Thermal Profile Welding Inspection

NDT welding inspection systems are insurance for Metal Fabricators and Tube & Pipe Producers

Welding Defects usually are classified into two categories—major flaws that can cause weld failure and minor variances that have negligible effect on weld quality. Metal Fabricators and Tube and Pipe producers are constantly managing material costs, yield, efficiency and quality to improve profitability, acquire and retain clients and mitigate liability costs. The costs of shipping defective product are difficult to quantify. However, the risks and costs associated with repairs, loss of customers, or subsequent legal and liability action are potentially huge—they are the main impetus for installing NDT systems for welding inspection in the first place. Welding inspection that measures the thermal gradient of the heat affected zone are presented here.

An important distinction to make with the thermal profile welding inspection is that it does not rely on temperature for the monitoring. What the system measures and analyzes is the thermal gradient. This approach thereby renders knowing the absolute temperature redundant and what is monitored is the change in the heat affected zone.

Thermal Profile welding inspection increase weld quality assurance, productivity and reduces liability.

A new technology is now available which provides real-time, in process, at the weld, weld monitoring and welding inspection and detection of welding defects and discontinuities. AS NDT welding inspection systems go, the TPS is an in process device which utilizes the thermal distribution of the heat affected zone to detect the welding irregularities of the temperature field during solidification, of the welded seam.

Thernal Profile Welding Inspection is Suitable For:

• MAG, TIG, Plasma, Laser, HFI/ ERW ; up to 180m/min welding speed
• Welding automation as batch production and continuous production as in tube and pipe.

Thermal Profile Welding Inspection Benefits & Features:

• Early Detection of weld defects and irregularities and process anomalies
• Mill or production equipment integration (I/O signaling, Alarm generation, production tags)
• Complete traceability and documentation for quality audits and liabilities
• Net reduction in waste and increase in quality
• Real-time visibility and Alerts of what is happening at the weld.
• Store 999 recipes or presets which can be recalled manually or via I/O
• Set user rights and access privileges
• Connect to a network to archive, upload, download and view real-time results
• Operator acceptance and quick learning curve – straightforward operation

The TPS is a thermal profile scanner, when combined with the weld monitor controller, allows the operator to see what is happening at the weld. Outputs to the HMI include the heat profile, weld speed, volts, amps, gas flow. Operating at 400Hz, the system can scan on welding applications to a speed of 180m/min. The glassless optics and the air/water-cooled housing permit the continuous reliable operation of the scanning head under the most difficult environmental conditions.

 

 

 

Welding Defects:

• Off seam Weld
• Mismatch
• Porosity
• Burn through
• Lack of Fusion
• Cold Spots (Pasty Weld)
• Lack of Penetration
• Energy input fluctuations
• Material variances
• Hot Cracking
• Asymmetric welding

Please visit the section on tube&pipe for specific application details to this industry. We invite individuals looking at NDT welding inspection systems, to contact us for details on this proven technology.