• Proceedings of the KWS Conference
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• 2005.11a
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• pp.55-57
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• 2005

In this study, modeling of the CD stud welding system was conducted considering mechanical and electrical components. The electrical components such as arc resistance, cable resistance, capacitance, internal resistance and cable inductance were found to affect the output waveform significantly. The calculated results showed food agreements with the experiment results within 20% error. The main defect of CD stud welding with 1010 steel stud and SS400 steel plate was the void trapped between stud and base metal. The effect of the spring force and stud tip size on void formation was investigated.

• Journal of Welding and Joining
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• v.24 no.3
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• pp.34-41
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• 2006

The CD (Capacitor Discharge) stud welding utilizes the arc heat and pressure to attach the stud to the workpiece, which consists of the arc. ignition, arcing and pressure welding stages. In order to predict the dynamic behavior of the CD stud welding process, mechanical and electrical models are employed in this work. While the mechanical model estimates the duration of each stage, the electrical model predicts the voltage and current waveforms using the RLC circuit. Effects of process parameters such as the electric components and spring force are analyzed through simulation. It is found that the contact resistance and gap between the stud and base metal influence the tip fusing and arcing duration. The calculated results showed reasonably good agreements with the experiment results.

• Proceedings of the KWS Conference
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• 2007.11a
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• pp.53-56
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• 2007

Magnesium sheet used in electrical device due to mobility and EMF shielding characteristics. Magnesium case by press forming was advantageous compare with conventional die casting process, because of its thin gauge of wall and surface quality. But it need to makes the boss to fix inner part or assemble the case. CD stud welding was effective way for joining the boss to the thin gauge case of the electrical devices. In this study, we investigated the performances of the magnesium boss welder To measure the process parameters such as the force and the weld current, we design the monitoring system for CD stud welding. We test the characteristics of CD stud welding for AZ31 sheets at some variables. Finally we select the optimum welding range of magnesium sheets in CD stud welding process.

• Journal of Welding and Joining
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• v.24 no.3
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• pp.42-48
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• 2006

Since the voids occur at the CD stud welds, the mechanism of void formation and void reduction method are investigated in this work. It is speculated that the voids are formed because of high short-circuit current above 1000A. When the simple flow model is used to estimate the void trapping condition, the most voids are trapped at the weld mainly due to fast cooling rate of the CD stud weld. Since it is almost impossible to remove the voids completely, a method is proposed to reduce the void by decreasing the short-circuit current at the end of the arcing time. The experimental results show that the void is reduced by decreasing the short-circuit current to 1000A.