Reconstructing a three-dimensional P-GMAW weld pool shape from a two-dimensional visual image

The online detection of the three-dimensional (3D) shape of a weld pool is a key unsolved question for weld shape control. In this paper, a method to reconstruct the 3D shape of a weld pool boundary from a two-dimensional (2D) visual image is proposed. Firstly, a new 3D model was developed to describe the weld pool geometry in pulsed gas metal arc welding (P-GMAW). In this model, four parameters could be used to determine the weld pool shape: the maximum width W, the length of the pool tail L, the height of the rear of the pool H and the projection of the rear angle onto the work piece plane θL. Then, the clear weld pool images from the P-GMAW were captured from the upper side, and a series of algorithms were developed to extract the model geometrical parameters from these images. Finally, the 3D shape of the weld pool was reconstructed from the 2D images. The results were then validated with metallograph observations. The measurement error of this method was investigated, and methods for improvement were discussed.