• Journal of computational fluids engineering
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• v.18 no.4
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• pp.61-68
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• 2013

Laser welding is widely used in the industry for the advantage of small heat affected zone and short weld process time. Conduction limit welding can be used to modify the surface characteristic and it is important to identify the heat affecting area correctly for the improvement of manufacturing accuracy. Since time and length scale associated with laser welding process are extremely small, numerical study can be a useful tool. In this study, two-dimensional axi-symmetric version of energy equation with enthalpy method has been used to analyze the effect of laser input conditions on final shape by the laser welding process. The proposed numerical procedure has been benchmarked with several experimental results and compared well. The modified Marangoni and Peclet number have been introduced using controllable input variables. Simple parametric researches have been performed for high Pr number material. The results show that higher Marangoni number increase fluid mixing, thus generating convex type weld pool. On the other hand, the width of the weld pool is proportional to Peclet number.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1294-1298
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• 2007

Welding process monitoring is advantageous for maintaining weld quality and numerous sensing techniques have been developed for laser welding. Coaxial image monitoring enables direct monitoring of the weld pool shape and keyhole behavior, but requires the complex optical system and the image processing technique. In this study, we coaxially acquired the weld pool images during laser lap welding by using the camera and special illumination. The welding characteristics - pool width and length, keyhole shape, etc - were extracted by using image processing and the relationship between these characteristics and the penetration depth were investigated.

• Journal of Welding and Joining
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• v.27 no.6
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• pp.9-16
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• 2009

In this paper, the coaxial monitoring system to capture image of weld pool was developed in laser-arc hybrid welding. In order to obtain the reliable image, green laser was used as a illumination system and measuring components such as band pass filter, ND (Neutral Density) filter and shutter speed was designed and optimized. Using this monitoring system, weld pool images were captured according to laser power, welding speed, welding current and interspace between laser and arc through the experiment. ANOVA (Analysis of Variation) was carried out to identify the influence of process variables on bead widths extracted from captured images of monitoring system. Welding speed and current were major factor to affect weld pool.

• Proceedings of the KWS Conference
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• 1994.10a
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• pp.115-118
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• 1994

• Journal of Welding and Joining
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• v.20 no.1
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• pp.62-68
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• 2002

This study investigated the feasibility of penetration depth measurement using infrared temperature sensing on the weld surface. The detection point was optimized by FEM analysis in the laser keyhole welding. The profile of the weld surface temperature was measured using infrared detector array. Surface temperature behind the weld pool is proportional or exponentially proportional to penetration depth and bead width. From the results, the monitoring device of surface temperature using infrared detector array was applicable fur real time penetration depth control.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.763-768
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• 2002

This paper presents a mathematical model predicting the temperature distribution in rotating GMA welding. The bead width increases with rotation frequency at the same rotation diameter because the molten droplets are deflected by centrifugal force. The numerical solution is obtained by solving the transient three-dimensional heat conduction equation considering the heat input from the welding arc, cathode heating and molten droplets. Generally in GMA welding the heat input may be assumed as a normally distributed source, but the droplet deflection causes some changes in the heat input distribution. To estimate the heat flux distribution due to the molten droplet, the contact point where the droplet is transferred on the weld pool surface is calculated from the flight trajectory of the droplets under the arc plasma velocity field obtained from the arc plasma analysis. The numerical analysis shows a tendency of broadened bead width and shallow penetration depth with the increase of rotating frequency. The simulation results are in good agreement with those obtained by the experiments under various welding conditions.

• Journal of Welding and Joining
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• v.28 no.6
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• pp.21-27
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• 2010

Due to excellent weld quality, orbital welding with TIG is widely applied to pipe welding. But concave back bead is formed easily in overhead and inclined-up position of butt orbital welding. It is difficult to find a paper to overcome this problem. In this study, in order to make convex back bead in overhead and inclined-up position of pipe 5G welding, control method of molten pool was actively investigated. Melt run welds were conducted on thickness 4.0mm SS400 with overhead and inclined-up position and was observed the variation of bead shape after welding with the bead former developed. The height of back bead showed the trend of increase as the distance from molten pool to the bead former was decreased. Also, there is no trend in the bead width of front and back as welding position was changed or the distance from molten pool to the bead former was decreased.

• Journal of Advanced Marine Engineering and Technology
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• v.26 no.4
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• pp.464-471
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• 2002

Porosity formation in partial penetration welds by high power lasers is a serious problem in industry. There are two main causes that induce porosity formation. One form of porosity is due to gases (e.g. hydrogen, oxygen) dissolving into the weld pool because of the high temperature and then the rapid solidification traps gases as a bubble in the weld metal. The second problem is voids formed by the keyhole collapsing due to unstable keyhole fluid dynamics. The voids that form at the bottom of the keyhole are relatively large and irregular in shape compared to the gas bubbles; this void formation is the primary concern in this paper. The reduction of voids formed by keyhole collapse is achieved by improving the stability of keyhole. Two methods to improve keyhole stability are discussed in this paper: pulse modulation and beam incident angle. Pulse modulation of the laser beam was performed between 100 Hz and 500 Hz to find out the optimum frequency for the keyhole dynamics. The incident beam angle changed the impact angle of the laser beam to the work surface in a range of 0 to 25 degrees. Glycerin in a semi-solidified state is used as a medium for performing the welding because its transparency allows of visualization of the keyhole.

• Journal of Welding and Joining
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• v.8 no.3
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• pp.70-78
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• 1990

The harsh nature of welding environments makes welding a prime candidate for process automation. Among the variety of welding processes available, gas metal arc welding is one of the most frequently used methods, primarily because it is highly suited to a wide range of applications, and also to automation. Automatic seam tracking method is one of the most demanded techniques for automatic control of arc welding. In this study a seam tracking system has been developed by using the welding arc itself as a sensor. This paper described the principle and experimental result of the arc sensor system, as well as the development and application of the automatic CO_2$ welding for the horizontal fillet welding. A basic problem in horizontal fillet welding is the prevention of hanging bead formation such as undercut at the vertical plate and overlap at the horizontal plate. To produce the symmetric bead shape, the relationship of bead shape to welding parameters(welding velocity, weaving width, weaving speed, tip to workpiece distance) was also investigated.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.4
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• pp.97-103
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• 1997

Designing a feedback controller requires a dynamic model of the process to be controlled. But the GMA welding process models have not been fully developed for many reasons such as complexity of the welding process and lack of reliable sensors. Because of the complexity of the welding system, we obtained a dynamic model for control using system identification routines, rather than derived a model from fundamental physical laws. The controller was designed based on the experimentally derived linear dynamic model of the welding process. In order to demonstrate application of the designed controller, the simulation was carried out.