• Proceedings of the KWS Conference
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• 2005.11a
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• pp.114-116
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• 2005

There are some problems when weld gray cast iron which is used well in automobile industry with auto MIG welding. the problems are followed like this 1) Occurrence of porosity and hardening organization. 2) Occurrence of crack due to lower elongation of gray cast iron when restraint stress works on. 3) Occurrence of porosity and unstable bead shape due to unstable arc under low current MIG welding.. especially there is a restraint on chemical composition of weld metal because the weldment demands more than 570Hv hardness. so it is hard to use Fe-Ni wire to prevent cracks occured on weldment and new welding method is needed to resolve that problems. This study shows how to prevent porosity and cracks occurring when weld gray cast iron trimming die and shows a new welding method for press die of gray cast iron

• Laser Solutions
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• v.18 no.1
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• pp.1-6
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• 2015

High welding speed and narrow weld seam are favorable for welding of magnesium alloy. Magnesium alloy is recommended for the smart frame because it has several advantages such as low density, high thermal conductivity, EMI shielding capability and good cast ability. This study is for the assembly welding of the magnesium smart frame with high productivity, good performance and low cost. The window for battery on AZ91D frame produced by die-casting was prepared by CNC machining. Corresponding AZ31 blank of 0.2mm thickness was prepared by die-blanking cut. All system set was fixed at the stationary bed but the laser beam was manipulated by scanner up-to 1,000mm/s speed. The weld joint between AZ31 sheet and AZ91D frame was welded by fiber laser on 850~1,000W output power. The joint showed penetration enough but some humping bead. The distortion by the weld heat was almost free because of the quick dissipation of the heat by small beam size and fast welding. Consequently, the thinner magnesium foil was assembled successfully to the magnesium frame of mobile phone.

• Transactions of Materials Processing
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• v.21 no.8
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• pp.467-472
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• 2012

Shaving shear-welding is a solid-state welding process, which utilizes plastic deformation of surplus material. The solid-state nature of this process contributes to high integrity and strength of the weld. The objective of this study was to investigate the effects of process variables on the material flow patterns and identify the process condition for obtaining the best weld. FEM simulations were carried out along with experimental characterizations. The results showed the importance of the cutter angles and the overlap lengths, and helped attain the optimum shaving shear-welding die and the best process condition.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.78-81
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• 2000

In this study the plasic flow before welding stage in the cahamber is analyzed by FEM and experiments during the porthole extrusion process. The analysis is concerned with plastic flow in the port and welding chamber of rectangular hollow section extrusion through the porthole die with mandrell. Numerical simulation by finite element code to investigate the plastic flow is discussed for both tapered inlet and straight inlet chamber. To visualize the flow in extrusion process split dies and punches are designed and manufactred by wire EDM. Experiments are carried out by using the plasticine as a model material at room temperature. The theoretical predictions are reasonable agreements with experimental results in the welding lines and the deformed profiles.

• Journal of Welding and Joining
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• v.28 no.3
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• pp.79-85
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• 2010

Hardfacing is one of the frequently applying method to increase surface hardness in hot forging die. Recently, hardfacing receives great attention due to it's repair availability and low cost. In hot forging die, crack resistance and thermal shock resistance have been considered as major properties, However there are few studies for the assessment of these properties. So, it is necessary to establish the assessment method for crack resistance and thermal shock resistance in hardfacing for hot forging die. In this study, flux cored arc welding was applied to make hardfacing welds. Three point bending test was carried out to assess hardfacing weld's crack resistance, and high temperature bending test using salt bath was developed for thermal shock resistance. Consequently, it was possible to assess crack resistance and thermal shock resistance of hardfacing welds for hot forging die quantitatively.

• Journal of the Korean Society for Precision Engineering
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• v.24 no.11
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• pp.44-51
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• 2007

Condenser tubes are mainly produced by precision extrusion with a porthole die and are used in the flow pass of refrigerant cooling systems in automobiles. The recent technical trend of condenser tube requires the tube to be of more multi cellizing, high strength and small size, and to increase the heat transfer area and heat efficiency. Hence, this paper is shown that the results of FE-simulation are in good agreement with the experimental ones. Finally, the extrusion die shape is proposed through analysis of FE-simulation and performance of trial extrusion. Chamber shape dimension and initial temperatures of die is adjusted analysis results. And the possibility of extrusion is estimated that forming load, welding pressure and stress analysis of die in this paper. The validity of simulated results was verified into extrusion experiments on the condenser tubes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.227-230
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• 2009

The aim of this study was to improve extrudability limit, eliminate welding line and obtain optimum thixoextrusion conditions for manufacturing tubes of 7075 Al wrought alloy. By thixoextrusion, it was possible to improve deformability, control isotropy with extrusion direction, eliminate welding line (seamless) and save cost due to low energy consumption compared with conventional extrusion processes. The welded part was not observed at the welding line area. The grains of thixoextruded tube were homogeneously distributed and equiaxed grains were observed. Therefore, thixoextrusion is the most effective variable for the control of the magnitude of the welding line.

• Proceedings of the KWS Conference
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• 2001.05a
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• pp.189-191
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• 2001

This study introduces the new way for the evaluation criteria of the Mash-Seam Tailored Blank weldability, The materials used are low carbon automotive galvanized and high strength steels and the evaluation of weldability are examined with various thickness. Welding tests were conducted for both similar thickness and dissimilar thickness cases. The criteria developed for optimum welding conditions were based on the relationship among results of die press forming test, weld transverse tensile test, Erichsen test and microhardness measurements. The application of the developed criteria(fracture ratio, strength ratio, etc) in obtaining optimum welding condition revealed that a weld which satisfied ant of the criteria did not fracture during actual die press test.

• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2001.05a
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• pp.282-288
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• 2001

This paper deals with determining the proper friction welding condition and analyzing various mechanical properties of friction welded joints of the bladepart heat resisting steel(STD11) for cold die punch to the shank part alloy steel(SCM440). And the in-process real-time weld quality evaluation technique by acoustic emission during friction welding of STD11 to SCM440 steels with higher confidence and reliability has been much required even though it might be the first trial approach for developing it. Also, the high temperature properties of STD11-SCM440 weld were considered in this paper.

• Proceedings of the KWS Conference
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• 2001.10a
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• pp.81-84
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• 2001

This study introduces the new way for the evaluation criteria of the Mash-Seam Tailored Blank weldability, The materials used are low carbon automotive galvanized and high strength steels and the evaluation of weldability are examined with various thickness. Welding tests were conducted for both similar thickness and dissimilar thickness cases. The criteria developed for optimum welding conditions were based on the relationship among results of die press forming test, forming limit diagram, Erichsen test and microhardness measurements. The application of the developed criteria(fracture ratio, strength ratio, etc) in obtaining optimum welding condition revealed that a weld which satisfied ant of the criteria did not fracture during actual die press test and FLD dome test.