Electro-mechanical molten pool control for adapting deviations in the process boundary conditions during automated gas shielded metal arc welding

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In the automation of MSG welding processes, there is a major problem in ensuring weld seam quality despite varying process boundary conditions. Although there are currently strategies by which these deviations are detected by sensors (usually sensors in leading position) and automatically compensated by correction of the welding torch position and/or adaptation of the welding parameters, this is only possible within limited process limits (usually varying the welding speed). Adaptation strategies for manual welding, however, offer the advantage that, depending on the manual welder's experience, it can be used in considerably larger process windows and thus compensate for larger deviations from the process boundary conditions. These strategies mainly involve adapting the welding speed, changing the positioning and/or orientation of the welding torch as well as the locally adapted supply of energy and filler materials. The decision as to which strategy is suitable for each individual case is made intuitively by the manual welder based on his training and many years of experience.The aim of the project is, therefore, to transfer the procedure for manual welding to the automated welding process and thereby considerably extend the process limits for adapting the welding process in case of deviations in the process boundary conditions. An important prerequisite for the transfer to automated welding is the development of adaptation strategies based on the manual welder's approach, which is essentially aimed at the development and control of the weld pool. Furthermore, decision criteria based on digitized knowledge of welding experts about when and in which situation a suitable adaptation strategy should be used have to be developed.