Laser welding is a widely used technology in the automotive industry due to its numerous advantages, including high welding speed, high productivity, easy automation, and minimal distortion. In order to fill gaps and enhance the strength and overall quality of the weld, a filler wire is used. However, process stability is strongly influenced by the interaction between the laser beam and the filler wire. Therefore, it is crucial to closely monitor the process parameters. In this paper, we investigate the use of electrified wire technology to monitor wire flow. The electrified wire system is a reliable technology for supervising wire melting dynamics basing on electrical measurement. We particularly focus on the correlation between the melt mode and the laser-to-wire distance: the Dx value. In a first step, we compare direct observations of the welding process using a high‑speed camera with data from the electrified wire system. Then, the electrified wire data are analyzed using two distinct approaches based on statistical analysis and topological features. We conclude that there is a correlation between the Dx value and the statistical properties of the data. Furthermore, the topological analysis shows promising results for predicting defect formation. These findings provide a foundation for the development of a reactive control system to monitor filler wire dynamics during laser welding.
Keywords
- Electrified Wire
- Filler Wire
- Laser Welding
- Monitoring