• Laser Solutions
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• v.17 no.2
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• pp.11-18
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• 2014

This research was conducted as a fundamental study to apply tailored blank welding technique into automotive production process. Specially we tried to apply the TWB technique to exhaust system. The materials used in this work were ferritic 439 stainless steel sheet with a thickness of 1.2mm and 0.8mm. Welding tests were conducted for BOP test and dissimilar thickness (0.8 to 1.2t) cases. Major process parameters were position of focus, travel speed, shielding gas and joint (gap) condition. As a result, there are nothing significant welding characteristic compare with TWB of carbon steel. Stainless steel shows the good weldability and mechanical properties (tensile, hardness and forming strength) also shows high level. Just problem is gap condition. However, also in this case, it shows not only good forming strength but also base metal fracture after tensile test. And to conclude, it is good opportunity to make lightweight design muffler using TB welding technique.

• Proceedings of the KWS Conference
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• 2006.05a
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• pp.266-268
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• 2006

The effects of the brazing temperature and homogenizing time for brazed specimens on the joint of Ni-based superalloys such as Haynes 250, Inconel 617 and Hastelloy-X were investigated. The brazing alloy is nickel base MBF 15. The foil had a thickness of $38{\mu}m$, which was used two sheets of that for the all experiments. The experimental brazing was carried out by a brazing process in a vacuum of approximately $2{\times}10^{-5}$ Torr, an applied pressure of about 0.74MPa and the three kinds of brazing temperatures were 1100, 1150, and $1190^{\circ}C$ for a holding time of 5 to 1440 minutes. Microstructural observations were made on the cross-sectional samples by using an optical microscope(OM), scanning electron microscope(SEM), and electron probe X-ray microanalyzer(EPMA). The tensile tests were performed at room temperature with a cross head speed 1.5 mm/min according to ASTM E8M. The results show that excellent joint tensile strengths of as high as 788MPa were obtained when processed at $1190^{\circ}C$ for 5 minutes.

• Transactions of Materials Processing
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• v.15 no.2 s.83
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• pp.132-137
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• 2006

This paper is concerned with the thermo-mechanical behavior including temperature dependent strain-rate sensitivity of steel sheet for an auto-body. In order to identify the temperature dependent strain-rate sensitivity of SPRC35R and SPRC45E, uniaxial tension tests are performed with the variation of the strain-rates from 0.001 /sec to 200 /sec at environmental temperatures varied from $-40^{\circ}C\;to\;200^{\circ}C$. The thermo-mechanical response at the quasi-static state is obtained with the static tensile test and at the intermediate strain-rate is from the high speed tensile test. Experimental results show that the strain-rate sensitivity increases at low temperature. It represents that as the strain-rate increases, the variation of flow stress becomes sensitive on the temperature. The results indicate that the flow stress of SPRC35R is more dependent on the changes of strain-rate and temperature than those of SPRC45E.

• Journal of Korea Foundry Society
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• v.17 no.6
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• pp.585-591
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• 1997

Hyper-eutectic Al-17.5wt%Si alloy bars of 25 mm in diameter were produced by horizontal continuous casting process. Effect of both casting speed and primary Si refiner (AlCuP) on microstructure and mechanical properties of the alloy have been investigated. With increasing a weight fraction of AlCuP, the average primary Si size decreased down to $20 {\mu}m$. On the contrary, there was no notable changes of microstructure and primary Si size according to the casting speed in the experimental range of this study, indicating that the cooling rate should be increased to optimize and refine microstructure and primary Si size. The experimental results including hardness, tensile strength and wear resistance tests of the processed alloy bars showed a good possibility to develop the high performance wear resistant Al-Si alloy.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.1
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• pp.90-95
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• 2017

Recently, smaller and lighter products have become of interest in industry applications that increasingly demand thin plate joints of thickness 1.0 mm or less using friction stir welding. In this study, high frequency spindles that run at 3,500-6,500 rpm are introduced for thin friction stir-welded plates. Weldability tests are performed for the butt-joint method of Al5052-H32 alloy of 1.0 mm thickness under 3,500-6,500 rpm spindle revolution with 250-400 mm/min feed speed. An optical microscope was used to analyze the bid structure of the welded zone and stir zone. The tensile-strength and hardness of the welded zone were then measured.

• Journal of Auto-vehicle Safety Association
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• v.9 no.3
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• pp.7-12
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• 2017

The whiplash is the most important issue of low speed rear-impact. So auto makers are committed to developing a seat to improve whiplash injury. Most NCAP tests have been used by same pulse (Mid Velocity 16kph). Only Euro NCAP uses different pulse that consists of Low, Mid, High velocity. But Euro NCAP also uses same pulse in Mid velocity as other NCAP test. That Mid velocity NCAP pulse was made by rear impact that has 90's vehicle structure properties. That pulse was used until now days. However these days, auto maker use more high tensile steel than 90's as customer and society demand more fuel efficiency and light vehicle with good safety structure. So modern vehicles have different pulse patterns of rear impact than NCAP pulse and 90's vehicle crash properties. In this paper, the test was conducted by following condition. Target car was impacted by the rigid barrier with certain velocity. Finally target vehicle gained delta V 16kph which was same velocity as NCAP Mid Velocity pulse. It is critical velocity which occur long period neck injury. It is very different pulse that was gained by real car impact from NCAP pulse. And it has higher peak G with high fluctuation and short duration than NCAP pulse.

• Journal of Advanced Marine Engineering and Technology
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• v.29 no.8
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• pp.891-898
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• 2005

Inertia welding is a solid-state welding process in which butt welds in materials are made in bar and in ring form at the joint race, and energy required lot welding is obtained from a rotating flywheel. The stored energy is converted to frictional heat at the interface under axial load. The quality of the welded joint depends on many parameters, including axial force, initial revolution speed and energy amount of upset. working time, and residual stresses in the joint. Inertia welding was conducted to make the large exhaust valve spindle for low speed marine diesel engine. superalloy Nimonic 80A for valve head of 540mm and high alloy SNCrW for valve stem of 115mm. Due to different material characteristics such as, thermal conductivity and flow stress. on the two sides of the weld interface, modeling is crucial in determining the optimal weld geometry and Parameters. FE simulation was performed by the commercial code DEFORM-2D. A good agreement between the Predicted and actual welded shape is observed. It is expected that modeling will significantly reduce the number of experimental trials needed to determine the weld parameters. especially for welds for which are very expensive materials or large shaft. Many kinds of tests, including macro and microstructure observation, chemical composition tensile , hardness and fatigue test , are conducted to evaluate the qualify of welded joints. Based on the results of the tests it can be concluded that the inertia welding joints of the superalloy exhaust valve spindle are better properties than the material specification of SNCrW.

• Journal of the Korean Society of Marine Environment & Safety
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• v.28 no.4
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• pp.639-647
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• 2022

The use of flames is essential in cutting, bending, and welding steel during a ship's construction process. While acetylene fuel is commonly used in steel cutting and the manufacturing process in shipyards, the use of propane as an alternative fuel has recently been increasing, due to the lower risk of explosion and propane's relatively low calorific value. However, propane fuel has a relatively slow processing speed and high slag generation frequency, thereby resulting in poor quality. Propylene is another alternative fuel, which has an excellent calorific value. It is expected to gain wider use because of its potential to improve the quality, productivity, and efficiency of steel processing. In this study, the combustion characteristics of propane and propylene fuel during steel plate processing were analyzed and compared. The reduction of greenhouse gases and other harmful gases when using propylene flame was experimentally verified by analyzing the gases emitted during the process. Heat distribution and tensile tests were also performed to investigate the effects of heat input, according to processing fuel used, on the mechanical strength of the marine steel. The results showed that when propylene was used, the temperature was more evenly distributed than when propane fuel was used. Moreover, the mechanical tests showed that when using propylene, there was no decrease in tensile strength, but the strain showed a tendency to decrease. Based on the study results, it is recommended that propylene be used in steel processing and the cutting process in actual shipyards in the future. Additionally, more analysis and supplementary research should be conducted on problems that may occur.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.4
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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.

• Journal of Advanced Marine Engineering and Technology
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• v.12 no.3
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• pp.57-67
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• 1988

Although handicapped by the inability to bridge the size gap between small laboratory sample and large engineering component, the V charpy test sample method does possess certain advantages, such as each of preparation, simplicity of test method, speed, low cost in test machinery, and low cost per test. On the other hand, the COD test method does posses advantages, which reduce the size gap between the laboratory sample and actual engineering component. Consequently, the correlation between V charpy absorbed energy and the critical COD value is required for estimating critical COD value from the simple V charpy test results. In this paper, the high tensile strength steel AH36 plate specimens having a single edge cracked notch were investigated to find out the correlation between V charpy absorbed energy and critical COD value in the welded parts under such various welding methods as shielded metal arc welding, the submerged arc welding and the electro gas welding by means of V charpy impact test and static 3-point bending test. Main results obtained are as follow ; 1. The relationships between V charpy absorbed energy Wc' and critical COD value ($\delta_c$)show; $\delta_c$=0.0065 Wc'+0.1906. 2. Ductile- brittle transition behaviours can be estimated by means of fracture appearance and general yielding behaviours. 3. The V charpy absorbed energy of SMAW is higher than that of SAW, EGW and similar relationships are obtained in the COD tests.