• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 2004년도 ICCAS
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• pp.499-503
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• 2004

This application-oriented paper describes an automated welding carriage system to weld a thin corrugated workpiece with welding seam tracking function. Hyundai Heavy Industries Corporation has developed an automatic welding carriage system, which utilizes pulsed plasma arc welding process for corrugated sheets. It can obtain high speed welding more than 2 times faster than traditional TIG based welding system. The aim of this development is to increase the productivity by using automatic plasma welding carriage systems, to track weld seam line using vision sensor automatically, and finally to provide a convenience to operator in order to carry out welding. In this paper a robust image processing and a distance based tracking algorithms are introduced for corrugated workpiece welding. The automatic welding carriage system is controlled by the programmable logic controller(PLC), and the automatic welding seam tracking system is controlled by the industrial personal computer(IPC) equipped with embedded OS. The system was tested at actual workpiece to show the feasibility and performance of proposed algorithm and to confirm the reliability of developed controller.

• Journal of Welding and Joining
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• 제24권5호
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• pp.49-56
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• 2006

For laser welding in shipbuilding industry, gap bridging capability is one of the most important characteristics to achieve the high productivity and good weld quality. Recently, laser-GMA hybrid welding process is regarded as a distinctive method to overcome the tight gap tolerance with improving the productivity. In this study, the influence of process parameters on the bead formation was experimentally analyzed and the relationship between the process parameters and geometric imperfections was investigated. It was revealed that undercut, excessive weld metal, excessive penetration and incompletely filled groove were the major geometric imperfections. The optimized wire feeding and arc pressure were necessary to ensure the gap bridging ability. The approach to select the process parameters was conducted for butt welding with up to 2mm joint gap, in which the sound weld beads were generated without changing the welding speed.

• Journal of Welding and Joining
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• 제27권4호
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• pp.67-72
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• 2009

In this paper, arc characteristics of V groove joints using pulsed GMA welding were found out. The bevel angles of $22.5^{\circ}$ and $30.0^{\circ}$ were chose to make the V groove configuration with the groove angles of $45^{\circ}$ and $60.0^{\circ}$, respectively. In the experiment, the arc current waveform measurement and the high speed photography were taken to investigate the arc characteristics for a single-beveled asymmetric workpiece. Consequently, the welding current was changed abnormally around the edge of groove. As the arc moved close to the groove face, the welding current was increased rapidly because the welding arc was affected by the inclined surface. Also the welding current waveforms were measured for the double-sided symmetric workpiece to verify the previous measurements for the single-beveled workpiece, and similar current waveforms were found.

• 한국레이저가공학회지
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• 제8권3호
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• pp.11-19
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• 2005

In automotive industry, light weight vehicle is one of issues because of the air pollution and the protection of environment. Therefore, automotive manufacturers have tried to adopt light materials such as aluminum alloy to production line. Aluminum welding using laser has some advantages high energy density and high productivity. It is very important to understand weld characteristic according to welding condition in order to determine the possibility of application to car body. In this study, Nd:YAG laser welding of 5182 aluminum alloy with filler wire AA5356 was carried out through experimental design according to wire feed rate, laser power and welding speed. Weld bead shape in terms of cross section photo, bead with, height of reinforcement and penetration depth and mechanical property in terms of tensile strength and formability was investigated. Analysis of variation (ANOVA) was performed to know the effect of weld parameter for weldability, laser power was statistically most significance factor of three variables.

• 한국생산제조학회지
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• 제22권4호
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• pp.700-707
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• 2013

Owing to high oil prices and environmental issues, the automobile industry has conducted considerable research and made large investments to manufacture a high-efficiency automobiles. In the case of automobile wheels in which a lightweight material is used to increase the fuel efficiency a mold is used to increase the production efficiency; however, the use of the molding method for this purpose is very expensive. Therefore an automobile wheel consists of two parts. In this study a two-piece automobile wheel is manufactured by the friction stir welding(FSW) of Al6061-T6 to reduce the manufacturing cost and process complexity. The FSW welding tool geometry and rotational speed, and the feed rate are key factors that significantly affect the weld strength. Therefore tensile tests were conducted on specimens produced using various welding conditions, and the optimal FSW welding conditions were applied to manufacture aluminum wheels. To ensure reliability, prototype aluminum wheels were manufactured and their mechanical reliability and safety were evaluated using a durability test, fatigue durability test, and impact test. Through this study, aluminum wheel production was made possible using the FSW method.

• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2002년도 Proceedings of the International Welding/Joining Conference-Korea
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• pp.600-605
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• 2002

The keyhole formed by high energy density laser-material interaction periodically collapses due to surface tension of the molten metal in partial penetration welds. The collapse sometimes traps a void at the bottom of the keyhole, and it remains as welding defects. This phenomenon is seen as one cause of the instability of the keyhole during laser beam welding. Thus, it seems likely that improving the stability of the keyhole can reduce voids and uniform the penetration depth. The goal of this work is to develop techniques for controlling laser weld keyhole dynamics to reduce weld defects such as voids and inconsistent penetration. Statistical analysis of the penetration depth signals in glycerin determined that keyhole dynamics are chaotic. The chaotic nature of keyhole fluctuations and the ability of laser power modulation to control them have been demonstrated by high-speed video images of laser welds in glycerin. Additionally, an incident leading beam angle is applied to enhance the stability of the keyhole. The quasi-sinusoidal laser beam power of 400Hz frequency and 15$^{\circ}$ incident leading beam angle were determined to be the optimum parameters for the reduction of voids. Finally, chaos analyses of uncontrolled signals and controlled signals were done to show the effectiveness of modulation on the keyhole dynamics. Three-dimensional phase plots for uncontrolled system and controlled system are produced to demonstrate that the chaotic keyhole dynamics is converted to regular periodic behavior by control methods: power modulation and incident leading beam angle.

• 한국해양공학회지
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• 제24권6호
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• pp.92-96
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• 2010

Recently, the application of aluminum alloys has been increasing for lightweight and high quality transport vehicles. Therefore, the proposal has been made to apply high speed hybrid welding methods to the marine grade aluminum alloy (A5052) used for shipbuilding by combining a 3-KW CW Nd : YAG laser and the MIG welding process. In this study, the characteristics of the welding parameters were investigated for a hybrid butt joint. This paper also describes the determination of the heat distribution in a weldment and the welding residual stress using a finite element method. Mechanical experimentation was also used to ascertain the reliability of the weldment.

• Journal of Welding and Joining
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• 제16권2호
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• pp.100-110
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• 1998

In this paper, the laser weldability of thin gage steels for automobile application is discussed. Welding was carried out with a high power carbon dioxide laser system, and the laser energy was concentrated through a plano-convex lens. Test results showed that the joint gap in the butt welding proved to be one of the critical conditions for an acceptable weld. In the case where the ratio of the gap clearance to the material thickness was slightly bigger than optimal value, the weld strength was reduced showing weld metal fracture. It was possible to obtained a weld penetration ratio of 0.91 when the vertical offset ratio was controlled to be 0.4 or smaller. Results also demonstrated that the weld strength of the lap joint was influenced by travel speed. At the travel speeds lower than 37 mm/s, the weld strength indicated higher value than that of class A recommendation strength of a resistance spot weld based on the KS code. It was clear that the complicated effect of specimen alignment should be considered so as to make a sound weld with high integrity when the laser process was applied to the long weld line.

• Journal of Welding and Joining
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• 제30권4호
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• pp.38-43
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• 2012

Using a fiber laser heat source, an oil pressure sensor was fabricated to measure the pressure in commercial vehicles. A stepping motor was used for the rotational and translational motion in the diaphragms and hardware joining. Laser welding process algorism including shielding gas control and vision system was integrated by using LabVIEW software for the high quality welding and in-line monitoring purpose. For the maximum flexibility in pressure transmission to the pressure sensor, thin sheet metal diaphragm, $25{\sim}50{\mu}m$(SUS-316L), was used and the diaphragms were optimally designed with FEM analysis. The welded samples were cross-sectioned the observation showed that the maximum depth ratio was more than seven times of diaphragms. The maximum welding speed was measured to be as high as 50in/mm by the developed automation mechanism. The fabricated prototypes were tested for the proof pressure, spring constant and sealing. The FEM results of spring constant measurement was as accurate as up to 80% of the design value and the sensor was safely operated up to the nominal pressure of 10bars.

• 한국철도학회:학술대회논문집
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• 한국철도학회 2003년도 추계학술대회 논문집(II)
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• pp.163-169
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• 2003

In order to develop domestic railway technology, it is necessary that manufacturing technology of turnout should be kept up with update level, because turnout is the core component of high speed railway. Manganese crossing made of high manganese alloy steel is a important component of turnout. So far, this could not have been welded with rail steel due to metallic problem in Korea. However, joint technology hereunder between manganese crossing and rail by using Flash Butt Welding which is developed by Kangwon Railtech Co., Ltd is the state of the art and enable to realize rail continuousness in turnout section, speed up train velocity, reduce maintenance cost, and enhance riding quality.