A novel approach to the holistic 3d characterization of weld seams—paving the way for deep learning-based process monitoring

In an industrial environment, the quality assurance of weld seams requires extensive efforts. The most commonly used methods for that are expensive and time-consuming destructive tests, since quality assurance procedures are difficult to integrate into production processes. Beyond that, available test methods allow only the assessment of a very limited set of characteristics. They are either suitable for determining selected geometric features or for locating and evaluating internal seam defects. The presented work describes an evaluation methodology based on microfocus X-ray computed tomography scans (µCT scans) which enable the 3D characterization of weld seams, including internal defects such as cracks and pores. A 3D representation of the weld contour, i.e., the complete geometry of the joint area in the component with all quality-relevant geometric criteria, is an unprecedented novelty. Both the dimensions of the weld seam and internal defects can be revealed, quantified with a resolution down to a few micrometers and precisely assigned to the welded component. On the basis of the methodology developed within the framework of this study, the results of the scans performed on the alloy AA 2219 can be transferred to other aluminum alloys. In this way, the data evaluation framework can be used to obtain extensive reference data for the calibration and validation of inline process monitoring systems employing Deep Learning-based data processing in the scope of subsequent work.