• Journal of Advanced Marine Engineering and Technology
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• v.36 no.6
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• pp.802-807
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• 2012

Self-piercing rivet is sheet joining method. It is being used more to join aluminum alloy sheets. Self-piercing riveting is a large-deformation process that involves piercing. The self-piercing rivet, under the press from the punch, pierces the top sheet and forms a mechanical interlock with the bottom sheet. In this study, forging process was designed for manufacturing self-piercing rivet. The forging process has been simulated by using commercial FEM code DEFORM-2D. In simulation of forging process for manufacturing rivet, process sequence, formability, forging load, and distributions of stress and strain were investigated. The suitable forging process could be designed by comparisons of simulation results. The developed process consists of four stages: upsetting, first chamfering, back extrusion, and second chamfering. The simulated results for forging process were confirmed by experimental trials with the same conditions.

• Transactions of Materials Processing
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• v.16 no.8
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• pp.603-613
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• 2007

This paper is concerned with joining of thin metal sheets by single stroke clinching process. This method has been used in sheet metal work as it is a simple process and offers the possibility of joining similar-dissimilar thin sheet metals. Clinching generates a joint by overlapping metal sheets deforming plastically by punching and squeezing sequence. AA 5754 aluminum alloy of 0.5 mm thick sheets have been selected as a modal material and the process has been simulated under different process conditions and the results have been analyzed in terms of the quality of clinch joints which are influenced mainly by tool geometries. The rigid-plastic finite element method is applied to analyses in this paper. Analysis is focused mainly on investigation of deformation and material flow patterns influenced by major geometrical parameters such as die diameter, die depth, groove width, and groove corner radius, respectively. To evaluate the quality of clinch joints, four controlling or evaluation parameters have been chosen and they are bottom, neck thickness of bottom and top sheets, and undercut thickness, respectively. It has been concluded from the simulation results that the die geometries such as die depth and diameters are the most decisive process parameters influencing on the quality of clinch joints, and the bottom thickness is the most important evaluation parameter to determine if the quality of clinch joints satisfies the demand for industrial application.

• Journal of Welding and Joining
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• v.27 no.4
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• pp.54-59
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• 2009

In the process to manufacture for metallic structures, control of welding deformation is one of an important problems connected with reliability of the manufactured structures so that welding deformation should be measured and controlled with quickly and actively. Also, welding parameters which have as lot of effects on welding deformation such as arc voltage, welding current and welding speed can also be controlled. The objectives for this study were to develop a simple 2-D FEM to calculate not only the transient thermal histories but also the sizes of fusion and heat-affected zone (HAZ) in multi pass arc welds including the butt and fillet weld type with dissimilar thickness, and to concentrate on a developed model for the finding the parameters of Godak's moving heat source model based on a GA. The developed model includes a GA program using MATLB and GA toolbox, and a batch mode thermal model using ANSYS software. Not only the thermal model was verified by comparison with Goldak's work but also the developed model was validated with molten zone section experimental data.

• Journal of Welding and Joining
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• v.32 no.2
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• pp.29-36
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• 2014

Recently, in order to enhance the function and usefulness of products, cladding of dissimilar materials that maximizes the performance of the material is being widely used in all areas of industry as an important process. Clad steel plate, produced by cladding stainless steel plate, an anticorrosive material, on carbon steel plate, is being used to produce pressure vessels. Stainless steel plate has good corrosion resistance, and carbon steel plate has good rigidity and strength; clad steel can satisfy all of these qualities at once. This study aims to find the ${\delta}$-ferrite behavior, mechanical properties, structure change, integrity and reliability of clad steel weld on hot rolled steel plates. For this purpose, multi-layer welding, repair welding and post weld heat treatment were implemented according to welding procedure specifications (WPS). In order to observe the mechanical properties and toughness of clad steel weld zone, post weld heat treatment was carried out according to ASME Sec. VIII Div.1 UW-40 procedure for post weld heat treatment. With heat treatment at $625^{\circ}C$, the hold time was used as the process variable, increased by intervals that were doubled each time, from 80 to 1,280 min. The structure of weld part was typical cast structure; localized primary austenite areas appeared near central vermicular ferrite and fusion line. The heat affected zone showed rough austenite structure created by the weld heat input. Due to annealing effects of heat treatment, the mechanical properties (tensile strength, hardness, impact value) of the heat affected area tended to decrease. From the results of this study, it is possible to conclude the integrity of clad steel welds is not affected much in field welding, repair welding, multi-layer welding, post weld heat treatment, etc.

• Bulletin of the Society of Naval Architects of Korea
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• v.9 no.2
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• pp.43-48
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• 1972

Inertia friction welding, a relatively recent innovation in the art of joining materials, is a forge-welding process that releases kinetic energy stored in the flywheel as frictional heat when two parts are rubbed together under the right conditions. In a comparatively short time, the process has become a reliable method for joining ferrous, and dissimilar metals. The process is based on thrusting one part, attached to a flywheel and rotating at a relatively high speed, against a stationary part. The contacting surfaces, heated to plastic temperatures, are forged together to produce a reliable, high-strength weld. Welds are made with little or no workpiece preparation and without filler metal or fluxes. However, In order to obtain a good weld, the determination of the optimum weld parameters is an important problem. Especially, because the amount of the flywheel mass will be determined according to the initial rotating velocity values at the constant thrust load, the initial rotating velocity is an important factor to affect a weld character of the inertia-welded IN713C-SAE8630, which is used for the wheel-shafts of turbine rotors or turbochargers, exhausting valves, etc. In this paper, the effects of initial rotational velocity on a weld character of inertia-welded IN713C-SAE8630 was studied through considerations of weld parameters determination, micro-structural observations and tensile tests. The results are as the following: 1) As initial rotating velocity was reduced to 267 FPM, cracks and carbide stringers were completely eliminated in the micro-structure of welded zone. 2) As initial rotating velocity was reduced and flywheel mass was increased correspondingly, the maximum welding temperatures were decreased and the plastic working in the weld zone was increased. 3) As initial rotating velocity was progressively decreased and carbides were decreased, the tensile strengths were increased. 4) And also the fracture location moved out of the weld zone and the tensile tests produced, the failures only in the cast superalloy IN713C which do not extend into the weld area. 5) The proper initial rotating velocity could be determined as about 250 thru 350 FPM for the better weld character.

• Journal of Welding and Joining
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• v.1 no.2
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• pp.45-52
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• 1983

Many pressure vessels for the hot H$\sub$2//H$\sub$2/S service are made of 2+1/4Cr-1Mo steel with austenitic stainless steel overlay to combat agressive corrosion due to hydrogen sulfide. Hydrogen dissolves in to materials during operation, and sometimes gives rise to unfore-seeable damages. Appropriate precautions must, therefore, be taken to avoid the hydrogen induced damages in the design, fabrication and operation stage of such reactor vessels. Recently, hydrogeninduced cracking (or Disbonding) was found at the interface between base metal and stainless weld overlay of a desulfurizing reactor. Since the stainless steel overlay weld metal is subjected to thermal and internal-pressure loads in reactor operation, it is desirable for the overlay weld metal to have high strength and ductility from the stand point of structural safety. In section III of ASME Boiler and Pressure Vessel Code, Post-Weld Heat Treatment(PWHT) of more than one hour per inch at over 1100.deg. F(593.deg. C) is required for the weld joints of low alloy pressure vessel steels. This heat treatment to relieve stresses in the welded joint during construction of the pressure vessel is considered to cause sensitization of the overlay weld metal. The present study was carried out to make clear the diffusion of carbon migration by PWHT in dissimilar metal welded joint. The main conclusion reached from this study are as follows: 1) The theoretical analysis for diffusion of carbon in stainless steel overlay weld metal does not agree with Fick's 2nd law but the general law of molecular diffusion phenomenon by thermodynamic chemical potential. 2) In the stainless steel overlay welded joint, the PWHT at 720.deg. C for 10 hours causes a diffusion of carbon atoms from ferritic steel into austenitic steel according to the theoretical analysis for carbon migration and its experiment. 3) In case of PWHT at 720.deg. C for 10 hours, the micro-hardness of stainless steel weld metal in bonded zone increase very highly in the carburized layer with remarkable hardening than that of weld metal.

• Proceedings of the KWS Conference
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• 2005.06a
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• pp.106-108
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• 2005

The instrumented fuel irradiation test at a research reactor is needed to evaluate the performance of the developed nuclear fuel. The fuel elements can be designed to measure the center line temperature of fuel pellets during the irradiation test by using temperature sensor. The thermal sensor was composed of thermocouple and sensor sheath. Micro-laser welding technology was adopted to seal between seal tube and sensor sheath with thickness of 0.15 mm. The soundness of welding area has to be confirmed to prevent fission gas of the fuel from leaking out of the element during the fuel irradiation test. In this study, fundamental data for micro-laser welding technology was proposed to seal temperature sensor sheath of the instrumented fuel element. And, micro-laser welding for dissimilar metals between sensor sheath and seal tube was characterized by investigating welding conditions. Moreover, the micro-laser welding technology is closely related to advanced industry. It is expected that the laser material processing technology will be adopted to various a pplications in the industry.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.2
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• pp.1-7
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• 2021

A computer simulation was performed to study the effectiveness of temperature on the type of laser heat source in the context of the heterogeneous welding of aluminum and copper materials. Three different types of heat sources were used in the computer simulation: 1) Single Beam Straight Scan, 2) Single Beam Wobble Scan, and 3) Dual Beam Straight Scan. Among these sources, dual beam straight scan was found to be the most effective from the viewpoint of heat source control. Because the difference between the melting temperatures of copper and aluminum is approximately 400℃, a clear separation of heating temperature was required, and the dual beam straight scan provided superior controllability in this regard. When using the dual beam, the temperature of the 90:10 split was considerably easier to control than that of the 50:50 split. The optimal offset was calculated to be 4 mm off to the copper side, where the melting temperature and thermal conductivity were higher. In this manner, computer simulation was effectively used for determining the optimal laser beam hear source control without performing an actual laser welding experiment.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.8
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• pp.18-24
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• 2021

Polymers, polymer compounds, are very moldable at low temperatures and have good strength against weight, and hence, are often used in the interior and exterior materials of cars. Owing to the increasing environmental problems, emission regulations have become stricter, which has increased the use of lightweight polymers as substitutes for metal materials. Therefore, as the use of polymer increases, extensive research is being conducted on the bonding technology of polymers, such as polyurethane and epoxy. However, the increased cost and environmental pollution by adhesives caused by the polymer manufacturing plant depend on the chemical composition or the manufacturer's mix ratio. To compensate for this issue, a laser beam is irradiated through a highly permeable polymer (PC) placed on top of an absorbent polymer (ABS) to transfer the laser output to the ABS polymer and fuse them at the interface. Moreover, enabling laser penetrating bonding by placing a stainless steel wire mesh between the two polymers can achieve improved bonding strength compared to conventional heterogeneous polymer bonding.

• Journal of Powder Materials
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• v.29 no.4
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• pp.309-313
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• 2022

In this study, additive manufacturing of a functionally graded material (FGM) as an alternative to joining dissimilar metals is investigated using directed energy deposition (DED). FGM consists of five different layers, which are mixtures of austenitic stainless steel (type 316 L) and low-alloy steel (LAS, ferritic steel) at ratios of 100:0 (A layer), 75:25 (B layer), 50:50 (C layer), 25:75 (D layer), and 0:100 (E layer), respectively, in each deposition layer. The FGM samples are successfully fabricated without cracks or delamination using the DED method, and specimens are characterized using optical and scanning electron microscopy to monitor their microstructures. In layers C and D of the sample, the tensile strength is determined to be very high owing to the formation of ferrite and martensite structures. However, the elongation is high in layers A and B, which contain a large fraction of austenite.