Giannotti on Wednesday, February 26, 2020 @ 10:00 AM

Highly precise welding procedures commonly found in power generation applications where thick walled sections of pipe are welded together using multi-pass TIG welding procedures have demanding quality monitoring requirements. One of the most important monitoring tasks is to monitor the quality of the melt pool from the back side of the weld. In the case of orbital welding two sections of pipe together, this is often done by using a Xiris weld camera mounted inside the pipe looking at the backside of the root pass of an orbital welding head operating from the outside of the pipe.

If a Xiris weld camera is mounted inside the pipe looking at the melt pool, what is visible is a high intensity spot surrounded by an area of lower intensity (see Figure 1 below).  Precision fabricators are often interested in the shape, size and location of the precise boundary of the melt pool relative to the weld seam. Segmentation of the edge of the melt pool is therefore an important first step to measure the shape of the melt pool.

Xiris was given this task to first detect the edges of the melt pool, then measure the size, various shape parameters, and the center of the object relative to the weld seam.




Fig. 1:  Original Image of Melt Pool


Fig. 2 Segmented Region of Interest

Once the Melt Pool can be correctly segmented from the rest of the image, the Xiris Blob Analysis tool can be used to compute various measurements of the region of interest, such as; centroid, area, perimeter, bounding box, and roundness, that together, provide information such as; to how well the melt pool is forming, if the welding torch is burning through, if the weld torch is tracking the seam properly and other process features.

Image processing tools, like Blob Analysis, can be used to find valuable shape, size and location information of key features of the welding process. When combined with a Xiris weld camera, real time analysis can be achieved.

Better Images. Better Decisions. Better Process Control.

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Topics: weld camera, fabricators, TIG welding

Three Benefits of Adding Audio to your Weld Camera

Posted by David Giannotti on Tuesday, January 07, 2020 @ 11:55 AM

Experienced, professional welders agree that sound is often just as valuable in monitoring welding as being able to see what is going on in the welding process. Issues with wire feed speed, voltage, shielding gas, current and other parameter inputs can all be heard, sometimes more than they can be seen. Giving operators another tool to improve their welding operations and the quality of their products is why Xiris has added audio capture to its industry-leading weld cameras.

Today, we’re sharing 3 ways audio can help your welding process.

1. Multisensory monitoring improves quality. There are many ways to monitor welding operations, such as current, voltage, visual inspection, machine vision sensing, thermal imaging and more. Each method has its own advantages as well as shortcomings. Using multiple monitoring techniques can minimize, or even eliminate these shortcomings.

Audio is another tool to add to your toolbox. Acoustic monitoring may help to overcome some of the challenges of monitoring “dynamic welding characteristics, especially near the arc due to the high temperature, spatter formation, fumes, etc.” 1

2. Audio recording and playback improves real-time monitoring. In order to monitor and immediately control your welding process, you need to know exactly what is happening as it happens. Audio recording and playback allows operators to hear changes as they happen and make the necessary adjustments immediately.

Many factors can affect the generation of welding sounds, such as the volume of the burning arc, the shielding gas flowrate, vibration of the droplet transfer into the welded pool and the noise of the welding apparatus.

3. Audio monitoring can help reduce downtime. Off-line inspections are time-consuming and costly. Finding and correcting welding defects after the welding process is even more costly. Adding audio monitoring to your welding process allows operators to catch mistakes immediately and correct the problem, before wasting time or materials.

Xiris’ weld cameras, equipped with high dynamic range imaging and now equipped with audio monitoring, can help operators be confident in the quality of their welds and decrease the time spent on post-weld inspection and rework.


For over 10 years, Xiris has focused on helping our customers to detect, identify, address and prevent defects in their welding processes.  We know that better images lead to better decisions and better process control. Now, customers can combine those images with audio to further improve their decision-making process.


1 Lv N., Chen S. (2011) Investigation on Acoustic Signals for On-line Monitoring of Welding. In: Tarn TJ., Chen SB., Fang G. (eds) Robotic Welding, Intelligence and Automation. Lecture Notes in Electrical Engineering, vol 88. Springer, Berlin, Heidelberg

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Topics: quality control, weld camera, weld monitoring, audio

What Does Welding Sound Like? SMAW

Posted by Cameron Serles on Tuesday, December 03, 2019 @ 01:00 PM

“Most welding shop foremen who interview welders give them a weld test and know from halfway across the shop by the sound of the weld if that welder will pass the test.”1 This quote from highlights how important sound is in welding. This is why our team at Xiris has added audio monitoring to our popular weld cameras.
SMAW- Audio in Welding

Since launching our audio package, we have been diving into audio monitoring in more detail, talking about how monitoring audio can benefit operators and what to listen for in GMAW and GTAW. Today, we’re looking—and listening—in more detail to SMAW, or stick welding.

Like GMAW, SMAW should sound like cooking bacon.2 If the arc sounds overly loud, your amperage might be set too high.3

To set up your welder, strike an arc and listen to the crackle of the rod. Adjust the power setting (amperage) until you hear the sound of bacon or eggs frying.2

It may take years for welders to amass the experience necessary to recognize what quality welds sound like. As you are welding, it is important to pay attention to the sound of your stick welds. Soon, you will be able to determine if you have a quality weld.

This video shows SMAW in action and shares what it sounds like in a variety of situations:



Better Images. Better Decisions. Better Process Control.

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Topics: quality control, weld camera, welding, weld monitoring, audio, SMAW

Using Pseudo Color to Highlight Features in Welding

Posted by Cameron Serles on Tuesday, November 12, 2019 @ 11:45 AM

Weld cameras can produce color and monochrome images. Often monochrome images are selected as they provide the best resolution for a wide variety of applications. The monochrome images generated by the camera are often further processed to make the informational detail of the weld process more useful and interesting to the observer.

Usually, a tone mapping process is applied to the weld camera images to provide an enhanced image with maximum contrast for the user, such as what is done with images from the Xiris XVC-1000 weld camera. However, sometimes an additional technique called pseudo coloring can be done on the tone mapped image to provide additional visibility of key features to the user.


Pseudo coloring is when each grey level (or intensity value) in a monochrome image is assigned a color. The resulting image can make the identification of certain features easier for the observer, as the perceived difference in color space for the operator is bigger than between successive grey levels alone. Details such as the leading edge of a melt pool, the boundary between a torch and weld arc, the interface between the weld arc and the melt pool, or the texture of the melt pool can all be made more visible to the operator using pseudo coloring.

Monochrome Image from a TIG Weld

TIG Weld with Pseudo Coloring
Monochrome Image from a TIG Weld Same Image, with Pseudo Coloring


Why bother with pseudo coloring? You might think that your images look just fine in black and white, right? And they probably do. However, in some welding applications, adding color to an image can make it much easier to distinguish between different objects especially when they are almost the same level of intensity such as in the images above. Try it in WeldStudio™, Xiris’ software utility for weld cameras, to see if it helps.



Better Images. Better Decisions. Better Process Control.

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Topics: quality control, weld camera, High Dynamic Range, HDR, pseudo color

What Does Welding Sound Like? GTAW

Posted by Cameron Serles on Tuesday, October 29, 2019 @ 11:30 AM

To accompany the launch of Xiris’ new audio monitoring technology, we are continuing our series about sound in welding. So far, we have covered the announcement of our audio monitoring equipment, benefits of adding audio to your weld camera, and sound in GMAW

Today we are investigating sound in GTAW, or TIG welding.
GTAWGTAW is typically characterized by a high-pitched hum or buzz.1

The polarity of the electrical current—whether it’s AC or DC—affects sound in TIG. AC TIG is much louder than DC. As amperage increases, welding noise will also increase.2

At lower frequencies, you will hear a slow pulse sound as you weld. One operator described it as “Braaap, Braaap, Braaap.” As the power frequency increases, such as to 80-90 hz, the sound becomes “sharper:” “BRAP, BRAP.” With the frequency between 100-120 hz, the “brap” sound becomes a whine. At this point, the arc is moving much more quickly, going from positive to negative hundreds of times a second.2

As in GMAW, sound in GTAW can alert operators to mistakes or faults in their welding.

For example, a torch-to-workpiece angle greater than 20-25 degrees may cause a popping sound as well as poor weld quality.3 A high pitched buzzing sound can signify lower penetration of the heat into the parent material.4

An important consideration in monitoring sound in welding is the environment that you’re working in. Each shop or factory has its own unique acoustics. Some frequencies may echo and welding machines can seem very loud or sound different depending on where they’re located.

For this reason, it is important to spend time assessing your welds, monitoring your equipment and learning what a good weld sounds like in your facility.

Watch a video of welding aluminum with GTAW, and how the frequency settings change the sound:


Better Images. Better Decisions. Better Process Control.

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Topics: quality control, weld camera, welding, GTAW, weld monitoring, audio

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