Dariusz Ceglarek

Fusing optical coherence tomography and photodiodes for diagnosis of weld features during remote laser welding of copper-to-aluminum

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This study has been designed to investigate whether variations in the features of laser weldments can be isolated and diagnosed by fusing photodiodes and optical coherence tomography (OCT). Two manufacturing scenarios (variation in laser power and focal offset) have been considered during remote laser welding of 0.2 mm thick Cu foils on 2 mm thick Al 1050 plates with an adjustable ring mode laser integrated with a 1D oscillation head. The process was monitored by measuring weld penetration depth with OCT and by process emissions (plasma and back-reflection) via photodiodes. The acquisition frequency of all signals was 40 kHz. Strong correlations (r > 0.75) were shown between plasma, back-reflection, and OCT signals and measured depth and width of the weld. Weak correlations (r < 0.5) between voids, cracks, and sensor signals were observed. Although plasma is the predominant signal that carries most of the information about the process, and the OCT allows direct measurement of ...

Applying optical coherence tomography for weld depth monitoring in remote laser welding of automotive battery tab connectors

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This paper addresses in-process monitoring of weld penetration depth (WPD) during remote laser welding of battery tab connectors using optical coherence tomography (OCT). The research aims at studying the impact of welding process parameters on the accuracy of WPD measurements. In general, the highest measurement accuracy is achievable by positioning the OCT measuring beam toward the bottom of the keyhole. However, finding and maintaining the alignment between the OCT measuring beam and the bottom of the keyhole is a challenging task because of the dynamic changes in the size and shape of the keyhole itself. The paper addresses the above challenge by (1) developing welding process parameters for the Al-Cu thin foil lap joint (Al 1050 foil 450  μ m and Ni-plated Cu foil 300  μ m) using a novel adjustable ring mode (ARM) laser and (2) integrating OCT technology with two beams: one targeting the bottom of the keyhole and another as a reference to the part surface (T...

Keyhole mapping to enable closed-loop weld penetration depth control for remote laser welding of aluminum components using optical coherence tomography

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Remote laser welding (RLW) combines the positive features of tactile laser welding with additional benefits such as increased processing speed, reduced operational cost and service, and higher process flexibility. A leading challenge preventing the full uptake of RLW technology in industry is the lack of efficient closed loop in-process (CLIP) monitoring and weld quality control solutions. This underpins the need to fuse multiple sensor technologies and data analytics with predictive engineering simulations. Although the development and integration of a variety of sensors covers the radiation spectrum from ultraviolet to far-infrared, the flawless deployment of CLIP solutions is still challenged by the need for the following: signal denoising in the case of process instability; real-time data analytics; and adaptive control engineering architecture to cope with process variations induced by manufacturing tolerances. This paper focuses on the aspect of weld penetration depth control ...


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