The Xiris Blog

What Does Welding Sound Like? GMAW

Posted by Cameron Serles on Wednesday, October 02, 2019 @ 01:00 PM

Each type of welding has a unique sound. Sometimes that sound can signify problems. Other times it tells the operator that everything is going exactly right. Xiris has now added audio monitoring to our industry-leading weld cameras. This innovative system gives welders a new tool to monitor and improve their operations.

However, it often takes years of experience to be able to distinguish the slight differences in sound that separate a good weld from a bad one. And if you’re new to welding or you’ve not been monitoring by sound before, how do you know what to listen for?
GMAW

Today, we’re looking at GMAW, or MIG welding, and sharing the various sounds you may hear and what they mean.

  1. Frying Bacon: This is the most common description for what GMAW sounds like. The torch will sizzle, with the occasional pop. This usually means that your welder is set up properly and you are laying a quality bead.
  2. Popcorn Popping: If your welding sounds more like popcorn than bacon, with lots of snapping and popping, this may signify that your wire speed is too fast. “The wire is hitting the surface and not melting into the metal fully, creating a weak and dangerous weld.”1
  3. Hissing, as though gas is leaking: Often means too slow of a wire speed. This is also a weak, unsafe weld.1
  4. -  Popping and Hissing: This usually signifies a problem with the shielding gas. You will also see excessive sparks and slag, and pores in the finished weld. Check that the gas is on, there is gas in the tank and the tank pressure is correct.1
  5. Irregular: Another issue that can be identified by sound is wire stickout. If your stickout is too long, the arc may sound irregular – constantly changing in pitch and/or volume.2

The voltage and current setting on your welder, as well as the metal that you are welding, all affect the sound of the arc in GMAW.3 For example, stainless steel welding uses three different approaches: dip transfer, globular transfer or spray arc. Each of these techniques has a different sound, as the arc moves from low power to high through the metal transfer cycle.4

In dip transfer (low amperage welding, which is ideal for thinner materials), you hear a fast crackling—the coveted bacon sound. Globular transfer, which is not often used, makes an uneven, splattering sound, with occasional hisses. Spray transfer has a consistent hissing sound as the hot metal transfers to the parent material in a steady stream.

It is important to learn your equipment, understand your materials and experiment with different settings. Monitor the sound and appearance of the arc and critically evaluate the quality of your welds. Soon you will know what to listen for.

Watch a video that shows how varying the wire feed speed and voltage changes the sound of MIG welding: https://www.youtube.com/watch?v=kmcO0lFfn1k.

 

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos!

Instagram LinkedIn FacebookTwitter

 

Sources: 

1https://garage.eastwood.com/eastwood-chatter/listen-to-your-mig/

2https://www.millerwelds.com/resources/article-library/mig-welding-the-basics-for-mild-steel

3https://forum.millerwelds.com/forum/welding-discussions/4179-mig-welding-sound

4https://www.theshedmag.co.nz/home/2018/7/8/tackling-stainless-a-guide-to-stainless-steel-welding

 

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

How to Make Welding More Environmentally Friendly

Posted by Robin Montgomery on Wednesday, September 18, 2019 @ 02:05 PM

In today’s world, environmental issues are becoming more and more important in all aspect of business. Currently, “humanity uses the equivalent of 1.7 Earths to provide the resources we use and absorb our waste”1. So, we want to share how you can do your part by making your welding processes more environmentally friendly through scrap and waste reduction.

 

Implementing camera systems for inspection and monitoring can help you reduce waste in your welding processes. Camera systems give you instantaneous feedback, allowing operators to immediately adjust their process before defects or scrap is created. Our customers are often our best cheerleaders: Brian Dobben, from Flowserve, credits Xiris’ dual-camera weld monitoring system with roughly an 80-95% reduction in weld defects long-term. The monitoring feedback helps reduce the scrap from welding processes that are not in control, helping operators to weld with better precision, making better, stronger welds. The end result? Final products that last longer, with less frequent replacements in the field, contributing to less waste. 


Enviro Blog XVC

Enviro Blog - Tennaco WI
Weld Camera System Weld Inspection System

 

Other examples exist, such as use of cameras in the classroom. By using weld cameras at schools, weld instructors can drastically reduce the weld coupons, energy and consumable materials they use by recording some of their welding lessons using a weld camera. By recording some welding lessons, the instructor doesn’t have to waste energy and materials by continuously repeating their demonstrations.

 

Cameras for monitoring and inspection can be used in a variety of different welding applications to help operators improve their quality and therefore reduce their scrap. Every step counts towards helping the environment, so take that first step by implementing a camera system with that automated welding process.

 

 

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos!

Instagram LinkedIn FacebookTwitter

 

Source: 

1https://www.footprintnetwork.org/our-work/ecological-footprint/

Topics: quality control, weld camera, weld inspection, High Dynamic Range, HDR, sustainable, environmentally friendly

How to Implement Audio Monitoring for your Welding Operation

Posted by Cameron Serles on Tuesday, September 03, 2019 @ 11:32 AM

Our team at Xiris has released an audio monitoring package for our weld cameras. Today, we’re sharing how you can set up audio monitoring capability with weld cameras for your operations.

Audio monitoring with weld cameras involves both hardware—the microphone and other equipment—and software—Xiris’ WeldStudio™ software.           

Audio Monitoring Hardware

Audio monitoring starts with the microphone. The welding environment is not very friendly for electronics and sensitive equipment, so Xiris has developed a rugged microphone capable of capturing the full spectrum of audio using a specialized sensor. This sensor captures sound frequency from 40hz up to 20khz. This means that you not only get the low rumbles at the bottom of the range, but you also get the sizzle and pop at the high end.

The microphone has been “ruggedized” so that it is suitable for the welding environment. A protective covering provides thermal, environmental and dust protection for the sensitive microphone elements. The microphone is also directional, meaning once it is pointed at the welding process, it will ignore some of the surrounding noises.

The microphone has been designed to be located near the welding camera, although it can be positioned elsewhere if needed.

Cables and wires connect the microphone and transmit the audio signals to the Xiris HMI computer, which contains Xiris’ specially developed audio processing card. It is here that the signal is processed and conditioned for integration with the video images.

Audio Monitoring Software

The audio feature is part of Xiris’ WeldStudio™ software utility, where operators are able to play back, record and adjust the audio that they’re hearing. The audio signal is synchronized with the video stream from the weld camera, so operators can see and hear what’s happening with their welding at the same time.

Audio 2 image

User Interface of WeldStudio™ with audio feature.

Using equalization controls, operators are able to reduce or eliminate certain frequencies, such as those caused by other mechanical noises or environmental noises unrelated to the welding. The software allows operators to completely control the equalization curve to meet their specific needs, suppressing or enhancing certain frequency ranges depending on what they want to listen to. Audio is a module in the WeldStudio™ software, so the touch and feel of the interface and the tools within the program will feel familiar to experienced users.

Summary

Video monitoring using weld cameras has brought many benefits to fabricators and their operations. However, there was something missing. Sound.

Experienced welders understand how sound can help to tune and monitor their welding processes. With this new audio monitoring package, Xiris is providing this capability as an option with the Xiris weld camera system.

 

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos!

Instagram LinkedIn FacebookTwitter

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

Video Learning Guides for WeldStudio™

Posted by Brian Wirth on Wednesday, August 07, 2019 @ 11:47 AM

Even the best users sometimes find it difficult to read through an operating manual for a software product. Recognizing this, Xiris Automation has created a series of easy-to-use training videos to help users set up and use the WeldStudio™ software utility provided by Xiris. There are currently 15 short videos available, with more being constantly created as new features are added to the WeldStudio™ software. The current video guides include the following topics:

  • WeldStudioTM Features Overview
  • WeldStudioTM Installation
  • Camera Tools (multiple videos)
  • Image Tools (multiple videos)
  • Media Tool
  • Virtual Camera & Raw Video Playback
  • Backing Up & Restoring Settings

This video series offers the user a very detailed explanation of how to install the WeldStudioTM utility, providing an in-depth look at all of the features in the program used to control the Xiris weld cameras. Special detail is provided on how to use the impressive video processing options WeldStudio™ has to offer, as well as details on how to properly record and playback video and raw images.

Xiris customers have exclusive access to the video guides through our Support Center website. The Xiris Support Center is a great resource for customers providing access to product manuals, the latest software updates and more. If you’re an existing customer and would like to access the WeldStudio™ Video Guides, contact support@xiris.com to get connected with Support Center today!

Video Learning Guides Available

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos!

Instagram LinkedIn FacebookTwitter

Topics: weld camera, WeldStudio, video guides, training

Xiris Launches Audio Monitoring for Weld Cameras!

Posted by Cameron Serles on Tuesday, July 23, 2019 @ 11:25 AM

Xiris is proud to announce a revolutionary addition to our industry-leading cameras: SOUND!

At Xiris, we strive to be a world leader in developing sensors and inspection systems for welding processes. Our team of multidisciplinary experts have extended our weld camera product line with the addition of audio capture and monitoring capability. We are committed to continuously improving our products to meet the needs of our customers, and audio monitoring is something our clients have been asking for.

Adding audio capture and playback to Xiris’ weld cameras introduces a new dimension to welding quality control. Now fabricators can use two sensory inputs – sight AND sound – to help them determine if the welding process is functioning correctly or needs fine tuning to provide the best weld process possible. This enhancement gives operators another tool to assess, monitor and improve the consistency and effectiveness of their welding processes.

Xiris Launches Audio monitoring for welding camerasAn Audio Waveform Picture from the Xiris Audio Recorder

A study in the January 2017 edition of the Journal of Intelligent Manufacturing found that multisensory evaluation of seam welds was 97% more accurate recognizing defects. Various academic and anecdotal studies confirm that sound is key to real-time monitoring of welding quality and process control for intelligent manufacturing.

Welders draw on years of experience to recognize what quality welds sound like. Each type of welding can generate a unique sound signature when it is “in tune” and when it is “out of tune”. In upcoming blogs, we will be talking about the different types of welding and what to listen for. We will also share more details about the Xiris audio recording and playback option and how you can add it to your operations.

Subscribe to our blog so you don’t miss out!

 

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos!

Instagram LinkedIn FacebookTwitter

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

Xiris Launches New Support Center

Posted by Robin Montgomery on Wednesday, June 19, 2019 @ 12:00 PM

Our team at Xiris has always been dedicated towards providing an excellent customer experience, from the products we design and build, to how we support our customers before and after a sale is made. Creating the Support Center for our customers was our next step in improving the overall customer experience.


View of Support Center for Xiris Customers

 

Whether you are an end user customer, OEM or distributor, there is content that has been customized for you. The new Support Center includes specific product related documents, manuals and installation guides such as trade articles, white papers, how-to articles, video tutorials, case studies, dictionaries or glossaries, and soon it will have a frequently-asked questions (FAQ) section. Essentially, the Support Center will contain anything that helps our customers and partners use and grow their understanding of our products or services such as our Weld Cameras or our Tube and Pipe Weld Inspection Systems.

 

Customers can create an account and have access to the latest product information and user manuals 24 hours per day, 7 days per week. Forrester, a researching company, found that 70% of customers prefer to use a company’s website to get answers to their questions rather than calling or emailing customer service1. We are embracing this and providing a platform that customers can use to answer their own questions.

 

Xiris always tries to be proactive in all areas of our business, including creating happy and successful customers. Our new Support Center is allowing customers to answer all of their own questions about our Weld Cameras and Tube and Pipe Weld Inspection Systems on a user friendly platform. This results in happy customers with a great overall experience using Xiris products and services.

 

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos and join our Weld Video of the Month Club!

Instagram LinkedIn FacebookTwitter

Sources: 

1https://go.forrester.com/

Topics: weld camera, weld inspection, Tube and Pipe welding, weld camera system, inspection system, online support, customer service

Latest Posts

Follow Me