Low-cost simulated MIG welding for advancement in technical training

The simulated MIG lab (sMIG) is a training simulator for Metal Inert Gas (MIG) welding. It is based on commercial off the shelf (COTS) components and targeted at familiarizing beginning students with the MIG equipment and best practices to follow to become competent and effective MIG welders. To do this, it simulates the welding process as realistically as possible using standard welding hardware components (helmet, gun) for input and by using head-tracking and a 3D-capable low-cost monitor and standard speakers for output. We developed a simulation to generate realistic audio and visuals based on numerical heat transfer methods and verified the accuracy against real welds. sMIG runs in real time producing a realistic, interactive, and immersive welding experience while maintaining a low installation cost. In addition to being realistic, the system provides instant feedback beyond what is possible in a traditional lab. This help students avoid learning (and unlearning) incorrect movement patterns.