No contrast stretching or retouching applied.

At the trailing end of the pool the solidification front travels along with the torch. The boundary between the liquid and the solidified metal stays sharp for the whole recording, and bright particles drifting on the pool surface can be followed until they are captured by the advancing front.

Deep in a narrow gap there is very little light beside the arc itself. The flanks still stay readable, and at the wire tip the material transfer can be followed droplet by droplet. Short exposures freeze the motion, and the global shutter exposes the whole frame at one instant, so a droplet is not smeared across scan lines.

Molten steel radiates strongly in the near infrared. The ReconFlex™1920NA is built for that band, so the pool and the parts around it stay legible while the arc is burning — the tungsten, the filler rod and the pool surface are all readable in the same frame.

Visible-light cameras lose that detail to arc glare. Thermal cameras see the heat but not the geometry.

The scene above under one of the software colour maps. The recording is unchanged — only the mapping differs.

The solidified seam trailing the arc, from the same recording.

Up to 140 dB of dynamic range, shaped by a seven-point spline tone curve, lets the arc and the cooled seam sit in one exposure. HDR runs at up to 100 fps; where speed matters more than range, plain 8-bit or 12-bit readout goes far higher. Either way you do not need a second camera, a second pass or a different filter to inspect the result.

Exposure runs from 4 µs to 200 ms, and the software adjusts frame rate to exposure automatically, so the settings stay valid when the process changes.

The weld camera software plays synchronised camera streams against the measured welding voltage and current. Timestamps are matched to the microsecond, so a current dip and the frame it belongs to sit at the same position on the timeline. Isotherm contours are drawn live over the image, and any stream can be recoloured without touching the recording.

The same recording, switched between mappings. Isotherm contours and the voltage and current traces are unaffected.

Outer isotherm contour

Outer isotherm contour

Welding voltage

Welding current

Streams to HDF5, or to MPEG with the AV1 or FFV1 codec when you need a lossless archive.

HDR mode up to 140 dB at up to 100 fps, seven-point spline tone mapping, free colour mapping, and automatic frame-rate control tied to exposure time.

Temperature-zone detection, automatic determination of welding speed, and weld parameter inspection run on the live stream.

Voltage and current are digitised in the camera electronics and carry the same time base as the images — no external synchronisation box.