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In situ detection of welding defects: a review

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Abstract

Weld defect detection is a crucial aspect for improving the productivity and quality of the welding process. Several non-destructive methods exist for the identification of defects post weld deposition. However, they only help assess the quality of the component and offer no inputs while the welding process is being performed. Real-time or in situ weld defect detection aids in the detection of defects during the welding process, allowing to take corrective measures or halt the welding to avoid further wastage of time and material. The current paper provides a brief description of various types of weld defects and the commonly used non-destructive testing (NDT) techniques used for identifying weld defects. It then proceeds to provide a detailed review of various methods available for in situ weld defect detection, classifying them based on their input signals. It also classifies the methods based on the type of algorithm used, along with an intuitive explanation of the commonly used algorithms in weld defect detection. The methods covered in this manuscript make use of different input signals that include audio, welding current and voltage, and optical signals also highlighting methods that use a combination of the abovementioned signals for in situ prediction of weld defects. A critical analysis of the efficacy, advantages, and drawbacks of each method is presented. Further, this work highlights a few research gaps identifying avenues for future research in this area.

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Acknowledgements

The authors gratefully acknowledge the support of the Science and Engineering Research Board, Department of Science and Technology, Government of India under the Ramanujan Research Grant (Grant number: SB/S2/RJN-093/2015) and Core Research Grant (CRG/2020/005089); authors also acknowledge the support of the Naval Research Board (NRB/4003/PG/436).

Funding

This work was supported by the Science and Engineering Research Board, Department of Science and Technology, Government of India under the Ramanujan Research Grant (Grant number: SB/S2/RJN-093/2015) and Core Research Grant (CRG/2020/005089). Authors also acknowledge the support of Naval Research Board (NRB/4003/PG/436).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Tirupati, Tirupati, India

    Anirudh Sampath Madhvacharyula, Srihari Chitral, N Venkaiah & Degala Venkata Kiran

  2. Department of Electrical Engineering, Indian Institute of Technology Tirupati, Tirupati, India

    Araveeti V Sai Pavan & Subrahmanyam Gorthi

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  1. Anirudh Sampath Madhvacharyula
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  2. Araveeti V Sai Pavan
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  3. Subrahmanyam Gorthi
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  4. Srihari Chitral
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  5. N Venkaiah
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Contributions

Anirudh Sampath Madhvacharyula: Conceptualization, methodology, formal analysis, writing original draft, and visualization

Araveeti V Sai Pavan: Conceptualization, methodology, formal analysis, writing original draft, and visualization

Subrahmanyam Gorthi: Conceptualization, methodology, supervision, formal analysis, writing - review and editing, and visualization

Srihari Chitral: Conceptualization, methodology, formal analysis, writing original draft, and visualization

N. Venkaiah: Conceptualization, methodology, supervision, formal analysis, writing - review and editing, and visualization

Degala Venkata Kiran: Conceptualization, methodology, resources, supervision, formal analysis, writing - review and editing, visualization, project administration, and funding acquisition

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Recommended for publication by Commission V - NDT and Quality Assurance of Welded Products.

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Madhvacharyula, A.S., Pavan, A.V.S., Gorthi, S. et al. In situ detection of welding defects: a review. Weld World 66, 611–628 (2022). https://doi.org/10.1007/s40194-021-01229-6

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