• Journal of Welding and Joining
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• v.24 no.2
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• pp.48-56
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• 2006

The fatigue strength of the welds is affected by such factors as the weld geometry, microstructures, tensile properties and residual stresses caused by fabrication. It is very important to evaluate the structural integrity of the welds in nuclear power plant because the weldment undergoes the most of damage and failure mechanisms. In this study, the fatigue assessments for a reactor vessel outlet nozzle with the weldment to the piping system are performed considering the welding residual stresses as well as the effect of local brittle zone in the vicinity of the weld fusion line. The analytical approaches employed are the microstructure and mechanical properties prediction by semi-analytical method, the thermal and stress analysis including the welding residual stress analysis by finite element method, the fatigue life assessment by following the ASME Code rules. The calculated results of cumulative usage factors(CUF) are compared for cases of the elastic and elasto-plastic analysis, and with or without residual stress and local brittle zone effects, respectively. Finally, the fatigue life of reactor vessel outlet nozzle weld is slightly affected by the local brittle zone and welding residual stresses.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.626-631
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• 2002

This paper describes the weldability and mechanical behavior of JIS S45C medium carbon steel (corresponding to KS SM45C and SAE 1045) for machine structures in CW Nd:YAG laser welding. ill general, medium carbon steels have a limited application to the industrial fields in spite of good mechanical characteristics. This is due to welding difficulty because of the high carbon contents and impurities in this material. Therefore, in this study the laser weldability of medium carbon steel with adjusted contents of S and P has been investigated in order to extend the application to medium carbon steels. Several experiments and numerical simulations have been conducted to determine the characteristics of mechanical behavior in CW Nd:YAG laser welds. The results of the simulations concur with the experiment results. From the result of this study, the application possibility of CW Nd:YAG laser welding to medium carbon steel has been confirmed. Also, the appropriateness of mechanical behavior simulation has been verified to analyze and predict the welding phenomena.

• Journal of Welding and Joining
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• v.29 no.1
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• pp.46-51
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• 2011

TSV technology raises several reliability concerns particularly caused by thermally induced stress. In traditional package, the thermo-mechanical failure mostly occurs as a result of the damage in the solder joint. In TSV technology, however, the driving failure may be TSV interconnects. In this study, the thermomechanical reliability of TSV technology is investigated using finite element method. Thermal stress and thermal fatigue phenomenon caused by repetitive temperature cycling are analyzed, and possible failure locations are discussed. In particular, the effects of via size, via pitch and bonding pad on thermo-mechanical reliability are investigated. The plastic strain generally increases with via size increases. Therefore, expected thermal fatigue life also increase as the via size decreases. However, the small via shows the higher von Mises stress. This means that smaller vias are not always safe despite their longer life expectancy. Therefore careful design consideration of via size and pitch is required for reliability improvement. Also the bonding pad design is important for enhancing the reliability of TSV structure.

• Journal of Welding and Joining
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• v.28 no.3
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• pp.73-78
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• 2010

The purpose of this study is to develop the control technology of the welding distortion caused by Auto NG-GTA(Narrow Gap-GTA) welding process at the STS 304 multi-pass butt weldment. Heat input model for Auto NG-GTA welding process was established and verified by measuring temperature change and molten pool shape at the bead-on-plate weldment. With the heat input model developed, the effect of tension load on the welding distortion at the STS 304 multi-pass butt weldment was evaluated using the thermo-elasto-plastic FE analysis. In accordance with FEA results, the angular distortion and transverse shrinkage sharply decreased with an increase in tension load. This result indicated that tensioning method was an effective countermeasure against the welding distortion of the STS 304 multi-pass butt weldment.

• Proceedings of the KWS Conference
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• 2009.11a
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• pp.87-91
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• 2009

Welding is one of the most important joining processes and the effect of welding residual stresses in the structure has a great deal of influence on its quality. In this paper, recent development in computational welding mechanics, particularly calculation of welding residual stresses, is introduced. The hypoelastic formulation of finite element analysis for thermoelastic-plastic deformation is applied to welding processes to find residual deformations and stresses. Leblond's phase evolution equation coupled with the energy equation is employed to calculate the phase volume fraction; this plays an important role as a kinetics parameter affecting phase fraction effects in the mechanical constitutive equation of welded materials. Furthermore, transformation plasticity is taken into account for an accurate evaluation of stress. The influence of the phase transformation and the transformation plasticity on residual stress is investigated by means of numerical analyses using metallurgical parameters in Leblond's phase evolution equation that are adjusted with respect to various cooling rates in a CCT-diagram. Coding implementation is conducted by way of the ABAQUS user subroutines, UMAT.

• Journal of Welding and Joining
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• v.3 no.2
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• pp.42-51
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• 1985

The dynamic fracture toughness, fracture characteristics, impact tension and tensile properties of Al-Mg-Si T5 alloy and Al-Zn-Mg T6 alloy respectively welded with filler metal of Alcan 4043 were investigated. The dynamic fracture toughness values were obtained rapidly and simply for the specimen of small size by using instrumented Chirpy impact testing machine. the testing temperatures of the specimen were a range of room temperature and-196.deg. C. The results obtained in this experiment are summarized as follows. With decreasing the testing temperatures, dynamic tensile stress and fracture load were increased, on the other hand the deflection and impact value showed decreasing tendency in order of base metal>HAZ>weld. Changes of total absorbed energy were more influenced by the crack propagation energy than the crack initiation energy. At the low temperatures, the unstable rapid fracture representing the crack propagation appeared for the specimens of Charpy press side notched in Al-Zn-Mg alloy, but it was difficult to obtain the unstable rapid fracture in Al-Mg-Si alloy. Because of the development of plastic zone at the notch root, it was difficult to obtain thevalid $K_{1d}$ value in Al-Mg-Si alloy. Therefore the fatigue cracked specimens were effective in both Al-Mg-Si and Al-Zn-Mg alloys. With decreasing the impact testing temperatures, specimens underwent a transition from dimple-type transgranular fracture to lamella surface-type intergranular fracture because of the precipitate at the grain boundaries, impurities and crystal structure of the precipitates.s.

• Journal of Welding and Joining
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• v.16 no.2
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• pp.111-121
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• 1998

It is well recognized that a excessive temperature gradient from the junction of head to skirt in axial direction in a hot pressure vessel can cause unpredicted high thermal stress at the junction and/or in axial direction of a skirt. this thermal stress resulting from axial thermal gradient may be a major cause of unsoundness of structural integrity. In case of cyclic operation of hot pressure vessels, the thermal stress becomes one of the primary design consideration because of the possibility of fracture as a result of cyclic thermal fatigue and progressively incremental plastic deformation. To perform thermal stress analysis of the junction and cylindrical skirt of a vessel, or, at least, to inspect quantitatively the magnitude and effect of thermal stress, the temperature profile of the vessel and skirt must be known. This paper demonstrated the temperature distribution and thermal stress analysis for the junction of skirt to head using F.E. analysis. Effect of air pocket in crotch space was quantitatively investigated to minimize the temperature gradient causing the thermal stress in axial direction. Effect of the skirt height on thermal stresses was also studied. Analysis results were compared with theoretical formulas to verify th applicability to the strength calculation in design field.

• Journal of Welding and Joining
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• v.22 no.4
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• pp.50-58
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• 2004

In this study, high temperature tensile properties of high strength steels(POSTEN60, POSTEN80) were investigated. The three-dimensional thermal elastic-plastic analyses were conducted to investigate the characteristics of welding residual stresses in welds of high strength steels on the basis of thermal and mechanical properites at high temperature obtained from the experiment. According to the results, high temperature tensile strength of POSTEN60 steel deteriorated slowly to 10$0^{\circ}C$. As the temperature went up, the tensile strength became better because of blue shortness, and it deteriorated radically after reaching to the maximum value around 30$0^{\circ}C$. For the POSTEN80 steel, high temperature tensile strength deteriorated slowly to 20$0^{\circ}C$. As the temperature went up the tensile strength became better and it deteriorated slowly to $600^{\circ}C$ after reached to the maximum value around 30$0^{\circ}C$. Strain of high strength steels at the elevated temperature increased radically after the mercury rose to $600^{\circ}C$. The strain hardening ratio of POSTEN60 steel was larger then that of POSTEN80 steel at the elevated temperature as in the case at the room temperature and it became smaller radically after the mercury rose to 40$0^{\circ}C$. And, in the welding of high strength steels, increasing tensile strength of the steel (POSTEN60

• Journal of Welding and Joining
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• v.26 no.6
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• pp.74-80
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• 2008

A finite element modeling approach has been described for the simulation and analysis of the micron-scaled solid particle impact behavior in kinetic spraying process, using an explicit code (ABAQUS 6.7-2). High-strain-rate plastic deformation and interface bonding features of the copper, nickel, aluminum, and titanium were investigated via FEM in conjunction with the Johnson-Cook plasticity model. Different aspects of adiabatic shear instabilities of the materials were characterized as a concept of thermal boost-up zone (TBZ), and also discussed based upon energy balance concept with respect to relative recovery energy (RRE) for the purpose of optimizing the bonding process.

• Journal of Welding and Joining
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• v.17 no.3
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• pp.90-95
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• 1999

The increase in high speed, multi-function and high I/O pin semiconductor devices highly demands high pin count, very thin, and high density packages. BGA is one of the solutions, but the package has demerits in package reliability, surface mounting problems due to the PCB warpage and solder joint crack related with TCE mismatch between the materials. On this study to verify the thermal fatigue lifetime of the solder joint FEM and experiments were performed after surface mounting BGA with different solder composition and reliability conditions. FEM showed optimum composition of Ag3.2-Sn96.5 and under the composition minimum creep deformation of the solder joint was calculated, and the thermal fatigue lifetime was improved. In view of temperature cycle condition, the conditions of $-65^{\circ}C$to $150^{\circ}C$ showed minimum lifetime and t was 1/3 of $0^{\circ}C$ to $125^{\circ}C$ condition. Test board was prepared and solder joint crack was verified. Until 1000cycle on soder joint crack was observed.