铝合金焊接接头的形貌特征抗干扰检测
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1.内蒙古工业大学机械工程学院 呼和浩特010051;2.北奔重型汽车集团有限公司包头014030; 3.内蒙古工业大学材料科学与工程学院呼和浩特010051

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TG441.7;TN06

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内蒙古自治区自然科学基金(2024MS05043,2022ZD03)、内蒙古工业大学科学研究项目博士基金(BS2021033)资助项目


Interference-resistant detection of morphological characteristics in aluminum alloy welded joints
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1.School of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot 010051,China; 2.Beiben Heavy Truck Group Co., Ltd., Baotou 014030,China; 3.School of Materials Science and Engineering, Inner Mongolia University of Technology, Hohhot 010051,China

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    摘要:

    接头形貌特征参数是铝合金焊接质量评估的核心指标之一。针对铝合金焊接接头形貌检测中的反光现象及焊后板材表面污染而导致的光条纹亮度不均、中心线提取失真的问题,提出一种融合线结构光与特征辅助贴纸的双目视觉抗干扰检测方法,并采用U-Net神经网络焊接件区域定位与改进骨架化-灰度重心法相结合的光条中心线亚像素提取策略,实现了在复杂干扰下的高质量条纹图像获取。结果表明,所提方法有效抑制了板材反光与污染干扰,焊接件区域定位准确率稳定超过99%,实现了接头形貌的高精度三维重建,对焊缝余高和宽度的检测相对误差分别不超过6.0%和4.0%,显著提升了条纹信息的解析精度与鲁棒性。为了探究铝合金激光-熔化极惰性气体保护电弧(metal inert gas, MIG)复合焊接工艺参数与接头形貌质量的关系,以6 mm厚6061铝合金板材为对象,设计8组不同能量配比参数下的激光-MIG复合焊接实验,并依据ISO 10042: 2018国际标准评价接头质量。结果表明,随着能量配比的增加,焊缝余高和宽度逐渐减小并趋于稳定;当激光与MIG电弧的能量比为1.01~1.36时,接头质量均满足ISO 10042: 2018的B级要求,接头质量优良。显示了所提方法在复杂环境下接头形貌特征检测的可靠性,为铝合金接头质量的自动化评定提供技术支撑。

    Abstract:

    The morphological characteristics of the weld joint are a core indicator for assessing the quality of aluminum alloy welds. To address issues in the morphological detection of aluminum alloy weld joints, specifically specular reflection and the uneven brightness of light stripes caused by surface contamination after welding, which lead to distortions in extracting the centerline, an anti-interference detection method using binocular vision combined with line-structured light and feature-assisted stickers is proposed. This approach integrates a U-Net neural network for welding zone localization with an improved skeletonization-gray-gravity method for sub-pixel extraction of the light stripe centerline, enabling high-quality stripe image acquisition under complex interference. The results demonstrate that the proposed method effectively suppresses interference from plate reflection and contamination, with a consistent positioning accuracy exceeding 99% for the welding zone. This approach achieves highprecision 3D reconstruction of the joint morphology, with relative errors in the detection of weld reinforcement and width not exceeding 6.0% and 4.0%, respectively, significantly enhancing the analytical accuracy and robustness of the stripe information. To investigate the relationship between process parameters and joint morphology quality in laser-metal inert gas (MIG) hybrid welding of aluminum alloy, experiments were conducted on 6-mm thick 6061 aluminum alloy plates using eight sets of parameters with different energy ratios. The joint quality was evaluated according to the ISO 10042:2018 international standard. The results indicate that as the energy ratio increases, the weld reinforcement and width gradually decrease and stabilize. When the energy ratio between the laser and the MIG arc ranges from 1.01 to 1.36, the joint quality meets the ISO 10042:2018 Level B requirements, indicating excellent joint quality. This confirms the reliability of the proposed method for detecting joint morphological features in complex environments, providing technical support for the automated assessment of aluminum alloy joint quality.

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黄永,甘世明,邢满禧,王瑞,孙振邦.铝合金焊接接头的形貌特征抗干扰检测[J].电子测量与仪器学报,2026,40(6):78-88

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  • 在线发布日期: 2026-08-12
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