• Journal of Welding and Joining
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• v.21 no.4
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• pp.80-86
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• 2003

Arc-spot welding is generally used in joining of precise parts such as case and core in electric compressor. It is important to control joining deformation in electric compressor because clearance control of micrometer order is needed for excellent airtightness and anti-nose. The countermeasures for this deformation in field have mainly been dependent on rule of try and error by operator's experience because of productivities. For control this deformation problem without influence on productivities, development of exact simulation model should be needed. In this study, on the basis of previous study, the analysis model io predict deformation of precise order in arc-spot welded structure with non-uniform stiffness is brought up through feedback and tuning between monitoring data and analysis results. For this, deformation monitoring system was built and boundary condition considering mechanical melting temperature was applied.

• Journal of Welding and Joining
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• v.15 no.1
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• pp.55-65
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• 1997

The stress intensity factor has been calculated for the cracked plate subjected to remote normal stress and reinforced with a plate by symmetric spot welding. The solution was based on displacement compatibility condition between the cracked sheet and the reinforcement plate. It is shown that the results from the derived equation for stress intensity factor were agreed with previous solutions. The reinforcement effect gets better as a joining spot is closer to the crack tip and the other joining spots become nearer to the crack surface.

• Journal of the Korean Society for Nondestructive Testing
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• v.25 no.3
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• pp.209-214
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• 2005

Spot welding is the most widely used in automotive and aerospace industries. The quality of weld depends upon the size of nugget between the overlapped steel plates. Recently, the thickness of the steel plates is much thinner and hence, it introduces the smaller size of nugget. Therefore, it is necessary not only to develop the criterion to evaluate the quality of weld but also to obtain the optimal welding conditions for the better performance. In this paper, the steel plates, 0.5 mm through 1.5 mm thickness, have been spot welded at different welding conditions and the nugget sizes are examined by ultrasonic technique (C-scan type). The relationships between the nugget sizes and the weldability have been investigated. The result of ultrasonic technique shows the good agreement with that of the tensile test.

• Journal of Welding and Joining
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• v.17 no.2
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• pp.44-52
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• 1999

This study deals with spot weld ability of dissimilar aluminum alloy sheets in order to take advantage of its lightweight and strength. The paper also shows the relationship between weld elements(i.e. current, welding time and tip force) and weld quality on the resistance spot weld part of the same and dissimilar Al alloy. The conclusions are: (1) Because of excessive tip force, deep indentation remained at the Al 5182 side which is lower stiffness at the dissimilar Al alloy. (2) Weld quality (i.e. tensile shear strength) of dissimilar Al alloy is superior to that of the same Al 6061 alloy. (3) As long cycles, fatigue life of spot weld specimen on dissimilar Al alloy sheets was better than that of the same Al alloy.

• Journal of Welding and Joining
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• v.20 no.2
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• pp.102-108
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• 2002

Resistance spot welding of aluminum alloys is based upon Joule heating of the components by passing a large current in a short duration. Since aluminum alloys have the potential to replace steels fur automobile body assemblies, it is important to study the process robustness of aluminum spot welding process. In order to evaluate the effects of process parameters on the weld quality, major process variables and abnormal process conditions were selected and analyzed. A newly developed two-stage, sliding-level experiment was adopted fur effective parameter design and analysis. Suitable ranges of welding current and button diameters were obtained through the experiment. The effects of the factors and their levels on the variation of acceptable welding current were considered in terms of main effects. From the results, it is concluded that any abnormal process condition decreases the suitable current range in the weld lobe curve. Pareto analysis of variance was also introduced to estimate the significant factors on the signal-to-noise (S/N) ratio. Among the six factors studied, fit-up condition is found to be the most significant factor influencing the SM ratio. Using a Pareto diagram, the optimal condition is determined and the SM ratio is significantly improved using the optimal condition.

• Transactions of the Korean Society of Automotive Engineers
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• v.22 no.4
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• pp.30-35
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• 2014

According to weight lightning trend of automobile body, necessity of resistance spot welding (RSW) of Mg alloy on automobile industry is increasing rapidly because of the highest specific strength among commercial metals. Mg alloy has low electric resistance and high thermal conductivity like as Al alloy, so that needs applying high current in short time when welding. Thick oxide film of Mg alloy pollutes the electrodes and makes partial current carrying paths when on welding. Partial current carrying paths signify excessive concentration of current. There can initiate expulsion easily and reduces electrode life rapidly. Generating partial current carrying paths and expulsions are influenced by shapes of electrode. Therefore, electrode life also influenced by shape. In this study, we perform life test of RSW electrode of radius type. Measure tensile shear load and nugget size every spot alternately. As a result, radius type electrode can extend life over twice as dome type electrode.

• Transactions of Materials Processing
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• v.19 no.8
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• pp.460-467
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• 2010

It was studied that two plates of aluminum can be welded by extru-riveting experiments with extru-rivet welding dies, and that the welding strength and metal flow on the welding section were analyzed by computer simulation according to the welding variable such as the diameter of extrusion insert dies. It was known by computer simulation that welding strength on the welding section of plates could be influenced by the diameter of extrusion insert dies. And it was known by experiments that two plates of aluminum can be welded on a spot point on aluminum plate by extru-rivet welding process, and that welding strength is higher and higher if the diameter of extrusion insert die is smaller and smaller, and that welding strength is the highest when diameter of extrusion insert dies is ${\emptyset}4.2$mm in the case that the diameter of rivet is 5 mm, when aluminum 5052 two plates with 1.5 mm thickness and one plate with 3mm thickness for rivet plate are used as welding material.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.2
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• pp.290-296
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• 2012

Cold-rolled carbon steel sheets are commonly used in railroad car or commercial vehicles such as the automobile. These are mainly fabricated by spot welding which is a kind of electric resistance welding. But fatigue strength of spot welding joint is lower than that of base metal due to high stress concentration at nugget edge of the spot welded part. And fatigue strength of them is especially influenced by not only geometrical and mechanical factors but also welding conditions of the spot welded joint. So for fatigue design of gas welded joints such as TS-type joints, it is necessary to obtain design information on stress distribution at the weldment as well as fatigue strength of spot welded joints. And also, the influence of the geometrical parameters of spot welded joints on stress distribution and fatigue strength must be evaluated. And analysis approach for fatigue test using design of experiment are evaluated optimum factor in TS-type welded joint and geometrical parameters of materials. Using these results, that factors applied to fundamental information for automation of fatigue design.

• Transactions of the Korean Society of Automotive Engineers
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• v.7 no.6
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• pp.214-221
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• 1999

Spot welding is very important and useful technology in fabriaction of the thin sheet structure such as the automobile, train and air craft, Because fatigue strength of the spot welding point is however considerably lower than base metal due to stress concentration at the nugget edge, reasonable fatigue strength evaluation of spot welded lap joint is very important to estimate the reliability and durability of th spot welded structure and to establish a criterion of ling life fatigue design. For reasonalbe fatigue strength evaluation, it is necessary to estimate the fatigue strength of spot welded lap joints, systematically. So far, many investigators have numerically and experimentally studied on the systematic fatigue strength estimation for various spot welded lap joints, and the methods suggested has been considerably accumulated. By the way, for applying them in practical fatigue design of the thin sheet structure fabricated by spot welding ,it is also necessary to verify their efficiency and reliability on the predicted results, Therefore, in this study, a statistical fatigue strength estimation method for spot welded lap joints was developed by using the Weibull probability distribution function. From the result, it was found that fatigue strength and fatigue life of the spot welded lap joints having various dimension were able to be statically predicted . And also, a reliable criterion for long life fatigue design of the spot welded lap joint could be established.

• Journal of Welding and Joining
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• v.18 no.3
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• pp.114-121
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• 2000

Since resistance spot welding has become one of the most popular sheet metal fabrication processes, a strong emphasis is being put on the quality of the welds. Throughout the years many quality estimation systems have been developed by many researchers to ensure weld quality. In this study, the process variables, which were monitored in the primary circuit of the welding machine, are used to estimate the weld quality with Hopfield neural network. The primary dynamic resistance is vectorized and stored as five patterns in the network. As the welding is done, the dynamic resistance patterns are recognized and the quality is estimated with the proposed method. Due to the primary process variables, it is possible to utilize this algorithms as an in-process real time quality monitoring system.