• Transactions of the Korean Society of Automotive Engineers
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• v.7 no.6
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• pp.279-286
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• 1999

Failure of spot-weld joints in car body may cause noise, vibration and safety problems. Systematic procedures for estimating fatigue strength of general spot-weld joints are developed in this paper. Fatigue test results for various spot-welded specimens are analysed using the finite element method. It is found that the maximum principal strain at the nugget boundary on the inner surface governs the fatigue failure of spot-welded joints.

• Journal of Welding and Joining
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• v.8 no.2
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• pp.1-12
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• 1990

본 고에서는 알루미늄 점용접시의 용접품질 및 용접봉 수명에 미치는 요소와 점용접부 설계방법에 대하여 간략히 설명하였다. 점 용접방법은 알루미늄 뿐만 아니라 steel의 박판용접에도 많이 사용되고 있으며, 특히 최근 공정자동화에 맞추어 가장 쉽게 자동화할 수 있는 용접 방법 중의 하나이다. 그러나 아직까지는 용접품질을 보증할 수 있는 비파괴 검사방법이 없기 때문에 새로운 비파괴 검사방법 개발 혹은 컴퓨터를 이용한 용접품질 추적방법에 대한 많은 연구가 요청된다. 한편 용접부 설계 관점에서는 조그만 단순 시편이 아닌 설계구조물을 이용한 용접강도 해석방법에 대한 연구가 미약하므로 이에 대한 많은 연구도 요청되고 있다.

• Proceedings of the KWS Conference
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• 2009.11a
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• pp.118-118
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• 2009

자동차의 경량화, 안전성 그리고 내식성 향상을 위하여 고강도 강판 및 도금 강판의 적용이 증가하면서 자동차 산업의 많은 부분에서 적용되는 저항 점용접에서도 고강도 강판과 도금강판의 적용이 증가하는 추세이다. 이에 따라 고강도 강판과 도금 강판의 낮은 용접성을 개선하기 위하여 기존의 단상 AC 용접기에서 전류 파형의 형태를 개선한 인버터 DC 용접기가 차체 조립라인에서 많이 사용되고 있다. 본 연구에서는 고강도 강판의 저항 점용접의 연속타점 시 단상 AC용접기와 인버터 DC용접기의 전극의 연속타점 수명의 차이를 비교하고 분석하기 위해 590MPa 급 전기아연도금강판을 이용하여 AWS 규격에 연속타점실험을 기준으로 단상 AC 와 인버터 DC 용접기의 연속타점 실험을 실시하였다. 연속타점실험 중에 전극의 형상관찰을 위해 100타점 간격으로 carbon paper를 이용해 전극 직경 변화를 관찰 하였으며, 100 타점간격으로 동저항을 측정하고 인장 전단 시편과 Peel test 시편을 제작하여 연속타점 시 단상 AC와 인버터 DC 용접기의 저항 점용접 연속타점 수명을 비교 분석하였다. 그리고 연속타점 실험 후 사용된 전극의 표면과 단면 형상을 각각 OM, SEM, EDX로 분석하여 전극 표면의 Zn과 합금화 된 전극의 합금층을 분석하였다. 그 결과 590MPa급 전기아연도금강판의 저항 점용점 연속타점 수명평가에서 인버터 DC 용접기가 단상 AC 용접기보다 200타점 더 우수한 연속타점 수명을 보유하였다. 특히 인장강도 기준 측면에서는 인버터 DC 용접기의 전극 연속타점수명은 매우 우수하다.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.3 s.174
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• pp.567-580
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• 2000

This paper proposes an integrated approach, which is independent of specimen geometry and loading type, for predicting the fatigue life of spot welded specimens. We first establish finite element models reflecting the actual specimen behaviors observed on the experimental load-deflection curves of 4 types of single spot welded specimens. Using finite element models elaborately established, we then evaluate fracture parameter J-integral to describe the effects of specimen geometry and loading type on the fatigue life in a comprehensive manner. It is confirmed, however, that J-integral concept alone is insufficient to clearly explain the generalized relationship between load and fatigue life of spot welded specimens. On this ground, we introduce another effective parameter $J_e$ composed of $J_I$, $J_{II}$, $J_{III}$, which has been demonstrated here to more sharply define the relationship between load and fatigue life of 4 types of spot welded specimens. The crack surface displacement method is adopted for decomposition of J, and the mechanism of the mixed mode fracture is also discussed in detail as a motivation of using $J_e$.

• Journal of Welding and Joining
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• v.13 no.2
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• pp.60-67
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• 1995

The factors affecting on the fatigue strength of spot_welded specimens have been studied. The influence of initial overloads on the fatigue life of spot_welded tensile_shear specimens is investigated by considering fatigue crack initiation and crack propagation. The change of strain range and the influence of initial overload are correlated on the basis ol strain results. The results of this study are as follows. l) The initial absolute strain range decreased with initial overloads increase, and absolute strain range decreased before transformation of waveform of strain, but increased after transformation of waveform of strain. 2) In case of subsequent point of inflection of offset strain, the increment of this strain decreased with initial overload increase. 3) As initial overloads increase, the deformation behavior of spot welded parts is restricted after overloading.

• Transactions of the Korean Society of Automotive Engineers
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• v.11 no.3
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• pp.209-213
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• 2003

It is advantage of accelerated vibration testing to compress service exposures to operating vibration into a reduced laboratory test by increasing the amplitude or frequency of the applied input excitations. This paper proposes an accelerated test method to estimate the high-cycle fatigue life under random excitation. The method consists of conducting a test with amplified input excitation and extrapolating linearly the lift in the accelerated condition into the real lift in field condition. The extrapolation is carried out applying the high-cycle irregular excitation fatigue theory including the rainflow counting, Miner’s damage accumulation rule, and Goodman’s mean stress correction. As a verification, those estimated lift is compared with that acquired by experiment f3r the simple case of spot welding specimen with good agreement. This testing procedure will provide an useful scheme that can reduce testing period associated with developing time schedule of new product.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.3
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• pp.457-463
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• 2016

The newly developed super ductile duplex stainless steel (SDSS) has good strength and ductility, and it can be used to reduce weight and improve the fabrication efficiency of a carbody of a rolling stock. In this study, spot weldability tests were conducted to take advantage of SDDSS in a carbody for an intermodal tram. Specimens of various thickness (0.4 to 5.0 mm) were prepared to find the proper welding conditions, and tensile load tests were conducted to evaluate the tensile-shear strength of spot welded joints. Then, nugget diameters were measured to verify the quality. The tensile-shear strength was found to be proportional to the heat parameter. It was verified that the tensile-shear strengths and nugget sizes of the joints satisfy the standard requirements. The overall weldability tests confirmed that SDDSS can be used effectively for the carbody of an intermodal tram.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.10
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• pp.1213-1219
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• 2012

A remote $CO_2$ laser system can rapidly change both the distance and the direction of the laser beam by moving a lens and rotating mirrors. It is then easy to weld complex patterns of weld lines. A conventional spot weld joint specimen and a remote $CO_2$ laser weld joint specimen with complex weld line patterns were prepared and tested both statically and dynamically. The relationships between the fatigue strength, i. e. the maximum cyclic force, and the fatigue life were obtained. The fatigue strength of the tested welded joints at two million cycles was found to be approximately 10% of the static strength. Furthermore, it was observed that the fatigue fracture mode changed with the level of the applied cyclic force. The fatigue crack origins were confirmed as the highest stress points found in the structural analysis. The maximum cyclic stress for different weld patterns converges as the fatigue life approaches two million cycles.

• The Journal of the Acoustical Society of Korea
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• v.38 no.3
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• pp.334-339
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• 2019

In this study, the vibration test method to nondestructively evaluate the possibility of vehicle BSR (Buzz, Squeak, Rattle) noise generation in spot-welded structures was proposed. The weld quality was predicted by analyzing the local vibration transmission characteristics for the beam-shaped structure attached to testing spots. The bending stiffness was evaluated from the identified vibration properties. From the change in the stiffness, the weld quality was evaluated. For verification of the proposed method, the welded specimens were fabricated with partial changes in welding parameters. The local vibration transfers were measured. The frequency bands affected by the weld quality was identified. The capability of evaluating the welding parameters including defect position and quality variations was investigated. The proposed method enables fast quality evaluation to minimize the possibility of BSR noise generation in the manufactured vehicle.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.3 s.174
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• pp.743-751
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• 2000

Because welding residual stress is formidable result in electric resistance spot welding process, and it detrimentally affect to fatigue crack initiation and growth at nugget edge of spot welded la p joints, it should be considered in fatigue analysis. Thus, accurate prediction of residual stress is very important. In this study, nonlinear finite element analysis on welding residual stress generated in process of the spot welding was conducted, and their results were compared with experimental data measured by X-ray diffraction method. By using their results, the maximum principal stress considered welding residual stress at nugget edge of the spot welded lap joint subjected to tension-shear load was calculated by superposition method. And, the $\Delta$P- $N_f$ relations obtained through fatigue, tests on the IB-type spot welded lap joints was systematically rearranged with the maximum principal stress considered welding residual stress. From the results, it was found th2at fatigue strength of the IB-type spot welded lap joints could be systematically and more reasonably rearranged by the maximum principal stress($\sigma$1max-res considered welding residual stress at nugget edge of the spot welding point.