• Proceedings of the KWS Conference
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• 2002.10a
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• pp.193-198
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• 2002

In 1his paper, applicability of laser welding to joining process of single crystal nickel base superalloy turbine blades was investigated. Because heat input of laser welding is more precisely controlled 1han TIG welding, it is possible to optimize solidification microstructure of the welds. Since in single crystal nickel base superalloy the crystal orientation have a significant effect on the strength, it is important to control the solidification microstructure in the fusion zone. A single crystal nickel base supera1loy, CMSX-4, plates were bead-on welded and butt welded using a $CO_2$ laser. The effects of microstructure and crystal orientation on properties of the weld joints were investigated. In bead-on weldling, welding directions were deviated from the base metal [100] direction by 0, 5, 15 and 30 degrees. The welds with deviation angles of 15 and 30 degrees showed fusion zone transverse cracks. As the deviation angles became larger, the fusion zone had more cracking. In the cross section microstructure, the fusion zone grains in 0 and 5 degrees welds grew epitaxially from the base metal spins except for the bead neck regions. The grains in the bead neck regions contained stray crystals. As deviation angles increased, number of the stray crystals increased. In butt welding, the declinations of the crystal orientation of the two base metals varied 0, 5 and 10 degrees. All beads had no cracks. In the 5 degrees bead, the cross section and surface microstructures showed that the fusion zone grains grew epitaxially from the base metal grains. However, the 10 degrees bead, the bead cross section and surface contained the stray crystals in the center of the welds. Orientations of the stray crystals accorded with the heat flow directions in the weld pool. When the welding direction was deviated from the base metal [100] direction, cracks appeared in the area including the stray crystals. The cracks developed along the grain boundaries of the stray crystals with high angles in the final solidification regions at the center of the welds. The fracture surfaces were covered with liquid film. The cracks, therefore, found to be solidification cracks due to the presence of low melting eutectic. As the results, in both bead-on welding and butt welding the deviation angles should be control within 5 degrees for preventing the fusion zone cracks. To investigate the mechanical properties of the weld joints, high temperature tensile tests for bead-on welds with deviation angles of 0 and 5 degrees and the butt welds with dec1ination angles of 0, 5 and 10 degrees were conducted at 1123K. The the tensile strength of all weld joints were more 1han 800MPa that is almost 80% of the tensile strength of the base metal. The strength of the laser weld joints were more than twice that of tue TIG weld joints with a filler metal of Inconel 625. The results reveals 1hat laser welding is more effective joining process for single crystal nickelbase superalloy turbine blades 1han TIG welding.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.10a
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• pp.170-173
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• 2002

The object of this study is to investigate the effect of compounded welding through the AE (Acoustic Emission) characteristics on static tensile test. This study was carried out a SM 490A, high tension steel using the low hydrogen type E4316 of electronic shield metal arc welding and compound wire of $CO_2$gas arc welding. $CO_2$welding, weak in the intensity of HAZ (Heat Affected Zone), can be improved by being combined with coated arc welding, Coated arc welding, weak in the intensity of the bead, can be improved by being combined with $CO_2$welding. Especially, electronic coated arc welding and $CO_2$welding complement the mechanical intensity of HAZ and the bead with each other. So, compounded welding increases the intensity in the special parts and enhances the quality of goods.

• International Journal of Korean Welding Society
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• v.1 no.2
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• pp.36-44
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• 2001

To get the appropriate welding process variables, mathematical modeling in conjunction with many experiments is necessary to predict the magnitude of weld bead shape. Even though the experimental results are reliable, it has a difficulty in accurately predicting welding process variables for the desired weld bead shape because of nonlinear and complex characteristics of welding processes. The welding condition determined for the desired weld bead shape may cause the weld defect if the welding current/voltage/speed combination is improperly selected. In this study, the $2^{n-1}$ fractional factorial design method and correlation parameter were used to investigate the effect of the welding process variables on the fillet joint shape, and the multiple non-linear regression analysis was used for modeling the gas metal arc welding(GMAW）parameters of the fillet joint. Finally, a fuzzy rule-based method and a neural network method were proposed so that the complexity and non-linearity of arc welding phenomena could be effectively overcome. The performance of the proposed neuro-fuzzy system was evaluated through various experiments. The experimental results showed that the proposed neuro-fuzzy system could effectively check the welding conditions as to whether or not weld defects would occur, and also adjust the welding conditions to avoid these weld defects.

• Journal of the Korean Society of Industry Convergence
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• v.13 no.4
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• pp.197-203
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• 2010

Laser welding is widely used for precision welding because of superior mechanical properties and high productivity. Generally the accuracy of the welding is determined by the distribution of the bead which is affected by the structural vibrations of the equipment. This study was originated to stabilize a laser welding machine to minimize the bead distribution for the precise joining. The structural properties of the laser welding machine have been investigated to analyze the major factors of the vibrations to cause the bead distribution. The ideas for the design improvement have been applied to the simulation model to identify the effects and further to achieve the stability design and to minimize the bead distribution. The result shows that a few simple design alterations can substantially suppress the structural vibrations and improve the welding accuracy. The procedure used for this study can also be applied to similar welding equipments for improving the structural stability and the welding accuracy.

• Journal of Welding and Joining
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• v.14 no.4
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• pp.33-42
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• 1996

In recent years there has been a significant growth in the use of the automated and/or robotic welding system, carried out as a means of improving productivity and quality, reducing product costs and removing the operator from tedious and potentially hazardous environments. One of the major difficulties with the automated and/or robotic welding process is the inherent lack of mathematical models for determination of suitable welding process parameters. Partial-penetration, single-pass bead-on-plate welds were fabricated in 12mm AS 1204 mild steel flats employing five different welding process parameters. The experimental results were used to develop three empirical equations: curvilinear; polynomial; and linear equations. The results were also employed to find the best mathematical equation under weld bend width to assist in the process control algorithms for the Gas Metal Arc Welding(GMAW) process and to correlate welding process parameters with weld bead width of bead-on-plates deposited. With the help of a standard statistical package program. SAS, multipe regression analysis was undertaken for investigating and modeling the GMAW process, and significance test techniques were applied for the interpretation of the experimental data.

• Journal of Welding and Joining
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• v.29 no.4
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• pp.80-84
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• 2011

In the 5xxx series Al-Mg alloy, magnesium addition can increase the strength of aluminum alloy by solid solution strengthening but it has a relatively low melting and boiling temperature. During full -penetration laser welding of the Al-Mg alloys, its low boiling point and high vapor pressure brings about the spiky humping bead on the bottom side. Under back-side shielding, the spiking of back bead can be reduced but it restraints the process flexibility. In this study, a square pulse waveform modulation was employed to stabilize keyhole and back bead surface without back-side shielding. By using an experimental design, the bead shapes were evaluated for various process parameters such as the focal position, welding velocity and waveform parameters and the smooth back bead shape could be achieved.

• Journal of Welding and Joining
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• v.35 no.1
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• pp.16-25
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• 2017

Gas Metal Arc Welding is a widely used process in Industry due to its high productivity and potential to automation. The present study investigates the effects of the welding speed, arc voltage, welding current and shielding gas on the bead geometry for a low-carbon steel. The Response Surface Methodology (RSM) is used to choose an experimental design and perform test runs accordingly in order to produce mathematical models predicting the geometry, the hardness and the heat input of the bead as functions of the welding parameters. The direct and interaction effects of the four welding parameters are represented graphically and allow to determine an optimum set of welding parameters.

• Proceedings of the KWS Conference
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• 2003.05a
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• pp.155-158
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• 2003

Orbital GTA welding is used in the pressure pipe line of auto-mobile, LNG and plant piping. To weld the pipe line safely, to some extent, the back bead must be formed in the root pass. In the plate welding the back bead can be observed, but in the pipe welding, the back bead can not be observed directly. In the welding around circumference, the parameters such as gravity, surface tension and arc force are different at each position. And then D/B for welding condition at each position are required. We also studied about the setting of the optimum orbital welding condition by controlling heat input.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.7 no.6
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• pp.57-63
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• 1998

An adaptive control in the robotic GMA welding is employed to monitor information about weld characteristics and process parameters as well as to modify those parameters to hold weld quality within acceptable limits. Typical characteristics are the bead geometry, composition, microstructure, appearance, and process parameters which govern the quality of the final weld. The main objectives of this thesis are to realize the mapping characteristics of bead width through learning. After learning, the neural estimation can estimate the bead width desired form the learning mapping characteristic. The design parameters of the neural network estimator(the number of hidden layers and the number of nodes in a layer) are chosen from an estimation error analysis. A series of bead of bead-on-plate GMA welding experiments was carried out in order to verify the performance of the neural network estimator. The experimental results show that the proposed neural network estimator can predict the bead width with reasonable accuracy and guarantee the uniform weld quality.

• Journal of Welding and Joining
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• v.31 no.4
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• pp.62-66
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• 2013

Overlay welding is carried out to improve the corrosion resistance, wear resistance and heat resistance on the surface of the chemical plant and steelmaking plant structures. In overlay welding, control of the bead size and the temperature distribution of weldment are particularly important because that is directly connected to the improvement of quality and productivity. The aim of this study is to model the welding heat source that is very useful to analyze the bead size and temperature distribution of weldment. To find the welding heat source model, numerical analyses are performed by using FE software MSC-marc.