Weld seam error

Ensur­ing integri­ty and performance

Weld seam error

The qual­i­ty of a weld seam plays a cru­cial role in the man­u­fac­tur­ing indus­try, as it direct­ly impacts on the strength and reli­a­bil­i­ty of weld­ed com­po­nents. Despite advanced weld­ing tech­nolo­gies, weld seam errors may occur, which are of dif­fer­ent nature and cause. Iden­ti­fi­ca­tion and min­i­miza­tion of such errors is of great impor­tance, to ensure the struc­tur­al integri­ty and per­for­mance of the man­u­fac­tured components.

Struc­tur­al impacts

Weld seam errors in general

Weld seam errors can take dif­fer­ent forms, and have dif­fer­ent impacts visu­al­ly as well as struc­tural­ly. Among the most fre­quent weld seam errors are poros­i­ty, tears, incom­pat­i­bil­i­ties in weld­ing com­po­si­tion and improp­er weld seam geometry.

  • Poros­i­ty: Poros­i­ty occurs when gas bub­bles are enclosed in the solid­i­fied weld seam. This can impact on the mechan­i­cal prop­er­ties of the con­nec­tion, par­tic­u­lar­ly with regard to the ten­sile strength and tightness.
  • Tears: Tears in the weld seam can occur as a result of dif­fer­ent ther­mal expan­sion rates, incor­rect weld­ing para­me­ters or mate­r­i­al incom­pat­i­bil­i­ties. These tears can sig­nif­i­cant­ly decrease the struc­tur­al strength.
  • Incom­pat­i­bil­i­ties in the weld­ing com­po­si­tion: An improp­er weld­ing com­po­si­tion, either due to insuf­fi­cient mix­ing or unsuit­able mate­r­i­al com­bi­na­tions, can result in weak­ness­es in the weld joint. This can lead to pre­ma­ture fatigue and breaking.
  • Improp­er weld seam geom­e­try: Errors in the weld seam geom­e­try, such as uneven width or insuf­fi­cient pen­e­tra­tion can affect the struc­tur­al integri­ty and lead to stress concentrations.
  • Splat­ter: Small met­al drops can be eject­ed from the join­ing zone dur­ing the weld­ing process. Par­tic­u­lar­ly for elec­tron­ic com­po­nents, this can result in unwant­ed rejects.

Dili­gence and accuracy

Weld seam errors dur­ing laser welding

Dur­ing laser weld­ing, an advanced weld­ing tech­nique, spe­cif­ic chal­lenges must be observed. The high­ly con­cen­trat­ed ener­gy of the laser can lead to quick changes in tem­per­a­ture, which increas­es the prob­a­bil­i­ty of weld seam errors.

  • Ther­mal stress: The intense heat of the laser can result in ther­mal stress, which leads to defor­ma­tions and ten­sion in the weld joint. This requires pre­cise con­trol of the weld para­me­ters, to ensure even heat distribution.
  • Inert gas man­age­ment: The cor­rect man­age­ment of inert gas­es is cru­cial to pre­vent oxi­da­tion and con­t­a­m­i­na­tions in the weld zone. Insuf­fi­cient pro­tec­tion can result in poros­i­ty and oth­er defects.
  • Weld seam track­ing: Mon­i­tor­ing of the weld seam dur­ing the laser weld­ing process is crit­i­cal in order to detect poten­tial errors ear­ly. Auto­mat­ed sys­tems and sen­sors are often indis­pens­able here.

Min­i­miza­tion of weld seam errors requires care­ful process con­trol, high­ly pre­cise tech­nolo­gies and thor­ough knowl­edge of the mate­r­i­al prop­er­ties. This applies par­tic­u­lar­ly to laser weld­ing, where demands on pre­ci­sion and con­trol are espe­cial­ly high.

Pre­ci­sion. Effi­cien­cy. Quality.

Our solu­tions

Thanks to the high dynam­ic range of the 4D.TWO®, you can detect process devi­a­tions with a com­par­a­tive­ly low rate of pseu­do errors. With the com­bi­na­tion of chan­nels into com­bi chan­nels, you also save time dur­ing trou­bleshoot­ing, as you can clas­si­fy errors.

Find out more about the 4D.watcher

4D.watch­er with 4D.TWO®

As reli­able com­plete solu­tion for process mon­i­tor­ing and qual­i­ty assur­ance dur­ing laser beam weld­ing, cut­ting and sol­der­ing, the WELD­WATCH­ER® is an excel­lent solu­tion. The effi­cient online mon­i­tor­ing sys­tem is used in many areas of indus­tri­al production.
Find out more about the WeldWatcher®

WELDWATCH­ER®

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If you would like to learn more about our prod­ucts and ser­vices, or would like to request a cus­tomized offer, please do not hes­i­tate to con­tact us. You can con­tact us by phone, via email or by using our con­tact form. We look for­ward to receiv­ing your enquiry!

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Con­tact us!

If you would like to learn more about our prod­ucts and ser­vices, or would like to request a cus­tomized offer, please do not hes­i­tate to con­tact us. You can con­tact us by phone, via email or by using our con­tact form. We look for­ward to receiv­ing your enquiry!

Con­tact
Sched­ule con­sul­ta­tion appointment
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