Insight

High speed camera imaging of laser welding with cold wire

A major automotive supplier uses the MeltView SYNC high-speed camera for welding process development.

Short circuit GMAW captured with DART welding camera

The MeltView DART camera automatically adjusts between welding and non-welding to provide a clear image, as shown in this video of short circuit GMAW.

MeltView SYNC high speed welding camera video of pulsed GMAW round corner

The SYNC camera mounts to the welding torch to capture the welding process continually at high speeds, up to 1300 frames per second as shown here.

15 WEL 141 GTAW 1F T-Joint

The MeltView PACT welding camera mounts directly to a manual welding torch and displays a close-up view of the weld for the training of welders.

APEX2 welding camera for manual welding education, GTAW

With the APEX2, instructors can show students what they see in real-time on a big screen and record video for playback.

CASE STUDY: Monitor Alignment of Keyhole TIG Welds

TIG Welding || Fabricating 600mm (63 inch) diameter, 9mm (3/8 inch) thick stainless steel pipe for transporting drinking water.

APEX2 welding camera for manual welding education, GMAW

Display a real-time, close-up, in-focus video of your manual welding process for as long as you weld.

Welding camera view of fillet weld GMAW FCAW spray and short circuit

MeltTools Sync welding camera shows manual fillet welding using GMAW and FCAW processes in spray and short circuit mode.

MeltView SYNC high-speed imaging of FCAW

At over 300 frames per second, these features start to become visible, and the SYNC can record video continuously at up to 1200 fps to capture most welding phenomena in great detail.

Watch laser welding of stainless tube with a welding camera

The MeltView MIRA camera provides a clear view of the tube welding process with no image processing and no lag.

Welding camera view of puddle and background GTAW

The MeltView MIRA2 with LUCI software makes it easy to switch among inspection, background and puddle views during welding.

How to Detect Welding Defects with a Welding Camera

Defects in the alloy layer defeat the purpose of cladding and result in costly scrap, re-work or even failure of the component in the field. Monitoring the overlay process is difficult due to geometry and high temperatures.

Monitoring Bore Cladding

Defects in the alloy layer defeat the purpose of cladding and result in costly scrap, re-work or even failure of the component in the field. Monitoring the overlay process is difficult due to geometry and high temperatures.

Micro Welding Camera

Micro welding processes call for optical magnification and high resolution cameras due to the fine scale of the weldments. The welding camera should provide an excellent image during both welding and non-welding.

The Frames Per Second Question

For real-time monitoring, the key question is, what is the top frame rate that the human visual system can perceive? For recording and playback, the key question is, how fast are the welding events that you want to observe happening?

High Frame Rate Welding Cameras

While high frame rate welding cameras produce amazing images of welding, they generate huge amounts of data, and pose two additional hurdles: limited on-board recording space and camera bulk too large to fit on a welding robots.

Welding Process Development Tools

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. However, a high-speed welding camera can lift the curtain on droplet detachment, spatter generation, puddle dynamics, and other secrets of the weld.

Monitoring pipe mill welding

Process operators are faced with making accurate adjustments to the equipment during welding, and the right camera provides the operator with a clear, real-time view of the weld puddle that helps him to take corrective actions and keep a constant eye on the welding process.

Monitoring plasma arc welding

Plasma keyhole welding offers high integrity welds and high productivity, and finds plenty of applications in industries that manufacture products from stainless and titanium; however, the torch is often positioned such that visual monitoring of the weld process by the operator difficult.

Welding Education

Verbal and written descriptions of arc physics and limited vision of the real arc bores our students. Can we capture some exciting stuff for them with today’s optics?

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MeltTools' cameras are designed & manufactured to suit your specific application.