Welding Defect Analysis and Treatment Methods

Robot welding uses argon-rich mixed gas shielded welding. Common welding defects that may occur during welding include weld deviation, undercut, and porosity. A detailed analysis is as follows:

1. Weld offset may be due to incorrect welding position or a problem with the welding torch's search. In this case, consider the accuracy of the TCP (tungsten center point position) and adjust it. If this occurs frequently, check the zero position of each robot axis and recalibrate it to correct it.

2. The occurrence of undercut may be due to improper selection of welding parameters, incorrect welding gun angle or welding gun position. You can adjust the power appropriately to change the welding parameters, adjust the welding gun posture and the relative position of the welding gun and the workpiece.

3. The appearance of pores may be due to poor gas protection, too thick primer on the workpiece or insufficient drying of the protective gas. This can be solved by making corresponding adjustments.

4. Excessive spatter may be caused by improper selection of welding parameters, gas composition or too long extension of welding wire. You can adjust the power appropriately to change the welding parameters, adjust the gas proportioner to adjust the mixed gas ratio, and adjust the relative position of the welding gun and the workpiece.

5. An arc pit is formed at the end of the weld after cooling. When programming, add the arc pit function in the work step to fill it.

Common robot system failures during welding

1. Gun collision. This may be caused by deviations in workpiece assembly or inaccurate welding gun TCP. Check the assembly or correct the welding gun TCP.

2. An arc fault occurs and the arc cannot be struck. This may be because the welding wire does not touch the workpiece or the process parameters are too small. You can feed the wire manually, adjust the distance between the welding gun and the weld, or adjust the process parameters appropriately.

3. Shielding gas monitoring alarm: There is a fault in the cooling water or shielding gas supply. Check the cooling water or shielding gas pipeline.

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