• 한국안전학회지
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• 제21권5호
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• pp.17-21
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• 2006

In this study, SPCC cross-tension type specimens produced under various spot welding conditions were tensile and fatigue tested. Decrease of 2 kA in normal current condition of 10 kA caused a large amount of reduction in both static joining strength and fatigue life. And 2 kA increase resulted in increase of static joining strength and an increase in low cycle regime but a decrease in high cycle regime, revealing the fact that fatigue strength rather than static joining strength would be a major factor during design process in view of the body endurance. As a results of estimating the fatigue lifetimes of various types of spot weld specimens. equivalent stress intensity factor is the proper parameter for predicting the lifetimes of various types of specimens. which can be expressed as ${\Delta}K_{eq}(N/nm^{1.5})=11550N^{-0.36}_{f}$.

• 한국공작기계학회논문집
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• 제17권5호
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• pp.58-63
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• 2008

Cold rolled and high strength steel were used for vehicle bodys to satisfy environmental regulation and improve fuel ratio. This paper presented a method far determining the fatigue life of cold rolled steel sheet EZNCEN and high strength steel sheet HS40R spot weldment used in vehicles. We can estimate the fatigue life of the spot weldments from the MSC/FATIGUE using the finite element method. The maximum load is found in the nugget part of both surfaces. The cold rolled steel and the high strength steel showed the maximum stress 746MPa and 730MPa in the effective nugget part when the weld current was 8KA and 7KA, respectively. Also the some weld current of the cold rolled steel and high strength steel is applied, the fatigue life of high strength steel is obtained about four times longer than the cold rolled steel.

• 대한조선학회논문집
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• 제42권2호
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• pp.129-135
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• 2005

At present, fatigue design of welded structures is primarily based on a nominal stress or hot spot stress approach with a series of classified weld S-N curves. Although well accepted by major industries, the nominal stress based fatigue design approach is cumbersome in terms of securing a series of S-N curves corresponding to each class of joint types and loading modes. The hot spot stress based fatigue design has a difficulty of finding a proper stress through the global model, the midium size model, and the detail model of ship structure. Also, it is difficult to link proper displacements within three different mesh size models. Recently, the structural stress is proposed as a mesh-size insensitive structural stress definition that gives a stress state at weld toe with relatively large mesh size. However, this method requires an experimental validation in obtaining the fatigue strength of weldments. Therefore, in this study, a series of experiment is performed for various sizes of weldments.

• Journal of Welding and Joining
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• 제5권1호
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• pp.64-72
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• 1987

The Weldability of gavannealed steel using spot welder has been studied. The Results obtained are a follows; 1) Welds size and strength were increased depending on the welding time and welding current. But, the increasing rate has been decreased. 2) Deposited zinc has affected on the wear of welding tips and growth of welds but has not affected the weld's structures. 3) On shear testing of the specimen, button fracture has been observed and the value was approximately 540Kg (welds dia. approximately .phi.4mm)

• 대한금속재료학회지
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• 제49권12호
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• pp.967-976
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• 2011

Conventional fracture tests of resistance spot welds have been performed without consideration of the paint baking process in the automobile manufacturing line. The aim of this paper is to investigate the effect of the paint baking process on load carrying capacity and fracture mode for resistance spot welded 590 dual phase (DP), 780DP, 980DP, 590 transformation in duced plasticity (TRIP), 780TRIP and 1180 complex phase (CP) steels. With paint baking after resistance spot welding, the l-shape tensile test (LTT) and nano-indentation test were conducted on the as-welded and paint baked samples. Paint baking increased the load-carrying capacity of the resistance spot welded samples and improved the fracture appearance from partial interfacial fracture (PIF) to button fracture (BF). Improvement in fracture appearance after LTT is observed on weldments of 780 MPa grade TRIP steels, especially in the low welding current range with paint baking conditions. The higher carbon contents (or carbon equivalent) are attributed to the low weldability of the resistance spot welding of high strength steels. Improvement of the fracture mode and load carrying ability has been achieved with ferrite hardening and carbide formation during the paint baking process. The average nano-indentation hardness profile for each weld zone shows hardening of the base metal and softening of the heat affected zone (HAZ) and the weld metal, which proves that microstructural changes occur during low temperature heat treatment.

• Journal of Welding and Joining
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• 제27권4호
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• pp.73-78
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• 2009

Characterization of the microweld CCFL electrode for the TFT-LCD backlight unit was carried out in terms of the glass beading heat treatment conditions. We evaluate the weld zone and parent metal of the microweld CCFL electrodes that were exposed to simulated glass beading heat treatment. The CCFL electrode was composed of the cup made with pure Ni, the pin made with pure Mo and the lead wire made with Ni-Mn alloy. Each part of the electrode was assembled together by micro spot welding process and then the assembled electrodes were exposed to simulated glass beading temperatures of $700^{\circ}C,\;750^{\circ}C$ and $800^{\circ}C$. The microstructures of the microweld CCFL electrode were observed by using optical microscope, scanning electron microscope and EDS. Micro-tensile and microhardness test were also carried out. The results indicated that the grain coarsening in the HAZs(heat affected zones) for both the cup-pin weld and pin-lead wire were exhibited and the grain coarsening of the HAZ for the cup and the lead wire was more obvious than the HAZ of the pin. The micro-tensile test revealed that the fracture occurred at the cup-pin weld zone for all test conditions. The fracture surface could be classified into two parts such as pin portion and cup portion including weld nugget. The failure was seemed to be initiated from the boundary between nugget and pin through the weld joint. The result of the microhardness measurement exhibited that the relatively low hardness value, about 105HV was recorded at the HAZ of the cup. This value was about 50% less than that of the original value of the cup. The reduction of the microhardness was considered as the cause of the grain coarsening due to welding process. It was also appeared that there was no change in electric resistance for the standard electrodes and heat treated electrodes.

• Journal of Mechanical Science and Technology
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• 제19권10호
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• pp.1856-1863
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• 2005

In this study, a visual sensor system for weld seam tracking the I-butt weld joints in GMA welding was constructed. The sensor system consists of a CCD camera, a diode laser with a cylindrical lens and a band-pass-filter to overcome the degrading of image due to spatters and arc light. In order to obtain the enhanced image, quantitative relationship between laser intensity and iris opening was investigated. Throughout the repeated experiments, the shutter speed was set at 1/1000 second for minimizing the effect of spatters on the image, and therefore the image without the spatter traces could be obtained. Region of interest was defined from the entire image and gray level of the searched laser stripe was compared to that of weld line. The differences between these gray levels lead to spot the position of weld joint using central difference method. The results showed that, as long as weld line is within $\pm15^{o}$ from the longitudinal straight line, the system constructed in this study could track the weld line successfully. Since the processing time is no longer than 0.05 sec, it is expected that the developed method could be adopted to high speed welding such as laser welding.

• Journal of Welding and Joining
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• 제16권2호
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• pp.100-110
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• 1998

In this paper, the laser weldability of thin gage steels for automobile application is discussed. Welding was carried out with a high power carbon dioxide laser system, and the laser energy was concentrated through a plano-convex lens. Test results showed that the joint gap in the butt welding proved to be one of the critical conditions for an acceptable weld. In the case where the ratio of the gap clearance to the material thickness was slightly bigger than optimal value, the weld strength was reduced showing weld metal fracture. It was possible to obtained a weld penetration ratio of 0.91 when the vertical offset ratio was controlled to be 0.4 or smaller. Results also demonstrated that the weld strength of the lap joint was influenced by travel speed. At the travel speeds lower than 37 mm/s, the weld strength indicated higher value than that of class A recommendation strength of a resistance spot weld based on the KS code. It was clear that the complicated effect of specimen alignment should be considered so as to make a sound weld with high integrity when the laser process was applied to the long weld line.

• Journal of Welding and Joining
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• 제19권4호
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• pp.379-383
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• 2001

Resistance spot welding has been widely used in the sheet metal joining processes because of low cost, high productivity and convenience. Recently, automobile and aerospace industries are trying to replace partly steel sheets with aluminum alloy sheets. But in the case of dissimilar materials, to apply resistance spot welding has been known to be very difficult owing to the effect of melting temperature. On this study, an effort was made to apply spot welding of dissimilar sheet metals, 2024 aluminum alloy and zinc coated steel sheet, evaluate the spot weld quality with tensile-shear strength test and nondestructive evaluation technique, C-scan image methodology. In this study results, as the current below 11 kA, melting of materials is not achieved well. Also as the current exceeds to 13.5 kA, the more spatters happen at welded zone and tensile-shear strength lowered. So, the feasibility of C-scan image technique proposed in the study is found to be suitable evaluation method for resistance spot weldability.

• Journal of Welding and Joining
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• 제29권5호
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• pp.58-62
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• 2011

Stainless steels are alloy steels with a nominal chromium content of at least 11 percent, with other alloy additions. The stainlessness and corrosion resistance of these alloy steels are attributed to the presence of a passive oxide film on the surface. When exposed to conditions like Resistance Spot Welding (RSW) process that remove the passive oxide film, stainless steels are subject to corrosive attack. And exposure to elevated temperatures causes oxidation (discoloration) of areas around indentation in Spot welding. In this paper, deal with the effect of shielding gas (Ar) preventing the corrosion, oxidation of stainless steel. And find the optimal shielding gas flow rate. In addition, suggest effective purging method for direct/indirect spot welding process.