• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.4
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• pp.484-489
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• 2011

Nowadays, the automobile manufactures make a great efforts to reduce manufacturing cost, body weight and to develop eco-environmental parts in order to be more competitive and solve global warming. For these reasons, materials of automobile's parts are changed over from general carbon steel and stainless steel to plastic and Aluminum. And, laser welding technology is introduced to apply welding between aluminum parts. In this paper, the data of laser welding parameters is collected through lots of the experiment according to the material, welding speed and laser power to apply laser welding in Aluminum fuel filler neck assembly. After manufacturing prototype of aluminum fuel filler neck, vibration durability test, tensile strength test and salt water test are applied to verify product's satisfied function.

• Journal of Power System Engineering
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• v.20 no.3
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• pp.51-56
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• 2016

In this study, the tensile tests and hardness tests were carried out for the joints characteristics in friction stir welds of Al 5052 alloy. Three way factorial design was applied to optimal welding conditions, whose control factors were shoulder diameter, rotation speed and welding speed of tool. From the results of this study, the optimum condition for maximum yield strength was predicted as the shoulder diameter of 15 mm, welding speed of 500mm/min and rotating speed of 1000 rpm. And the presumed optimal yield strength was estimated to be $167.36{\pm}7.82MPa$ with 99% reliability. In addition the increaser rotation speed of tool and the decreaser welding speed, the decreaser the hardness at welding part.

• Journal of Welding and Joining
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• v.12 no.1
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• pp.80-93
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• 1994

The microstructure and fractography of the friction welded joint of Al to Cu have been investigated in order to understand the formation of intermetallic compounds and their effects on the failure in tensile test of the joint. The variation of welding pressure did not affect significantly the tensile strength of joint. However, the tensile strength of joint decreaed as welding time increased. The thickness of reaction layers of welded joints was several micro-meters and mainly composed of intermetallic compounds of $CuAl_2$, $Cu_9Al_4$ and Al+$CuAl_2$. The thickness of $CuAl_2$, $Cu_9Al_4$ was increased with welding time. However, $CuAl_2$ was gradually changed to $Cu_9Al_4$ which caused the decrease of tensile strength . Even though the morphology of fractured surfaces depended upon the welding time, the failure occurred along $CuAl_2$ intermetallic compound itself or between $CuAl_2$ and $Cu_9Al_4$ in most cases.

• Journal of Welding and Joining
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• v.21 no.2
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• pp.57-63
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• 2003

Since new types of vehicles or structures made from thin aluminum alloy are under rapid development and some products are already on the market, welding of aluminium sheet is increasing. MIG(Metal Inert Gas), MIG-Pulse, TIG(Tungsten Inert Gas) welding are the typical Ai welding. MIG welding has the advantage of high speed, but it is difficult to apply to the thin plate, because of bum-through by the high heat input and spatter. MIG-Pulse welding can weld without spatter and burn-through, but when the gap exists at the welding joint, there is quite a possibility of bum-through. TIG welding is difficult to weld at a high speed. AC Pulse welding alternates between DCEP(Direct Current Electrode Positive) and DCEN(Direct Current Electrode Negative). DCEN is higher wire melting rate than DCEP, while lower temperature of droplet than DCEP. In AC Pulse welding, far fixed welding current, wire melting rate increases as the EN ratio increases. For fixed wire feed rate, welding current decreases as the EN ratio increases. Because of these features, the temperature of droplet, the depth of penetration, the width of bead decrease and the reinforcement height increases as EN ratio increases, and these are able to weld at a high speed, lower heat input. It is the purpose of this study that design of AC pulse current waveform for MIG welding of Al sheet and estimation of output characteristic.

• Journal of Welding and Joining
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• v.32 no.1
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• pp.28-33
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• 2014

In this paper, I-butt welding with 6mm thickness using Plasma-GMA welding was carried out. And weld characteristics of the Al-5083 aluminium alloy for Plasma-GMA hybrid welding was evaluated. The orthogonal experimental design was used to investigate the influence of plasma-MIG welding parameters such as plasma current, wire feeding rate, MIG-welding voltage and welding speed on the weld bead geometry and tensile strength using the ANOVA(Analysis of Variation). Then we conducted evaluation of contribution for process parameters. ANOVA results show that bead dimensions are affected by wire feeding speed, welding voltage and welding speed and tensile strength is mainly affected by welding speed and plasma arc current. Tensile strength was decreased by rise in plasma welding current because GMA welding current was decreased by plasma arc.

• Proceedings of the KWS Conference
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• 1998.05a
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• pp.108-111
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• 1998

• Journal of Advanced Marine Engineering and Technology
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• v.10 no.1
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• pp.65-73
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• 1986

Surface fatigue crack propagation tests by plane bending fatigue were conducted on the welding specimens of an aluminium alloy, A5083-0, having an edge through thickness notch to study the fatigue crack growth characteristics. Moreover, the experiments were performed in order to clarify the fatigue crack initiation and growth. The properties of fatigue crack growth were quantitatively inspected in welded metal, heat-affected zone and base metal of the welding specimens. The main results obtained are summarized as follows: 1. It is found that the hardness distributions of A5083-0 aluminium alloy weldments are quite different with those of steel material weldments, so that the hardness distribution becomes lower in the following order: base metal, heat-affected zone and weld metal. 2. It is observed that the grain size of this specimen weldment appears to be almost equal to the base metal, when TIC welding method is adopted. 3. In a surface fatigue crack initiation and growth, the fatigue crack does not begin by opening-closing mechanism until hardening is saturated at the crack tip. 4. The fatigue crack growth characteristics of A5083-0 alluminium alloy weldments can be concluded.$${\frac{da}{dn}}=C({\Delta}K)^n=3.8{\times}10^{-9}{({\frac}{1}{2}{\Delta}S_t{\sqrt{{\pi}a}})}^{2.4}$$

• Proceedings of the KWS Conference
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• 2007.11a
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• pp.279-281
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• 2007

This paper reviews corrosion characteristics of welded in the area of 409 Stainless Steel, Aluminium and Carbon steel. The effects of alloying elements and welding conditions on the intergranular-corrosion in weldment of the 409 stainless steels(SS) were investigated. And then this was to investigate factors affecting the composition and concentrations of fumes generated from various types of welding processes. It is also suggested that the direct relationship between the corrosion characteristics and welding type be clarified by experimental and analytical results.

• Journal of Advanced Marine Engineering and Technology
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• v.17 no.4
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• pp.100-106
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• 1993

A study on optimizing the friction welding of copper(C1100) to aluminium(A1050) for developing the electrical sleeve was experimentally carried out and also on real-time nondestructive evaluation of the friction weld quality (strength) was accomplished by acoustic emission technique. The results obtained are summarized as the following ; 1) The heating upset $U_1$(mm) or total upset U(mm) tends to increase according to the increase of heating time $t_1$(sec). The relations between $U_1$ and $t_1$ or U and $t_1$are computed as follows when n=2000rpm, $P_1$=4, $P_2$=8kgf/$mm^2$, and $t_2$=6sec. U=1.6$e^{0.39t_1}$ $U_1$=3.65$e^{0.25t_1}$. 2) It was notified that the proper welding conditions by considering on both strength with more than 100% joint effieciency and toughness are heating time of 1.5-2.25 sec under n=200rpm, $P_1$=4, $P_2$=8kgf/$mm^2$, $t_2$=6sec. 3) It was confirmed that both AE total counts(N, counts) and the weld tensile strength (${\sigma}$, kgf/$mm^2$) of the welded joints increase as the increase of heating time, respectively, the relations between N and $t_1$, ${\sigma}$ and $t_1$ are computed from data points by regression analysis using the least square method as follows in case of the above proper condition ; N=50108+23917(ln $t_1$)${\sigma}$$=11.85+2.06(ln $t_1$). 4) Both empirical and calcularated equations of relationship between .sigma. and N are very coincident with a high reliability, as the following in case of the above proper welding condition ; Calculated : ${\sigma}$=0.00008N+7.5 Empirical :${\sigma}$= $8.17e^{0.0000072N}$. 5) It was confirmed that the real-time nondestructive weld strength evaluation for friction welding of copper(C1100) to aluminium(A1050) could be possible by acoustic emission technique.

• Proceedings of the KSR Conference
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• 2004.10a
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• pp.668-673
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• 2004

The Friction Stir Weld (FSW) has been prevailing in the rolling stock manufacturers now a day especially in Europe and Japan, that will be an inevitable welding method in Korean domestic railway industry in the near future. The Welding Institute (TWI) in United Kingdom (UK), who has the right of international patents, invented FSW. To meet the recommendation of Cullen's Report for Ladbroke Grove Rail Inquiry (LGRI) in UK, the FSW is considering for the only alternative welding method to improve the aluminium welding quality, i.e. for improve unzipping defect and crashworthiness on car body in Europe Railways within Railway Safety Research Program.