There are many types of traditional welding defects, which can be divided into two categories: external defects and internal defects according to their location in the weld. External defects are also called appearance defects.
External defects are located on the surface of the weld and can be observed with the naked eye or a low-power magnifying glass.
Internal defects are located inside the weld and must be discovered by applying destructive inspection or specialized non-destructive inspection methods.
(Welding defect)
Common classification methods for welding defects are as follows:
Welding robot is an industrial robot engaged in welding. It mainly consists of two parts: robot and welding equipment. Taking arc welding as an example, it consists of a welding power source (including its control system), a wire feeder (arc welding), a welding gun, etc. Arc welding robots mostly use melting electrode or non-melting electrode gas shielded welding methods. Common welding power sources can be installed on the robot for arc welding. It should also be equipped with sensing systems, such as laser or camera sensors and their control devices. Based on the production and use of welding robots for many years, the most common types of defects in robot welding are summarized, as well as the corresponding measures and methods.
1. Problems with welding bead deviation and welding track cannot be corrected
First, in the teaching mode, the idling procedure ensures that the welding position is correct. Secondly, consider the problem when searching for the welding gun. At this time, it is necessary to consider the way the welding robot searches for the weld bead (arc or laser) for settings. Finally, analyze whether the TCP (welding gun center point position) is accurate and make adjustments. If this happens frequently, check the zero position of each axis of the robot and recalibrate it to correct it.
2. A large number of undercut problems occur
Consider improper selection of welding parameters, excessive current, excessive voltage, welding gun posture that is not conducive to welding, and whether the welding position is restricted, and make appropriate adjustments.
3. The problem of dense pores appears
It may be that the gas protection is poor, the welding surface of the workpiece is not clean enough, or the shielding gas is not dry enough, which can be solved by making corresponding adjustments.
4. The problem of excessive splashing
It may be due to improper selection of welding parameters, gas composition, or the extension length of the welding wire is too long. You can appropriately adjust the machine power to change the welding parameters, adjust the gas proportioning instrument to adjust the mixed gas ratio, and adjust the relative position of the welding gun and the workpiece.
5. An arc crater is formed at the end of the weld after cooling.
When programmable, a submerged crater function can be added to the work step to fill it.
6.Cannot start arc
It may be that the welding wire does not contact the workpiece or the process parameters are too small. You can manually feed the wire, adjust the distance between the welding gun and the weld, or adjust the process parameters appropriately.
7. Poor weld formation
It may be due to the uneven assembly gap of the weldment, the welding swing amplitude is too high or too low, the current selection is inappropriate, and the welding speed does not match the parameters.
