• Journal of Welding and Joining
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• v.35 no.2
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• pp.13-22
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• 2017

In laser full penetration welding process, full penetration hole(FPH) is formed as a result of force balance between the vapor pressure and the surface tension of the surrounding molten metal. In this work, a three-dimensional numerical model based on a conserved-mass level-set method is developed to simulate the transport phenomena during laser full penetration welding process, including full penetration keyhole dynamics. Ray trancing model is applied to simulate multi-reflection phenomena in the keyhole wall. The ghost fluid method and continuum method are used to deal with liquid/vapor interface and solid/liquid interface. The effects of processing parameters including laser power and scanning speed on the resultant full penetration hole diameter, laser energy distribution and energy absorption efficiency are studied. The model is validated against experimental results. The diameter of full penetration hole calculated by the simulation model agrees well with the coaxial images captured during laser welding of thin stainless steel plates. Numerical simulation results show that increase of laser power and decrease of welding speed can enlarge the full penetration hole, which decreases laser energy efficiency.

• Proceedings of the KIEE Conference
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• 1994.07b
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• pp.1416-1418
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• 1994

Expressions for the displacement of a bimorph, one end fixed and the other free, has been introduced when sinusoidal inputs were applied to the ceramic plates on a thin metal plate. Maximum displacements at the free end and strains at the position of strain gage attached were measured when various wave forms, voltages, and frequencies were applied to the bimorph whose length is 6.6[cm], width 2.5[cm], and thickness 0.0365[cm]. Under the constant voltage ( $70[V_{peak}]$ ), the strains and the displacements at the free end were larger than the case of the sinusoidal input when the square wave was applied and were smaller when triangular wave. It was shown that the displacements at the free end and the strains of the gage position were increased as the applied voltage in the range of $30-90[V_{peak}]$ and effective length were increased. And it was also found that the resonant frequency of a bimorph was decreased as its effective length was increased, and that the displacements and the strains were maximum at the resonant frequency.

• Analytical Science and Technology
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• v.22 no.3
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• pp.263-271
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• 2009

The purpose of metal artifacts conservation is recovering the original state of objects and preventing it from further corrosion. Four different consolidants are selected that are widely used for bronze objects conservation. This study found out the characteristics of thin film by various experiments and analysis for the bronze plates coated using each solutions. After a series of analysis, resin B and V showed good coating properties. However, the evaluation point suited to this purpose are adhesive strength, stability against yellowing and corrosion resistance. Therefore, resin B of four different consolidants could expect to get the most suitable consolidation effect for consolidation purpose.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.8
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• pp.933-940
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• 2011

Thin sheets with a corrugated structure are generally used for the fabrication of heat exchangers for electronics, airplanes, and vehicles. However, it is difficult to fabricate corrugated structures, especially those with a bent angle, using the conventional stamping process because of its intrinsic formation mechanism. We propose a novel rubber-forming process for the effective pressing of the both tilted sides of a plate under the same pressure to form exact corrugated shapes. We use finite element analysis and experiments to study the rubber-forming process parameters, and we evaluate the maximum allowable bent angle for high-quality formation. We show that the proposed method is effective for the fabrication of bent plates with low cost.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.6
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• pp.100-107
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• 2021

As a significant technology in the smartization era promoted by the Fourth Industrial Revolution, the secondary battery industry has recently attracted significant attention. The demand for lithium-ion batteries (LIBs), which exhibit excellent performance, is considerably increasing in different industrial fields. During the manufacturing process of LIBs, it is necessary to join the cathode and anode sheets with thicknesses of several tens of micrometers to lead taps of the cathode and anode with thicknesses of several hundreds of micrometers. Ultrasonic welding exhibits excellent bonding when bonded with very thin plates, such as negative and positive electrodes of LIBs, and dissimilar and highly conductive materials. In addition, ultrasonic welding has a small heat-affected zone. In LIBs, Cu is mainly used as the negative electrode sheet, whereas Cu or Ni is used as the negative electrode tab. In this study, one or two electrode sheets (t0.025 mm Cu) were welded to one lead tab (t0.1 mm Cu). The welding energy and pressure were used as welding parameters to determine the welding strength of the interface between two or three welded materials. Finally, the effects of these welding parameters on the welding strength were investigated.

• Transactions on Electrical and Electronic Materials
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• v.14 no.3
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• pp.133-138
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• 2013

Acrylonitrile-butadiene-styrene (ABS) plastic is a polymer material extensively used in electrical and electronic applications. Nickel (Ni) thin film was deposited on ABS by electroless plating, after its surface was treated and modified with atmospheric plasma generated by means of dielectric barrier discharges (DBDs) in air. The method in this study was developed as a pre-treatment for electroless plating using DBDs, and is a dry process featuring fewer processing steps and more environmentally friendliness than the chemical method. After ABS surfaces were modified, surface morphologies were observed using a scanning electron microscope (SEM) to check for any physical changes of the surfaces. Cross-sectional SEM images were taken to observe the binding characteristics between metallic films and ABS after metal plating. According to the SEM images, the depths of ABS by plasma are shallow compared to those modified by chemically treatment. The static contact angles were measured with deionized (DI) water droplets on the modified surfaces in order to observe for any changes in chemical activities and wettability. The surfaces modified by plasma showed smaller contact angles, and their modified states lasted longer than those modified by chemical etching. Adhesion strengths were measured using 3M tape (3M 810D standard) and by 90° peel-off tests. The peel-off test revealed the stronger adhesion of the Ni films on the plasma-modified surfaces than on the chemically modified surfaces. Thermal shock test was performed by changing the temperature drastically to see if any detachment of Ni film from ABS would occur due to the differences in thermal expansion coefficients between them. Only for the plasma-treated samples showed no separation of the Ni films from the ABS surfaces in tests. The adhesion strengths of metallic films on the ABS processed by the method developed in this study are better than those of the chemically processed films.

• Journal of Powder Materials
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• v.22 no.2
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• pp.93-99
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• 2015

This study investigated the microstructure and tensile properties of a recently made block-type Ni-Cr-Al powder porous material. The block-type powder porous material was made by stacking multiple layers of powder porous thin plates with post-processing such as additional compression and sintering. This study used block-type powder porous materials with two different cell sizes: one with an average cell size of $1,200{\mu}m$ (1200 foam) and the other with an average cell size of $3,000{\mu}m$ (3000 foam). The ${\gamma}$-Ni and ${\gamma}^{\prime}-Ni_3Al$ were identified as the main phases of both materials. However, in the case of the 1,200 foam, a ${\beta}$-NiAl phase was additionally observed. The relative density of each block-type powder porous material, with 1200 foam and 3000 foam, was measured to be 5.78% and 2.93%, respectively. Tensile tests were conducted with strain rates of $10^{-2}{\sim}10^{-4}sec^{-1}$. The test result showed that the tensile strength of the 1,200 foam was 6.0~7.1 MPa, and that of 3,000 foam was 3.0~3.3 MPa. The elongation of the 3,000 foam was higher (~9%) than that (~2%) of the 1,200 foam. This study also discussed the deformation behavior of block-type powder porous material through observations of the fracture surface, with the results above.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.757-762
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• 2002

Many reports have been shown that the buoyancy, electromagnetic force, surface tension, and gas shear stress are the driving forces of weld pool circulation in arc welding. Among them, the surface tension of molten metal plays an important role in the flow in weld pool, which are clarified by the specially designed experiments with small particles as well as the numerical simulations. The surface tension is also related to the penetration in arc welding. Therefore, a quantitative evaluation of surface tension is demanded for the development of materials and arc process control. However, there are few available data published on the surface tension of molten metals, since it depends on the temperature and the composition of materials. In this study, a new method was proposed for the evaluation of surface tension and its temperature dependence, in which it is evaluated by the equilibrium condition of acting forces under a given surface geometry, especially back surface. When this method was applied to the water pool and to the back surface of molten pool in the stationary gas tungsten arc welding of thin plate, following results were obtained. In the evaluation of surface tension of water, it was shown that the back surface geometry was very sensitive to the evaluation of surface tension and the evaluated value coincided with the surface tension of water. In the measurement of molten pool in the stationary gas tungsten arc welding, it was also shown that the comparison between the surface tension and temperature distribution across the back surface gave the temperature dependent surface tension. Applying this method to the mild steel and stainless steel plates, the surface tension with negative gradient for temperature is obtained. The evaluated values are well matched with ones in the published papers.

• Composites Research
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• v.13 no.6
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• pp.39-46
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• 2000

Electrical discharge machining (EDM) cuts metal by discharging electric current across a thin gap between tool and workpiece. Electrical discharge wire cutting, a special form of EDM, uses a continuously moving conductive wire as an electrode, and is widely used for the manufacture of punches, dies and stripper plates. In the wire cutting process, the moving wire is usually supported by cantilever arm and wire guides. As the wire traveling speed has been increased in recent years to improve productivity, the vibration of the cantilever arm occurs, which reduces the positional accuracy of the machine. Therefore, the design and manufacture of the cantilever arm with high dynamic characteristics have become important as the machining speed increases. In this paper, the cantilever arm for guiding the moving wire was designed and manufactured using carbon fiber epoxy composite in order to improve the static and dynamic characteristics. Specimens for the composite cantilever arm were manufactured and tested to investigate the effect of the number of reinforcing plies and length fitted to steel flange on the load capacity. Also, the finite element analysis using layer and contact elements was performed to compare the calculated results with the experimental ones. From the results, the prototype of the composite cantilever arm for the electrical discharge wire cutting machine was manufactured and the static and dynamic characteristics were compared with those of the conventional steel cantilever arm.

• Magazine of the Korean Society of Agricultural Engineers
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• v.9 no.2
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• pp.1301-1305
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• 1967

Ground water flow can be studied with model test. Model test of ground water works are necessary for economic and safe design of the works. Also influence of the ground water flow to the durability and safety of hydraulic structures can be studied with this model. a. Sand model ; Water flow through porous media is the principle of sand model. Darcy's formula is the basic equation, $q=k{\frac{dh}{ds}}^{\circ}. The effect of the ground water flow on the grain system itself is represented with this model only. b. Hele-Shaw model ; In this model use is made of the viscous flow analogy. Viscous fluid such as glycerine flowing through two parallel plates depends on Poiseuille law, $q=-c{\frac{dh}{ds}}$. The analogue can be used vertically and horizontally. c. Heat model ; This is based on the analogy of the Fourier's law for heat conduction and Darcy's law for ground water flow. Especially unsteady problem can be studied with this model. A difficulty of the construction of this model is the isolation, which has to prevent losses of the heat. d. Electirc model ; Ohm's law for electric current is analogous to Darcy's law. Resistance material such as metal foil, graphite block, water with salt added, gelatine with salt added, ete. is connected to electric sources and resistor, and equi-voltage line is detected with galvanometer, $N_aCl$, $CuSo_4$, etc. are used as salt in the model. e. Membrane model ; This model is based on the facts that the deflection of a thin membrane obeys Laplace's equation if there is no load in the direction perpendicular to the membrane, and if the dellection is small.