• Proceedings of the KWS Conference
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• 2009.11a
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• pp.27-27
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• 2009

드라이브 샤프트는 일반적으로 엔진에서 발생된 회전력을 바퀴에 직접 전달하는 동시에 조향기능을 수행하는 자동차 부품이다. 최근에 경량화를 통한 에너지 절감을 위하여 기존 스틸소재를 알루미늄으로 대체하는 방안에 대한 연구가 집중되고 있다. 그러나 알루미늄 단일소재로 드라이브 샤프트를 제조하는 것은 비경제적이며 또한 기 개발된 자동차 부품들과의 연결을 고려하여 알루미늄 튜브와 스틸 요크의 이종금속 접합기술이 요구된다. 전자기 펄스용접은 전자기력을 이용하여 용접대상물을 고속으로 충돌시켜 용접하는 기술로서 열 발생이 적어 재료의 특성차로 인한 결함 및 변형이 발생하지 않아, 이종금속간 고품질 용접이 가능하며, 전자기 펄스 용접부의 품질과 밀접한 관계를 갖는 공정변수 경우 모재와 접합재의 재질 따라 적정 공정변수 범위가 변화되므로 공정에 따른 데이터의 축적은 대단히 중요하다. 전자기 펄스 용접을 이용한 이종금속 접합시 접합부 품질에 영향을 미치는 공정변수는 충전전압, 모재와 접합재 사이의 간격 및 접합재의 직경과 두께의 비(D/T비)로서 보고되었으며, Al/Steel 이종 금속 접합시 이들 공정변수가 접합부에 미치는 영향 및 최적의 공정변수 도출을 위한 연구는 시도되지 않았다. 따라서 본 연구는 전자기 펄스 용접기술을 이용한 Al/Steel 이종금속 접합 실험을 통하여 전자기 펄스용접의 적정성과 최적의 충전전압, 모재와 접합재 사이의 간격, D/T비를 도출하고자 한다. 전자기 펄스 용접 장치는 한국생산기술연구원과 웰메이트(주)에서 공동으로 개발한 $120{\mu}F$의 캐패시터 6개로 구성된 'W-MPW36'을 사용하였으며 이 장치의 최대충전전압과 최대접합용량은 각각 10kV, 36kJ이다. 접합재는 전기 전도율의 높은 Al 1070 파이프를 사용하였으며 모재는 기존 스틸 요크재인 SM45C 환봉을 사용하였다. 기보고된 연구를 통하여 코일과 접합재 사이의 간격이 좁을수록 높은 전자기력이 접합재에 작용하는 것을 확인하였으나 코일내 접합재와 모재 삽입 편의를 위하여 1mm로 설정하였다. 접합부의 품질 평가를 위하여 수압시험을 실시하였으며, 시험 후 접합부 단면을 주사전자현미경(SEM)을 이용하여 관찰하였다.

• Transactions of the Korean Society of Automotive Engineers
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• v.4 no.3
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• pp.112-121
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• 1996

Applications of bonded dissimilar materials such as metal/ceramics and resin/metal joints, are very increasing in various industry fields. It is required to find crack propagation direction and path applying to the fracture mechanics on the bonded joint of dissimilar meterials. In this paper, crack propagation direction and path were simulated numerically by using boundary element method. Crack propagation angle is able to easily determine based on the maximum stress concept. Fracture tests of Al/Epoxy dissimilar materials with an interface crack are carried out under various mixed mode conditions by using the specimens of bonded scarf joints. It is found that the experimental results are well coincide with the analysis results of boundary element method.

• Journal of the Korean Society for Nondestructive Testing
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• v.14 no.3
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• pp.194-205
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• 1994

이종재료 접합재의 연구개발(R&D)이나 품질보증(QA)분야에서 최적 접합조건의 신속한 결정과 사용중 접합재의 접합강도에 결정적으로 영향을 미치는 접합계면의 박리 미접합부등의 비파괴진단 평가기법에 적극 활용되고 있는 초음파비파괴평가(UNDE)기법의 주된 특징과 적용한계, 향후 연구되어야할 과제등을 최근의 특징적인 연구경향과 적용예를 중심으로 소개하고자 한다. 본고(本稿)에서 기술하는 초음파비파괴평가기법은 부분적으로는 기술의 안정화단계에 까지 상당히 접근하여, 현재 국내 반도체산업의 품질보증분야에서는 접합재료 접합계면의 비파괴적해석에 그 유용성이 어느정도 확인되고 있으나 정량적비파괴평가(QNDE)와 검사시스템의 꽃이라 불리는 전문가시스템화에의 접근에는 아직 해결되어야할 문제가 많다. 따라서, 저자들은 앞으로 접합재료 접합계면의 비파괴적해석에 관련한 연구사례와 결과를 정량적비파괴평가의 중요성과 방향성에 초점을 두고 본학회지를 통하여 계속 연재할 계획이다.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.7
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• pp.1159-1169
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• 2003

This paper investigates the effects of T-stress and plastic hardening mismatch on the interfacial crack-tip stress field via finite element analyses. Plane strain elastic-plastic crack-tip fields are modeled with both MBL formulation and a full SEC specimen under pure bending. Modified Prandtl slip line fields illustrate the effects of T-stress on crack-tip constraint in homogeneous material. Compressive T-stress substantially reduces the interfacial crack-tip constraint, but increases the J-contribution by lower hardening material, J$\_$L/. For bimaterials with two elastic-plastic materials, increasing plastic hardening mismatch increases both crack-tip stress constraint in the lower hardening material and J$\_$L/. The fracture toughness for bimaterial joints would consequently be much lower than that of lower hardening homogeneous material. The implication of unbalanced J-integral in bimaterials is also discussed.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.9
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• pp.1357-1363
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• 1997

Currently it is increasing to use th bonded dissimilar materials in the various field of advanced engineering such as the highly rigid and lighter vehicle, plastic molding LSI package and metal/ceramic bonded joint. In spite of such a wide application of the bonded dissimilar materials, the evaluation method of the bonding strength has not been established yet. Therefore in this paper we analyze the interface crack problem by introducing fracture mechanics parameters as the basic research about estimating of the strength of adhesive joints. The variation of stress intensity factor according to the elastic modulus of adherend and thickness of bonded layer are investigated. Numerical results are based on the results of boundary element analysis of four different type butt joints subjected to uniaxial tension loading.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.3
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• pp.341-346
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• 2010

The effect of specimen geometry on the bending and tensile strengths of dissimilar joints ($\beta-Si_3N_4/S45C$) with copper interlayers was evaluated. The average bending strength of specimens with circular cross sections was higher than that of specimens with rectangular cross sections. The crack initiation stress ($\sigma_i$) was successfully determined by the acoustic emission (AE) method and was approximately 60~80% of the bending strength. The residual stresses near the interfaces on the ceramic side were measured by X-ray diffraction before conducting the bending test. The bending strength and the crack initiation stress decreased with an increase in the residual stresses. The effect of the bending strain component was evaluated by the tensile testing; the tensile strength decreased with an increase in the bending strain component and was approximately 80% of the bending strength.

• Journal of the Korean Society of Safety
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• v.6 no.2
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• pp.5-13
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• 1991

In this paper, the interfacial stress intensity factors( $K_{i}$＝ $K_1$＋i $K_2$) for the edge interface crack in the dissimilar materials(isotropic-isotropic materials, isotropic-composite materials) were analysed by BEM(Boundary Element Method). The fatigue crack growth behaviour was investigated by load constant fatigue test. From the experimental results, the relationship between da/dN and interfacial stress intensity facto, ( $K_{i}$ or $K_1$) can be expressed by Paris'law for homogeneous materials.s.s.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.7
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• pp.171-176
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• 2003

In this study, stress analysis using Boundary Element Method (BEM) was carried to investigate stress distribution in the brazing joint between a Hardmetal and a HSS. The two models were proposed to analyze the stress singularity in the interfaces of the brazing joint. The material type, thickness of the filler metal and the length of the vertical brazing adhesive are considered in the BEM analysis. As results, the peak point of the stress is founded to be in the lower interface of the brazed joint. It should be noted that the maximum stress of the peak point is being affected by the thickness and length of the brazing joint.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.6
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• pp.898-904
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• 2003

Using the modified Irwin model and the modified Dugdale model, the plastic zone size near the interface crack tip in a ductile layer bonding two dissimilar elastic substrates is predicted. Validity of the models is examined by finite element method. The effects of several factors such as the mode mixity, T-stress and material properties are explored. The plastic zone size significantly decreases with the Poisson's ratio of the ductile layer.

• The Transactions of the Korean Institute of Electrical Engineers C
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• v.49 no.4
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• pp.239-245
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• 2000

A copper-tungsten sintered alloy(WCu) has been friction-welded to a tough pitch copper (Cu) in order to investigate friction weldability. The maximum tensile strength of the SWu-Cu friction welded joints had cp to 96% of those of the Cu base metal under the condition of friction time 0.6sec, friction pressure 45MPa, upset pressure 125MPa and upset time 5.0sec. And it is confirmed that the tensile strength of friction welded joints are influenced highly by upset pressure rather than friction time. And it is considered that mixed layer was formed in the Cu adjacent side to the weld interface, W particles included in mixed layer induced fracture in the Cu adjacent side to the weld interface and also, thickness of mixed layer was reduced as upset pressure increase.