<p dir="ltr" id="isPasted">Manufacturing facilities face significant safety and quality control challenges, with over <a href="https://fatfinger.io/quality-control-for-enhanced-workplace-safety-in-manufacturing/">137,000</a> work-related injuries reported in 2021 alone. Traditional safety monitoring and quality control methods often need help to catch up, especially in areas like PPE compliance, hazardous material handling, and complex machinery operations. Poor maintenance, undertrained employees, and non-compliance with safety procedures remain persistent issues in the industry.</p><p dir="ltr">Computer vision technology is emerging as a solution, with the market projected to reach <a href="https://www.forbes.com/councils/forbestechcouncil/2024/03/12/what-to-know-about-implementing-computer-vision-for-quality-control/">$39</a> billion by 2029. These systems provide automated, real-time monitoring capabilities that enhance safety compliance and quality assurance, enabling manufacturers to detect defects, monitor worker safety, and ensure regulatory compliance with unprecedented accuracy.</p><p dir="ltr">This article will explore how Matroid's advanced computer vision platform addresses these critical challenges and real-world implementation in manufacturing environments, especially in the manufacturing industry.&nbsp;</p><h2 dir="ltr">Introduction to Matroid: Vision, Specialization, and Technology</h2><h3 dir="ltr">Matroid's Approach to Computer Vision for Manufacturing</h3><p dir="ltr">Matroid stands at the forefront of manufacturing automation with its end-to-end computer vision platform that transforms complex visual data into actionable insights. The platform's distinguishing feature is its no-code interface, enabling industry professionals to develop and deploy custom detectors without programming expertise. This democratization of computer vision technology allows manufacturing teams to implement advanced inspection solutions<a href="https://www.matroid.com/">&nbsp;rapidly</a>.</p><h3 dir="ltr">Why Matroid's Computer Vision is Different</h3><p dir="ltr">What sets Matroid apart is its camera-agnostic system that seamlessly integrates with existing infrastructure, supporting both legacy and new camera systems of any resolution. The platform excels in precise defect classification beyond simple anomaly detection to provide detailed analysis of issues like weld integrity, porosity, and spatter.&nbsp;</p><p dir="ltr">Real-time monitoring capabilities enable 24/7 surveillance with instant alerts, while the system's ability to handle video data proves crucial for process monitoring and SOP verification.</p><h2 dir="ltr">Key Manufacturing Problems Solved by Matroid's Computer Vision</h2><h3 dir="ltr">Defect Detection and Quality Assurance</h3><p dir="ltr">Matroid's visual anomaly detection system employs deep learning algorithms to identify real-time manufacturing defects. The technology can detect subtle irregularities, including cracks, chips, scratches, dents, and discoloration, even under varying lighting conditions. This comprehensive detection capability extends across the entire production cycle, from raw material inspection to final product assessment.</p><h3 dir="ltr">Assembly Verification and Production Traceability</h3><p dir="ltr">The platform's computer vision system continuously monitors assembly processes, ensuring precise component placement and sequence verification. The system creates detailed digital records of production processes, enabling manufacturers to track products throughout their lifecycle and maintain compliance documentation. This automated verification significantly reduces human error and improves overall production accuracy.</p><h3 dir="ltr">Cycle Time Monitoring and Asset Maintenance</h3><p dir="ltr">Matroid's system performs automated cycle time analysis, measuring and optimizing production cycles while identifying inefficiencies. The platform's predictive maintenance capabilities monitor equipment health through visual inspection, detecting early signs of wear or malfunction. This proactive approach helps prevent unplanned downtime and maintains consistent production flow. The system provides real-time alerts and analytics, enabling quick adjustments to optimize production processes and maintain operational efficiency.</p><h3 dir="ltr">Safety and Compliance</h3><p dir="ltr">Matroid's computer vision platform enhances safety monitoring and delivers significant ROI by reducing production inefficiencies. These savings can be reinvested into safety measures, creating a cycle where improved safety leads to higher efficiency. The platform aligns production, quality, and safety objectives by automating real-time surveillance and hazard detection, benefiting both EHS and production teams.</p><h3 dir="ltr">Real-Time Safety Incident Reporting</h3><p dir="ltr" id="isPasted">The system automatically employs advanced detectors to identify real-time critical safety violations. For example, at Service Center Metals, Matroid's implementation improved airbag compliance rates by continuously monitoring shipping docks from below <a href="https://www.matroid.com/case-studies/how-matroids-ai-computer-vision-can-transform-workplace-safety/">25%</a> to over <a href="https://www.matroid.com/case-studies/how-matroids-ai-computer-vision-can-transform-workplace-safety/">90%</a>. The platform can detect hazards, including unsafe operator practices around molten metal and unauthorized entry into restricted zones, triggering immediate alerts to supervisors.</p><h3 dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733840146708-molten-metal-explosion.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Matroid's platform can detect hazards, including unsafe operator practices around molten metal and unauthorized entry into restricted zones, triggering immediate alerts to supervisors.</span></span></span></h3><h3 dir="ltr">PPE Compliance Monitoring</h3><p dir="ltr">Matroid's detectors excel in PPE compliance verification through its "automated pair of eyes" approach. The system can rapidly identify workers without required safety equipment such as hard hats, safety goggles, masks, and work boots. Custom detectors can be trained within minutes using existing visual datasets, compared to traditional methods that might take weeks or months to implement.&nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1737386416971-Single_Image_General_Manufacturing.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Matroid's detectors can rapidly identify workers without required safety equipment such as hard hats, safety goggles, masks, and work boots.</span></span></span>The platform integrates with existing camera infrastructure and provides instant notifications when violations occur, enabling immediate corrective action. This proactive monitoring has proven particularly effective in high-risk environments, where consistent PPE usage is crucial for worker safety.</p><h2 dir="ltr">Real-World Applications of Matroid's Computer Vision Technology</h2><h3 dir="ltr">Leveraging Computer Vision for Safety and Efficiency in Metal Forming</h3><p dir="ltr">The metal forming industry has seen significant transformation through Matroid's implementation, particularly demonstrated at Service Center Metals (SCM). Their experience showcases the practical impact of computer vision in manufacturing environments.</p><h3 dir="ltr">Improving Efficiency</h3><p dir="ltr">Matroid's AI system has transformed remelt furnace operations by precisely monitoring skimming and timing activities. The platform has significantly reduced metal loss by identifying optimal operator practices and correcting inaccuracies in manual metal charging, leading to more precise inventory management. This automation has decreased reliance on expensive primary aluminum while maintaining production quality.</p><h3 dir="ltr">Enhancing Quality Control</h3><p dir="ltr">The system's advanced detection capabilities enable real-time monitoring of manufacturing processes, identifying subtle defects and anomalies that might escape human inspection. At SCM, the technology has proven particularly effective in monitoring aluminum extrusion operations, ensuring consistent product quality through automated visual inspection.&nbsp;</p><p dir="ltr">The platform provides immediate alerts when deviations from quality standards are detected, ensuring timely corrective actions. Beyond immediate quality control improvements, these efficiencies generate savings that can fund safety enhancements, fostering a cycle of improvement across quality, safety, and production domains.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733840162062-computer-vision-in-metal-forming.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Matroid's computer vision platform provides immediate alerts when deviations from quality standards are detected, ensuring timely corrective actions.&nbsp;</span></span></span></p><h3 dir="ltr">Workplace Safety in Metal Forming</h3><p dir="ltr">The Matroid’s CV technology safety system proactively identifies hazards, including improper PPE usage and unsafe operator practices around molten metal. This comprehensive monitoring has resulted in zero safety incidents since implementation, demonstrating a <a href="https://www.matroid.com/case-studies/how-matroids-ai-computer-vision-can-transform-workplace-safety/">400%</a> increase in unsafe observation detection and correction.</p><h2 dir="ltr">Matroid's End-to-End Computer Vision Platform</h2><h3 dir="ltr">BUILD: Training and Custom Detectors</h3><p dir="ltr">Matroid's platform democratizes computer vision through its no-code interface, enabling users to create custom detectors without programming expertise. The system allows professionals to build specialized detectors using annotated data, with the ability to train models within minutes compared to traditional methods that might take weeks or months. Users can leverage existing visual datasets or create new ones, making the platform adaptable to specific manufacturing requirements.</p><h3 dir="ltr">TEST: Feedback and Model Interpretability</h3><p dir="ltr">The platform incorporates an intuitive testing phase where users can rapidly iterate and refine their detectors. Teams can easily compare and track performance improvements through automated detector versioning. The system provides transparent feedback on detector accuracy and performance, enabling users to understand the decision-making process and make necessary adjustments for optimal results.</p><h3 dir="ltr">DEPLOY: Real-Time Analytics and Integration</h3><p dir="ltr">Matroid's deployment capabilities are camera-agnostic, seamlessly integrating with legacy and new camera systems of any resolution. The platform provides real-time alerts and analytics through various inputs, including production systems, QMS, and mobile devices<a href="https://www.qualitymag.com/articles/98221-advances-in-computer-vision-offer-a-clearer-path-to-reliable-quality-control">1</a>. This comprehensive monitoring system operates 24/7, delivering continuous insights into machine and personnel activities without disruption.</p><h3 dir="ltr">MANAGE: Ongoing Monitoring and Retraining</h3><p dir="ltr">The platform facilitates continuous improvement through automated monitoring and management tools. Users can extract and process relevant camera information efficiently, producing video summaries and cycle-time analysis of operations. The system's ability to adapt to changing conditions and requirements ensures sustained performance, while analytics help optimize detector efficiency over time.</p><h2 dir="ltr" id="isPasted">The Future of Manufacturing Safety and Quality Control with Matroid</h2><p dir="ltr">Matroid's computer vision platform represents a significant leap forward in manufacturing safety and quality control. The system's ability to provide continuous, real-time monitoring while requiring minimal technical expertise has proven transformative across various manufacturing environments.&nbsp;</p><p dir="ltr">With demonstrated success in improving safety compliance rates by over 300% and achieving zero safety incidents in high-risk environments, the platform's dual impact on cost savings and workplace safety is transformative.&nbsp;</p><p dir="ltr">Manufacturers can achieve long-term operational excellence by reinvesting efficiency gains into safety applications, ensuring that quality, production, and safety teams work cohesively towards shared goals. The combination of automated defect detection, PPE compliance monitoring, and process optimization capabilities delivers a comprehensive solution that addresses critical manufacturing challenges.</p><p dir="ltr">Elevate your manufacturing operations with <a href="https://www.matroid.com/">Matroid's</a> advanced computer vision technology. Their platform delivers immediate safety compliance and quality control enhancements by seamlessly integrating with your existing infrastructure. Experience the benefits of automated visual inspection and real-time monitoring by <a href="https://www.matroid.com/get-a-demo/" target="_blank" rel="noopener noreferrer">scheduling a demonstration with Matroid's team today.</a></p><h2 dir="ltr">References</h2><ol><li dir="ltr"><p dir="ltr"><a href="https://fatfinger.io/quality-control-for-enhanced-workplace-safety-in-manufacturing/">https://fatfinger.io/quality-control-for-enhanced-workplace-safety-in-manufacturing/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://trdsf.com/blogs/news/manufacturing-safety-concerns">https://trdsf.com/blogs/news/manufacturing-safety-concerns</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.forbes.com/councils/forbestechcouncil/2024/03/12/what-to-know-about-implementing-computer-vision-for-quality-control/">https://www.forbes.com/councils/forbestechcouncil/2024/03/12/what-to-know-about-implementing-computer-vision-for-quality-control/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.viact.ai/post/top-5-computer-vision-use-cases-in-manufacturing">https://www.viact.ai/post/top-5-computer-vision-use-cases-in-manufacturing</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.qualitymag.com/articles/98221-advances-in-computer-vision-offer-a-clearer-path-to-reliable-quality-control">https://www.qualitymag.com/articles/98221-advances-in-computer-vision-offer-a-clearer-path-to-reliable-quality-control</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://mindtitan.com/resources/industry-use-cases/computer-vision-in-manufacturing/">https://mindtitan.com/resources/industry-use-cases/computer-vision-in-manufacturing/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.matroid.com/leveraging-computer-vision-to-improve-efficiency-quality-control-and-workplace-safety-in-metal-forming/">https://www.matroid.com/leveraging-computer-vision-to-improve-efficiency-quality-control-and-workplace-safety-in-metal-forming/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.matroid.com/safety-compliance-in-the-workplace/">https://www.matroid.com/safety-compliance-in-the-workplace/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://slashdot.org/software/p/Matroid/">https://slashdot.org/software/p/Matroid/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.viact.ai/post/top-5-computer-vision-use-cases-in-manufacturing">https://www.viact.ai/post/top-5-computer-vision-use-cases-in-manufacturing</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.matroid.com/automated-visual-anomoly-detection/">https://www.matroid.com/automated-visual-anomoly-detection/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.matroid.com/safety-compliance-in-the-workplace/">https://www.matroid.com/safety-compliance-in-the-workplace/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.matroid.com/leveraging-computer-vision-to-improve-efficiency-quality-control-and-workplace-safety-in-metal-forming/">https://www.matroid.com/leveraging-computer-vision-to-improve-efficiency-quality-control-and-workplace-safety-in-metal-forming/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.matroid.com/case-studies/how-matroids-ai-computer-vision-can-transform-workplace-safety/">https://www.matroid.com/case-studies/how-matroids-ai-computer-vision-can-transform-workplace-safety/</a></p></li></ol>

Struggling with safety compliance and quality control in manufacturing? Discover how Matroid’s no-code computer vision platform is transforming the industry with real-time defect detection, PPE monitoring, and predictive maintenance.

Leveraging Computer Vision to Tackle Safety and Quality Challenges in Manufacturing

<p dir="ltr" id="isPasted">Manufacturing defect rates have risen with metal fabrication facilities facing unprecedented challenges in maintaining quality control amid increasing operational complexity.&nbsp;</p><p dir="ltr">As production lines become more sophisticated and quality standards more stringent, traditional inspection methods must be revised for modern manufacturing demands.</p><p dir="ltr">Matroid is transforming this landscape by democratizing computer vision technology, making advanced automation accessible to industry professionals without coding expertise. Through its innovative platform, Matroid enables manufacturing teams to implement sophisticated defect detection and process monitoring solutions that can be deployed within minutes rather than months.</p><p dir="ltr">The impact is significant in welding applications, where Matroid's computer vision technology can evaluate multiple quality parameters simultaneously - from porosity and spatter to burn-through - with the precision of a weld engineering expert.&nbsp;</p><p dir="ltr">This scalable approach to quality control is proving essential as manufacturers face mounting pressure to maintain precision while managing costs.</p><p dir="ltr">We will explore in detail how Matroid's computer vision technology is changing the landscape of metal manufacturing, examining its technical capabilities, practical applications, and the tangible benefits it brings to production environments. &nbsp;For decision-makers, we'll look at how this technology sets new standards in automated quality control and process optimization.</p><h2 dir="ltr">Industry Challenges and Opportunities in Metal Manufacturing</h2><p dir="ltr">The metal manufacturing industry faces unprecedented pressures, with many organizations' quality control costs consuming <a href="https://www.weboccult.com/blog/computer-vision-for-quality-control-in-manufacturing-a-comprehensive-guide">15-20%</a> of annual sales revenue. Traditional manual inspection methods, while common, are increasingly inadequate for modern manufacturing demands, showing inconsistency rates increase due to operator fatigue and subjective assessments.</p><p dir="ltr">According to the US. Census Bureau <a href="https://www.census.gov/library/stories/2021/09/manufacturing-continues-to-be-among-top-five-largest-employment-sectors.html">study</a> shows that production facilities struggle with a critical shortage of skilled workers, with nearly one-fourth of the manufacturing workforce aged 55 or older. This demographic shift and early retirement trends post-pandemic have created significant gaps in quality control expertise and operational efficiency.</p><h3 dir="ltr">The Role of Automation and Computer Vision</h3><p dir="ltr">Computer vision technology is emerging as a transformative solution, capable of analyzing images and video from any imaging technology, spanning resolutions from low (VGA) to ultra-high (gigapixel) and across various spectra, including visible light, infrared, and x-ray. &nbsp;This enables the detection of the smallest and most challenging defects in manufacturing processes, enhancing quality control and operational efficiency.</p><p dir="ltr">Unlike traditional rule-based inspection systems, modern computer vision &amp; AI solutions can detect and classify multiple defect types simultaneously, from surface imperfections to welding anomalies.</p><p dir="ltr">Automated inspection systems are valuable in welding applications, where they can evaluate multiple quality parameters - including porosity, spatter, burn-through, edge welds, and cold welds - with consistent precision.&nbsp;</p><p dir="ltr">Computer vision &amp; AI address the skilled labor shortage and significantly improve inspection accuracy, with some implementations showing up to <a href="https://cloud.google.com/blog/products/ai-machine-learning/improve-manufacturing-quality-control-with-visual-inspection-ai">10x</a> improvement in defect detection compared to conventional methods, which leads to dramatic cost savings in cost per part and rework efforts and also improves production throughput.</p><h2 dir="ltr">Matroid's Vision and Technological Focus</h2><p>Founded in 2016 by Stanford professor and founding member of Databricks Reza Zadeh, Matroid has established itself as a leader in enterprise-level computer vision &amp; AI software platform, backed by <a href="https://growjo.com/company/Matroid">$33.5M</a> in funding from prominent investors, including NEA, Energize Ventures, and Intel Capital.&nbsp;</p><p dir="ltr" id="isPasted">The Matroid <a href="https://www.matroid.com/">platform</a> domain experts from manufacturing to rapidly deploy and adapt custom detectors that can leverage camera systems' imagery/ video types to detect and classify defects, monitor manual assembly operations, verify SOPs are followed, and provide continuous cycle-time analysis with unprecedented precision across various production environments.</p><h3 dir="ltr">Custom Detectors and Real-Time Monitoring</h3><p dir="ltr">Matroid's platform distinguishes itself through its no-code software to build and deploy detector systems, allowing manufacturing teams to develop specialized detection models through an intuitive point-and-click interface.&nbsp;</p><p dir="ltr">These vision detectors can simultaneously evaluate multiple quality parameters in metal processing applications - from weld porosity and spatter to surface defects and assembly errors - while maintaining consistent accuracy across varying conditions.</p><p dir="ltr">The platform's camera-agnostic system integrates seamlessly with existing infrastructure, supporting everything from standard industrial cameras to specialized equipment like borescopes, microscopes, and X-ray systems.&nbsp;</p><p dir="ltr">Real-time alerts and analytics are delivered directly with production systems (PLCs, SCADA, MES, ERP) and mobile devices. This enables immediate response to the right people and systems at the right time to detect anomalies and maintain digital traceability throughout manufacturing.</p><h2 dir="ltr">How Matroid’s Computer Vision Powers Welding Applications</h2><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/20FpAGGAqmk?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 460px;"></iframe></span><br></p><h3 dir="ltr">Detecting Defects in Metal Manufacturing</h3><p dir="ltr">Matroid's computer vision enables quality control oversight across the entire metal manufacturing process. The <a href="https://www.matroid.com/automated-visual-anomoly-detection/">system</a> identifies structural defects at the casting stage, like cracks, porosity, cold flow, and hot tears.&nbsp;</p><p dir="ltr">Within the stamping processes, Matroid detectors are used to replace manual visual inspection by automating the inspection of stamped parts for tears and splits. &nbsp;This gives near real-time feedback to production engineers on how the presses are performing and gives insights into potential adjustments to prevent further defects.&nbsp;</p><p dir="ltr">In the final inspection, the platform performs comprehensive checks to ensure consistently high quality, effectively reducing returns and warranty claims.</p><h3 dir="ltr">Computer Vision in Welding</h3><p>Matroid's technology monitors operations such as spot welding, MIG welding, and continuous seam welding through real-time monitoring and instant defect detection. The system evaluates multiple quality parameters simultaneously, identifying common issues like porosity, spatter, cold welds, edge welds, and burn-through, just as a weld engineering expert would.&nbsp;</p><p dir="ltr">The platform's deep learning capabilities enable it to detect defects as a person could through visual media (images/video). The solutions are designed for rugged &amp; dynamic manufacturing environments.&nbsp;</p><h3 dir="ltr">Root Cause Analysis and Real-Time Adjustments</h3><p dir="ltr">Matroid's <a href="https://www.qualitymag.com/articles/98221-advances-in-computer-vision-offer-a-clearer-path-to-reliable-quality-control">solution</a> provides detailed defect classification and analysis through its integrated system. The system immediately alerts operators when issues are detected through direct integration with production systems, QMS, and mobile devices. &nbsp;Production teams can take corrective action when they have near real-time classification information and analytics; for example, when burn-through is detected on welds, the welding engineer can make more effective adjustments to robotic welding systems faster. &nbsp;This reduces rework and defect risks and improves production throughput.&nbsp;</p><p dir="ltr">The platform operates 24/7, providing continuous monitoring and real-time insights into production operations. Through its historical data analysis capabilities, manufacturing teams can capture actionable insights and implement zero-defect initiatives.</p><h2 dir="ltr">Real-World Applications and Benefits&nbsp;</h2><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731927333487-1731927333487.png" id="isPasted" class="fr-fic fr-dii"></p><h3 dir="ltr" id="isPasted">Traditional Methods vs. Computer Vision &amp; AI for Welding</h3><p dir="ltr">Traditional welding inspection methods, relying on manual or basic automated systems, provide only binary pass/fail results. These systems need help to meet modern manufacturing demands, where quality teams need detailed defect analysis and real-time process adjustments.&nbsp;</p><p dir="ltr" id="isPasted">Manual inspections introduce delays between defect occurrence and detection, while inspector fatigue and varying experience levels lead to inconsistent results. Computer vision &amp; AI solutions powered by deep learning technology transform this landscape by enabling real-time identification and classification of specific weld defects.&nbsp;</p><p dir="ltr">Matroid's system automatically detects and categorizes issues such as porosity, burn-through, and spatter, immediately notifying weld engineers for rapid response. This immediate feedback loop allows manufacturing teams to quickly identify root causes and implement real-time process adjustments.</p><p dir="ltr">The deployment of edge or on-premises installations ensures minimal latency for real-time monitoring while maintaining data security. This approach enables manufacturing teams to shift from reactive quality control to proactive process optimization.&nbsp;</p><p dir="ltr">Through consistent quality assessment and automated defect classification, companies can reduce inspection time, minimize waste, and improve overall welding quality. The system's integration with existing production processes creates a seamless transition from traditional inspection methods to advanced computer vision &amp; AI solutions.</p><h2 dir="ltr">The Deployment of Matroid’s Solution</h2><h3 dir="ltr">Easy Integration and Deployment</h3><p dir="ltr">Matroid's computer vision &amp; AI platform integrates seamlessly with existing manufacturing infrastructure through multiple deployment options. The system can be implemented as downloadable software for on-premises installation or as a Cloud software service, allowing manufacturers to choose the deployment method that best suits their operational needs.&nbsp;</p><p dir="ltr">This flexibility enables manufacturing teams to maintain data security while leveraging advanced detection capabilities. &nbsp;Matroid’s platform makes integration into various control systems, MES, QMS, ERP, and databases easy so that production can work with real-time data and has enhanced traceability of the products produced.&nbsp;</p><h3 dir="ltr">Compatibility with Multiple Camera Technologies</h3><p dir="ltr">The platform's camera-agnostic approach sets it apart in the manufacturing sector. Matroid works with existing and new vision systems, supporting any image-or-video-based camera regardless of resolution (VGA - giga-pixel) or spectra (visible, infrared, X-ray, etc.).</p><p dir="ltr">This allows manufacturers to reuse their existing machine vision cameras and use the right imaging technology for the application at hand while maintaining the ability to detect visual defects. The system connects effortlessly with industrial cameras, supporting continuous 24/7 monitoring and real-time insights into manufacturing processes.</p><h2 dir="ltr">Future of Welding with Computer Vision &amp; AI</h2><p dir="ltr">Integrating computer vision technology in welding operations represents a significant leap forward in manufacturing quality control. Matroid's platform transforms traditional inspection methods by enabling real-time defect detection and detailed classification, which enables immediate process adjustments.&nbsp;</p><p dir="ltr">By combining deep learning capabilities with enterprise-grade deployment options, manufacturers can achieve consistent quality while reducing operational costs. The platform's ability to empower domain experts in manufacturing, work with existing infrastructure, and support multiple camera technologies makes it a practical solution for facilities of all sizes.</p><h2 dir="ltr">Ready to make your welding operations efficient and reliable with advanced computer vision?</h2><p dir="ltr">Discover how Matroid's platform can enhance your quality control processes and drive real-time improvements. Visit Matroid's <a href="https://www.matroid.com/">website</a> to explore their innovative solutions for metal manufacturing.</p><h2 dir="ltr">References</h2><ol><li dir="ltr"><p dir="ltr"><a href="https://info.matroid.com/visual-inspection-computer-vision-software">https://info.matroid.com/visual-inspection-computer-vision-software</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.dayjob.com.au/metal-fabrication-challenges-with-sustainability/">https://www.dayjob.com.au/metal-fabrication-challenges-with-sustainability/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.matroid.com/automated-visual-anomoly-detection/">https://www.matroid.com/automated-visual-anomoly-detection/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.qualitymag.com/articles/98221-advances-in-computer-vision-offer-a-clearer-path-to-reliable-quality-control">https://www.qualitymag.com/articles/98221-advances-in-computer-vision-offer-a-clearer-path-to-reliable-quality-control</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.weboccult.com/blog/computer-vision-for-quality-control-in-manufacturing-a-comprehensive-guide">https://www.weboccult.com/blog/computer-vision-for-quality-control-in-manufacturing-a-comprehensive-guide</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://cloud.google.com/blog/products/ai-machine-learning/improve-manufacturing-quality-control-with-visual-inspection-ai">https://cloud.google.com/blog/products/ai-machine-learning/improve-manufacturing-quality-control-with-visual-inspection-ai</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.matroid.com/automated-visual-anomoly-detection/">https://www.matroid.com/automated-visual-anomoly-detection/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.qualitymag.com/articles/98221-advances-in-computer-vision-offer-a-clearer-path-to-reliable-quality-control">https://www.qualitymag.com/articles/98221-advances-in-computer-vision-offer-a-clearer-path-to-reliable-quality-control</a></p></li></ol>

Discover how computer vision is solving quality challenges in metal manufacturing through enhanced defect detection, proactive process monitoring, and flexible integration solutions.

AI-Powered Welding: How Computer Vision Solutions Drive Precision and Efficiency in Metal Manufacturing

<p dir="ltr" id="isPasted">Since its founding nearly 25 years ago, welding specialist<a href="https://www.elektrolas.com/en/" target="_blank">&nbsp;Elektrolas</a> has evolved from a company that supplies and maintains welding equipment to one that also offers training and quality management services and, most recently, welding automation services. In parallel to this expansion, the Dutch company has also evolved in terms of the technologies it uses. Notably, it has embraced the use of 3D printing (specifically,<a href="https://ultimaker.com/3d-printers/s-series/ultimaker-s5/" target="_blank">&nbsp;UltiMaker’s S5 ProBundle</a>), which has enabled it to improve automated welding setups and streamline operations.</p><h2 dir="ltr">The road to 3D printing adoption</h2><p dir="ltr" id="isPasted">Like many companies familiar with more conventional production techniques, Elektrolas did not immediately recognize the benefits of integrating 3D printing into its processes. It took Thije van Delft, Technical Manager at Elektrolas, to invest in the technology himself and test out how it could be used in a welding context.</p><p dir="ltr">He says: “I had done some tests in school using 3D printers, and I asked the company owner [Joost van den Hooven] if I could buy one. He said it wasn’t possible, so I said ‘I will buy one myself’ and purchased a very simple 3D printer for a couple hundred euros and started with that. We did some tests and after some time, Joost was convinced”. From there, Elektrolas consulted with the engineering students participating in traineeships at the company (who were familiar with 3D printing through their studies) about which 3D printer hardware they should invest in. After much deliberation, UltiMaker’s S5 ProBundle was chosen.</p><h2 dir="ltr">Unlocking new applications</h2><p dir="ltr">The UltiMaker 3D printer has played an important role at the company, particularly as Elektrolas has ramped up its automation department (spearheaded by van Delft), supplying robotic and cobot welding systems to customers in the Netherlands and beyond. To date, the company has sold and installed dozens of cobot welding systems, which empower its customers to accelerate their lead times and achieve consistent quality, all while mitigating labor shortages in the welding sector.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjMzMTE3NjI2LWluc2lkZXdlbGQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Thije van Delft with the UltiMaker S5 ProBundle, and the cobot welding rig in the back.</span></span></span></p><p dir="ltr" id="isPasted">3D printing has come into play in the production of clamps, which are installed on welding cobots to keep things running smoothly and to ensure the freedom of movement of the robotic arm. Van Delft explains: “We have a holder and an arm clamp that attach the torch hose to the robot. This is made up of two parts: one part that clamps to the robot and one part that attaches to the hose. These are fixed with a fixing pin. If you wanted to make that using milling or other conventional processes, it would not be possible.”</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2NzgwMjQ1LWxvdyBpbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The complex form of the clamp makes it perfect to be 3D printed at a cost and timeframe impossible to replicate in other manufacturing methods. Image credit: Elektrolas.</span></span></span></p><p dir="ltr" id="isPasted">The company has also found it possible to quickly iterate replacement parts for the 3D printed clamps. Made from Tough PLA, it does happen that the clamps break sometimes. “In this case it’s very easy to print a new one and send it the next day to the customer,” van Delft says. “The customer simply sends a picture of what part is broken, we start the printer, and the next day we can send it via DHL to the customer.” This, of course, has the obvious benefit of eliminating the need for large inventories of spare clamps, since they can be printed on demand.</p><p dir="ltr" id="isPasted">Elektrolas has also turned to 3D printing in the production of temporary holders that attach hand welding torches to robotic or cobot systems. In this case, UltiMaker’s solution enabled Elektrolas to meet the needs of one of its customers who wanted to integrate a manual welding torch in an automated system. “We called the supplier of this welding torch, but the automatic version had a delivery time of 10-12 weeks,” van Delft recalls. By designing and 3D printing a holder to attach the welding torch to the robot, Elektrolas was able to offer its customer a stopgap solution while they waited for the final part from the welding torch supplier. This enabled them to keep their automated welding production up and running rather than being setback by system downtimes.</p><h2 dir="ltr">Why the UltiMaker’s S5 ProBundle?</h2><p dir="ltr">While both UltiMaker and Elektrolas are based out of the Netherlands, the local appeal was only part of the equation when the welding company started looking for a 3D printing solution to adopt three years ago. UltiMaker’s S5 ProBundle is a professional-grade solution that combines UltiMaker’s reliable dual-extrusion technology with advanced features like automated material management, superior air filtration, and humidity control for filament. The 3D printer also has a sizable print volume (330 x 240 x 300 mm), which was an important factor for Elektrolas as the company often prints large components.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2ODQ0NTY0LWRlZXAgLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Multiple prints can be completed simultaneously in the S5’s large print bed.&nbsp;</span></span></span></p><p dir="ltr" id="isPasted">Ease of use and print quality were also top of mind for van Delft and his team. The UltiMaker S5 ProBundle delivered on both fronts. Elektrolas has achieved consistency from print to print thanks to the ability to save setup and print settings in Cura. As van Delft explains, he and his team are able to design the parts they need in SolidWorks and print them on demand with the touch of a button. This is also thanks to the work of their trainee students, who have pre-programmed print settings, and UltiMaker’s intuitive user interface, which enables one-button printing. “If, for example, a client wants to weld with some special machine but there is no welding torch on the robot, we can take a normal welding torch and sketch a holder in SolidWorks and then print it.” Using this approach, test parts can be delivered the next day.</p><p dir="ltr">In terms of printing materials, Elektrolas is primarily working with<a href="https://ultimaker.com/materials/s-series-tough-pla/" target="_blank">&nbsp;UltiMaker Tough PLA</a>, a technical PLA filament that offers good toughness (similar to ABS), as well as minimal warping and excellent printability at an affordable cost. While not the most robust material in UltiMaker’s portfolio, Tough PLA does meet the needs of the welding company for the clamps and holders. Even the material’s weaknesses have proven to be a benefit. “I have twice received a request for a new 3D printed clamp because the operator of the robot made a mistake and broke the clamp when the torch hit some corner when the robot was moving,” van Delft elaborates. “Here it is good that the clamp breaks, because it protects the torch from breaking. The clamp is not expensive and easy to replace, the torch is not.”</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2OTA5Mjg1LWxvdyByZXMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The 3D printed clamps enable the welding hoses to be safely secured. By printing in Tough PLA, the clamps are robust but also quick and affordable to replace when needed.</span></span></span></p><p dir="ltr" id="isPasted">Elektrolas also benefits from other features that come with the S5 ProBundle, including Air Manager, an enclosure that provides closed inside-out airflow and filters up to 95% of ultrafine particles (UFPs) generated in the printing process, and the S5 Material Station. This piece of equipment stores and protects up to six spools of filament and offers end-of-filament detection and automatic spool switching, which facilitates lights-out printing. “If you have a big print, it is maybe 35-45 hours of printing,” van Delft adds. “Since we have big prints, the material station can change the PLA by itself and keep the print going until it’s ready the next day.”</p><p dir="ltr">For 3D printer maintenance and technical support, Elektrolas turns to <a href="https://www.makerpoint.nl/nl-nl/" target="_blank">MakerPoint</a>, a Dutch supplier of 3D printing systems and maintenance provider based in Arnhem, Best, and Harlingen.</p><h2 dir="ltr">Intuitive 3D printing for traditional manufacturing</h2><p dir="ltr">Elektrolas is one of many businesses in the traditional manufacturing sphere that has reaped the benefits of UltiMaker’s professional 3D printing solutions. For example,<a href="https://www.wevolver.com/article/eriks-leveraging-3d-printing-to-improve-manufacturing-processes" target="_blank">&nbsp;industrial supplier ERIKS BV</a> relies on UltiMaker systems for a range of applications, including prototyping, tooling, customized jigs and fixtures, and replacement parts. You can find more<a href="https://www.wevolver.com/profile/team.ultimaker" target="_blank">&nbsp;UltiMaker client stories here</a>.</p>

Dutch welding solutions specialist Elektrolas uses the UltiMaker 
S5 ProBundle to minimize machine downtimes and facilitate cobot welding for its customers.


How UltiMaker 3D Printing Supports Automated Welding

<p>In order to get the most out of your 3D printer, you need to align the material you are using with the requirements of your application. This is especially true when creating high-performance parts such as those enabled by carbon fiber. In this post, we will be zooming in on the practical applications of 3D printed carbon fiber composites across multiple categories in order to explore how this unique material is driving efficiency and precision in everything from welding to robotic automation.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/mf0I5aXjr08?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted">Carbon fiber composite 3D printing in action</h2><p>The following are four example applications that are well served by the unique properties that carbon fiber offers:</p><h3>Enhancing Welding Processes with Custom Fixtures</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692016897308-Enhancing-Welding-Processes-with-Custom-Fixtures-UltiMaker-3D-printing.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">In the realm of welding, precision and accuracy are paramount. Custom fixtures, specifically designed to hold the pieces together before the welding process, play a crucial role. These fixtures need to be sturdy and heat-resistant, given the high temperatures involved in welding.</p><p>One of&nbsp;<a href="https://ultimaker.com/learn/the-advantages-of-3d-printing-with-carbon-fiber/" target="_blank">the advantages of 3D printing with carbon fiber</a> is that it&rsquo;s possible to create custom fixtures that meet these stringent requirements. The high heat deflection temperature and rigidity of the new UltiMaker PET CF after annealing, in particular, makes it perfect for the task. The ability to design these fixtures in CAD and print them directly reduces labor time and ensures a tight tolerance fit, improving the overall efficiency and quality of the welding process.</p><h3>Bending Dies for Versatile Metal Shaping</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692016916593-Bending-Dies-for-Versatile-Metal-Shaping-UltiMaker-3D-printing.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Bending dies are crucial tools used with a hydraulic press to shape and form metal parts. Depending on the job specifics or facility requirements, these parts may need frequent customization. Traditional manufacturing methods can be time-consuming and costly for such instances.</p><p>With 3D printing technology, you can create custom bending dies quickly and efficiently. Carbon fiber composites stand out as the material of choice here, thanks to their exceptional rigidity. This means the part can hold its form under more pressure than many other polymers, ensuring the die maintains the intended shape and produces accurate, high-quality metal parts.</p><h3>Robotic Automation with End-of-arm Tooling</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692016937822-Robotic-Automation-with-End-of-arm-Tooling-UltiMaker-3D-printing.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">In the field of manufacturing automation, robotic arms are invaluable tools for performing repetitive tasks with exceptional precision. The tools at the end of these arms, known as end effectors, can vary greatly depending on the specific application, from gripping devices to welding torches.</p><p>The ability to 3D print these end effectors with carbon fiber composites presents a game-changing opportunity. The lightweight nature of carbon fiber composite reduces the overall weight of the robotic arm, increasing its payload capacity, speed, and maneuverability. This not only enhances productivity but also extends the lifespan of the robotic arm by reducing wear and tear.</p><h3>Ensuring Precision with Alignment Tools</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692016963917-Ensuring-Precision-with-Alignment-Tools-UltiMaker-3D-printing.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Alignment tools or gauges are used in manufacturing and assembly processes for quick and precise measurements. These tools need to be rigid to ensure they don&rsquo;t flex or compress during measurements, which could lead to inaccuracies and inconsistent assemblies.</p><p>Carbon fiber composites, with their inherent rigidity, make an excellent choice for these tools. The ability to 3D print these tools means you can customize them for any specific measurement requirement, ensuring your manufacturing process is as accurate and efficient as possible.</p>

In this post, we will be zooming in on the practical applications of 3D printed carbon fiber composites across multiple categories in order to explore how this unique material is driving efficiency and precision in everything from welding to robotic automation.

Finding the perfect carbon fiber 3D printing application

<h2 id="isPasted">What Is Plasma Welding?</h2><p>Plasma arc welding (PAW) is a fusion welding process that uses a non-consumable electrode and an electric plasma arc to weld metals. Similarly to TIG, the electrode is generally made out of thoriated tungsten.<strong>&nbsp;Its unique torch design produces a more focused beam than TIG welding</strong>, making it a great choice for welding both thin metals and creating deep narrow welds.</p><p>Plasma welding is often used to <a href="https://fractory.com/stainless-steel-welding-explained/" target="_blank">weld stainless steel</a>, aluminum, and other difficult metals compared to traditional methods. Similarly to <a href="https://fractory.com/gas-welding-explained/" target="_blank">oxy-fuel welding</a>, this process can also cut metal (<a href="https://fractory.com/plasma-cutting/" target="_blank">plasma cutting</a>), making it a versatile tool for fabricators and manufacturers.</p><h2>Plasma Arc Welding Process</h2><p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe width="640" height="360" src="https://www.youtube.com/embed/588EJInHLsc?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><p id="isPasted">The plasma arc welding process revolves around the principle of striking an arc between a non-consumable tungsten electrode and the workpiece. The plasma nozzle has a unique design feature, where the electrode is located within the body of the torch. <strong>This allows the arc plasma to exit the torch separated from the shielding gas envelope.</strong></p><p>Additionally, the narrow opening of the nozzle increases the plasma gas flow rate, allowing for deeper penetration. While filler metal is typically supplied at the weld pool&rsquo;s leading edge, it is not the case when creating root pass welds.</p><p>The complexity of the plasma welding torch sets it apart from gas tungsten arc welding. <strong>Plasma welding torches operate at very high temperatures</strong>, which can melt away their nozzle, making it a requirement to always be water-cooled. While these torches can be manually operated, nowadays, <strong>most modern plasma welding guns are designed for automatic welding</strong>.</p><p>The most <a href="https://fractory.com/welding-defects-types-causes-prevention/" target="_blank">common defects</a> associated with plasma welding are tungsten inclusions and undercutting. Tungsten inclusions occur when the welding current exceeds the capabilities of the tungsten electrode and small droplets of tungsten get entrapped in the weld metal. Undercuts are generally associated with keyhole mode PAW welding and can be avoided by using <a href="https://weldknowledge.com/2015/10/03/plasma-arc-welding-paw-with-activated-flux/" rel="noopener" target="_blank">activated fluxes</a>.</p><h3>Plasma Arc Welding Operating Modes</h3><p>Three operating modes are used in plasma welding, wherein it can be operated at varying currents:</p><h4>Microplasma (0.1 &ndash; 15A)</h4><p>This operating mode can run arcs at low currents and remain stable up to 20mm arc length.</p><p>Microplasma welding is used to join thin sheets up to 0.1 mm in thickness, which is optimal for creating wire meshes with minimal distortion.</p><h4>Medium current (15 &ndash; 200A)</h4><p>The characteristics of the plasma arc are quite similar to TIG welding, but the arc is stiffer since the narrow opening of the torch restricts the plasma. We can increase weld pool penetration by speeding up the plasma flow rate, but this increases the risk of shielding gas contamination.</p><p>Medium current or melt-in mode offers better penetration than TIG and improved protection. The only drawback is that the torch requires maintenance and is bulkier compared to a TIG torch.</p><h4>Keyhole mode (over 100A)</h4><p>A powerful plasma beam is used to engage in high-current aka keyhole mode by increasing the gas flow and welding current. This mode allows deep penetration, using a single pass (up to 10mm thick for some materials) to create a consistent weld pool from molten metal.</p><p>Similarly to <a href="https://fractory.com/electron-beam-welding-ebw-explained/" target="_blank">electron beam welding</a>, the keyhole mode is great for welding thicker materials at high welding speeds. To guarantee satisfactory welds, filler material is generally added. Its welding applications include mechanised welding, positional welding, and pipe welding.</p><h3>Comparison of Plasma and TIG Welding</h3><p>Normally, a tungsten electrode is used in TIG welding to strike an arc between the torch and the workpiece. The plasma process works similarly but uses a different setup in its welding torch. The constricted nozzle design allows electrons to move at high velocities. This ionises the gas, creating a plasma jet with a high heat concentration, offering deeper penetration.</p><p>As plasma welding offers greater precision than TIG welding, it has a smaller <a href="https://fractory.com/heat-affected-zone-causes-effects-reduction/" target="_blank">heat-affected zone</a> which is perfect for creating narrower welds. Ideally, plasma welding is a better choice than TIG welding, as it is an evolution of the latter. The technology behind its equipment allows it to run with lower current demand, better arc stability which leads to better stand-off distance, and better <a href="https://fractory.com/engineering-tolerances/" target="_blank">tolerances</a> if the arc length is changed.</p><p>TIG welding however is a simpler method due to the complex parameters available for plasma gas welding. An operator would need extra training in order to transition from the already advanced TIG welding to PAW. And last, TIG welding equipment is cheaper and requires less maintenance than plasma arc welding&rsquo;s sensitive and complex torch.</p><h3 id="isPasted">Materials</h3><p>Similarly to TIG welding, plasma welding is suitable for the majority of well-known metals, although it might not be the most <a href="https://fractory.com/design-to-cost-dtc/" target="_blank">cost-effective</a> solution for some of them:</p><ul><li><p>Alloy Steel</p></li><li><p><a href="https://fractory.com/aluminium-grades/" target="_blank">Aluminium</a></p></li><li><p>Bronze</p></li><li><p>Carbon Steel</p></li><li><p>Copper</p></li><li><p>Iron</p></li><li><p>Inconel</p></li><li><p>Lead</p></li><li><p>Magnesium</p></li><li><p>Monel</p></li><li><p>Nickel</p></li><li><p><a href="https://fractory.com/what-is-stainless-steel/" target="_blank">Stainless Steel</a></p></li><li><p>Titanium</p></li><li><p>Tool Steel</p></li><li><p>Tungsten</p></li></ul><h3>Equipment</h3><p>The key components of plasma welding equipment are:</p><h4>Plasma torch</h4><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689323314641-plasma-welding-torch.jpg.jfif" style="width: 768px;" class="fr-fic fr-dib"><span class="fr-inner"></span></span></span></p><figure id="isPasted"><figcaption>Plasma torch &ndash; plasma gas is separated from the shielding gas envelope.</figcaption></figure><p></p><figure id="isPasted"><figcaption><br></figcaption></figure><p><span style="background-color: transparent;">The unique design of the water-cooled plasma torch is the main distinguishing factor from other welding processes. Its operating principles have already been explained in previous sections.</span></p><p>Depending on the weld material and desired weld characteristics, different types of nozzle tips can be selected.</p><h4>Control console</h4><p>While conventional welding techniques directly connect a torch to a power source, plasma arc welding uses a control console between the two.</p><p>Some of the console features are the torch protection circuit, high-frequency arc starting unit, power supply for the pilot arc, water, and gas valves, individual meters for plasma, and shielding gas flows.</p><h4>Power supply</h4><p>Plasma arc welding uses DC power (rectifiers or generators) of at least 70 volts for open circuit voltage with drooping characteristics to have greater control in generating weld beads.</p><h4>Gases used</h4><ul><li><p>Plasma gas &ndash; exits the constricting nozzle separately from the shielding gas envelope and becomes ionised</p></li><li><p>Shielding gases (argon, helium, hydrogen) &ndash; inert gas protects the weld from the atmosphere</p></li><li><p>Back-purge and trailing gas &ndash; certain materials require special conditions</p></li></ul><h4>Wire feeder</h4><p>Plasma welding may use wire feeders with a constant velocity that can be modified to run from 254 mm per minute to 3180 mm per minute.</p><h3>Applications</h3><h4>Steel tubes</h4><p>PAW is a great welding method in manufacturing steel tubes as it can be performed at high-speed welding with great metal penetration. Some industries prefer the plasma welding process to conventional TIG since its system is faster and uses less filler material.</p><h4>Electronics</h4><p>One of the welding parameters of the plasma welding process is it can run at low current modes. This mode allows small metal component welding, which deals with delicate materials sensitive to environmental factors.</p><h4>Medical industry</h4><p>Medical devices require precise components in order to run effectively. PAW is perfect for welding these components as it can reliably create a consistent weld bead.</p><h2>Advantages of Plasma Welding</h2><ol><li><p>Can be operated in every welding position.</p></li><li><p>Fast travel speeds from concentrated heat input.</p></li><li><p>Keyhole welding allows for complete penetration.</p></li><li><p>Low current mode is suitable for thin and sensitive components.</p></li></ol><h2>Disadvantages of Plasma Welding</h2><ol><li><p>Expensive equipment and components.</p></li><li><p>Requires training and skill to create good welds.</p></li><li><p>Produces 100dB noise.</p></li><li><p>Creates ultraviolet and infrared radiation.</p></li><li><p>Water cooling is necessary because of high working temperatures.</p></li><li><p>Delicate equipment needs a higher amount of maintenance.</p></li></ol>

Plasma welding is an arc welding process that uses a plasma torch to join metals. The principle of this method is derived from GTAW aka TIG welding, where an electric arc is struck between the electrode and the workpiece.

Let’s dig deeper and explore what plasma welding is all about.

Plasma Arc Welding (PAW) Explained

<p data-pm-slice="1 3 []" id="isPasted">Submerged arc welding is a standard industrial process wherein an arc is formed between a workpiece and an electrode. It was invented in 1935 by the E. O. Paton Electric Welding Institute in Kyiv, Ukraine as a driving force behind the Second World War. One of the most notable applications of this invention is the&nbsp;<a href="https://en.wikipedia.org/wiki/T-34" rel="noopener" target="_blank">T34 military tank</a>.</p><p>While this <a href="https://fractory.com/types-of-welding-processes/" target="_blank">welding technology</a> has been around for almost a century, it is still an essential choice for many industries.</p><h2 id="isPasted">What Is Submerged Arc Welding?</h2><p>Submerged arc welding (SAW) is a welding method where similarly to other arc welding processes, the base metals are joined by forming an electric arc between the workpiece and an electrode.</p><p>SAW process&rsquo;s defining element is how it protects the weld metal from atmospheric contamination.&nbsp;<strong>Submerged arc welding uses a powdered flux layer, generating shielding and slag while creating a smooth and clean weld.</strong> Other methods use shielding gas (<a href="https://fractory.com/mig-vs-tig-welding/" target="_blank">MIG/TIG welding</a>), flux-cored wire (<a href="https://fractory.com/flux-cored-arc-welding-explained/" target="_blank">FCAW</a>), flux-coated electrode (<a href="https://fractory.com/shielded-metal-arc-welding/" target="_blank">SMAW</a>), or controlled environment (<a href="https://fractory.com/plasma-arc-welding-paw-explained/" target="_blank">plasma welding</a>) for protecting the weld.</p><h2>How Does the Submerged Arc Welding Process Work?</h2><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg4MDM3NDg5NTYwLXN1Yi1hcmMtd2VsZGluZy1lcXVpcG1lbnQtNC5qcGcuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Submerged arc welding creates consistent welds by using a blanket of granulated flux. For this reason,&nbsp;<strong>the process can be operated only on positions that are flat and horizontal</strong>, with the weld advancing by either moving the welding system or the workpiece.</p><p>Flux is fed into the joint manually or by using a flux hopper. A single electrode or multiple wire electrode system is placed into the working area, surrounded by the flux blanket. Parameters such as the welding current, arc voltage, and wire feed speed are set depending on the&nbsp;<a href="https://fractory.com/types-of-metal/" target="_blank">type of metal</a>, its thickness, and desired&nbsp;<a href="https://fractory.com/mechanical-properties-of-materials/" target="_blank">mechanical properties</a>. Electric current is supplied to the electrodes, producing intense heat that melts and fuses the base material and the filler wire to the bead.</p><p>The molten metal cools down, creating strong uniform welds and reusable granular flux at the surface and slag underneath. A hopper collects the reusable flux, while slag is usually peeled off manually.</p><p>SAW produces high-quality welds with fewer&nbsp;<a href="https://fractory.com/welding-defects-types-causes-prevention/" target="_blank">weld defects</a> than other processes. However, this does not mean that defects won&rsquo;t ever occur. When they do, it&rsquo;s generally related to wrongly set welding parameters.</p><h2>Flux</h2><h3>Granular Flux</h3><p>Granular flux inside a hopper is usually composed of oxides from aluminium, calcium, magnesium, manganese, silicon, titanium, and zirconium. This composition suits the type of electrode to achieve the metal&rsquo;s desired properties as it chemically reacts as it melts.</p><h3>Bonded Flux</h3><p>Bonded flux is produced by drying the composition and slowly baking it, usually with a compound such as sodium silicate. As an advantage, bonded flux can contain alloying elements, offering flexibility for some applications and protection against rust.</p><h3>Fused Flux</h3><p>Fused flux is produced by melting the composition inside an electric furnace. The molten flux is formed into homogenous particles as it solidifies. It is excellent for creating consistent welds along the bead.</p><h2>Wire Electrode</h2><p>SAW uses a wire spool to feed the wire electrode into the weld.&nbsp;<strong>The wire&rsquo;s thickness is usually between 1.6mm and 6mm</strong>. Electrodes may come in the form of solid, twisted, or cored wire and may be operated using different power sources.</p><p>Specific circumstances may need the use of modified wire electrodes and electrode systems to achieve the desired weld profile:</p><ul><li><p>Twin-wire</p></li><li><p>Multiple wires</p></li><li><p>Single wire with hot/cold addition</p></li><li><p>Metal powder additive</p></li><li><p>Tubular wire</p></li></ul><p>Multiple wire systems typically use a lead wire to improve penetration, while a trailing wire is used to add extra fill and improve the bead profile. Additional wires are used in the electrode system to add more deposition to the weld pool.</p><h2 id="isPasted">Materials</h2><p>Submerged arc welding process is used with the following materials:</p><ul><li><p>Copper alloys</p></li><li><p>Low to medium-carbon steels</p></li><li><p>Low-alloy steels</p></li><li><p>Mild steels</p></li><li><p>Nickel-based alloys</p></li><li><p><a href="https://fractory.com/quenching-explained/" target="_blank">Quenched</a> and&nbsp;<a href="https://fractory.com/tempering-explained/" target="_blank">tempered steel</a></p></li><li><p>Stainless steels</p></li><li><p>Uranium alloys</p></li></ul><h2>Power Source</h2><p>Submerged arc welding can operate on multiple power outputs, allowing it to manipulate the weld results. Multiple electrode systems enable SAW to run wires at different power sources, to better control the bead profile and penetration.</p><p>DCEP offers the most stability and penetration, while DCEN is optimal in increasing deposition rates. Running this welding process in AC is the middle ground where a balance between the two is achieved.</p><h2>Applications and Industries</h2><p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe width="640" height="360" src="https://www.youtube.com/embed/NrGzYK-H5oI?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-gtm-yt-inspected-9="true" id="978819855" title="SUBMERGED ARC WELDING MACHINE"></iframe></span></p><h3 id="isPasted">Fabrication</h3><p>SAW is one of the preferred welding processes in fabricating pressure vessels, pipes, and boilers due to its strength in longitudinal and circumferential welding. This welding operation achieves a smooth weld pool from the continuously fed electrode.</p><h3>Shipbuilding</h3><p>The flexibility of SAW process allows it to be performed both indoors and outdoors which makes it suitable for shipbuilding. It&rsquo;s perfect for creating long, straight welds for heavy metals which make up ship parts.</p><h3>Automotive</h3><p>Metals used in the automotive and military industry are fit for SAW, along with the speed and efficiency it brings. This welding method is also perfect for automation, with the option to have multiple or single-pass welds based on the metal&rsquo;s thickness.</p><h3>Railways</h3><p>The submerged arc process allows deep weld penetration, which is attractive to the railway industry.</p><h2>Advantages of SAW</h2><ol><li><p>The blanket of granular flux creates minimal welding fume and spatter.</p></li><li><p>Allows performing semiautomatic or fully automatic welding.</p></li><li><p>Flexible for both indoor and outdoor applications.</p></li><li><p>Creates smooth, uniform and deep welds.</p></li><li><p>Around 50-90% of the flux is reusable and recyclable.</p></li></ol><h2>Limitations of SAW</h2><ol><li><p>Limited to flat and horizontal welding positions</p></li><li><p>A rather narrow range of weldable metals.</p></li><li><p>Requires post-welding slag removal.</p></li><li><p>Practically restricted to circumferential and long straight beads.</p></li><li><p>Precise parameters are required to achieve desired weld deposit since welds aren&rsquo;t visible while welding.</p></li></ol>

Submerged arc welding is a standard industrial process wherein an arc is formed between a workpiece and an electrode. It was invented in 1935 by the E. O. Paton Electric Welding Institute in Kyiv, Ukraine as a driving force behind the Second World War. One of the most notable applications of this invention is the T34 military tank.

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