3D Laser Diagnostics Technology as a Digital Welding Quality Management Tool

Abstract

The article presents a new industrial technology for the objective quantitative evaluation of weld quality and welder proficiency, based on the method of three-dimensional laser diagnostics (3DLD). The method utilizes high-resolution laser scanning to create a digital twin of the weld surface and compares it with a calculated reference profile derived from the Laplace equation of capillary equilibrium. The system computes the Welder Qualification Index (WQI) and the Weld Profile Quality Index (WPQI) on a scale from 0 to 100, providing full visualization of deviations and eliminating the subjectivity inherent in manual visual testing. This technology enables the evaluation of welder performance, the quality of welding consumables, and equipment stability. Furthermore, it facilitates the resolution of inspection disputes through geometric analysis of transition zones and serves as the baseline for establishing a digital passport of welder qualifications. The 3DLD method has been successfully validated under industrial conditions and at international competitions; it can function as a platform for digital welding quality management in compliance with the principles of Industry 4.0.