• Journal of Welding and Joining
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• 제15권2호
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• pp.54-63
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• 1997

For the purpose of establishing laser welding condition (laser power, welding speed and beam focus) and of evaluating tailored blanks for two kinds of thin steel sheets SPCC and SK5M using in the thin plate structure such as automobile, train, and so on, investigated their $CO^2$ laser weldability under various initial welding conditions. SPCC thin sheet showed good weldability under some welding conditions. But, high carbon steel sheet SK5M needed heat treatment after welding to obtain ductility of the welded joint. And next, tailored blank was tested through deep drawing to evaluate reliability of their obtained laser welding conditions. The forming depths by tailored blank were SPCC+SPCC=22-25mm and SK5M+SK5M=13-25mm.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1998년도 춘계학술대회논문집
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• pp.36-39
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• 1998

To predict strain distributions and weld line movements in the forming processes of tailored blank sheets, the 2-dimensional finite element formulation is developed. The welding zone is modelled with the several, narrow finite elements. The material properties of weld elements are calculated from those of base metals, based on the experimental evaluation. To verify the finite element formulation developed, the forming process of an autobody door inner panel section is simulated. FEM predictions are compared and showed good agreements with experimental measurements.

• 한국레이저가공학회지
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• 제2권3호
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• pp.42-51
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• 1999

This research was conducted as a fundamental study to apply tailored blank welding technique into automotive production process. The materials used in this study were 2.0mm thickness low carbon steel sheets and 1.2mm Zn-coated low carbon steel sheets. To ensure the reproducibility and to consider various factors, experiments were. conducted by applying Taguchi experimental method with 6 factors. Every welding process was repeated 3 times to offset the effect of uncontrolled factors. Elongation and LDH(Limited Dome Height)were measured to evaluate formability of specimens and Optical microscopy, XRD, SEM, and EDS analysis were performed to observe the microstructures and to determine the solidification mode in the weld. The elongation of specimen welded with optimum condition was 83% of base metal, and LDH was 84% of base metal. In case of laser treated specimen where Zn coating was removed, elongation was 85% of base metal, and LDH was 85% of base metal. In fusion zone, phases were consisted of quasi-polygonal ferrite, banitic ferrite, and martensite.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 춘계학술대회 논문집
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• pp.1376-1380
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• 2005

In recent automotive industry, vehicle weight can be reduced by one-step forming of tailored blanks welded with two or more sheets of metal blanks. Tailored blank(TB) welding is a production method for blanks involving welding together materials of different quality, thickness, and coating, and has proved popular in fabrication automotive parts. This paper deals with the forming characteristics of mash seam welded tailored blanks. Using these forming characteristics, the bumper beam was developed using the mash seam welded tailored blank with the different thickness. We performed the forming simulation with respect to strain distribution on blank during the stamping of the bumper rail part. Based on these results, we made some stamping tryouts with selected types of blank designs to investigate the formability of tailored blank with different thickness. During the tryouts, we knew that it was important the BHF(Blank Holding Force). We obtained to reducing 10.5% weight and cost with adapting the bumper beam of automotive component using the tailored blank of mash seam welding.

• 소성∙가공
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• 제7권4호
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• pp.354-363
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• 1998

In order to analyze the stretch forming characteristics of tailored blanks, laser welded blanks of different thickness and strength combinations were prepared and stretching tests were done. The stretching formability of laser welded blanks was reduced as increasing the deformation restraining force ($strength{\times}thickness$) ratio between two welded sheets. Weld line movement was attributed to strain concentration at weaker sheets and resulted in fracture at weaker sid, so that fracture could be predicted by the forming limit of the weak sheet. In the case of a welded blank with the similar deformation restraining force rations between two welded sheets, crack occurred at weld and its forming limit was about 15% less than the base sheet. The effects of lubrication and weld line position on stretch-ing formability were also investigated by experiments. Lower friction did not always give better formability for tailored blanks. Stretching formability was observed to be improved as increasing the area of weak sheet.

• Journal of Welding and Joining
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• 제17권2호
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• pp.66-75
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• 1999

Weld bead quality in tailored blank(TB) is critically affected by edge preparation of sheets. The edge quality of prepared sheets for TB can be classified into straightness and the cross section quality of sheared plane such as a ratio of shear face, shear plane angle, etc. In order to have a good edg quality for butt-welding sheets, precision shearing will be recommended. In this paper, the feasibility of a conventional mechanical shearing as the edge preparation for tailored blanks is studyied. It reveals that fine shearing may not be the unique solution as it is generally accepted. To obtain the good shearing condition with a conventional mechanical shearing, experiments were carried out using Tahuchi method. The major parameters affecting a sheared contour are the clearance between upper blade and lower blade, and shear angle. The optimal shearing condition yields a very good straightness along the entire length of the cut, which gives a butt joint gap less than 10% of the base material thickness. The good cross section of sheared plane is also achieved in the optimal shearing condition such as a ratio of the shear face above 65%, a cross section's shear plane angle above 85%, little burr, which is providing finally good weld beads.

• 소성∙가공
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• 제9권6호
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• pp.582-589
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• 2000

In recent automotive industry, vehicle weight can be reduced by one-step forming of tailored blanks welded with two or more sheets of metal blanks. Mash seam welding shows an overlap joint, a much wider welding area, and heat affected zone(HAZ) than a laser welding. This paper deals with the forming characteristics of mash seam welded tailored blanks. Mash seam welded blanks of same or different thickness combinations were prepared, and tensile, hardness, erichsen, and dome stretching tests were done.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1997년도 춘계학술대회논문집
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• pp.55-58
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• 1997

In automotive industries, stamping of laser-welded blank gives many merits which brings about dimensional accuracy, strong body assembly and high productivity. However the welding of blanks with different thickness or/and different strength materials introduces many challenging formability problems for process development and tool design. In this paper, the deformation characteristics for deep drawing process of laser-welded blank with different thickness sheets are investigated by experiment and FEM simulation. And also the optimal location of weld line in laser-welded blank with different thickness sheets is calculated to compensate for the movement of weld line on deep drawing process. In addition, the effect of location of weld line is clarified using FEM simulation.

• 소성∙가공
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• 제7권1호
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• pp.23-35
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• 1998

In order to analyze the tensile deformation characteristics of laser welded tailored blanks. laser welded blanks of different thikness and strength combinations were prepared and tensile tests were done. The tensile elongation along the direction perpendicular to weld line of laser welded blanks was reduced as increasing the deformation restraining force (strength X thicknes) ratio between two welded sheets and fracture occurred at weaker side of base sheets if void ration of welded sheets and fracture occurred at weaker side of base sheets if void ratio of weld section was less than 45% The tensile elongation along weld line reached above 90% of the elongation of base material if welding was done perfectly. Total elongation along the direction perpendicular to weld line was able to be predicted by force equilibrium and power law behavior of base sheets and it was related with the deformation of stronger sheet and formability of weaker side.

• 한국레이저가공학회지
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• 제1권1호
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• pp.4-10
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• 1998

A basic research for tailored blank welding between mild steel and Zn-coated steel was carried out with $CO_2$ laser beam. The materials used in this work were low carbon steel sheet with a thickness of 1.2mm and Zn-coated steel sheet with the same thickness and 6.3$\mu$m Zn coating. Experiments were carried out by applying the Taguchi method in order to obtain optimized conditions for the application of tailored blank laser welding method in practical manufacturing process. Optical microscopy, XRD, SEM and TEM analysis were performed to observe microstructures and to determine the solidification mode of welded zone. Also mechanical properties were measured by microhardness test tensile test and Erichsen test in order to evaluate the formability of welded specimen. There was no trapped Zn in the fusion zone, and the phases in this region consisted of polygonal ferrite, quasi-polygonal ferrite, banitic ferrite and martensite. The elongation value of welded specimen was more than 80% of that value in the substrate and LDH value was more than 90% of that value in the substrate metal.