TY - CONF A1 - Fabry, Çağtay T1 - WelDX Projektvorstellung N2 - Der Vortrag gibt eine Übersicht über die fortlaufende Entwicklung des WelDX Projektes an der BAM. Die Notwendigkeit des Datenaustausches für die deutsche Forschungslandschaft im Bereich des Lichtbogenschweißens wird motiviert und die wesentlichen Funktionen der weldx Python-Bibliothek anhand von Forschungsbeispielen dargestellt. T2 - Sitzung des DVS Fachausschuss FA03 - Lichtbogenschweißen CY - Ilmenau, Germany DA - 13.05.2025 KW - Forschungsdatenmanagement KW - Lichtbogenschweißen KW - Digitalisierung KW - Weldx PY - 2025 AN - OPUS4-63278 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Fabry, Çağtay T1 - Welding Process Data Management - openBIS workflows and lab integration N2 - Arc welding processes are an important manufacturing technology applied to a wide range of critical materials and components such as offshore constructions, pressure vessels and additive manufacturing. Data management for experimental arc welding research faces the challenge of constantly changing experimental setups, incorporating a wide range of custom sensor integrations. Measurements include timeseries process and temperature recordings, 3D-geometry data and video recordings of the process from a sub-millisecond scale to multiple hour-long experiments. In addition, various manual pre-processing steps of the workpieces need to be considered to track the complete manufacturing process and its analysis – from raw materials to final dataset and publication. As a unified RDM system, the BAM Data Store offers the capability to incorporate all steps – albeit not without its own challenges. The talk gives an overview of the different workflows and processing steps along the welding experiments together with their integration into the BAM Data Store. Current solutions and ongoing integration work is explained and discussed. This includes the direct integration and upload of automated processing steps into the Data Store from different machines and sensors using custom Python APIs. Ultimately the complete processing chain across multiple internal steps should be represented in the Data Store. T2 - openBIS user group meeting 2025 CY - Berlin, Germany DA - 22.09.2025 KW - Data Store KW - Openbis KW - Research Data Management KW - Research data KW - Digitalisation PY - 2025 AN - OPUS4-64203 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Pittner, Andreas A1 - Fabry, Çağtay T1 - Automated welding of support structures for offshore wind turbines N2 - Offshore wind energy plays an important role for the desired transition towards a carbon dioxide free industry within the next decades. However, the grounding of the offshore wind plants governs the overall installation process besides bureaucratic bottlenecks. The application of lightweight principles in steel construction, e.g. the usage dissolved load-bearing structures, so called Jackets foundations, offer great potential in reducing the resource consumption, especially with respect to the needed amount of steel. In this context this paper focuses on a fully digitalization of the welding manufacturing and as well as testing chain to enable a fully automated manufacturing as well as quality assessment of tubular nodes as key element of Jackets foundation structures. Furthermore, the relationship between the seam shape geometry and resulting fatigue strength is evaluated by numerical methods incorporating bionic principles. It is shown that tubular nodes can be welded fully automatically taking geometry tolerances into account. Moreover, the seam shape could be manufactured as requested by the numerical models which offers great potential for an extended lifetime. Subsequently, the improvements in resource efficiency and reduction of carbon dioxide emissions are evaluated by a life-cycle-assessment. T2 - THERMEC'2023 International Conference on PROCESSING & MANUFACTURING OF ADVANCED MATERIALS: Processing, Fabrication, Properties, Applications CY - Vienna, Austria DA - 02.07.2023 KW - Offshore Wind energy KW - Automated welding KW - Life cycle assessment KW - Jacket foundations KW - Fatigue life PY - 2023 AN - OPUS4-59501 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Fabry, Çağtay T1 - Towards arc welding reference data: Open Science laboratories at BAM N2 - As industries move for ever faster development and adoption cycles of emerging new technologies in the field of welding, the meticulous and longer-winded approach of the scientific research process can feel harder to integrate. To help bridge this gap and increase the speed, quality, and adoption rate of publicly funded research, the Bundesanstalt für Materialforschung und -prüfung (BAM) continues to work towards enabling scientists with direct access to necessary software tools and - in the future – highest quality welding research reference data to further foster collaborations. On the experimental side, the arc welding group at BAM division 9.3 “welding technologies” is continuing to expand and upgrade its capacities of robotic welding systems with integrated state of the art sensor technologies and software solutions. This allows all experiments to be recorded and measured in micro-millimeter accuracy and at sub-millisecond precision, including welding process data, complete spatial geometry and temperature measurements, process video recordings and more. The custom software-based solutions and interfaces allow scaling of the welding systems from large thick plate offshore applications to small additive repair weldments in wind turbine blades to multi-hour continuous weldments in additive manufacturing applications. In addition to the data gathered during the welding process itself, the relevant testing results and materials properties produced at BAM or externally can be integrated seamlessly. This allows detailed traceability of all results back to the actual welding process. Regardless of the scope and application, complete datasets can be made accessible for research or industry partners in the highest resolution based on the open source WelDX (welding data exchange) file format. Figure 1. Welding experiment representation including dynamic process data, cross-section imaging and hardness measurements from a single weldx file. The talk will give an overview of the experimental facilities and workflows as well as current software developments with a focus on research data quality assurance, traceability, and accessibility. Based on the integration into latest research trends and activities of the “welding technologies” division, the path to publishing reference datasets for arc welding process for various applications and materials is outlined and discussed. T2 - 4th Symposium on Materials and Additive Manufacturing - Additive 2024 CY - Berlin, Germany DA - 12.06.2024 KW - Additive Manufacturing KW - Arc welding KW - DED-arc KW - Research data KW - Reference data PY - 2024 AN - OPUS4-60249 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Fabry, Çağtay T1 - WelDX – progress report on the welding data exchange format N2 - The presentation shows the current development status of the Welding Data Exchange (weldx) format based on the Advanced Scientific Data Format (ASDF). The use of a complete single pass arc welding experiment example stored in a single weldx file and validated against a predefined schema definition is presented. The example includes generic experimental metadata, the workpiece geometry and materials definition following associated standards, the weld process spatial movement description, the welding process parameter descriptions and welding process measurements. The inclusion of 3D scan data of the workpiece description is also included. The full code and data is available on GitHub: https://github.com/BAMWelDX/IIW2021_AA_CXII T2 - 2021 IIW Annual Assembly and International Conference on welding and Joining CY - Online meeting DA - 07.07.2021 KW - Arc welding KW - Digitalization KW - Open science KW - Research data management KW - WelDX PY - 2021 AN - OPUS4-53401 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Fabry, Çağtay T1 - WelDX - a file format for processing and archiving welding research data N2 - The talk gives an introduction into gas metal arc welding and its relation to plasma science as well as current challenges in welding research concerning research data management and the application of the FAIR principles. The WelDX project is introduced and the main goals are discussed and contrasted with the current features of the weldx API. Different internal and public facing use cases focusing on research data management and their implementation using weldx are presented. The interactive part of the presentation displays some advanced multi layer use cases and data analysis using the weldx API as well as the integration of materials properties into weldx. T2 - International Workshop on FAIR Data in Plasma Science CY - Online meeting DA - 16.05.2022 KW - WelDX KW - Open science KW - Research data management KW - Arc welding KW - Digital transformation PY - 2022 AN - OPUS4-55153 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Fabry, Çağtay T1 - Welding Process Data Management - Perspectives on the BAM Data Store N2 - Arc welding processes are an important manufacturing technology applied to a wide range of critical materials and components such as offshore constructions, pressure vessels and additive manufacturing. Data management for experimental arc welding research faces the challenge of constantly changing experimental setups, incorporating a wide range of custom sensor integrations. Measurements include timeseries process and temperature recordings, 3D-geometry data and video recordings of the process from a sub-millisecond scale to multiple hour-long experiments. In addition, various manual pre-processing steps of the workpieces need to be considered to track the complete manufacturing process and its analysis – from raw materials to final dataset and publication. As a unified RDM system, the BAM Data Store offers the capability to incorporate all steps – albeit not without its own challenges. The talk gives an overview of the different workflows and processing steps along the welding experiments together with their integration into the BAM Data Store. Current solutions and ongoing integration work is explained and discussed. This includes the direct integration and upload of automated processing steps into the Data Store from different machines and sensors using custom Python APIs. Ultimately the complete processing chain across multiple internal steps should be represented in the Data Store. T2 - Data Store Days CY - Berlin, Germany DA - 09.03.2025 KW - Data Store KW - Openbis KW - Research Data Management KW - Reference Data KW - Welding PY - 2025 AN - OPUS4-62976 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Fabry, Çağtay A1 - Pittner, Andreas A1 - Rethmeier, Michael T1 - Arc-sidewall-attaching-driven control of swing arc motion in narrow gap GMAW N2 - A novel, event-driven approach to controlling the weaving motion in swing arc narrow gap GMAW is presented in this study. The control method is based on independently detecting the arc attachment event at each sidewall of the narrow groove to adjust the weaving motion in real time. Previous arc sensing approaches for swing arc principles are based on evaluating and comparing arc sensor readings collected during the dwell periods at each sidewall. Not only does this require the torch to be positioned at the groove centre and the arc motion to be symmetric, but previous methods have also been shown to rely on complex parametrization of control parameters. The newly presented approach is based on the real-time monitoring of the welding current progression during the approach of the arc towards the sidewall of the groove independently on each side. As soon as the arc attachment at the sidewall is detected based on a characteristic rise in the current signal, the weaving motion is stopped. For reference experiments in a 21-mm wide groove, the weaving angle amplitude is controlled and limited to 50° on both sides individually, resulting in stable process conditions and uniform sidewall fusion. It is further shown that the newly developed control method can successfully be applied to groove widths of 18 mm and 24 mm without reconfiguration of the control parameters, highlighting the flexibility of the approach. KW - Gas metal arc welding KW - Narrow gap KW - Arc sensor KW - Control PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-647640 DO - https://doi.org/10.1007/s40194-025-02238-5 SN - 0043-2288 SP - 1 EP - 11 PB - Springer Science and Business Media LLC AN - OPUS4-64764 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - GEN A1 - Fabry, Çağtay A1 - Hirthammer, Volker A1 - Scherer, Martin K. T1 - weldx-widgets: advanced visualisation and jupyter widgets for weldx N2 - This package provides advanced visualisation and interactive widgets for the weldx core package. KW - Weldx KW - Welding KW - Research data KW - Visualisation PY - 2025 DO - https://doi.org/10.5281/zenodo.17790485 PB - Zenodo CY - Geneva AN - OPUS4-64973 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - GEN A1 - Fabry, Çağtay T1 - pytcs: a TwinCAT Scope text export file reader N2 - A Python package for reading exported TwinCAT Scope Files. Export your TwinCAT Scope .svdx files to .txt/.csv and read them into Python. KW - Python KW - TwinCAT Scope KW - File reader KW - File format KW - Measurement data PY - 2025 DO - https://doi.org/10.5281/zenodo.17791125 PB - Zenodo CY - Geneva AN - OPUS4-64975 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Fabry, Çağtay T1 - WelDX – data and quality standards for welding research N2 - The WelDX research project aims to foster the exchange of scientific data inside the welding community by developing and establishing a new open source file format suitable for documentation of experimental welding data and upholding associated quality standards. In addition to fostering scientific collaboration inside the national and international welding community an associated advisory committee will be established to oversee the future development of the file format. The proposed file format will be developed with regards to current needs of the community regarding interoperability, data quality and performance and will be published under an appropriate open source license. By using the file format objectivity, comparability and reproducibility across different institutes and experimental setups can be improved. T2 - Open Research Data - Open your data for research CY - Berlin, Germany DA - 21.10.2019 KW - Welding KW - Research data management KW - Open science KW - Open data KW - Digitalization PY - 2019 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-493842 DO - https://doi.org/10.5281/zenodo.3514199 AN - OPUS4-49384 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Fabry, Çağtay T1 - Digitalization and Open Science in Welding Research N2 - The talk will give an overview of past, ongoing and future activities at BAM welding divisions, specifically those regarding prospects and challenges of the ongoing digital transformation and the move to more accessible research data (open science) with concerns to welding research. We will discuss current ways to publish and share research results inside the welding community and highlight approaches and advancements from other scientific fields to improve accessibility and reproducibility. We would also like to discuss the feasibility of integrating open science principles into the current IIW landscape of meetings, publications and education. In Addition we will introduce our upcoming series of workshops organized by BAM focusing on defining and implementing an open source file format specifically designed to publish and exchange high quality welding research data. T2 - The 72nd IIW Annual Assembly and International Conference 2019 CY - Bratislava, Slovakia DA - 07.07.2019 KW - Digitalization KW - Open science KW - Welding KW - Open data KW - Research data management PY - 2019 AN - OPUS4-49381 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Fabry, Çağtay T1 - WelDX - towards a common file format for open science in welding N2 - WelDX is a newly started research project at BAM publicly funded by the German Federal Ministry of Education and Research. Over the course of three years the project aims to build the foundation for a publicly accessible file format and to foster research collaboration in arc welding on a national and international level. The talk will motivate benefits and discuss challenges of using a common file format designed to describe, store and share arc welding research data in the scope of "Open Science". By using common open source software and tools, welding data will be made more accessible and reusable so that new scientific practices may emerge. The proposed file format aims to be easy to use for common welding applications while also offering the possibility to describe complex experiments for state of the art welding research. In addition the talk will illustrate how in the future other facilities and researchers will be able to use experimental arc welding data generated at BAM for their own research, for example to conduct their own data analysis or welding process and thermo-mechanical simulations. T2 - The 72nd IIW Annual Assembly and International Conference 2019 CY - Bratislava, Slovakia DA - 07.07.2019 KW - Welding KW - Research data management KW - Open science KW - Open data KW - Digitalization PY - 2019 AN - OPUS4-49382 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - RPRT A1 - Pittner, Andreas A1 - Fabry, Çağtay T1 - Abschlussbericht IGF 17.923 N: "Sensorgestütztes MSG-Engspaltschweißen von Feinkornstählen mit modifizierter Prozessführung im Dickblechbereich" N2 - Die im Forschungsvorhaben erzielten Ergebnisse zeigen konkrete technische Lösungen für die automatisierte Anwendung des MSG Engspaltschweißen, sowohl mittels optischer als auch prozessorientierter Sensorik, und sprechen damit ein breites Spektrum möglicher Anwender, insbesondere KMU, an. Die Seitenführung des Brenners auf Basis der optischen Messgrößen stellt eine robuste und einfach zu implementierende Möglichkeit zur Nahtverfolgung dar. Für die Höhenführung über der Schweißnaht wurde neben der Lösung mittels optischer Messverfahren zusätzlich eine direkt darauf aufbauende Möglichkeit zur Implementierung eines Lichtbogensensors abgeleitet. Das Vorgehen konnte sowohl für Sprühlichtbogenprozesse als auch bei Verwendung von Impulslichtbogenprozessen erfolgreich angewendet werden. Die zur Sicherstellung eines gleichmäßigen Flankeneinbrandes entwickelte Pendelregelung ist ebenfalls für unterschiedliche Lichtbogenarten einsetzbar und muss vom Anwender auch beim Einsatz einer großen Bandbreite unterschiedlicher Prozessparameter nahezu nicht konfiguriert werden. Neben der im Rahmen der Verfahrensprüfung untersuchten Pendelraupentechnik konnte die Übertragbarkeit des Vorgehens auch auf die Strichraupentechnik anhand von gezielten Schweißversuchen aufgezeigt werden. Die zunächst auf Basis der optischen Messwerte ausgelegte Füllgradregelung konnte die vorgesehenen Spaltvariationen von 18 bis 24 mm im Rahmen der durchgeführten Verfahrensprüfung ausgleichen. Die Ableitung eines äquivalenten Lichtbogensensors durch Kopplung beider Messprinzipien wurde am Laufzeitende des Vorhabens aufgezeigt, konnte jedoch durch zeitliche Beschränkung nicht für die Verfahrensprüfung berücksichtigt werden. In Absprache mit dem projektbegleitenden Ausschuss wurde die Entwicklung der Prozessregelung für das Vorhaben auf Schweißungen in Wannenlage und Grundwerkstoffe der Güte S355J2 beschränkt. Die Qualifizierung des Verfahrens unter Einsatz der beschriebenen Regelalgorithmen nach DIN EN ISO 15614-1 konnte für alle betrachteten Spaltbreiten zwischen 18 und 24 mm anhand einer 50 mm dicken Demonstratorprobe nachgewiesen werden. KW - Schutzgasschweißen KW - MSG-Engspaltschweißen KW - Prozesssteuerung KW - Lichtbogensensorik KW - Prozessregelung KW - GMAW KW - Narrow gap GMAW KW - GMAW control KW - Arc-sensing PY - 2017 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-390934 SP - 1 EP - 38 AN - OPUS4-39093 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - GEN A1 - Chaurasia, Prashant Kumar A1 - Fabry, Çağtay A1 - Pittner, Andreas A1 - Rethmeier, Michael T1 - Tandem-GMAW: advanced pulsed and short cicuiting process mode experimental data N2 - This dataset consists of raw recordings for 5 Tandem gas metal arc welding experiments (Tandem-GMAW / T-GMAW). KW - T-GMAW KW - High power welding KW - Deposition efficiency KW - Life Cycle Assessment PY - 2025 DO - https://doi.org/10.5281/zenodo.17951724 PB - Zenodo CY - Geneva AN - OPUS4-65206 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Chaurasia, Prashant Kumar A1 - Cagtay, Fabry A1 - Andreas, Pittner A1 - Rethmeier, Michael T1 - Automated in situ monitoring and analysis of process signatures and build profiles during wire arc directed energy deposition N2 - Wire arc directed energy deposition (DED-Arc) is an emerging metal additive manufacturing process to build near-net shaped metallic parts in a layer-by-layer with minimal material wastage. Automated in situ monitoring and fast-responsive analyses of process signatures and deposit profiles during DED-Arc are in ever demand to print dimensionally consistent parts and reduce post-deposition machining. A comprehensive experimental investigation is presented here involving real-time synchronous measurement of arc current, voltage, and the deposit profile using a novel multi-sensor monitoring framework integrated with the DED-Arc set-up. The recorded current–voltage transients are used to estimate the time-averaged arc power, and energy input in real time for an insight of the influence of wire feed rate and printing travel speed on the deposit characteristics. A unique attempt is made to represent the geometric profiles of the single-track deposits in a generalized mathematical form corresponding to a segmented ellipse, which has exhibited the minimum root-mean-square error of 0.03 mm. The dimensional inconsistency of multi-track deposits is evaluated quantitatively in terms of waviness using build profile monitoring and automated estimation, which is found to increase with an increase in step-over ratio and energy input. For the multi-track mild steel deposits, the suitable range of step-over ratio for the minimum surface waviness is observed to lie between 0.6 and 0.65. Collectively, the proposed framework of synchronized process monitoring and real-time analysis provides a pathway to achieve dimensionally consistent and defect-free parts, and highlights the potential for closed-loop control systems for a wider industrial application of DED-Arc. T2 - IIW Annual Assembly 2025 CY - Genova, Italy DA - 23.06.2025 KW - Additive Manufacturing KW - Arc welding KW - Real-time monitoring and control KW - Dimensional inconsistency KW - DED-arc PY - 2025 AN - OPUS4-65231 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Pittner, Andreas A1 - Fabry, Cagtay A1 - Thiele, Marc A1 - Artinov, Antoni A1 - Rethmeier, Michael T1 - Automated Arc Welding and Sensor Based Quality Assessment for Enhancing Fatigue Strength and Structural Reliability of Offshore Wind Turbine Supports N2 - Offshore wind energy plays a crucial role in achieving a carbon dioxide free industrial sector in the coming decades. However, foundation systems for offshore wind turbines significantly impact the overall installation process, posing technical and regulatory challenges. Adopting lightweight design principles in steel construction such as dissolved load bearing structures in jacket foundations offers substantial potential for reducing resource consumption, particularly steel usage. This presentation explores the complete digitalization of welding manufacturing and testing processes, enabling fully automated production and data driven quality assessment of tubular nodes, which are vital components of jacket foundations. The study also investigates the relationship between seam geometry and fatigue strength inspired by bionic design principles. The results demonstrate that tubular nodes can be welded entirely automatically, accommodating geometric tolerances, and that seam geometries ca n be precisely manufactured according to suggestions from e.g. numerical models or other sources . These advancements significantly enhance the fatigue strength and service life of offshore wind turbine support structures. T2 - IIW Annual Assembly 2025 CY - Genova, Italy DA - 23.06.2025 KW - Automated gas metal arc welding KW - Quality assessment and control KW - Support structures KW - Fatigue PY - 2025 AN - OPUS4-65232 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Fabry, Çağtay A1 - Pittner, Andreas A1 - Kaplan, Alexander A1 - Rethmeier, Michael T1 - Digitalisation and Carbon Footprint Evaluation of Gas Metal Arc Welding and Wire-Arc Directed Energy Deposition N2 - This paper showcases how a holistic approach to digitalisation enables data-driven welding applications, exemplarily for a gas metal arc welding (GMAW) laboratory. The workflow integrates advanced process monitoring, synchronised multi-sensor data acquisition and tools for data analytics. A welding domain-specific data exchange format weldx is presented that unifies and aggregates the data sets acquired during process monitoring with final component quality metrics, supporting reuse, traceability, and reproducibility. Two case studies illustrate the approach. First, GMAW parameters are adaptively adjusted according to local seam geometry to compensate joint-preparation deviations from nominal values typical for large-scale steel fabrication. Second, the seamless data aggregation along the welding production chain enables an automatic life-cycle assessment (LCA), quantifying the environmental impacts of additive manufacturing with DED Arc/M and attributing the dominant contributors to the carbon footprint. Collectively, the results indicate that a fully integrated experimental set-up together with standardised data structures and scalable analytics can couple monitoring, control, and sustainability, thereby realising the potential of digitalisation for high-quality and environmentally informed welding production. KW - Digitalisation KW - Arc welding KW - DED-arc KW - Life Cycle Assessment PY - 2026 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-656812 DO - https://doi.org/10.1088/1757-899X/1342/1/012067 SN - 1757-8981 VL - 1342 IS - 1 SP - 1 EP - 15 PB - IOP Publishing AN - OPUS4-65681 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -