Bruce Madigan

1107 Lewisohn Street Butte MT, 59701 madigan@weldworks.com Phone 406-782-5157

Selection of Welding Engineering Projects

	Manual Weld Training Monitor WeldWare, Inc.	Welding Process Monitoring Procedure Validation
	The Manual Weld Training Monitor consists of a small single board computer (SBC) in an enclosure that is mounted to the wall of a welder training booth. The SBC collects and processes arc voltage, arc current and wire feed speed data from SMA, GTA, GMA and FCA welding processes and provides real-time feedback to the welder via an LED display mounted within the welder's helmet. The welding procedure (limits for voltage, current and wire speed) and welder identification (name and ID number) are composed on a Palm Pilot hand-held computer and downloaded to the monitor. The monitor compares the defined limits to the actual welding data and calculates the percentage of time the limits were violated. The results for a weld session can then be uploaded back to the Palm Pilot and transferred to a desktop computer for further analysis and archiving.

	TIG-pc Weld Penetration Controller WeldWare, Inc.	Welding Process Control Procedure Development
	The TIG-pc Weld Penetration controller is used to measure and control the amount of penetration in a GTA weld . Weld penetration is inferred by calculating the natural frequency of weld pool oscillations. The TIG-pc controller measures weld pool oscillations from arc voltage and arc light and adjusts welding current to maintain the desired amount of weld penetration in response to disturbances that may otherwise change weld penetration (such as base metal thickness, joint fitup and heat sinking). Welding procedures where developed for 12mm to 100mm diameter pipe and tubing with wall thicknesses from 1mm to 12mm. Procedures where developed for steel, stainless steel, titanium and nickel-based alloys. TIG-pc is able to maintain weld penetration to within +/- 5% of the desired value compared to +/- 50% change in penetration for a similar weld without penetration control. TIG-pc is designed to integrate with a variety of welding equipment such as lathes, seamers and orbital heads.

	Weld Quality Manager WeldWare, Inc.	Welding Information Systems Weld Quality
	Weld Quality Manager (WQM) is a welding information system for capturing and analyzing weld quality data to reduce scrap and rework and therefore improve welding process throughput. WQM consists of three companion modules accessing an SQL database via network connections. The Data Entry module runs on a tablet PC with a wireless network connection and is used on the factory floor to collect weld quality data. The Data Entry module allows the inspector to view a picture of the part being inspected and graphically add defects (type and extent) directly on the picture at the proper location. The Setup module is used to configure the information (defect types, part pictures, inspector permissions, PQR, AWS, ASME and ISO Standards, etc...) that is available on the Data Entry module. The Analysis module is used to analyze the weld quality data.

	Automatic Welding Monitor WeldWare, Inc.	Welding Process Monitoring Procedure Validation
	The Automatic Welding Monitor (AWM) is used to verify welding procedure compliance for automated and robotic GMA and FCA welding processes. The AWM collects arc current, arc voltage and wired feed speed data during a weld and compares the actual values to the limits programmed into the unit by the welding engineer. The welding schedule can be programmed locally via a keypad and display on the unit or remotely via a network connection. Raw and summary data for the completed welds can be uploaded from the unit to a remote desktop PC for analysis and archiving. A local digital I/O interface on the AWM can be connected to a weld cell controller, such as a PLC. The AWM PLC interface allows welding schedules to be selected by the PLC automatically on-the-fly and can be configured to stop welding if a problem with the process is detected.

	Coaxial Vision Torch WeldWare, Inc.	Welding Process Monitoring and Control
	The WeldVision Coaxial Vision Torch (CVT) consists of a hollow GTAW torch fitted with a video camera mounted coaxially with the welding electrode. The design of the CVT, invented by Professor Richard W. Richardson of Ohio State University, allows a unique view of the welding process in real-time. Video image processing is used to extract information from the weld scene to provide feedback about the welding process. The CVT can be integrated into welding equipment to provide weld seam tracking and pool size control.

	Welding Power Source Remote Control Interface Arc Logic Company	Welding Systems Integration
	The Welding Power Source Remote Control Interface project resulted from the need of a client to connect multiple Weldlogic welding power sources, each containing only a single RS-232 serial interface. The welding power source was designed to communicate over the serial interface to a proprietary software setup program. The serial communications protocol was deciphered and reproduced to allow up to 8 welding power sources to be controlled from a single master control station.

	Weld Cell Controller Arc Logic Company	Welding Process Control Systems Integration
	A weld cell controller was developed to control the operation of a GTA/PA welding system including a welding power source, wire feeder and 3-axis rectilinear robot. The weld cell controller allows all aspects of the welding system, including arc current, arc voltage, wire feed speed and torch motion to be programmed via a graphical user interface. The welding procedure can be programmed for multiple segments based on time from the start of the welding or based on location of the welding torch. The weld cell controller contains user definable sensor inputs and control outputs that could be integrated into the overall control sequence. Real-time data collection allows post weld analysis for process control and historical record archiving.

	High-speed Video Analysis System Arc Logic Company	Process Monitoring, Modelling and Validation
	A low-cost High-speed Video Analysis System was developed for a client to enable more wide spread use of high-speed video in welding applications. A computer system for the Kodak Motion Corder line of cameras was designed to automate and control the operation of the camera and peripheral equipment such as data acquisition from welding sensors. By obtaining sensory data synchronously with process images, the welding process can be accurately analyzed and modelled. An image conversion and video production tool allowed the images downloaded from the camera to be complied to a video file complete with time stamp and sensor data overlay.

	Real-time Robotic Seam Tracker Arc Logic Company	Robotic Welding Process Control
	A seam tracking subsystem was developed and integrated into a arc welding robot controller (iRobots, formerly Cybo Robots). The seam tracker commanded the robot to oscillate the welding torch across the weld seam, perpendicular to the direction of torch travel. Signals from the welding process were sampled to extract features of the weld seam exposed by torch oscillation. The trajectory of the welding seam was updated based on feedback information from the seam tracker. The performance of the seam tracker was validated while welding a variety of weld joint (mis)configurations commonly found in production welding environments.

	Varestraint Weldability Test System Arc Logic Company	Welding Metallurgy Weldability Testing
	The Varestraint Weldability Test System (VWTS) produces precision GTA welds for determining the ability of a metal to be successfully welded. At the end of a weld, the sample being welded is bent to produce a prescribed amount of strain within the sample. A motion control card controls stepper motors for welding torch movement and a hydraulic cylinder for the sample bending ram. An A/D card collects information during the test and a digital I/O card controls the overall system operation. The VWTS user interface allows test parameters to be defined, saved and loaded. Material weldability can be defined quantitatively. VTWS systems are installed in a variety of locations including Edison Welding Institute, Knolls Atomic Power Lab and Westinghouse Savanah River Site.

	Architectural Long Span Bridge Construction Arc Logic Company	Welding Metallurgy, Procedure Development and Weld Quality Validation
	A client company was awarded a contract to construct an architectural long span bridge and it was the first contract for the company that must meet AWS and USDOT quality standards. A submerged arc welding (SAW) procedure was developed and qaulified for the construction of I-beams from high-strength-low-alloy steel. The company's weld quality standards methods where developed and executed to meet all applicable requirements.

	Arc Sensor Module NIST	Welding Process Monitoring Procedure and Quality Validation
	The Arc Sensor Module (ASM) was originally developed as a component of the Programmable Arc Welding System (PAWS) developed for the United States Navy. The ASM is a subsystem of a comprehensive welding process controller and communicates with a supervisor system controller. The ASM collects and analyzes arc voltage, arc current and wire feed speed data from the GMAW process in real-time to extract information about process stability . The ASM is capable of determining instabilties in the process that can lead to common defects such as porosity, burn-through and undercut.

	High-Speed Video Analysis System NIST	Welding Process Instrumentation Data Analysis
	A High-Speed Video Analysis System (HSVAS) was developed to investigate the GMA welding process . The HSVAS consisted of a HeNe laser, optical filters and focusing lenses, a high-speed video camera. A supervisory computer with a GUI was developed for system control and image acquisition and processing. Previously saved images of the welding process could be replayed in slow motion and processed to extract numerical data about the welding process. Using the data gathered via the HSVAS, numerical and analytical models of the welding process where developed.

	Contact Tube Wear Sensor NIST	Welding Process Monitoring Weld Quality Control
	The Contact Tube Wear Sensor (CTWS) was developed to automatically determine the condition of contact tube in the GMA welding process in real-time. The contact tube guides the consumable electrode (which becomes part of the weld metal) as the electrode exits the welding torch and transfers welding power to the electrode for the welding arc. The sliding contact between and the contact tube and welding electrode eventually wears the contact tube to the point that it no longer transfers welding power to the electrode properly and the welding process becomes unstable. The CTWS collects information from the welding process to determine the extent of contact tube wear and alerts the welding operator to replace a worn contact tube before the welding process becomes unstable and produces bad welds.

	Arc Length Controller for GMAW NIST	Welding Process Instrumentation Process Physics and Modelling
	A real-time arc length controller was developed for the GMA welding process . To develop the controller, data was collected using a high-speed video system and optical spectrum analyzer to measure arc light intensity. Numerical models of the welding arc were developed to determine the affect of arc current and arc length on arc light intensity. Simplified versions of the models where then executed on a computer controller to measure and adjust welding parameters to maintain arc length. The work condcuted for this project was basis for a academic dissertation.

	Arc Welding Seam Tracker EWI	Welding Process Control Procedure Development
	A seam tracking system for the GTA welding process was developed around the Coaxial Vision Torch (CVT) and delivered to Oak Ridge National Labs Y-12 Plant. The system consisted of a weld cell controller which controlled the welding and torch manipulation equipment, provided the user interface. The system was capable of changing cross-seam torch position to track the weld joint, adjusting welding current to control pool size and could also adjust wire feed speed to maintain constant joint fill. Welding procedures were developed for the system to weld 4 to 20 inch diameter pipe with 1/8 to 1/2 inch wall thicknesses made from steel, stainless steel and nickel-based alloys.

	Ultrasonic Welder Control EWI	Welding Process Control, Systems Integration and Procedure Development
	The Ultrasonic Metal Welder (UMW) consists of a high-power ultrasonic transducer and power source and and a hydraulic ram press. The ultrasonic and hydraulic power sources are under the control of the supervisory computer via an A/D, D/A and digital I/O card. A GUI allows welding parameters to be defined, saved and loaded and data collected during a weld to be analyzed and viewed. Weld procedures were developed for thin sheet stainless steel, titanium, alumnium and nickel alloys.

	Resistance Welding Electrode Life Testing EWI	Welding Process Control and Metallurgy Systems Integration
	The Ultrasonic Metal Welder (UMW) consists of a high-power ultrasonic transducer and power source and and a hydraulic ram press. The ultrasonic and hydraulic power sources are under the control of the supervisory computer via an A/D, D/A and digital I/O card. A GUI allows welding parameters to be defined, saved and loaded and data collected during a weld to be analyzed and viewed. Weld procedures were developed for thin sheet stainless steel, titanium, alumnium and nickel alloys.

	General Welding Engineering EWI	Welding Consulting, Process Instrumentation and Control, Systems Integration and Procedure Development
	Acted as a welding consultant for numerous companies in a variety of industrial sectors including automotive, heavy eqipment, aerospace, pharamcuetical, applieance and equipment manufacturers.  Provided expertise on procedure development, troubleshooting, welding metallurgy, automation, instrumentation, sensors and controls for arc welding processes.  Managed client and internal development projects from project propsals, sales, execution and final reporting.

	Weld Penetration Control OSUWE	Welding Process Control Process Physics and Modelling
	As an academic thesis project, a weld penetration controller system was designed and built for the GTA welding process . The controller was based on a 8 bit microcomputer with welding power source and torch motion control. This project was the predecessor of the TIG-pc system described above.

	Arc and Resistance Welding Engineering Sensotec	Welding Procedure Development, Maintenance and Troubleshooting
	Provided general welding engineering support for machine and automated welding of pressure and load transducer components. Developed and maintained welding procedures for thin and thick section welds using GTA and resistance (spot and seam) welding processes. Procedures were qaulified for austenitic and ferritic stainless steels and dissimilar metal welds.

	Welding Engineering Intern Sandia	Welding Process Control
	Developed a microcomputer based arc length controller for low current (2-10 A) GTA welding. Developed welding procedures for thin sheet, low current GTA welding of stainless steel, titanium and aluminum alloys.

	Manual Welding Klaas	Manual Welding, Fabrication and Layout
	Completed manual welding using arc (SMAW, GTAW, GMAW and FCAW) and resistance (spot and seam) welding processes. Routinely used oxyfuel cutting and air-carbon arc gouging. Fabricated components from raw plate and sheet metal stock from blueprints. Became certified in stainless steel SMAW for welding Navy nuclear propulsion components.