On October 11th, in Wuhan, the 29th National Welding Academic Conference with the theme of "Intelligent Welding for New Quality · Integration and Innovation for the Future" was grandly held. The conference attracted thousands of experts and scholars from universities, research institutes, and the industrial sector, who conducted in-depth discussions on academic development and innovative applications such as high-energy beam welding and additive manufacturing.
As an essential instrument for visual analysis of welding processes, high-speed cameras play a crucial role in welding process research, process optimization, and quality control. HF Agile Device Co.,Ltd participated in the exhibition with its independently developed high-speed camera NEO series featuring 85% high Quantum Efficiency (QE), and demonstrated to the participating experts and scholars typical application cases in themes including "High-Energy Beam and Special Welding, Arc Additive Manufacturing, Intelligent Welding and Process Monitoring, and Welding Structure Inspection and Evaluation".
During the welding process of high-energy beams (such as laser welding, electron beam welding, etc.), the interaction between the laser and materials is short and intense. The millisecond or even microsecond-level keyhole behavior is prone to causing defects such as pores, undercuts, and humps.
In a laser welding research experiment, it was necessary to explore the formation mechanism of micron-level pores during titanium alloy welding. By using a Revealer high-speed camera to record at a frame rate of 10,000 frames per second, transient behaviors such as keyhole collapse and molten pool backfilling were observed, and the moment of keyhole closure was captured, indirectly identifying the critical conditions for pore formation.
The stability of the additive manufacturing forming process directly determines the density and mechanical properties of the component, and the dynamic behavior of metal droplets and molten pools is the key to controlling the forming quality. High-speed cameras can capture processes such as droplet transfer and molten pool flow with high precision, providing key data for process development and quality control.
In a laser cladding powder feeding experiment, the Revealer high-speed camera NEO 25, combined with a doubler lens and pulsed laser, successfully captured the flight trajectory, melting state, and deposition process of micron-level metal powders under the action of laser. This provides a visual basis for the research team to design powder feeding nozzles and optimize light-powder coupling.
In another laser cladding experiment, the Revealer NEO 25 high-speed camera was used to achieve high-magnification observation of 1mm-level small molten pools. It clearly recorded the molten pool spreading, solidification front advancement, and interface reaction processes, providing data support for optimizing heat input and interface metallurgical bonding.
The intelligent welding sub-forum focused on intelligent perception, online monitoring, and real-time control of the welding process. As the core equipment of high-speed visual sensing, high-speed cameras can realize real-time capture of key features such as welding molten pools and droplet transfer. Combined with the synchronous recording of voltage and current signals from the welding electrical signal acquisition system, it provides multi-modal data support for the development of intelligent control algorithms.
In a MIG (Metal Inert Gas) welding research, the Revealer M series high-speed camera (with large memory and small size) was synchronized with the welding electrical signal acquisition system to realize the joint analysis of droplet dynamics and current-voltage signals. By observing the corresponding relationship between droplet size, transfer frequency, spatter morphology, and electrical signal fluctuations, the optimal process window was determined, which effectively suppressed welding spatter and improved weld forming quality.
In the welding structure inspection and evaluation sub-forum, high-speed cameras are widely used in the dynamic monitoring and behavior analysis of welding defects. Through real-time recording of defects such as cracks, pores, spatters, and discharge position deviations during the welding process, it provides visual image evidence for welding quality evaluation.
In a welding experiment of metal pins for power modules in a precision motor factory, process engineers introduced the Revealer high-sensitivity high-speed camera NEO 25. With a frame rate of 110,000 frames per second, it analyzed the entire process of arc discharge during pin welding at the microsecond level, quantified the spatiotemporal distribution characteristics and instability of the arc, and provided visual image evidence for improving welding quality and promoting the advancement of precision manufacturing processes.
Revealer high-speed cameras are evolving from tools for recording welding transient phenomena to scientific instruments for quantifying welding mechanisms. They assist researchers in analyzing molten pool dynamics and defect evolution processes at the microsecond level, and provide visual data support for "High-Energy Beam and Special Welding, Arc Additive Manufacturing, Intelligent Welding and Process Monitoring, and Welding Structure Inspection and Evaluation".
