• Journal of Welding and Joining
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• 제25권2호
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• pp.49-54
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• 2007

Since the wall thickness can be up to 6" or greater, welds must be made in many layers, each layer containing several passes. However, the welding time for the conventional welding processes such as SAW(Submerged Arc Welding) and FCAW(Flux Cored Arc Welding) can be required many hours. The aim of this paper is to develop a high speed welding system with multi-torch and laser vision sensor for increasing the production speed on the line and to remove the need for the operator so that the system can run automatically for the complete multi-torch multi-layer weld. It was shown that the developed laser vision sensor and analysis of arc blow for multi-torch were effective for multi-pass seam tracking and stable arc. A new automated multi-torch welding systems for thick wall applications has been proved in several production lines.

• Journal of Welding and Joining
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• 제30권6호
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• pp.120-125
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• 2012

Because ships and offshore structures have very large dimensions and complicated shapes, it is difficult to determine the deformation or internal stress in the structure by simple lab tests. Thus, a rigorous analysis by using the computer simulation technology is essential for obtaining their distortions by considering the entire production process characteristics. The rapid development of computer technology made it possible to analyze the heat transfer phenomena, deformation and phase transformation in the welded joint. For large shell structures, shell elements modeling contributed primarily to this development. But if a welding is done by multi-pass, shell elements whose thickness are unchangeable can hard to describe the local situation. Recently, it was researched how to introduce the imaginary temperature for V grooved multi-layer butt welding in strain-boundary method (a kind of shrinkage methodologies). In the present study, we formulated the imaginary temperature for the double bevel and double V groove by considering the thickness change of each pass through the bead and the thickness directions simultaneously and also demonstrated the feasibility of the formula by applying it to the thermal distortion analysis of the erection process of crane pedestal.

• 한국압력기기공학회 논문집
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• 제11권1호
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• pp.53-60
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• 2015

This study was investigated to develop process technology of laser cladding with austenite stainless steel for Weld Inlay repair of dissimilar metal weld in reactor vessel in/outlet nozzles. Weld Inlay experiments were performed by laser cladding repair system consisting of common manipulator, laser apparatus and welding process scheduler, etc. Single pass welding experiments were conducted in order to obtain the optimum welding process parameters for filler wires of ER309L and Alloy 52M before multi-layer laser cladding. Based on the above obtained results, multi-layer laser cladding experiments were carried out, and welding qualities for weld specimens were estimated by PT, OM, SEM and EDS analysis. Consequently, it was revealed that multi-layer laser cladding on austenite stainless steel using filler wires of ER309L and Alloy 52M could be possible to meet ASME Code standard without any weld defect.

• Journal of Welding and Joining
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• 제15권4호
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• pp.70-77
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• 1997

Welding is one of the most important and popular joining techniques employed in structures. In spite of, weld designs depend on the rules and regulations. Moreover, the study to optimize a shape of welding joint not may be sufficient and systematic on the theoretical and experimental sides. Therefore, in this study, a computer program based on thermal elasto plastic theory is developed for optimizing(minimizing) shape of weld joints. By the results, study is made on the characteristics of the distributions of welding residual stresses and plastic strains, and their production mechanisms. Also, Various kinds of tests are carried out to find out mechanical characteristics due to shape of weld joints. As a result of this optimization(minimization) of weld joints, the productivity and the reliability will be improved.

• Journal of Welding and Joining
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• 제13권1호
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• pp.138-144
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• 1995

Recently, as the industrial structure tends to become large, the thickness of structural plate becomes thicker. Therefore, the thicker the plate of welded structure is, the larger the shape of welded joint. The effect of large heat input makes large heat affected zone(HAZ). These bring to complict welding residual stress and to weaken material, which may cause extremely harm to the safety of structures. Nevertheless, welding is design is regulated by the KS, JIS or standard in the resister of shipping such as KR, ABS or LR. However, these rules are based on rather experimental than theoretical. In this study, the computer program of heat conduction, considering un-steady state and quasi-steady state, is developed for optimizing(minimizing) a shape of welded joint. The characteristics of heat on the welded joints with various shapes are clarified by the results of the analyses.

• Journal of Advanced Research in Ocean Engineering
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• 제1권2호
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• pp.106-114
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• 2015

In the fabrication of offshore oil and gas facilities, the significance of dimension control is growing continuously. But, it is difficult to determine the deformation of the structure during fabrication by simple lab tests due to the large size and the complicated shape. Strain-boundary method (a kind of shrinkage method) based on the shell element was proposed to predict the welding distortion of a structure effectively. Modeling of weld geometry in shell element is still a difficult task. In this paper, a concept of imaginary temperature pair is introduced to handle the effect of geometric factors such as groove shape, plate thickness and pass number, etc. Single pass imaginary temperature pair formula is derived from the relation between the groove area and the FE mesh size. By considering the contribution of each weld layer to the whole weldment, multi-pass imaginary temperature is also derived. Since the temperature difference represents the distortion increment, cumulative distortion curve can be drawn by integrating the temperature difference. This curve will be a useful solution when engineers meet some problems occurred in the shipyard. A typical example is shown about utilization of this curve. Several verifications are conducted to examine the validity of the proposed methodology. The applicability of the model is also demonstrated by applying it to the fabrication process of the heavy ship block. It is expected that the imaginary temperature model can effectively solve the modeling problem in shell element. It is also expected that the cumulative distortion curve derived from the imaginary temperature can offer useful qualitative information about angular distortion without FE analysis.

• 동력기계공학회지
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• 제18권4호
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• pp.85-90
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• 2014

In this paper, the transient thermal and residual stress analysis of the welding of 9% Ni steel plates using the FEA software ABAQUS are presented. The 9% Ni steel plates are welded manually with welding consumables of 70% Ni based Inconel type super-alloys (YAWATA WELD B (M)), producing a multi-pass/multi-layer butt weld. For these materials, temperature dependant mechanical and thermal material properties are used in the analysis. The back gouging is considered in welding process simulation. The FE thermal results are validated by comparing the real fusion profile and heat affected zone (HAZ). In addition, the continuous indentation test was conducted to measure the strength of base metal, HAZ and weld metal.

• 대한기계학회논문집A
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• 제41권4호
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• pp.307-312
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• 2017

레이저 클래딩은 아크 용접 및 용사와 같은 기존 클래딩 기술보다 우수한 장점을 가진다. 레이저 클래딩으로 형성한 클래드 층의 희석률은 낮으며 모재와의 결합력이 우수하고 결함이 거의 존재하지 않는다. 이러한 특징을 가진 레이저 클래딩을 실제 선박용 배기밸브에 적용하기에 위해 지난 제1보의 논문에서 조사한 공정변수에 따른 1 패스 클래드 층의 특성을 통해 넓은 면적에 클래딩 시 1 패스 클래드 층의 중첩이 필수적이라는 것을 알 수 있었다. 따라서 본 논문에서는 중첩률에 따른 멀티패스 클래드 층의 형상 차이를 비교하고 일정 중첩률 조건에서 EDS 및 EPMA를 통해 합금 성분 분포를 파악하였다. 실험결과, 중첩률이 증가할수록 클래드 층의 길이가 감소하고 높이가 증가하였으며 동일한 조건의 1 패스 클래드 층보다 높이가 상승하였다. 성분 분석을 통해 모재 희석이 많이 발생한 첫 번째 클래드 층에서 Fe이 높게 측정되었으나 나머지 영역에서는 희석이 감소하여 Co가 증가하고 Fe이 감소하였으며 균일한 성분 분포가 관찰되었다.

• Journal of Welding and Joining
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• 제28권4호
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• pp.18-25
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• 2010

Super-duplex stainless steels (SDSS) have a good balance of mechanical property and corrosion resistance when they consist of approximately equal amount of austenite and ferrite. The SDSS needs to avoid the detrimental phases such as sigma(${\sigma}$), chi(${\chi}$), secondary austenite(${\gamma}2$), chromium carbide & nitride and to maintain the ratio of ferrite & austenite phase as well known. However, the effects of the subsequent weld thermal cycle were seldom experimentally studied on the micro-structural variation of weldment & pitting corrosion property. Therefore, the present study investigated the effect of the subsequent thermal cycle on the change of weld microstructure and pitting corrosion property at $40^{\circ}C$. The thermal history of root side was measured experimentally and the change of microstructure of weld root & the weight loss by pitting corrosion test were observed as a function of the thermal cycle of each weld layer. The ferrite contents of root weld were reduced with the subsequent weld thermal cycles. The pitting corrosion was occurred in the weld root region in case of the all pitted specimen & in the middle weld layer in some cases. And the weight loss by pitting corrosion was increased in proportional to the time exposed at high temperature of the root weld and also by the decrease of ferrite content. The subsequent weld thermal cycles destroy the phase balance of ferrite & austenite at the root weld. Conclusively, It is thought that as the more subsequent welds were added, the more the phase balance of ferrite & austenite was deviated from equality, therefore the pitting corrosion property was deteriorated by galvanic effect of the two phases and the increase of 2nd phases & grain boundary energy.

• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2009년 추계학술발표대회
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• pp.37-37
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• 2009

Due to their high corrosion resistance and improved mechanical properties super-duplex stainless steel (SDSS) are extensively used in petrochemical plants such as facilities in modern oil platform and off-shore process equipment. It is well known that the best mechanical and corrosion resistance properties of super-duplex stainless steel are obtained with a microstructure having approximately equal amounts of austenite and ferrite. And it is also known that sigma($\sigma$), chi($\chi$), secondary austenite(${\gamma}2$), chromium carbides and nitride affected adversely their properties. Therefore these phases must be avoided. However, effects of succeeding weld thermal cycle on the change of microstructure of weldment at multi-pass weld were not seldom experimentally researched. Therefore in the present work, the change of weldmetal microstructure and the effect of microstructure on pitting corrosion property at $40^{\circ}C$ by succeeding each weld thermal cycle were researched. The thermal history of root side was measured experimentally and the change of microstructure of root weld according to thermal cycle of each weld layer was evaluated. And the relationship between microstructure of root weld and pitting corrosion property at $40^{\circ}C$ was also investigated. Results of the present work are show as below. 1. The ferrite contents of root weld are gradually reduced by succeeding weld thermal cycle. 2. The 2nd phases such as sigma($\sigma$), chi($\chi$), secondary austenite(${\gamma}2$), chromium carbides and nitride are increased gradually by succeeding weld thermal cycle. 3. The pitting corrosion was detected in root weld part and weight loss by pitting corrosion is increased in proportional to the time exposed over $600^{\circ}C$ of the root weld. 4. The succeeding weld thermal cycles affect the microstructure of the former weldments and promote the formation of 2nd phases. That is, the more succeeding welds are added, the more 2nd phases are gradually increased. Consequently, it is thougth that this adversely affects pitting corrosion property.