• Journal of Ocean Engineering and Technology
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• v.13 no.1 s.31
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• pp.88-93
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• 1999

This paper presents the experimental examinations and statistical quantitative analysis of the correlation between the cumulative counts of acoustic emission(AE) during plastic deformation periods of the welding and the tensile strength and other properties of the bar-to-bar welded joints of O.D. 16mm shaft(SM40C) as well as the various welding variables. And this is a new approach which attempts finally to develop real-time quality monitoring system for friction welding. The results lead to a practical possibility of real-time quality control more than 100% joint efficiency showing good weld with no micro structural defects.

• Journal of Ocean Engineering and Technology
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• v.13 no.3 s.33
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• pp.77-82
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• 1999

The compleete joining method for dissimilar hot die punch materials and its real-time evaluation method are not available at present. Brazing method has been used for joining them, but it is known that the welded joint by the brazing has the lower bonding efficiency and reliability than the diffusion welding. The friction wleding with a diffusion mechanism in bonding was applied in this study. So, this work was carried out to determine the optimal friction welding conditions and to analyze mechanical properties of friction welded joints of hot die punch materials (STD61 for the blade part of hot die punch) to alloy steel (SCM440 for the shank park of hot die punch) such as plunger. In addition, acoustic emission test was carried out during friction welding to evaluate the weld quality.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.6
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• pp.775-782
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• 2013

In this study, as a series of studies aimed at investigating the spatial randomness of fatigue crack growth for friction stir welded (FSWed) 7075-T651 aluminum alloy joints, the fatigue crack growth behavior of FSWed 7075-T651 aluminum alloy joints was investigated for LT orientation specimens. Fatigue crack growth tests were conducted under constant stress intensity factor range (SIFR) control for 5 specimens of the FSWed 7075-T651 aluminum alloy, including base metal (BM), heat affected zone (HAZ), and weld metal (WM) specimens. The mean fatigue crack growth rate of WM specimens was found to be the highest, whereas that of HAZ and WM specimens was the lowest. Furthermore, the variability of fatigue crack growth rate was found to be the highest in WM specimens and lowest in BM specimens.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.10
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• pp.280-288
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• 2016

This study proposes improved welding tools for magnesium alloys. Two types of tools were used for friction stir welding (FSW). The effect of the welding tools on the FSW joints was investigated with a fixed welding speed of 200mm/min and various rotation speeds of 400 to 800 rpm. After FSW, the joints were cross-sectioned perpendicular to the welding direction to investigate the defects. A tensile test and Vickers hardness test were conducted to identity the mechanical properties of the joints. Defects were observed when the rotation speed was 400 rpm, regardless of the welding tool, and the amount of defects tended to decrease with increases in rotational speed. Defect-free welds were obtained when the rotation speed was 800 rpm. The best weld quality was acquired using the C type welding tool. The rotation speed of 800 rpm and welding speed of 200 mm/min produced the best joining properties. The ultimate tensile strength, yield strength, and elongation of the welded region were 90.0%, 69.1%, and 83.2% those of the base metal, respectively.

• Proceedings of the KWS Conference
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• 1997.05a
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• pp.15-18
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• 1997

• Journal of the Korea Academia-Industrial cooperation Society
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• v.20 no.12
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• pp.513-518
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• 2019

Friction Stir Welding is a welding technique for metal materials that utilizes the heat generated by friction between the material to be welded and the welding tool that rotates at high speed. In this study, a numerical analysis method was used to analyze the change in the internal temperature of the welded material during friction stir welding. As the welding target material, AZ31 magnesium alloy was applied and the welding phenomenon was considered a flow characteristic, in which a melting-pool was formed. FLUENT was used as the numerical tool to perform the flow analysis. For flow analysis of the welding process, the welding material was assumed to be a high viscosity Newtonian fluid, and the boundary condition of the welding tool and the material was considered to be the condition that friction and slippage occur simultaneously. Analyses were carried out for various rotational speeds and the translational moving speed of the welding tool as variables. The analysis results showed that the higher the rotational speed of the welding tool and the slower the welding tool movement speed, the higher the maximum temperature in the material increases. Moreover, the difference in the rotational speed of the welding tool has a greater effect on the temperature change.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.15 no.1
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• pp.102-107
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• 2006

This study investigates the properties as the difference friction welding area on SM25C steel rod. The tensile and bending strength and of welded joints, the hardness distribution of welds, the microstructure of welds and the tensile fracture surfaces were mainly investigated through this experiment. The fixed friction welding conditions were revolution 2000rpm, friction pressure 70Mpa, friction time 1.5sec, upset pressure 100Mpa, upset time 2.0sec, upset length 2.8mm and changeable friction welding parameter was friction welding area.

• Proceedings of the KWS Conference
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• 2009.11a
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• pp.49-49
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• 2009

마찰교반접합법은 특정한 회전수로 회전하는 용접 툴을 이용하여 접합하고자 하는 피접합재의 맞댄면에 삽입시킨 후 툴을 이동시키거나 혹은 시편을 견고하게 고정시킨 장치(backing plate)가 움직여 고상 상태에서 접합이 이루어진다. 알루미늄, 마그네슘 등 비교적 융점이 낮은 저융점 재료의 재료에 처음 적용이 되어 많은 연구가 활발히 진행되었고 타 용접방법에 비해 우수한 접합특성을 나타내었다. 최근 이러한 마찰교반접합은 이러한 저융점 재료를 넘어서 스틸, 타이타늄, 니켈 등과 같은 고융점 재료 등에 대한 적용이 늘어나고 있다. 마찰교반접합을 이용하여 이러한 고융점 재료의 접합 경우 내마모성 및 내열성 등의 내구성이 갖추어진 툴과 이러한 툴을 냉각시킬 수 있는 냉각 장치 등이 필요로 하나 경제적 측면이나 접합부의 우수한 특성 등을 고려 할 때 그 적용 및 발전 가능성이 매우 높다고 볼 수 있다. 최근 무공해 연료로 각광받고 있는 액화천연가스 (LNG)의 수요가 급증함에 따라 LNG 저장탱크 소재로 널리 사용되고 있는 9% Ni강의 수요 또한 증가하고 있는 상황이다. 하지만 9% Ni 강은 극저온용 소재로 용접부의 저온인성 ($-196^{\circ}C$)이 가장 중요하기 때문에 저온인성을 확보하고자 Inconel 계나 Hastelloy계 등의 니켈 기 합금을 용접재료로 사용하고 있으나 이러한 용접재료는 가격이 매우 고가이며 또한 용접 후 용접부의 강도가 낮다는 문제가 제기되고 있다. 또한 LNG 탱크 제작시 사용되는 용접법은 GTAW, SAW 및 SMAW 이지만 국내에서는 주로 SMAW에 의존하고 있는 실정인 관계로 보다 더 경제적인 용접 프로세스의 적용 가능성이 검토되고 있는 상황이다. 본 연구에서는 마찰교반용접을 이용하여 두께 4mm의 9% Ni 강에 대해 맞대기 마찰교반접합을 실시하였다. 툴 회전 속도 및 접합 속도를 고정한 상태에서 접합을 실시 하였으며 접합 시 툴은 $Si_3N_4$로 제작된 툴을 사용하였다. 접합 후 외관상태 점검, 미세조직 관찰, 경도, 인장 강도 및 저은 충격 측정 등의 실험을 실시하였고, 이러한 결과를 이용하여 미세조직과 기계적 특성과의 관련성을 조사하였다.

• Journal of Ocean Engineering and Technology
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• v.10 no.2
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• pp.69-76
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• 1996

In-process quality control and high reliability of the weld are the major concerns in applying friction welding to the economical and qualified mass-production. Experimental examinations and quantitative analysis were performed for the optimiaztion of similar friction welding of hydraulic valve spool steels(SNCM220, SCM435, SACM645, SCM415, ${\varphi}24). The quantitative correlations were found between the initial cumulative counts of acoustic emission(AE) occurring during plastic deformation periods of the welding and the fatigue life as well as weld strength and welding conditions. A real-time evaluation system was developed for the friction weld quality by AE.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.6
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• pp.932-937
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• 2012

In the presented study, SM45C carbon steel parts were joined by friction welding. The welding process was carried out under optimized conditions using statistical approach. The study of SM45C is conducted with various combinations of process parameters. Parameter optimization, microstructure and mechanical property correlation are the major contribution of the study. The welded joints were produced by varying spindle revolution speed, friction pressure, upset pressure and burn-off length. Tension tests were applied to welded parts to obtain the strength of the joints. Fracturs properties were additionally obtained experimentally under fluctuated tensile loads. Microstructures using microphotographs were examined in the weld interface and weld region and heat affected zone and base metal and flash zone of welded parts. Finally, Hardness variations in welding zone and base metal were also obtained. Through these tests, the optimum conditions of parameters for ${\phi}20$ SM45C in friction welding were obtained when the friction spindle revolution was 1,950 rpm, the friction pressures was 30 MPs, upset pressures was 50 MPs.