Modeling, sensing and control of gas metal arc welding

S. Ozcelik, K. Moore, D.S Naidu9780080440668, 0-08-044066-5

Arc welding is one of the key processes in industrial manufacturing, with welders using two types of processes – gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW). This new book provides a survey-oriented account of the modeling, sensing, and automatic control of the GMAW process. Researchers are presented with the most recent information in the areas of modeling, sensing and automatic control of the GMAW process, collecting a number of original research results on the topic from the authors and colleagues.
Providing an overview of a variety of topics, this book looks at the classification of various welding processes; the modeling aspects of GMAW; physics of welding; metal transfer characteristics; weld pool geometry; process voltages and variables; power supplies; sensing (sensors for arc length, weld penetration control, weld pool geometry, using optical and intelligent sensors); control techniques of PI, PID, multivariable control, adaptive control, and intelligent control. Finally, the book illustrates a case study presented by the authors and their students at Idaho State University, in collaboration with researchers at the Idaho National Engineering and Environment Laboratory.

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Table of contents :
Front Cover……Page 1
Modeling, Sensing and Control of Gas Metal Arc Welding……Page 4
Copyright Page……Page 5
Contents……Page 12
Dedication……Page 6
Preface……Page 8
Acknowledgments……Page 10
List of Figures……Page 18
1.1 Introduction……Page 22
1.2 The Survey……Page 25
References List for Chapter 1……Page 28
2.1 Gas Metal Arc Welding……Page 30
2.2 Physics of Welding……Page 35
2.3 Melting Rate……Page 43
2.4 Metal Transfer Characteristics……Page 44
2.5 Weld Pool……Page 52
2.6 Process Voltages……Page 56
2.7 Heat and Mass Transfer……Page 58
2.8 Process Variables……Page 59
2.9 INEEL/ISU Model……Page 64
2.10 Empirical and Statistical Models……Page 73
2.12 Intelligent Modeling……Page 74
2.13 Other Issues on Modeling……Page 76
2.14 Power Supplies……Page 82
2.15 Other Issues on Power Supplies……Page 86
2.16 Classification of References by Section……Page 87
References List for Chapter 2……Page 88
3.1 Classification of Sensors……Page 116
3.3 Computer-Based Measurements……Page 120
3.4 Welding Parameters Monitoring……Page 121
3.5 Sensors for Line Following/Seam Tracking……Page 122
3.6 Arc Length Sensors……Page 124
3.7 Sensors for Weld Penetration Control……Page 126
3.8 Sensors for Weld Pool Geometry……Page 132
3.9 Optical Sensors……Page 134
3.11 Intelligent Sensing……Page 135
3.12 Other Issues on Sensing……Page 136
3.13 Classification of References by Section……Page 139
References List for Chapter 3……Page 142
4.1 Automatic Welding……Page 168
4.2 Control of Process Variables……Page 171
4.3 Classical Control: PI, PID and Others……Page 181
4.4 Multivariable Control……Page 182
4.5 Optimization and Optimal Control……Page 184
4.6 Adaptive Control……Page 185
4.7 Intelligent Control……Page 193
4.8 Statistical Process Control and Quality Control……Page 199
4.9 Other Control Methodologies and Issues……Page 200
4.10 Safety and Environmental Issues……Page 204
4.11 Classification of References by Section……Page 205
References List for Chapter 4……Page 208
5.1 Introduction……Page 240
5.2 Empirical Modeling of a GMAW Process……Page 243
5.3 SISO Current Control Using PI Controller……Page 256
5.4 Multi-Loop Control of the GMAW Process……Page 260
5.5 Adaptive Control of GMAW Process……Page 265
5.6 Control Strategy……Page 278
5.7 Summary……Page 289
5.8 Classification of References by Section……Page 291
References List for Chapter 5……Page 292
6.1 Control Technology and Automation in Welding……Page 296
6.2 Main Issues and Outlook……Page 297
6.3 Classification of References by Section……Page 299
References List for Chapter 6……Page 300
Bibliography……Page 302
Index……Page 368