Aluminum Welding Captured in Detail - Fronius CMT

Capturing high-quality images of aluminum can be quite challenging due to various factors.

However, in this video, we get a special glimpse into the Fronius CMT welding process, showcasing the intricate details of this technique captured using a thermal camera.

To accomplish this feat, a Xiris XIR1800 camera specifically calibrated for aluminum was used to acquire thermal images of the welding process. The camera was equipped with a filter precisely calibrated to measure temperatures up to 1000°C and work with a very short exposure time of about 0.5 ms, which is ten times faster than the standard exposure time of 5 ms.

The video above starts with image capture running with no trigger. The resulting image is variable, with lots of variation in brightness due to the GMAW expulsion.

About 8 seconds into the video, the voltage trigger was turned on and set to trigger at a specific point in the power waveform to allow the camera to image the "No Arc" condition.

This allowed image acquisition to occur when no arc was present, providing an accurate representation of the welding process. The difference in image quality is dramatic, highlighting how effective the trigger signal is in creating a stable video from the thermal camera.

In the above video, the wire used in the process was 1.2mm in diameter and the welding speed was about 5 meters (200”) per minute on a flat aluminum plate.

The image also reveals the extent of the mushy zone, where the melt pool transitions into a semi-solid state.

The cooling bead is also clearly depicted, representing the solidification of the molten aluminum.

Lastly, the image provides a clear view of the base material and the effective cleaning zone of aluminum oxide prior to welding, emphasizing the meticulous preparation required for successful aluminum welding.

XIR 1800 Thermal Camera: https://www.xiris.com/xiris-xir-1800/

Read Full Article: https://blog.xiris.com/blog/aluminum-...

Download Datasheet - https://info.xiris.com/xiris-camera-t...