• Journal of Welding and Joining
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• 제19권4호
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• pp.379-383
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• 2001

Resistance spot welding has been widely used in the sheet metal joining processes because of low cost, high productivity and convenience. Recently, automobile and aerospace industries are trying to replace partly steel sheets with aluminum alloy sheets. But in the case of dissimilar materials, to apply resistance spot welding has been known to be very difficult owing to the effect of melting temperature. On this study, an effort was made to apply spot welding of dissimilar sheet metals, 2024 aluminum alloy and zinc coated steel sheet, evaluate the spot weld quality with tensile-shear strength test and nondestructive evaluation technique, C-scan image methodology. In this study results, as the current below 11 kA, melting of materials is not achieved well. Also as the current exceeds to 13.5 kA, the more spatters happen at welded zone and tensile-shear strength lowered. So, the feasibility of C-scan image technique proposed in the study is found to be suitable evaluation method for resistance spot weldability.

• Journal of Welding and Joining
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• 제15권4호
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• pp.42-62
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• 1997

Resistance spot welding has been widely used in the sheet metal joining processes because of its high productivity and convenience. Recently, automobile industries are trying to replace partly steel sheets with aluminum alloy sheets. Among currently produced aluminum alloys, Al alloy sheets of Al-Mg-Si(6000 series) are being tested. Especially, 6000 series are the most probable substitute in view of strength and weldability. In this paper, an attempt was made to apply resistance spot welding to joining of dissimilar sheet metals (KS6383+SCPZn or KS6383+SHCP). An effort was made to balance heating rate in the Al alloy with that in the steel sheets by increasing electrode tip diameter. Although resistance spot welding of Al alloy sheet and sheet metals does not produce desirable nugget, it proved to have reasonable strength if optimal weld condition is found by tensile-shear strength and fatigue life test. Since spot weld joints in automobile are always experiencing repeated load, spot welding methodology proposed in this paper is found to be not suitable to automobile body manufacturing.

• 융복합기술연구소 논문집
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• 제5권1호
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• pp.7-12
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• 2015

Sheet metal formability can be defined as the ability of metal to deform without necking or fracture into desired shape. Every sheet metal can be deformed without failure only up to a certain limit, which is normally known as forming limit curve(FLC). In this paper, the dome stretching tests and tensile tests have been performed to obtain forming limit curve of aluminum alloy. During the experiment, failure strain is measured using digital image correlation(DIC) method. DIC method is a whole-field measurement technique that acquires surface displacements and strains from images information which characterized a random speckle as intensity grey levels. Recently years, this DIC method is being developed and used increasingly in various research. DIC results demonstrated the usefulness and ability to determine a strain.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1998년도 춘계학술대회논문집
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• pp.58-61
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• 1998

Anisotropy is closely related to the formability of sheet metal and should be considered carefully for more realistic analysis of actual sheet metal forming operations. In order to better describe anisotropic plastic properties of aluminum alloy sheets, a planar anisotropic yield function which accounts for the anisotropy of uniaxial yield stresses and strain rate ratios simultaneously was proposed recently[1]. This yield function was used in the finite element simulations of cup drawing tests for an aluminum alloy 2008-T4. Isotropic hardening with a fixed initial back stress based on experimental tensile and compressive test results was assumed in the simulation. The computation results were in very good agreement with the experimental results. It was shown that the initial back stress as well as the yield surface shape have a large influence on the prediction of the cup height profile.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1994년도 춘계학술대회 논문집
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• pp.118-128
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• 1994

The planar anisotropic FEM analysis for predicting the earing profiles and draw-in amounts in the deep-drawing processes is introduced. An implicit, incremental, updated Lagrangian formulation with a rigid-viscoplastic constitutive equation is employed. Contact and friction are considered through the mesh-based unit vectors and the normal contact pressure. the consistent full set of governing relations, comprising equilibrium and geometric constraint equations, is appropriately linearized. Barlat's strain-rate potential is employed, whose in-plane anisotropic properties are taken into account with anisotropic coefficients and potential parameter. The linear triangular membrane elements are used for depicting the formed sheet. with the numerical simulations of deep drawing processes of flat-top cylindrical cup for the 2090-T3 aluminum effects on the earing behavior are examined. Earing predictions made for the 2090-T3 aluminum alloy sheet show good agreement with experiments, although some discrepancies were observed in the directional trend of cup height and thickness strains.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2009년도 춘계학술대회 논문집
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• pp.429-431
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• 2009

Drawability and other mechanical properties of sheet metals are strongly dependent on their crystallographic orientations. In this paper the formability of the AA 5052 Al alloy sheets was investigated after asymmetric rolling and subsequent heat treatment. In most cases, after asymmetric rolling specimens showed a fine grain size and subsequent heat treated specimens showed that the ND // <111> texture component were observed. The anisotropy of formability is often described by the plastic strain ratios (r-value) as a function of the angle to the rolling direction in sheet metal. For a good formability, a high r-value is required in sheet metals. In the asymmetry rolled and subsequent heat treated Al alloy sheet, the variation of the plastic strain ratios have been investigated in this study, The plastic strain ratios of the asymmetry rolled and subsequent heat treated AA 5052 Al alloy sheets were higher than those of the original Al sheets. These could be related to the formation of ND // <111> texture components through asymmetric rolling in Al sheet.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2007년도 춘계학술대회A
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• pp.1322-1327
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• 2007

Many automotive companies have tried to apply the aluminum alloy sheet to car body because reducing the car weight can improve the fuel efficiency of vehicle. In order to do that, sheet materials require of weldablity, formability, productivity and so on. Aluminum alloy was not easy to join these metals due to its material properties. Thus, the laser is good heat source for aluminum alloy welding because of its high heat intensity. However, the welding quality was not good by porosity, underfill, and magnesium loss in welded metal for AA5182 aluminum alloy. In this study, Nd:YAG laser welding of AA 5182 with filler wire AA 5356 was carried out to overcome this problem. The weldability of AA5182 laser welding with AA5356 filler wire was investigated in terms of tensile strength and Erichsen ratio. For full penetration, mechanical properties were improved by filler wire. In order to optimize the process parameters, model to estimate tensile strength by artificial neural network was developed and fitness function was defined in consideration of weldability and productivity. Genetic algorithm was used to search the optimal point of laser power, welding speed, and wire feed rate.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2004년도 제5회 압연심포지엄 신 시장 개척을 위한 압연기술
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• pp.83-90
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• 2004

The drawbead is one of the most important factors in sheet metal forming for automotive parts. So clarifying the friction characteristics between sheets and drawbead is essential to improve the formability of sheet metal. Therefore in this study, drawbead friction test was performed at various panels(cold rolled steel sheets, galvanized steel sheets, electrogalvanized coating steel sheets, electrogalvanized Zn-Fe alloy steel sheets and aluminum alloy steel sheets). Circular shape bead has been used for the test. The results show that friction and drawing characteristics were mainly influenced by the nature of zinc coating.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 춘계학술대회 논문집
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• pp.477-479
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• 2008

Drawability and other mechanical properties of sheet metals are strongly dependent on their crystallographic orientations. In this paper the formability of the AA 5052 Al alloy sheets was investigated after asymmetric rolling and subsequent heat treatment. In most cases, after asymmetric rolling specimens showed a fine grain size and subsequent heat treated specimens showed that the ND//<111> texture component were observed. The anisotropy of formability is often described by the plastic strain ratios (r-value) as a function of the angle to the rolling direction in sheet metal. For a good formability, a high r-value is required in sheet metals. In the asymmetry rolled and subsequent heat treated Al alloy sheet, the variation of the plastic strain ratios have been investigated in this study. The plastic strain ratios of the asymmetry rolled and subsequent heat treated AA 5052 Al alloy sheets were higher than those of the original Al sheets. These could be related to the formation of ND//<111> texture components through asymmetric rolling in Al sheet.

• 한국마린엔지니어링학회:학술대회논문집
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• 한국마린엔지니어링학회 2001년도 추계학술대회 논문집(Proceeding of the KOSME 2001 Autumn Annual Meeting)
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• pp.88-91
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• 2001

New type of vehicles made from thin aluminum alloy are under rapid development and some product are already on the market, but when welding sheet metal joint of aluminum alloy, the main problem are burn-through by the high heat input. The purpose of this study, it is to prevent the burn-through and to shallow penetration that AC pulse welding has diminish the penetration and to lower the droplet temperature at Al sheet metal welding. In this study, we observed the bead appearance and whether it was appeared burn through or not , as the variation of the root gap in the lap and butt-joint welding process.