• Transactions of Materials Processing
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• v.8 no.1
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• pp.7-13
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• 1999

In this study, side panels were developed using the laser-welded tailored blank (T.B.) of both the same thickness and different thickness. At first, the formability of the same thickness T.B. was investigated to compare with one of the non-welded panel with respect to weldline movement and strain distribution in blank during the stamping process. Based on these results, we determined the weld line positions and the die step for T.B. forming of the blanks composed of different thickness combination. Then we made some stamping tryouts with selected types of blanks to investigate the formability of T.B. of the different thickness. During the tryouts, wrinkles were found in the a-pillar lower region which is under the deformation mode of the shrink flange. In the b-pillar region, fractures were also found. These defects have been reduced and corrected by controlling the blank design, the die faces and process parameters.

• Proceedings of the KWS Conference
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• 2000.04a
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• pp.260-263
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• 2000

In this study, constant amplitude fatigue tests on load-carrying fillet welded specimen carried out, and fatigue strengths were evaluated. Also, an attempt is made to develop a new analytical model with more accuracy to predict the fatigue crack propagation life of fillet welded cruciform joints of SWS 490B steels containing lack of penetration defects. from the result of this study, fatigue crack growth characteristics of load-carrying fillet welded cruciform joints, containing lack of penetration defacts are found to be affected by the weld geometry and the number of weld pass.

• Transactions of Materials Processing
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• v.9 no.1
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• pp.10-16
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• 2000

This research investigates microstructures and fatigue properties of the weldments of 6005A aluminum alloy developed for railroad vehicles. The samples were extruded into a truss structure and welded together using the gas metal arc welding process. The extruded sample showed a wide variation in grain size, possibly due to the frictional heating as well as the inghomogeneous metal flow in the extrusion die. The mechanical properties of the samples were affected by the mirocstructures. The fatigue strength of the welded structure was found to decrease significantly from that of the base metal. It was found that the fatigue characteristics of the welded structure were determined by the microstructure of the parent metal as well as weld defects such as porosities and the liquation cracks.

• Proceedings of the KSR Conference
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• 2005.11a
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• pp.1097-1102
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• 2005

Non-Destructive Testing (NDT) is test method which finds the mechanical or natural or artificial defects of the interior or exterior of those without destructing materials and welded products. NDT is a means to assess the perfection of a component or system perfection. NOT images defects using scattered light, sound, electric current, magnetic fields and X-ray. Each NDT method has merits and demerits in the detecting ability of defects according to evaluated subjects. Defects can affect the serviceability of the material or structure, so NDT is important in guaranteeing safe operation as well as in quality control. In this review, we considered the methods of NDT applied to current railway vehicle manufacturing.

• Journal of the Korean Society for Nondestructive Testing
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• v.34 no.1
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• pp.18-22
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• 2014

Residual stresses that occur during the welding process, are the main cause of failure and defects in welded structures. This paper, presents the use of an electronic processing laser speckle interferometer to measure the residual stress of a welded pipe for a nuclear power plant. A tensile testing machine was used to evaluate a welded pipe that failed in compression. The inform plane deformation and modulus of elasticity of the base metal and welds were measured using an interferometer. Varying the load on the welded pipe had a larger effect on the deformation of the base metal the other properties of the base metal and welds. The elastic moduli of the base metal and weld of the welded pipe were 202.46 and 212.14 GPa, respectively, the residual stress was measured to be 6.29 MPa.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.05a
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• pp.823-824
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• 2012

• Transactions of Materials Processing
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• v.10 no.3
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• pp.193-199
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• 2001

Forming more than two parts of sheet metal in a single stamping operation lowers production costs, reduces weight, and heightens dimensional accuracy. The tailored blank (TB) is a laser-welded or mash-seam-welded sheet metal with different thicknesses, different strengths, or different coatings. Recently, automotive manufacturers have been interested in tailored blanks because of their desire to improve the rigidity, weight reduction, crash durability, and cost savings. Therefore the application to auto-bodies has increased. However, as tailored blanks do not behave like un-welded blanks in press forming operations, stamping engineers no longer rely on conventional forming techniques. Field try-outs are very important manufacturing processes for an economic die-making. In the field try-outs, the rounded geometries of tool and the drawbead shape and size in die face are generally modified when the forming defects can not be removed by the adjustment of forming process parameters. In this study, the field try-outs of tailored door inner panel are introduced and evaluated. The behaviours of laser tailored blank associated with different thickness combinations in the forming process of door inner panel are described focusing on terms of experimental investigations on the formability.

• Journal of Ocean Engineering and Technology
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• v.26 no.1
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• pp.64-69
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• 2012

Dissimilar friction welds were produced using 15-mm diameter solid bars of chrome molybdenum steel (KS SCM440) and carbon steel (KS SM20C) to investigate their mechanical properties. The main friction welding parameters were selected to ensure good quality welds on the basis of visual examination, tensile tests, Vickers hardness surveys of the bond area and HAZ, and macro-structure investigations. The specimens were tested as-welded and post-weld heat treated (PWHT). The tensile strength of the friction welded steel bars was increased to 100% of the SM20C base metal under the condition of a heating time of more than four seconds. Optimal welding conditions were n = 2,000 (rpm), HP = 60 (MPa), UP = 100 (MPa), HT = 5 (s),and UT = 5 (s), when the total upset length was 7.8 (mm). The hardness distribution peak of the friction welded joints could be eliminated using PWHT. The two different kinds of materials were strongly mixed to show a well-combined structure of macro-particles, with no molten material, particle growth, or defects.

• Journal of Sensor Science and Technology
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• v.28 no.6
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• pp.371-376
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• 2019

We have developed an acoustic resonance inspection system to inspect the welding defects in the mechanical parts fabricated using friction stir welding method. The inspection system was consisted of a DAQ board, a microphone sensor, an impact hammer, and controlled by a PC software. The system was developed to collect and analyze the sound signal generated by hitting the sample with an impact hammer to determine whether it is defective. In this study, 100% welded good samples were compared with 95%, 90%, and 85% welded samples, respectively. The variation of the completeness in welding did not affect the visual appearance in the samples. As a result of analyzing the natural frequencies of the good samples, the five natural frequency peaks were identified. In the case of the defective samples, the frequency change was observed. The welding failure detection time was fast enough to be only 0.7 seconds. Employing our welding defect inspection system to the actual industrial field will maximize the efficiency of quality inspection and thus improve the productivity.

• International Journal of Naval Architecture and Ocean Engineering
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• v.6 no.4
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• pp.922-934
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• 2014

In casting steels for offshore construction, manufacturing integral casted structures to prevent fatigue cracks in the stress raisers is superior to using welded structures. Here, mold design and casting analysis were conducted for integral casting steel. The laminar flow of molten metal was analyzed and distributions of hot spots and porosities were studied. A prototype was subsequently produced, and air vents were designed to improve the surface defects caused by the release of gas. A radiographic test revealed no internal defects inside the casted steel. Evaluating the chemical and mechanical properties of specimens sampled from the product revealed that target values were quantitatively satisfied. To assess weldability in consideration of repair welding, the product was machined with grooves and welded, after which the mechanical properties of hardness as well as tensile, impact, and bending strengths were evaluated. No substantive differences were found in the mechanical properties before and after welding.