AI is taking over the world—well, not like in post-apocalyptic movies, where robots threaten humanity. Artificial Intelligence is used in various industries today, including welding.
Automated welding uses specialized equipment, welding robots, and software to produce welds with minimal human interaction. Robotic welders can produce quick, high-quality, repetitive welds, which are used in various industries such as automotive, aerospace, shipbuilding, and general metal fabrication.
Robots gained popularity in large-scale mass manufacturing to improve efficiency and battle the shortage of skilled welders. Automated welding is improving, which raises a serious question: Can AI replace skilled welders? Stick to our article to learn more about the future of welding.
Role of Welding Automation in Modern Welding
Welding automation involves using specialized equipment, welding robots, and advanced software to move, position, fixate, and weld two pieces with minimal operator intervention. With minimal interference, all equipment works in conjunction to increase the productivity, safety, speed, consistency, and quality of the weld.
Modern automation includes fully automated systems. Machines load, position, and unload parts, and robotic arms weld the pieces. However, there are collaborative robots, or cobots, that work alongside humans.
Automation systems vary in automation, flexibility, and scope of application. We are seeing fixed or hard automation that is ideal for mass production and simple, repetitive welding tasks. On the other hand, intelligent or flexible automation is highly customizable. You can reprogram and adjust the system to fit your needs.
Rise of Automated Welding and AI
The advantages of automated welding systems include increased productivity, reduced labor costs, and the ability to produce repetitive, high-quality welds. These benefits make automated welding a suitable option for mass production and larger manufacturers. However, one of the leading causes of the increased use of welding automation is the welder shortage.
The American Welding Society (AWS) estimates a shortage of 330,000 skilled welders by 2028. The majority of welders today are between 55 and 60 years of age. Combined with the relative lack of young welders entering the profession, we could be facing a significant shortage of skilled welders in the future.
Large manufacturing companies dealt with the crisis by investing in welding automation. Although the initial investment in equipment and robots is high, their efficiency, high speed, low maintenance, and reduced labor costs eventually pay off.
The advantages, combined with the welder shortage, have led to a rise in automated welding and AI in welding. Welding automation started in automotive production, but today, it is seen in aerospace, construction, shipbuilding, and more.
Advancements in Automated Welding and the Introduction of AI
New technologies and advancements in automated welding have made welding robots extremely precise and efficient. Improvements have enabled robots to work at high speeds and enhance the quality of the weld by providing real-time monitoring, adjustments, and learning.
Intelligent and adaptive welding systems have been constantly developed since the 2010s. AI, machine learning, and IoT are integrated into welding systems, allowing for predictive maintenance, adaptive welding, and remote monitoring.
Modern systems utilize AI to monitor weld quality in real-time and adjust parameters on the fly. Robots make adjustments based on material type, thickness, and joint configuration. Smart sensors monitor welding parameters such as voltage, amperage, arc length, or travel speed. If there are any abnormalities, the machine attempts to adapt or completely stops the process and notifies the operator.
Adding artificial Intelligence to the mix of automated welding enhances productivity and efficiency through optimized processes. It also improves quality control and reduces rework costs. By increasing quality and reducing rework, AI enhances competitiveness and profitability.
Are AI and Automated Welding the Same?
While both processes, AI and automated welding, are performed by robots, they are fundamentally different. It can get pretty confusing, but here are the most notable differences.
Automated welding involves using robots and equipment that are preprogrammed to complete a single welding task. These robots do not make any decisions; they just follow the instructions. With the simplest robots, operators must observe the entire process. If the robot encounters abnormalities, it can stop or signal the error.
Artificial Intelligence (AI) makes real-time decisions based on learning from experience and information. Once correctly configured and fed with information, AI algorithms evaluate historical data and optimize based on patterns. AI sensors can detect real-time abnormalities, adapt the parameters on the fly, or add suggestions that can further improve the quality or efficiency of the welding process.
AI systems often work in conjunction with regular robots to improve their efficiency and quality. However, adding intelligent sensors and machine learning can increase the overall costs of automation.
Can AI Completely Replace Skilled Welders?
As you can see, Artificial Intelligence can significantly improve the speed, efficiency, and quality of welding. Robots are getting better, but they cannot replace the human mind and judgment of a skilled welder.
It is still too early to expect fully automated AI systems to work without a human factor. AI-powered systems are perfect and often independent in high-volume production. However, with custom projects, tricky materials, and on-the-fly adjustments, human welders still hold the edge.
AI is indeed making everyday welding much faster and more convenient. However, skilled (human) welders will always be needed to make vital decisions on more complex and intricate projects. So, if you are afraid AI may take your job as a welder, be sure it will not happen anytime soon.
However, many large-scale manufacturers are switching to automation. That’s why we will discuss the strengths and weaknesses of both and give you some tips on how to stay in the game, even if the rules change.
AI Welders vs Manual Welders
Both automated (AI) welding and manual welding have their ups and downs. The final decision largely depends on factors such as precision, consistency, cost, flexibility, and skill requirements.
In a nutshell, automated welding is best suited for high-volume, consistent production in controlled environments. Meanwhile, manual welding remains essential for custom work, repairs, and tasks requiring adaptability and finesse.
AI-powered welding robots are leveling up as more information is available on the Internet. The more the machine learns, the better its judgment can be, but only to a certain point. Robots learn based on patterns, but once the situation throws them a curveball, they fail to react.
So, let’s further discuss the strengths and weaknesses of automated and manual welding.