Welding process development is a challenging task. Because the engineer must often operate the weld head remotely, by the time he or she inspects the completed weld, it has gone cold. Without being able to directly observe the weld, it’s very hard to identify experimental mistakes or conceptualize the effect of parameters on weld puddle behavior.

Enter the welding camera, a tool even more useful than an eye-witness. The camera allows the investigator to capture the making of the weld and review it step by step. This ability offers progressive manufacturers a huge advantage in developing welding processes and welding programs.

MeltTools designs and builds a wide range of industry-leading weld monitoring cameras that operate at 25-30 frames per second. However, for analytical purposes we offer the high speed MeltView SYNC camera that it is small enough to fit on a robot and can record up to 1200 frames per second.

Droplet detachment, spatter generation and puddle dynamics are all observable in incredible image quality with the MeltView SYNC. For example, the initiation of a stitch weld often utilizes a complex ramp up sequence to ensure proper fusion without spatter.

By observing this sequence at high speed, the waveform can be optimized and properly coordinated with robot movement. Robots are also used to speedily weld around curved paths, and a high speed camera can greatly help in programming torch angle and motion for strong, beautiful welds. Welding processes with multiple heat source processes (e.g. hybrid laser or tandem GMAW) pose additional challenges. A welding camera can be used to refine the role that each heat source has on the composite weld.

Videos of experiments may be compared side by side, repeatedly viewed and referred to months or even years down the line. Recorded video is also a very effective communication tool that may be used in company presentations and for reports.