• Journal of the Korea Academia-Industrial cooperation Society
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• v.11 no.9
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• pp.3155-3160
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• 2010

Nowadays, most car manufactures have tried to improve fuel efficiency and corrosion resistance of car body. Therefore, use of high strength steels and coated steel becomes more and more increased. In this study, spot weld characteristics according to lap sequence of sheets were analyzed using simulation method for three different steel sheet of car body which were EDDQ class coated steel with 0.7t, high strength steel 440R with 1.2t and advanced high strength steel DP 590 with 1.0t. Using simulation, weldability was evaluated by nugget size of welded zone according to nugget growth curve and welding current with respect to lap sequence of sheets. Contact resistance of each sheets contact point was used to analyze formation of nugget and optimal lap sequence was suggested.

• Journal of Digital Convergence
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• v.17 no.5
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• pp.217-223
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• 2019

A study in predicting defects of spot welding in real time in automotive field is essential for cost reduction and high quality production. Welding quality is determined by shear strength and the size of the nugget, and results depend on different independent variables. In order to develop the real-time prediction system, multiple regression analyses were conducted and the two dependent variables were obtained with sufficient statistical results with three independent variables, however, the quality prediction by the regression formula could not ensure accuracy. In this study, a multi-layer neural network circuit was constructed. The neural network by 10 dynamic resistance variables was constructed with three hidden layers to obtain execution functions and weighting matrix. In this case, the neural network was established with three independent variables based on regression analysis, as there could be difficulties in real-time control due to too many input variables. As a result, all test data were divided into poor, partial, and modalities. Therefore, a real-time welding quality determination system by three independent variables obtained by multiple regression analysis was completed.

• Proceedings of the KWS Conference
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• 2006.05a
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• pp.181-183
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• 2006

• Proceedings of the KWS Conference
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• 2006.05a
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• pp.160-162
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• 2006

• Journal of Welding and Joining
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• v.34 no.1
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• pp.21-25
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• 2016

The automotive vehicle is made through the following processes such as press shop, welding shop, paint shop, and general assembly. Among them, the most important process to determine the quality of the car body is the welding process. Generally, more than 400 pressed panels are welded to make BIW (Body In White) by using the RSW (Resistance Spot Welding) and GMAW (Gas Metal Arc Welding). Recently, as the needs of light-weight material due to the $CO_2$ emission issue and fuel efficiency, new joining technologies for aluminum, CFRP (Carbon Fiber Reinforced Plastic) and etc. are needed. Aluminum parts are assembled by the spot welding, clinching, and SPR (Self Piercing Rivet) and friction stir welding process. Structural adhesive boning is another main joining method for light-weight materials. For example, one piece aluminum shock absorber housing part is made by die casting process and is assembled with conventional steel part by SPR and adhesive bond. Another way to reduce the amount of the car body weight is to use AHSS (Advanced High Strength Steel) panel including hot stamping boron alloyed steel. As the new materials are introduced to car body joining, productivity and quality have become more critical. Productivity improvement technology and adaptive welding control are essential technology for the future manufacturing environment.

• Proceedings of the KWS Conference
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• 2004.05a
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• pp.154-155
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• 2004

표면처리강판은 내식성을 향상시키기 위하여 도금층위에 크로메이트 혹은 인산염처리를 행하고 있다. 크로메이트 처리는 Cr 피막 자체의 배리어특성과 피막에 함유되어 있는 Cr$^{+}$ 6 에 의한 자가보수성에 의하여 내부식성을 나타낸다. (중략)

• Journal of Welding and Joining
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• v.15 no.5
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• pp.74-83
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• 1997

Effect of welding parameters such as current, speed and electrode pressure on the weld quality of tin coated steels for small containers was discussed in this paper. Welding was performed with low frequency wire seam welding system which was loaded with 1.5mm in diameter copper wire electrode. The welding parameters were monitored at the position close to the welding spot so as to minimize the instrumentation error, and the signals were stored into a digital data acquisition system before analysis. Results showed that critical current for sufficient nugget size increased as the base material thickness increased, while the width of the optimum welding range was reduced. The acceptable welding condition derived from this study was found to be effective within the thickness range of $\pm$10% of the nominal (0.25mm) thickness. Tin coating layer was proved not to affect seriously on the weld quality, i.e. strength and formability, since consumable wire electrode was used in this process. Test results also demonstrated that the welding current was thought to be the most effective parameter to form an acceptable weld, while welding speed or electrode pressure exerted less effect on the nugget formation. However, these two parameters played an important role because the former was related to the nugget overlap interval, and the latter, to the formation of expulsion during welding.

• Journal of the Korean Society for Precision Engineering
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• v.3 no.2
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• pp.39-54
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• 1986

One of the important factors in practical welding situations is shunt effect which deteriorates weld quality due to a shunt current which flows in the exis- ting spot. Previously, this effect has not been analytically investigated, since the mechanism of shunt effect shows very complicated phenomena in the thermal and electrical behavior. In this paper this effect is extensively studied through theoretical and experimental analysis. The theoretical results obtained from a numerical analysis of the modelling of shunt effect are compared with experimental ones. Both results show good agreement and represent well the mechanism of shunt effect.

• Korean Journal of Metals and Materials
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• v.46 no.10
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• pp.672-682
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• 2008

The resistance spot welding of TRIP590 steels was investigated to enhance understanding of weld fracture during tensile-shear strength (TSS) test. The main failure modes for spot welds of TRIP590 steels were nugget pullout and interfacial fracture. The peak load to cause a weld interfacial failure was found to be related to fracture toughness of the weld and the weld diameter. Although interfacial fracture occurred in the samples, the load carrying capacity of the weld was high and not significantly affected by the fracture mode. Substantial part of the weld exhibits the characteristic dimple (or elongated dimple) fractures on interfacial fractured surface, in spite of the high hardness values associated with the martensite microstructures. The high load-bearing ability of the weld is directly associated with the area of ductile fracture occurred in weld. Therefore, the judgment of the quality of resistance spot welds in TRIP590 steels, the load carrying capacity of the weld should be considered as an important factor than fracture mode.

• Transactions of the Korean Society of Automotive Engineers
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• v.14 no.2
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• pp.174-183
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• 2006

The resistance spot-welded region in most current finite element crash models is characterized as a rigid beam at the location of the welded spot. The region is modeled to fail with a failure criterion which is a function of the axial and shear load at the rigid beam. The role of this rigid beam is simply to transfer the load across the welded components. The calculation of the load acting on the rigid beam is important to evaluate the failure of the spot-weld. In this paper, numerical simulation is carried out to evaluate the calculation of the load at the rigid beam. The load calculated from the precise finite element model of the spot-welded region considering the residual stress due to the thermal history during the spot welding procedure is regarded as the reference value and the value of the load is compared with the one obtained from the spot-welded model using the rigid beam with respect to the element size, the element shape and the number of imposed constraints. Analysis results demonstrate that the load acting on the spot-welded element is correctly calculated by the change of the element shape around the welded region and the location of welded constrains. The results provide a guideline for an accurate finite element modeling of the spot-welded region in the crash analysis of vehicles.