• 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.

• The Journal of the Acoustical Society of Korea
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• v.38 no.3
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• pp.334-339
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• 2019

In this study, the vibration test method to nondestructively evaluate the possibility of vehicle BSR (Buzz, Squeak, Rattle) noise generation in spot-welded structures was proposed. The weld quality was predicted by analyzing the local vibration transmission characteristics for the beam-shaped structure attached to testing spots. The bending stiffness was evaluated from the identified vibration properties. From the change in the stiffness, the weld quality was evaluated. For verification of the proposed method, the welded specimens were fabricated with partial changes in welding parameters. The local vibration transfers were measured. The frequency bands affected by the weld quality was identified. The capability of evaluating the welding parameters including defect position and quality variations was investigated. The proposed method enables fast quality evaluation to minimize the possibility of BSR noise generation in the manufactured vehicle.

• Proceedings of the KWS Conference
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• 1993.05a
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• pp.115-119
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• 1993

Many qualitive analyses of sampled process variables have been attempted to predict nugget size in resistance spot welding process. In this paper, dynamic resistance and electrode movement signal which is a good indicative of the nugget size was examined by introducing an artificial neural network estimator. An artificial neural feedforward network with back-propagation of error was applied for the estimation of the nugget size. To assess the advantage of this method. results have been compared with conventional regression method.

• Proceedings of the KWS Conference
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• 2008.05a
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• pp.36-36
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• 2008

• Proceedings of the KWS Conference
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• 2001.10a
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• pp.184-186
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• 2001

Quality estimation of the weld has been one of the important issues in RSW which is a main process of the sheet metal fabrication in auto-body industry. It was well known that among the various welding process variables, dynamic resistance has a close relation with nugget formation. In this study, a new quality estimation algorithm is developed with the primary dynamic resistance measured at welding machine timer. For this, Back propagation algorithm of neural network is used.

• Journal of Welding and Joining
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• v.15 no.6
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• pp.49-56
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• 1997

Effect of process parameters on the quality of condenser discharge weld for coated sheet steels was discussed. The welding specimens were coated with pure Zn of 20/20 g/m2 in the production line. Direct measurements of welding parameters such as the discharge current, the pressures and the voltage drop across the electrodes were carried out with welding process monitoring system. High speed camera was also utilized to analyze the weld formation process. Test results indicated that the relation between weld strength and applied energy was stabilized at the acceptable welding heat input range. It was thought that the acceptable welding heat input should be redefined based on the monitored data because the calculated value of the welding heat input could hardly be utilized if the discharge condition was changed. Mechanical test results and high speed photographs showed that expulsion deteriorated the weld quality and the strength at the same time especially when the size of the spatter was large enough to carry the molten metal, which should form the nugget, out of the welding spot. Results also demonstrated that the discharge current should be applied at the appropriate time during the process because sufficient nugget was not produced if the time was deviated from the optimum range.

• Journal of Welding and Joining
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• v.22 no.6
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• pp.19-24
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• 2004

The laser welding and its analysis of thin-sheet carbon steels were carried out with high power $CO_{2}$ laser. The main factor of weld quality of laser welding is gap and edge quality. This work was preformed to focus on the gap tolerance problem during laser welding. First, bead on plate welding of thin sheet was examined to investigate the effect of laser welding variables, and to obtain optimum welding condition. Butt welding was also carried out to show the effect of gap on the laser weldability of thin sheet. In order to investigate the effect of gap on formability of welded thin sheet, LDH test was caried out. At high welding speed, the partial penetration was obtained by low heat input. Otherwise, porosity was formed in the bead at low weld speed because of too much heat input. The optimum welding condition of welding was derived from bead width, penetration and hardness property. The maximum gap tolerance on laser welding was observed to be about 0.2mm. This gap size has good relationship with beam size of laser spot(about 0.3mm). The formability of welded sheet was about $80{\%}$ value of base metal and the gap size has not affected on the formability, although weld quality is dependent on the gap size.

• Proceedings of the KWS Conference
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• 2003.05a
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• pp.84-86
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• 2003

The laser welding and its analysis of thin-sheet carbon steels were carried out with high power CO$_2$1aser. Bead on plate welding of thin sheet was examined to investigate the effect of weld variables of laser welding, and to obtain optimum welding condition. Butt-welding was also carried out to show the effect of gap on the laser weldability of thin sheet. At high welding speed, the partial penetration was obtained by low heat input. Otherwise, porosity was formed in the bead at low weld speed because of too many heat input. The maximum gap tolerance on laser welding was observed to be about 0.2mm. This gap size has good relationship with beam size of laser spot(about 0.3mm). The formability of welded sheet was about 80% value of base metal and the gap size has not affected on the formability, although weld quality is dependent on the gap size.

• Transactions of the Korean Society of Mechanical Engineers
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• v.8 no.3
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• pp.257-263
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• 1984

저항 점 용접시 발생하는 어려운 문제점의 하나는 아무리 동일한 용접조건 하에서 용접을 한다하 더라도 균일한 용접품질을 얻을 수 없다는 점이다. 이는 주로 용접중의 전원에서의 변화로 인한 용접전류 및 전압변동, 용접모재의 표면상태 및 두께의 불균일, 두 전극의 마멸 및 맞춤상태 등의 인자 때문에 기인한다고 볼 수 있다. 이러한 문제점을 해결하기 위해서는 용접하는 도중에 수시 로 인자 때문에 기인한다고 볼 수 있다. 이러한 문제점을 해결하기 위해서는 용접하는 도중에 수 시로 용접 상태를 점검하여 용접조건을 그때 그때에 적합하게 변화시켜 주는 것이 바람직한데 우 선 용접상태를 판별하기 위해서는 용접품질(weld quality)을 잘 대변할 수 있는 용접법 변수를 찾 아내는 것이 중요한 일이다. 따라서 본 논문에서는 용접품질에 관련되는 변수중, 전기동저항과 전 극분리현상을 측정해서 마이크로 컴퓨터를 사용하여 관련되는 특정값들을 구했고 이들과 인장실 험에서 얻은 용접강도와의 상관관계를 얻음으로써 과연 어떠한 공정변수가 용접품질을 잘 대변해 줄 수 있는가를 실험적으로 조사하였다.

• The Transactions of the Korean Institute of Power Electronics
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• v.8 no.5
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• pp.397-406
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• 2003

Resistance spot welding is widely employed in a manufacturing process. In recent years, the requirement for more sophisticated quality control procedures has been in mass production industries. The requirements for high productivity and better weld qualities have lead to the development of more widely available microcomputer-based control. In this study, the inverter type power source and welding servo gun are developed. As the results, we have some advantages over the previous methods such as pneumatic gun. One of them is that the precise pressure control can be attained during the welding process. In addition, production time and cost can be decreased.