Modeling of MIG/MAG welding with experimental validation using an active contour algorithm applied on high speed movies

This paper investigates some issues in physical modeling of metal inert gas/metal active gas (MIG/MAG) welding process in the short arc mode. In this mode, a metal supply is molten in the arc state and then transferred to the weld pool during the short-circuit state. A hybrid model having two distinct continuous states whose switchings are controlled by two guard conditions is proposed. Due to the complexity of the physical phenomena involved in the welding process, simplifications are used to obtain a model accounting for the main physical contributions but simple enough to yield an efficient, fast and numerically tractable simulator which can be used intensively for evaluating different control strategies. In an attempt to validate the proposed model, different measurements have been made including supply voltage and current sampled synchronously with high speed digital video. In order to extract some relevant quantities representative of the metal transfer from image sequences, an active contour algorithm is developed and tested. The effectiveness of the proposed model in the prediction of major tendencies of a welding process, especially in the arc state, is shown using experimental data. Some limitations of the model during the metal transfer are also stressed and possible remedies are then proposed.