Preset automated welding systems lack the ability to compensate for perturbations that arise during the process. In situations where the welding parameters cannot be totally defined, a system that is capable of sensing the variations and modifying the machine behavior to cope with these perturbations in real-time is required. This paper presents results of an investigation to develop a system for weld penetration control of the submerged arc welding process. Changes in the temperature distribution surrounding the weld pool were measured using a thermopile infrared detector and used to control weld penetration through changes of wire feed speed (current) and arc voltage. Experiments were conducted on plates of constant thickness, step change in thickness and butt joints with variable gaps up to 1/8 inch. The results show that the system can be used to control weld penetration for the above perturbations which are commonly encountered during submerged arc welding.
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