• Journal of Welding and Joining
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• v.22 no.5
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• pp.65-72
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• 2004

The tendency and degree of hot cracking of high strength 5083, 6N01 and 7N01 Al alloy welds by using DCSP-GTAW through modified Varestraint test and autogenous butt welding were investigated. In hot cracking test, 6N01 alloy showed the highest susceptibility to hot cracking in the weld metal and HAZ. Cracking susceptibilities generally increased with increase of solidification temperature range of the base metal and bead penetration-to-width ratio of the weld metal. The cracks in welds of the alloys vertically formed to solid-liquid interface and propagated along with columnar grain boundaries. The fracture facets of cracks showed the typical morphology of solidification crack observed as dendritic structures. Especially, in 6N01 alloy, liquation cracks which were due to elements of Si, Fe and Mg also observed in HAZ near fusion boundary. In butt welding of different Al alloys, the bead crack was mainly occurred in the welds of 6N01, 7N01 and other Al alloys together with 6N01 or 7N01. In the butt welds of 7N01, it was found that the component of Cu had an effect on the higher susceptibility to the hot cracking.

• Journal of Welding and Joining
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• v.34 no.1
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• pp.68-74
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• 2016

Adoption of narrow gap welding shall be increased for the butt joint of thick plate, because the deformation and welding cost is reduced by decrease of cross-sectional area. However, sometimes narrow gap causes defects such as lack of fusion since it has small groove angle and narrow groove width. Therefore, GMAW, GTAW and SAW process shall be adopted to narrow gap welding with small bead hight and low deposition rate. In this study, Super-TIG welding using C-type strip was applied to semi-narrow gap butt joint in order to increase the welding productivity. High deposition rate 10kg/hr was obtained by high current 600A without undercut, humping bead and other welding defects. Measuring the mean and standard deviation of the melting depth to evaluate the developed processes, the fusion line type was determined by measuring the difference between maximum and minium melting depth. Furthermore, a model on arch fusion line and linear fusion line was suggested in order to prevent LF on groove wall in narrow gap butt welding.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.76-81
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• 2002

The dramatic increase in the depth of a weld bead penetration has been demonstrated by welding a stainless steel in GTA (Gas-Tungsten-Arc) process with activating flux which consists of oxides and halides. However, there is no commonly agreed mechanism fer the effect of flux on the process. In order to make clear the mechanism, each behavior of the arc md the weld pool in GTA process with activating flux is observed in comparison with a conventional GTA process. A constricted anode root is shown in GTA process with the activating flux, whereas a diffuse anode root is shown in the conventional process. These anode roots are related strongly to metal vapor from the weld pool and the metal vapor is also related to temperature distributions on the weld pool surface. Furthermore, it is suggested that a balance between the Marangoni force and the drag force of the cathode jet should dominate the direction of re-circulatory flow in the weld pool. The electromagnetic force encourages the inward re-circulatory flow due to the constricted anode root in the case with flux. The difference in flow direction in the weld pool changes the geometry or depth/width ratio of weld bead penetration.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.107-112
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• 2002

Ferritic stainless steels would be the most important alloys under the chloride environment. They are a cheaper alternative to austenitic stainless steels [1]. The present study is related to gas tungsten arc welding (GTAW) characteristics of Type 444 stainless steels. The heat of welding leads to grain coarsening in the HAZ and in the weld metal of ferritic stainless steels because they solidify directly from the liquid to the ferritc phase without any intermediate phase transformation. It is therefore recommended that these alloys be welded with a low heat input and at high welding speeds. Attempts to improve weldability were made by using of direct current straight polarity (DCSP) and pulsed current GTAW processes in this study. Measuring weld bead, grain size and Erichsen test were performed and the effects of heat input, pulse frequency on the weld metal and HAZ were studied. The main results were obtained as followings: decreasing heat input was effective to control the width of weld both in DCSP welding and in pulsed current welding; pulsed current welding was found to refine the grain size effectively and the finest grain size was found at the frequency of 150Hz in pulsed current welding; it was found that decreasing heat input also refine the HAZs effectively and the frequency had no different effect on HAZ at the same heat input; the ductility could be improved effectively in pulsed current welding.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.127-131
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• 2006

There are being a lot of studies for achievement of high speed Dehydration, high-strength and Lightweight of washing machine in the latest washing machine business. It is essential that Press-joining Strength of Spin Drum Seaming division is improved .to attain that target. Generally, we are using Mechanical press-joining by Seaming and T.I.G (Tungsten Inert Gas) welding among part joint method. Mechanical press-joining method that is mainly using for Stainless Steel (STS430) Drum have lots of merit that consumption of energy is low more than welding and production costs cut down and generation of the corrosion is solved by removing weld zone defect and materials having different properties are enable to join without special equipment. But, it is difficult to realize joint strength required at high speed operation because joint strength of mechanical press-joining method is low remarkably in comparison with welding. Also, there are a lot of analysis difficulties and very limited research is under way due to the dynamic factor such as multistage plastic working, elastic recovery, residual stress etc. The results of this study show optimal joining condition for mechanical press-joining by performing lots of tensile joining strength test with various specimen under multi-change of important design factor such as seaming width, bead area and bead depth etc.

• Journal of Welding and Joining
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• v.20 no.4
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• pp.510-516
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• 2002

Recently the laser welding technology has been applied increasingly for the automotive bodies. But the lap joint laser welding for 3 dimensional automotive body is new while the butt joint laser welding is well known as the tailored blank technology. In this study, the process window was found for the full penetration welding of the lap joint of the 1mm-thick high strength steel sheets. The limit curves and characteristic curves were suggested to define the boundaries and the contour lines in a space of the welding speed and the gap size. The characteristics of the weld sectional geometry were used to determine the limit curves. They are bead width, penetration depth and sectional area. After the observed data was analysed carefully, it was noticed that there was a transition point at which the sectional shape was changed and the bead area jumped as the welding speed was increased. Also a new concept of 'input energy Per volume' was suggested to distinguish the difference at the transition Point. The difference of sectional areas at the transition point can be related to the dynamic keyhole phenomena.

• Laser Solutions
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• v.14 no.2
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• pp.1-7
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• 2011

The latest trends of vehicle technology development are fuel efficiency improvement, body designs declining air resistance and lightweight of materials. Especially, as lightened weight of materials makes engine efficient so that vehicles keep the best performance, it is the best way to protect the environment and reduce fuel consumption. In this study, we conducted laser welding by using 3-dimension remote scanner that is 5J32 aluminium alloy. Furthermore, conduction experiment that was 3 times repeated for changing factors such as observing angle, laser power and welding speed. we observed exterior and cross section of weled part and tensile strength. When increasing laser power and decreasing laser speed, tensile strength increased. In order to evaluate factors that affect tensile strength qualitatively we conducted ANOVA. We assumed that the factors are observing angle, laser power and welding speed. Then we found that laser power and laser speed affect tensile strength. We conducted evaluation of weldability of aluminium alloy by above ways.

• Journal of Welding and Joining
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• v.16 no.1
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• pp.77-87
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• 1998

This paper deals with the effect of laser welding parameters on the weld formation. Thin steels for automotive application were prepared so as to be welded with high power carbon dioxide laser system. Major process parameters were position of focus and travel speed. The effect of shielding gas was also discussed by employing the high speed photometry. Test results showed that the optimal position of focus varied in accordance with the joint configuration; bead-on-plate, butt or lap welding. It was recommended that the position of focus for the lap welding be located at slightly inner part of the material to be welded. In this case, however, it was noticeable that the weld penetration ratio, d/t$_{0}$ dropped drastically at the critical region. Results also demonstrated that both the bead width and penetration reduced as the travel speed increased. The penetration ratio showed two distinct regions; stabilized zone at the lower range of the travel spped and sudden drop zone at the higher range of travel speed. Lower limit of the penetration for acceptable weld was proved to be about 90% of the parent metal thickness based on the physical properties of the weld. Mixed gas application for both the shielding of molten metal and laser induced plasma control was recommended as far as the penetration was concerned.d.

• Journal of Welding and Joining
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• v.23 no.6
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• pp.43-48
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• 2005

This work was carried out to obtain sound welds and to select a most suitable binary metal joint among three different dissimilar binary metal combinations such as Zr-4/Ta, Mo/Ta and Ti/Ta(seal tube/sensor sheath) joints fur the instrumented nuclear fuel irradiation test. To do this, Taguchi experimental method was employed to optimize the experimental data. In addition, metallography, micro-focus x-ray radiography and hardness test were conducted to examine the welds. From the weld bead appearance, penetration depth and bead width as well as weld defects standpoint, Zr-4/Ta joint is suggested for the circumferential joining between a seal tube and a sensor sheath. The optimized welding parameters based on Zr-4/Ta joint are suggested as well.

• Transactions of Materials Processing
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• v.30 no.3
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• pp.109-118
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• 2021

Recently, there has been an increased interest in the remanufacturing of mechanical parts using metal additive manufacturing processes in regards to resource recycling and carbon neutrality. DED (directed energy deposition) process can create desired metallic shapes on both even and uneven substrate via line-by-line deposition. Hence, DED process is very useful for the repair, retrofit and remanufacturing of mechanical parts with irregular damages. The objective of the current paper is to investigate the effects DED process parameters, including the effects of power and the scan speed of the laser, on deposition and residual stress characteristics for remanufacturing of mechanical parts using experiments and finite element analyses (FEAs). AISI 1045 is used as the substrate material and the feeding powder. The characteristic dimensions of the bead shape and the heat affected zone (HAZ) for different deposition conditions are obtained from the experimental results. Efficiencies of the heat flux model for different deposition conditions are estimated by the comparison of the results of FEAs with those of experiments in terms of the width and the depth of HAZ. In addition, the influence of the process parameters on residual stress distributions in the vicinity of the deposited region is investigated using the results of FEAs. Finally, a suitable deposition condition is predicted in regards to the bead formation and the residual stress.