• Proceedings of the KSR Conference
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• 2009.05b
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• pp.559-564
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• 2009

Aluminum extrude is increasing to vehicle body manufacture of a recent railroad vehicle. Conventional welding of this aluminum extrude has been used MIG welding or resistance spot welding mainly. But the advanced manufactures like Japan's tried to apply the friction stir welding and friction spot joining at railroad vehicle body manufacture process. Therefore in this paper we tried to study to apply friction stir welding to AL 6005-T6 extrude which has been manufactured the railroad vehicle mainly. In this study we investigated first the mechanisms to affect the welding strength in friction stir welding. After we made the 3 tools of different shape, we observed how the welding strength changed while changing the welding time and the rotation speed, the plunging depth.

• Korean Journal of Metals and Materials
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• v.50 no.2
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• pp.136-145
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• 2012

Resistance spot welding of TRIP780 steels was investigated to enhance understanding of weld fracture mode after tensile shear testing (TST) and L-shape tensile testing (LTT). The main failure mode for spot welds of TRIP780 steels was partial interfacial fracture (PIF). Although PIF does not satisfy the minimum button diameter (4${\surd}$t) for acceptable welds, it shows enough load carrying capacity of resistance spot welds for advanced high strength steels. In the analysis of displacement controlled L-shape tensile test results, cracks initiated at the notch of the faying surface and propagated through the interface of weldments, and finally, cracks change path into the sheet thickness direction. Use of the ductility ratio and CE analysis suggested that the occurrence of PIF is closely related to high hardness and brittle welds, which are caused by fast cooling rates and high chemical compositions of TRIP steels. Analysis of the hold time and weld time in a welding schedule demonstrated that careful control of the cooling rate and the size of a weld nugget and the HAZ zone can reduce the occurrence of PIF, which leads to sound welds with button fractures (BFs).

• Journal of Welding and Joining
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• v.33 no.5
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• pp.35-40
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• 2015

Characterization of microstructures and mechanical properties of 83mm thickness EH36-TM welds produced by the combined flux cored arc (FCA) and electro gas (EG) welding processes has been studied with the two different groove conditions, single-V (SV) and double-V (DV) bevels. The welding consumables used for FCA and EG welding processes were ASME/AWS A5.29 (E81T1-K2) and A5.26 (EG72T), respectively. Experimental results showed that all the mechanical properties of welds such as tensile property, CVN toughness and Vickers hardness met IACS requirements. The tensile strength of EG welded plates were reduced by approximately 4% (DV: 3.8%, SV: 4.2%) compared to the base metal. The hardness value of SV-beveled weld metal was slightly lower than that of DV-beveled one. There were no significant differences as per welding groove conditions except for the weld metal. In addition, at the fusion line, the toughness of SV condition was 20J lower and the weld metal was 40J lower than DV condition, respectively. On the basis of microstructural analysis, grain boundary ferrite (GBF) structures for SV condition were 2 times higher volume fraction than for DV condition and their packet sizes were coarsened to almost double. It was thus suggested that the GBF volume fractions and packet sizes in the weld metal of EH36-TM steel plates are the most important factors affecting the mechanical properties of the combined FCA and EG welded joint. Nevertheless, all the results of welds with both DV and SV conditions were found to be excellent.

• Journal of the Korean Society for Nondestructive Testing
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• v.33 no.2
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• pp.147-153
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• 2013

Recently the primary water stress corrosion cracking(PWSCC) has occurred in the dissimilar metal weld region between pressurizer nozzle and safe-end in nuclear power plants(NPPs). As material of the pressurizer nozzle, SA508 Gr. 3 low alloy steel was used. F316L stainless steel and Alloy 82/182 were used as safe-end and weld metal, respectively. Although mechanical properties are needed for evaluation of the structural integrity against flaw in the material, material specification and standard don't supply those properties. Therefore, the present study conducted tensile and fracture toughness tests on SA508 Gr.3 and F316L stainless steel at ambient temperature and operating temperature of NPPs and reported the tested results.

• Plant Journal
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• v.14 no.2
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• pp.45-50
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• 2018

Nuclear safety law's amendment caused many problems to use radiography testing(RT). Phased array ultrasonic testing(PAUT) was adapted instead of RT for NDE of welding points in boiler tubes these days. Unfortunately, PAUT doesn't give us the discrimination characteristics about flaws distinction and flaws size clearly. In this thesis, the distinction characteristics of flaw types and the detection characteristics of flaw size using PAUT of welding points in boiler tubes were analyzed. It was concluded that PAUT can distinguish between planar flaws and rounded flaws, but it is hard to tell apart the types of flaw respectively. We paid attention to the discrimination of flaws size because PAUT tends to underestimate the flaw size of porosity and underestimate or overestimate the flaw size of porosity.

• Journal of Welding and Joining
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• v.26 no.5
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• pp.60-65
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• 2008

Ferritic stainless steels of the 400 series have been available for automotive exhaust system, heat exchanger, radiater etc. in various industrial because heat resistance, corrosion resistance and strength are excellent. Especially, automotive exhaust system is required good heat resistance because typical temperature of exhaust system exposed during operation of engine is reach up to $800^{\circ}C$. However, research for effect of high temperature in ferritic stainless steels is not enough. In this study, high temperature tensile properties of lap weld of ferritic stainless steels(STS 429) were investigated. In accordance with heat input, lap welds had been produced and were evaluated at high temperature($800^{\circ}C$) to compare high temperature tensile properties. In addition, room temperature tensile tests were carried out for non-aging and aging specimens. As a result of R.T tensile test, non-aging specimens were fractured in base metal except for low heat input specimen and aging specimens were fractured in weld metal. Also high temperature tensile test were carried out by aging specimen. After high temperature tensile test, fracture of aged specimen was occurred in base metal except for low heat input specimen. Fracture surface of low heat input specimen in weld metal was confirmed as brittle fracture with observation using scanning electron microscope(SEM). Significant decrease in ultimate tensile strength (between 82 and 85%) was observed for aged ferritic stainless steels(STS 429) when tested at high temperature.

• Korean Journal of Metals and Materials
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• v.48 no.12
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• pp.1090-1096
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• 2010

This pitting corrosion study of welded joints of austenitic stainless steels (AISI 304L and 316L) has addressed the differentiating solidification mode using three newly introduced filler wires with a flux-cored arc welding process (FCAW). The delta ferrite (${\delta}$-ferrite) content in the welded metals increased with an increasing equivalent weight ratio of chromium/nickel ($Cr_{eq}/Ni_{eq}$). Ductility dip cracking (DDC) was observed in the welded metal containing ferrite with none of AISI 304L and 0.1% of AISI 316L. The potentiodynamic anodic polarization results revealed that the $Cr_{eq}/Ni_{eq}$ ratio in a 3.5% NaCl solution didn't much affect the pitting potential ($E_{pit}$). The AISI 316L welded metals with ${\ddot{a}}$-ferrite content of over 10% had a superior $E_{pit}$ value. Though the AISI 316L welded metal with 0.1% ferrite had larger molybdenum contents than AISI 304L specimens, it showed a similar $E_{pit}$ value because the concentration of chloride ions and the corrosion product induced severe damage near the DDC.

• Journal of Welding and Joining
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• v.28 no.6
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• pp.70-75
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• 2010

This study intends to investigate the weldability and mechanical characteristics of butt weld joints by LAFSW for dissimilar materials (Al6061-T6 and SS400). At optimum welding conditions, the tensile strength of dissimilar materials joints made by FSW is found to be lower than that of LAFSW. Due to the increase in plastic flow and formation of finer recrystallized grains at the TMAZ and SZ by laser preheating in LAFSW, the hardness in LAFSW appeared to be higher than that of FSW. Compared with FSW, finer grain size is observed and elongated grains in parent metal are deformed in the same direction around the nugget zone in TMAZ of Al6061-T6 by LAFSW. Whereas, at weld nugget zone, coarse grain size is appeared in LAFSW compared to FSW, which is owing to more plastic flow due to laser preheating effect. In dissimilar materials joints by LAFSW, ductile mode of fracture is found to occur at Al6061 side with fewer brittle particles. Mixed mode of cleavage area and ductile fracture is observed at SS400 side.

• Journal of Welding and Joining
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• v.31 no.5
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• pp.71-76
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• 2013

The effect of zirconate having - NH functional group on the T-peel and lap shear strength of $CaCO_3$ containing structural epoxy adhesive for car body assembly was investigated. Curing behavior of epoxy adhesive samples were investigated by differential scanning calorimeter (DSC) techniques. The addition of zirconate up to 7.5 phr did not affect the curing mechanism of epoxy adhesive. While the small amount of zirconate addition less than 1.1 phr increased the cross-linking density, the excess addition of zirconate resulted in the increase of uncross-linked impurity. From the increase of T-peel and lap shear strength and the change of fracture mode from the adhesive failure to the mixed one, it was considered that the small addition of zirconate was effective in improving the adhesion strength of epoxy adhesive to the adherend and inorganic filler surfaces. The formation of uncross-linked impurity with the excess addition of zirconate was considered to decrease the joint strength by decreasing the cohesive strength of the cured epoxy.

• Korean Journal of Metals and Materials
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• v.46 no.8
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• pp.495-505
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• 2008

With the high proportion of zinc coated steels in body-in-white assembly, newly developed surface roughness textured galvannealed steel sheets have been introduced. In this study, zinc coated and surface roughness textured steel sheets were welded by resistance spot welding to investigate its weldability including electrode wear test. Based on the results of tensile-shear test, nugget diameter changes, and electrode tip growth test, it was clear that both surface roughness textured steels (GA-T and GA-E) showed good weldability. Also, there was no large difference in weldability and electrode wear behavior between GA-T and GA-E steels which have different surface roughness morphology. An analysis of electrode degradation showed Fe and Zn penetration through the electrode tip surface at 2400 welds reached $55{\sim}60{\mu}m$ and $75{\sim}80{\mu}m$, respectively. Therefore, there is no significant effect of surface roughness morphology on spot weldability of surface roughness textured galvannealed steel sheets. However, slight difference in thickness of alloying layers existing on electrode tip was found between GA-T and GA-E steels.