Prediction Model for Back-Bead Monitoring during Gas Metal Arc Welding Using Supervised Deep Learning

Abstract

Creating and consistently maintaining the weld shape during gas metal arc welding (GMAW) is vital for ensuring and maintaining the specified weld quality. However, the back-bead is often not uniformly generated owing to the change that occurs in the narrow gap between the base metals during butt joint GMAW, which substantially influences weldability. Automating the GMAW process requires the capability of real-time weld quality monitoring and diagnosis. In this study, we developed a convolutional neural network-based back-bead prediction model. Specifically, scalogram feature image data were acquired by performing Morlet wavelet transform on the welding current measured in the short-circuit transform mode of the GMAW process. The acquired scalogram feature image data were then analyzed and used to develop labeled weld quality training data for the convolutional neural network model. The model predictions were compared with welding data acquired through additional experiments to validate the proposed prediction model. The prediction accuracy was approximately 93.5%, indicating that the findings of this study could serve as a foundation for the future development of automated welding systems.