• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.211-216
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• 2003

Weld line in injection molded part is one of the defect in injection molding process. Weld line deteriorates not only appearance quality but mechanical property. In this study weld line strength has been examined according to the injection operational conditions, materials and mold designs. PC and PP were used, and four different specimens were used in this experiment. Weld line strength decreased as injection temperature increases for PC. It was more dependent on mold temperature than injection temperature for PP Among the four different specimens, uneven thickness specimen showed the highest weld line strength.

• Journal of Advanced Marine Engineering and Technology
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• v.30 no.5
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• pp.636-644
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• 2006

Recently, there were some successful examples that the laser welding was introduced into production line. However, the spread of laser welding is not sufficient in many industries. There are several reasons why it is difficult to penetrate the laser welding into production lines. Because it is different from reflection, absorption and permeation of laser beam according to material and surface condition. Moreover, there are significant problems in processing such as absorption and scattering of beam by the induced plasma or plume. Therefore, understanding of mechanism on formation of weld defect in laser welding of the laminated core for motor is very important. In this paper, it was analyzed in terms of materials which was source of defect in laser welding and conventional arc welding. As a results of analysis, insulation coating film of the laminated core was judged to main factor of weld defect. it could be well aware as tracing carbon volume, and it was deduced that weld defect by insulation coating film was caused by difference of mechanism between the two heat sources.

• Proceedings of the KWS Conference
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• 1996.10a
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• pp.139-141
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• 1996

Among various welding parameters, the welding current which is inversely proportional to the tip-to-workpiece distance in GMAW is an essential parameter to monitor the GMAW process of horizontal fillet joints. For the case of weld defect such as overlap in horizontal fillet welding, therefore, the signal processing for process monitoring or automatic seam tracking should be modified by considering the weld pool surface geometry including the corresponding weld defect. In other words, the adequate signal processing algorithm is indispensible to improve the performance of the arc sensor. However, arc sensor algorithm already developed usually focus on weld seam tracing but do not considering the weld qualities. In this paper, various experiments were carried out to investigate the tendencies of the weld defects when weaving motion is added, and the experimental method based on 2$^n$ factorial design was proposed for deriving the mathematical model between the leg length and the various welding conditions. Moreover, a signal processing method based on the artificial neural network(Adaptive Resonance Theory) was proposed far discriminating the current signal of sound weld beads from that of weld beads with overlap. Finally, the algorithm for weld seam tracking combined with the mathematical modeling and the signal processing method was carried out to track the weld line in conjunction with the improvement of the weld qualities. The reliability of the proposed algorithms were evaluated through various experiments, which showed that the proposed algorithms could be effectively used for arc welding automation.

• Korean Chemical Engineering Research
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• v.49 no.1
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• pp.47-55
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• 2011

The optimum mold design and the optimum process condition were constructed upon executing process simulation of rubber injection molding with the commercial CAE program of MOLDFLOW (Ver. 5.2) in order to solve the process-problems of K company relating to cracks, which occurs at the inner cavity wall of C. V. joint boots. As a result it was confirmed that the real cracks occurs at the exactly same position of the cavity as exhibits the defects of weld and meld line and unsatisfactory curing according to the result of simulation. In order to prevent the occurrence of weld and meld line at the defect-position, the location of gate was altered to the optimum position of the cavity. Consequently the filling pattern was established to minimize the degree of the melt-fronts confronting or the melt-flows melding to prevent the occurrence of weld and meld line at the defect-position. It was observed that both gate-positions to maximize the degree of the formation of weld and meld line and air traps are located, respectively, in opposite direction each other with reference to the optimum gate position. In addition, the temperature of mold was raised by $10^{\circ}C$ and maintained at $170^{\circ}C$ for satisfactory curing.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.364-367
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• 2007

In nano-imprint lithography (NIL) process, which has shown to be a good method to fabricate polymeric patterns, several kinds of pattern defects due to thermal effects during polymer flow and mold release operation have been reported. A typical defect in NIL process with high aspect ratio and low resist thickness pattern is a resist fracture during the mold release operation. It seems due to interfacial adhesion between polymer and mold. However, in the present investigation, FEM simulation of NIL molding process was carried out to predict the defects of the polymer pattern and to optimize the process by FEA. The embossing operation in NIL process was investigated in detail by FEM. From the analytical results, it was found that the lateral flow of polymer resin and the applied pressure in the embossing operation induce the weld line and the drastic lateral strain at the edge of pattern. It was also shown that the low polymer-thickness result in the delamination of polymer from the substrate. It seems that the above phenomena cause the defects of the final polymer pattern. To reduce the defect, it is important to check the initial resin thickness.

• Journal of Welding and Joining
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• v.19 no.6
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• pp.608-613
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• 2001

In this study, the rotary bending fatigue test was carried out with two kinds of base metal, martensite stainless steel STR3 and austenite stainless steel STR35 and the dissimilar friction welded material with them. To compare the fatigue fifes according to the notch positions, the small circular defect was worked on the bonded line, 1.0mm and 0.5mm distance form the bonded line. The fatigue limits of the STR3 and STR35 base metal were 429.0MPa and 409.4MPa respectably. In comparison with fatigue life at the same notch positions, the STR35 specimens showed about 190% for base metal, 82% for 1.0mm distance notched specimens higher than that of the STR3. But the fatigue life of the 0.5mm distance notched STR35 specimen showed about 35% lower than that of the STR3 specimen. And the bonded line notched specimen was much lower fatigue life than the other specimens because of separation of the bonded line.

• Journal of Welding and Joining
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• v.18 no.4
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• pp.82-86
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• 2000

Gas metal arc welding(GMAW) is regarded as one of the best candidate for welding automation in industrial joining application. It is important to monitor the weld quality for the high performance weld automation. In GMAW, weld quality is closely related to arc stability especially. In this paper, arc light signal is measured and spectrum analyzed to the detect the variation of the weld quality. The FFT of the signal showed that the amplitude variance of FFT power spectrum was very large in poor weld process such as the decrease of weld bead width and height. The results show that it is possible to detect the weld defect position in weld process.

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.2
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• pp.186-192
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• 2002

The fatigue crack propagation characteristics were investigated on dissimilar friction weld of two kind of heat-resisting steels (STR3 and STR35) commonly used in valve materials for vehicles. A small circular artificial defect was machined to induce fatigue crack at bonded line, heat affected zone and base metal of the weld on the surface of the specimens. From the results of the experiment, the fatigue limits of the materials STR3 and STR35 were obtained to be 429.0MPa and 409.4MPa respectably. The STR35 base metal and 1.0mm HAZ specimens showed 190% and 82% higher fatigue life than STR3 base metal. And the fatigue life of 1.0mm HAZ specimen was shown 99% on STR3 and 29% on STR35 higher than that of their base metal. But the fatigue life of weld interface specimen was shown 18% on STR3 and 72% on STR35 lower than that of their base metal because of the weld interface separation.

• Journal of Welding and Joining
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• v.10 no.4
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• pp.240-249
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• 1992

The objective of this study is to investigate the characteristics of welded joints on the Zircaloy-4 resistance upset welding for HWR(Heavy Water reactor)fuel rods. To estimate the characteristics of welded joints, the various tests were performed on the test coupons systematically with a wide range of each welding parameters in terms of a tensile test, burst test, knoop hardness test and metallography. Major results obtained in this study are as follows: 1. The tube and machined with 120.deg. projection was the reliable weld joint design for the nuclear fuel rod end cap welding. 2. As the weld current and the amount of upset increased linearly with increasing welding main heat input, it could make an estimate of their variation in accordance with the phase shift control. 3. It was found that an increase in squeeze force has an effect on the upset contour of welded joint because the amount of upset were increased by the change of squeeze force.

• Journal of Institute of Control, Robotics and Systems
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• v.11 no.7
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• pp.595-601
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• 2005

A mobile robot system utilizing NDT (Non-Destructive Testing) method is designed and fabricated f3r automatic integrity evaluation of large sized industrial reservoirs and pipelines. The developed mobile robot can crawl over the outer surface of the industrial facilities even though the shape of the structures is various and unsymmetric. The robot detects defects such as pinholes, cracks and thickness reduction at the wall of the facilities using EMAT (Electro-Magnetic Acoustic Transducer). Image processing technology for weld line detection at the surface of the target and host programs including defect detecting algorithms are also developed. Automation of defect detection for these kinds of large facilities using mobile robots is helpful to prevent significant troubles of the structures without danger of human beings under harmful environment.