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Detection of welding wire length by active S11 measurement

  • A novel method to determine the extruded length of a metallic wire for a directed energy deposition (DED) process using a microwave (MW) plasma jet with a straight-through wire feed is presented. The method is based on the relative comparison of the measured frequency response obtained by the large-signal scattering parameter (Hot-S) technique. In the practical working range, repeatability of less than 6% for a nonactive plasma and 9% for the active plasma state is found. Measurements are conducted with a focus on a simple solution to decrease the processing time and reduce the integration time of the process into the existing hardware. It is shown that monitoring a single frequency for magnitude and phase changes is sufficient to achieve good accuracy. A combination of different measurement values to determine the length is possible. The applicability to different diameter of the same material is shown as well as a contact detection of the wire and metallic substrate.

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Author:Christoph SchoppORCiD, Felix Rohrbach, Luc Langer, Holger HeuermannORCiD
ISSN:0093-3813 (Print)
ISSN:1939-9375 (Online)
Parent Title (English):IEEE Transactions on Plasma Science
Document Type:Article
Year of Completion:2024
Date of the Publication (Server):2024/04/11
Tag:Circuit simulation; Hot S-parameter; Modeling; Plasma; Plasma diagnostics
Issue:Early Access
First Page:1
Last Page:6
Institutes:FH Aachen / Fachbereich Elektrotechnik und Informationstechnik
collections:Verlag / IEEE