How to Detect Welding Defects with a Welding Camera

A welding camera that provides a clear and consistent image of the weld means an operator can reliably detect defects in real time. This compilation of videos made with the MeltView DART camera demonstrates classic defects including undercut, burn through, porosity and lack of fusion.

With a sophisticated welding camera like the MeltView DART, it’s possible to see the entire perimeter of the puddle and identify proper wetting or, in the case of lack of fusion, the puddle advancing too quickly at the leading edge. Undercut is a related problem that may more often be observed at the side of the puddle.

Alignment of the torch to the joint is also critical and may be hard to judge from a distance, through a welding glass. Monitoring alignment is often the key reason that our customers give in searching for a welding camera. Here we show the torch off-center of the fillet joint, creating a useless – or worse, unreliable – weld.

Even phenomena that occur under the puddle or on the opposing surface of the weld can be detected with a clear image provided by a good welding camera. A small amount of burn through shows itself as a decrease in weld pool size, and other cases of burn through are strikingly obvious.

A clear puddle view at an optimal angle also reveals porosity as the weld forms, which may be due to shielding gas interference or disruption, or to defects in the underlying material, to name several causes.

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