{"id":2567,"date":"2021-03-04T14:36:18","date_gmt":"2021-03-04T13:36:18","guid":{"rendered":"https:\/\/www.claravision.com\/welding-analysis-everything-you-need-to-know\/"},"modified":"2021-04-29T08:48:30","modified_gmt":"2021-04-29T06:48:30","slug":"welding-analysis-everything-you-need-to-know","status":"publish","type":"post","link":"https:\/\/www.claravision.com\/en\/welding-analysis-everything-you-need-to-know\/","title":{"rendered":"Welding analysis : Everything you need to know"},"content":{"rendered":"

Quality control of welding beads is an extremely important step in the component manufacturing process<\/strong>. The analysis can be carried out in a number of ways. A visual inspection can be made before looking more closely for potential welding anomalies<\/strong><\/p>\n

But what is a weld bead? How does a visual inspection work? What machines can be used to analyse weld beads?<\/p>\n

\"robot

Welding robots in the automobile industry<\/p><\/div>\n

What is weld bead analysis?<\/h2>\n

Welding inspection gives the operator a precise visual of the quality of welds carried out on a component.\u00a0 <\/strong>This analysis is extremely important, since it helps calculate the weld\u2019s strength.\u00a0 This strength, or resistance to stress, is essential in order to guarantee component performance and durability<\/strong>.<\/p>\n

The quality control procedure comprises three steps.\u00a0 Firstly, a pre-weld check is carried out.\u00a0 Everything is reviewed, from an analysis of the materials to be welded to a macrographic inspection.\u00a0 <\/strong>Materials must be compatible with each other if they are to provide satisfactory resistance when welded together.<\/p>\n

\"Welded

Welded car chassis<\/p><\/div>\n

The next step is analysis of the welding process itself.\u00a0 This enables the operator to assess if the weld is being carried out correctly.\u00a0 The weld quality and speed and the occurrence of any distortions due to component misalignment, are all closely monitored throughout the welding process<\/strong>.<\/p>\n

A final check is carried out after completion of the weld, in order to determine the quality of the work.\u00a0 After a visual check, the component passes through specific equipment, not only to analyse the shape of the weld<\/strong>, but also to perform detailed dimensional measurements<\/strong>.<\/p>\n

This is to improve the design accuracy of future joints<\/strong> since by studying the weld structure, it is possible to detect different anomalies and thereby avoid repeating them in the future.<\/p>\n

\"controle

Visual check of a weld bead in the automobile industry<\/p><\/div>\n

Quality checks on weld beads are an essential step to ensure the final component is perfectly sound.\u00a0 In certain industries, the automobile industry for example<\/strong>, each finished product can sometimes involve hundreds of welds.<\/p>\n

A weakness in one or other seams could have serious consequences <\/strong>when the product is used.\u00a0 Precision is therefore extremely important and must be the main focus <\/strong>during the welding phase.<\/p>\n

The importance of macrographic analysis<\/h2>\n

Whether for a butt weld, a lap weld or a T weld, stringent macrographic analysis is important, so as to reveal any disparities <\/strong>that may be present in the resulting metal object.<\/p>\n

Firstly, a cross-section of the weld<\/strong> should be carried out.\u00a0 This is achieved by abrasive wet cutting.\u00a0 This method is used so as to avoid any possible heat damage to the part, as a damaged weld would affect the quality of the structural data<\/strong>.<\/p>\n

With the cross-section, you will have a complete visual of the area surrounding the joint, the heat-affected zone and the different weld pass.<\/p>\n

\"tronconneuse

Metallographic cutting and polishing equipment for weld analysis<\/p><\/div>\n

Calculations vary depending on the welding method.\u00a0 Certain methods require several weld passes, whereas others only need a single pass.\u00a0 Macrographic analysis will provide precise details on the structure of each weld.<\/strong>\u00a0 This examination can also show the size and shape of grains in the seam.<\/p>\n

The use of certain chemical products<\/strong> is required to reveal the weld and conduct the macrographic tests.\u00a0 These products will depend on the metal that is being analysed. For carbon steel with low alloy content, for example, you should use a solution of Nital and nitric acid<\/strong>.<\/p>\n

First, soak the cross-section in the solution to reveal the different passes of weld.\u00a0 This will make them easier to study.\u00a0 You must rinse the part thoroughly prior to analysis.<\/p>\n

Some parts should also be dipped in an ultrasonic bath <\/strong>for more in-depth cleaning.\u00a0 They should then be carefully dried before undergoing macrographic analysis.<\/p>\n

\"macro\"

Weld bead macrography, after chemical etching<\/p><\/div>\n

Once the weld has been revealed, you can subject it to a range of visual tests, analysing the number of passes and its solidity.<\/p>\n

Solutions to help you with weld bead analysis<\/h2>\n
\"mesure

Theoretical diagram of the measurements to be performed on a weld bead (VW standard)<\/p><\/div>\n

Many systems exist for analysing weld beads, however two stand out from the available solutions in terms of precision<\/strong>. These are the StructureExpert\u202fWeld-5 and StructureExpert Weld-11 systems.<\/p>\n

StructureExpert\u202fWeld-5, essential for weld analysis<\/h2>\n
\"weld\"

Imaging equipment for measuring weld beads: StructureExpert Weld-5<\/p><\/div>\n

This imaging workstation simplifies weld bead quality inspection <\/strong>substantially.\u00a0 <\/strong>After preparing your sample for analysis, you can use the workstation\u2019s optical system to obtain the data you require, with a high level of accuracy. \u00a0Designed to work in conjunction with the dedicated StructureExpert Weld software, the machine provides the operator with precise quality control data.<\/p>\n

The software, which can be completely customised<\/strong>, is also a great time saver.\u00a0 It adapts to the standards set out by the manufacturers.\u00a0 Your time is optimised and your analyses carried out more smoothly.\u00a0 Capable of magnifications of 2.5x – 50x, it can be used to study any component.\u00a0 Its field of view ranges from 80 to 4.5 mm, enabling precise readings <\/strong>when studying weld beads.<\/p>\n

\"mesure

Taking weld measurements using macrography<\/p><\/div>\n

Once the analysis is complete, you can produce reports for each component or for each weld bead.<\/p>\n

StructureExpert\u202fWeld-11, precision for your industry<\/h2>\n
\"controle

Dedicated imaging station for measuring laser weld beads: StructureExpert Weld-11<\/p><\/div>\n

Designed to meet all the demands of laser weld bead analysis, when it comes to precision the StructureExpert\u202fWeld-11 is a technological gem.<\/p>\n

With magnifications of 20x to 240x<\/strong>, this imaging equipment is one of the most precise on the market.\u00a0 Capable of observing weld beads of 8.27\u202fmm to 0.68\u202fmm, it is a solution that will greatly facilitate the complete analysis of your samples<\/strong>.<\/p>\n

Using a cross-section, it only takes a few clicks to obtain a sharp image with detailed measurements and an overview of your weld bead.\u00a0 Its dedicated software is supplied, enabling the storage of historical data <\/strong>for all of the analyses carried out using the machine.<\/p>\n

The data architecture enables operators to quickly locate a specific weld bead measurement.\u00a0 Statistical monitoring makes it possible to display welding procedure progress over time<\/strong>.<\/p>\n

In just a few moments, you can compare the data for different components, and therefore see evidence of improvements to your welding process.\u00a0 Particularly suited to analysing laser welds in the automobile industry, the StructureExpert\u202fWeld-11 is the perfect analysis tool for all of your laser weld quality control procedures.<\/p>\n

\"soudure

Macrography images of laser welds for the automobile industry<\/p><\/div>\n

The importance of welding inspection in the automobile industry<\/h2>\n

The automobile industry is one of the fields where welding is the most prevalent.\u00a0 Whether for assembling the different parts of a car or simple repairs, welding operations are legion in the industry<\/strong>. \u00a0Of course, specific checks are performed on the weld beads used on cars.<\/p>\n

Mostly carried out by MIG (metal inert gas) \/ MAG (metal active gas) welding, automobile welds have to meet very specific standards.\u00a0 <\/strong>In this industry, many criteria are to be avoided when the weld bead is formed.\u00a0 Among these:<\/p>\n

    \n
  • Undercuts<\/li>\n
  • Lack of penetration<\/li>\n
  • Incomplete fusion<\/li>\n
  • Spatter<\/li>\n
  • Slag inclusion<\/li>\n
  • Porosities<\/li>\n
  • Over-roll \/ overlap<\/li>\n<\/ul>\n

    Operators know these defects well, and know that they are to be avoided at all costs.\u00a0 This is why it is important to quickly carry out a thorough weld analysis on each sample.<\/p>\n

    Of course weld beads also undergo checks depending on the constraints and stresses they may be subjected to.\u00a0 The greater these are, the more draconian the acceptance criteria.<\/p>\n

    So that they can comply with all of the standards that apply to automobile manufacture, carmakers rely on reliable, precise weld quality control reports<\/strong>. \u00a0This is why the StructureExpert Weld solutions are essential for the automobile industry.<\/p>\n

    The industry requires many weld checks.\u00a0 Some components involve up to 500 welds<\/strong>.\u00a0 The StructureExpert Weld solution provides many advantages when used in the automobile industry.\u00a0 The dedicated software enables automatic report production per component.<\/p>\n

    \"rapport

    Component measurement report<\/p><\/div>\n

    This report includes the entire range of welds carried out on a given part.\u00a0 No need to browse through countless files to locate a specific weld for a component – everything is stored in one central location.<\/p>\n

    Also, thanks to additional software modules, a complete history of weld inspections is available, as well as statistical tracking.\u00a0 The statistics make it possible to monitor changes in the measurements and therefore how the welding process evolves over time, with access to all of the most common statistical calculations: Cp, Cpk, Cpu, Cpl\u2026.<\/p>\n

    \"Evolution

    Measurement tracking for the different weld beads on the same part<\/p><\/div>\n

    Macrography vs. micrography in quality control<\/h2>\n

    As previously stated, macrographical analysis is carried out on a cross-section.\u00a0 Polishing and etching is used to reveal the weld, which then undergoes a complete analysis process.<\/p>\n

    From the geometry of the joint to penetration depth, as well as\u00a0the extent of the heat-affected zone, <\/strong>everything is subjected to detailed calculations and collated in a report, so as to assess weld quality.\u00a0 Surface and internal imperfections are also listed, providing an overall defect analysis<\/strong>.<\/p>\n

    This analysis is carried out using solutions such as the StructureExpert Weld-5. \u00a0It enables analysis of most automobile industry weld beads, thanks to its magnification range of 2.5x to 50x.<\/p>\n

    The use of micrography on the other hand, provides a more detailed examination of the weld<\/strong>. \u00a0The technique enables precise analysis of porosities or micro-cracks in the weld.<\/p>\n

    A complete study of the grain size and structure is also available\u00a0thanks to this technique<\/strong>. \u00a0Using the data provided, improvements to weld strength can be made more easily, with perfection as the ultimate goal.<\/p>\n

    Accurate analysis can only be obtained with high-precision equipment.\u00a0 Solutions such as StructureExpert\u202fWeld-11 are perfect for this kind of task<\/strong>. \u00a0The lens on this machine can magnify the image\u00a0by up to 240x<\/strong>. \u00a0Used in conjunction with its dedicated software, the equipment will provide accurate quality control for every one of your welds.<\/p>\n

    Macroscopy, a quick visual check<\/h2>\n

    Finally, it is also important to perform a visual quality check on the weld<\/strong>. \u00a0In fact it is usually the first step in checking that a weld is sound.\u00a0 Visual checks and measurements must however be carried out in a very specific manner<\/strong>.<\/p>\n

    Firstly, it is important to have a good light source<\/strong> for this type of analysis.\u00a0 Next, the operator should be 50\u202fcm away from the surface that is being examined, and at an angle of more than 30\u202f\u00b0 in relation to the inspected part.<\/p>\n

    Naturally, the operator can also use a magnifying glass if required.\u00a0 A pocket mirror and a measuring tape will also be very helpful<\/strong>. \u00a0The seam should display:<\/p>\n

      \n
    • No penetration excess,<\/li>\n
    • No unevenness,<\/li>\n
    • No excess bead thickness.<\/li>\n<\/ul>\n

      Any defects can then be remedied ahead of the more detailed tests<\/strong>.<\/p>\n

      Welding quality control – conclusion<\/strong><\/h3>\n

      Whatever the level of precision required, stringent welding inspection is essential in terms of the robustness <\/strong>of your products. \u00a0Modern weld analysis relies on unparalleled precision technology<\/strong>, with high quality software, lenses and automation solutions. \u00a0In the automobile industry and others, our solutions help operators provide ever more accurate weld quality control analyses.<\/p>\n","protected":false},"excerpt":{"rendered":"

      Quality control of welding beads is an extremely important step in the component manufacturing process. The analysis can be carried out in a number of ways. A visual inspection can be made before looking more closely for potential welding anomalies But what is a weld bead? How does a visual inspection work? What machines can […]<\/p>\n","protected":false},"author":1,"featured_media":2492,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[153],"tags":[],"class_list":["post-2567","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-welding-control"],"acf":[],"yoast_head":"\nWelding analysis : Everything you need to know | Claravision<\/title>\n<meta name=\"description\" content=\"But what is a weld bead? How does a visual inspection work? 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