Machine Vision Based Control of Gas Tungsten Arc Welding for Rapid Prototyping 578

A machine vision system, based on CCD camera, is used to control the molten pool size during the gas tungsten arc welding (GTAW) process. The technique is tested by making a metallic part with a complex 3-D network of conformal channels on a hybrid rapid prototyping machine based on welding and milling. The test part demonstrated manufacturing flexibility and new technological opportunities required for prototyping injection mold tools. The real metallic part made in a layered fashion had good surface quality, dimensional accuracy, and high density.This work was financially supported by THECB’s Grants No. 0036133-0005-1997 and 003613- 0022-1999, NSF’s Grants No DMI-9732848 and DMI-9809198, and by the U.S. Department of Education Grant No. P200A80806-98.Mechanical Engineerin