Weld penetration verification of a tubular product

[ada6106]

We weld approximately 2 million tubular automotive products a year in our facility. During frequent welder setups and/or changeover, weld penetration must be verified when changing between different diameters and wall thicknesses. Unfortunately, the only success to date (our current process), is to cross section the weld and etch to verify the penetration as a percentage of the wall thickness. We have experimented with ultrasonic testing and have had success, but this technology only verifies that you have achieved 100% of the thickness and less. There is an upper control limit for penetration that ultrasonic can not verify. Does anyone know of or have experience with technology that can verify a weld without destructive testing. Any comments are appreciated. Thanks.

 

[collinsam]

The Weldprint real time quality monitoring system developed by WTi of Australia and distributed by ourselves in the UK will probably meet your requirements. Basically , by monitoring the weld current and/or voltage in real time it is possible to create reference signatures for good welds. These are then used against any future welds to determine weld quality. This a real time, on-line non invasive system. This is new, patented technology. If you need more info please contact me.
Regards
Collin Sampson

 

[ada6106]

Collin:

I have worked with weld monitoring systems recently as well. We have one system we are trying to prove out in my previous facility. Many other variables adversely affect the weld as well. Part cleanliness, tip to work distance, amount of chamfer on the tube as well as rpm of the machine. I would like to here more about the system though. What we are trying to establish is parameters that can guarentee a good weld penetration. We are still experiencing problems with the other variables.

 

[collinsam]

The Weldprint system can be programmed to distinguish between different types of weld defect automatically. It is excellent as a process improvement tool in the first instance and then as a quality monitoring tool once the
process has been improved.
For more info call me on 0044 1827 312455 or e-mail
collin@euroteck.co.uk