The common commercial charge coupled device (CCD) camera is combined with a composite light filter to form a vision sensing system of low cost. It can capture the whole image of a weld pool clearly during constant-current gas tungsten arc welding (GTAW). Based on the image-processing algorithm, the edges of the weld pool under different welding conditions can be extracted. Calibration is made to obtain the weld pool geometry in real size. The measured results are useful for developing a welding process control system and verifying the mathematical models of weld pool behaviours.
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