• Proceedings of the KWS Conference
• /
• 2002.10a
• /
• pp.425-429
• /
• 2002

It has been used many kinds of horizontal butt-welding methods at block-to-block erection stage in shipbuilding companies. For examples, some companies use conventional FCA W process with one side or both sides groove joint welding, others use carriage with torch holder type mechanized welding method. Although lots of efforts were done until now, some problems in quality and productivity still remain in ship's hull welding. In this study, we have attempted to raise productivity and quality on horizontal position of welding with following 3 items. 1) Prepare groove condition with no root gap for making easy fit-up work. 2) Develop improved MAG (100% $CO_2$ gas shielding) welding process with solid wire for making sound root bead from one side. 3) Develop and apply quite new automatic welding carriage. The stability of new welding process was confirmed by conducting mechanical tests of weldments to verify the soundness of weldments.

• Journal of Welding and Joining
• /
• v.20 no.4
• /
• pp.510-516
• /
• 2002

Recently the laser welding technology has been applied increasingly for the automotive bodies. But the lap joint laser welding for 3 dimensional automotive body is new while the butt joint laser welding is well known as the tailored blank technology. In this study, the process window was found for the full penetration welding of the lap joint of the 1mm-thick high strength steel sheets. The limit curves and characteristic curves were suggested to define the boundaries and the contour lines in a space of the welding speed and the gap size. The characteristics of the weld sectional geometry were used to determine the limit curves. They are bead width, penetration depth and sectional area. After the observed data was analysed carefully, it was noticed that there was a transition point at which the sectional shape was changed and the bead area jumped as the welding speed was increased. Also a new concept of 'input energy Per volume' was suggested to distinguish the difference at the transition Point. The difference of sectional areas at the transition point can be related to the dynamic keyhole phenomena.

• Journal of the Korea Institute of Information and Communication Engineering
• /
• v.10 no.7
• /
• pp.1326-1331
• /
• 2006

Weld root gap is a important fact of a falling-off weld quality in various kind of weld defect. The welding quality can be controlled by monitoring important parameters, such as, the Arc voltage, welding current and welding speed during the welding process. Welding systems use either a vision sensor or an Arc sensor, both of which are unable to control these parameters directly. Therefore, it is difficult to obtain necessary bead geometry without automatically controlling the welding parameters through the sensors. In this paper we propose a novel approach using neural networks for detecting and monitoring of weld root gap and bead shape. Through experiments we demonstrate that the proposed system can be used for real welding processes. The results demonstrate that the system can efficiently estimate the weld bead shape and detect the welding defects.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.32 no.6
• /
• pp.512-518
• /
• 2008

This study would like to evaluate the influences with the strength mismatch and the variation of the welding width of the narrow gap welding for the plastic parameter, the major constant determining the plastic ${\eta}$-factor of J-Integral, using 3-D FEM. For this, we evaluate the plastic ${\eta}$-factor according to the variation of the strength mismatch of weldment with same materials and welding width through FEM. Also, we proposed the equation of plastic ${\eta}$-factor considering the variation of the strength mismatch of weldment with similar materials and welding width.

• Journal of Welding and Joining
• /
• v.20 no.3
• /
• pp.122-128
• /
• 2002

The laser welding in the automotive industries has been used widely for the butt joint of blank sheets rather than the lap joint of automotive body panels. But as a substitute far the spot welding of automotive body panels, the so called three dimensional laser welding will be important far the body panel engineers. Specially the laser welding of body panels with a smooth weld line is applied increasingly, for example, to the side panels. So far, some criteria of the laser weld quality was suggested by in-house regulations or national standards from experiences and/or rule of thumbs. In the manufacturing places, a go or no-go criterion is adopted because of the simplicity or a lack of rational criteria. It is true specially for the selection of the process parameters, which gives the basic causes for the good quality of laser welds. In this study, the effects of joint combination, gap and welding speed on the lap joint $CO_2$ laser welding of two mild steel sheets with different thicknesses are obtained through a $2{\times}3{\times}7$ factorial experiment. The results of the weld quality are statistically analysed using analysis of variance (ANOVA) and compared between two characteristic zones, which are separated by the type of sectional shapes and the level of input energy per volume. The thickness combinations are 0.8mm/1.2mm, 1.2mm/0.8mm of mild steel sheets. The welding speed covers from the deep penetration to the partial penetration. The gap size has three levels of no-gap, 0.16m, and 0.26mm. The bead width, penetration depth and input energy per volume are measured and used as the weld quality criteria.

• Journal of Welding and Joining
• /
• v.21 no.3
• /
• pp.46-50
• /
• 2003

The horizontal fillet joint is one of the most important weld joints in the shipbuilding industry. High-speed rotating arc welding, which can increase the leg length, is an effective way to improve the weld productivity and quality for the horizontal fillet welding. Based on the Taguchi method, the effects of welding parameters on bead characteristics - leg length, asymmetry, undercut, overlap - are investigated fur high-speed welding process. As a result, the adequate welding parameters are selected for the required leg length, symmetric bead and no undercut. Besides, considerably consistent leg length is observed for the horizontal fillet welding with gap variation up to 3mm.

• Journal of Welding and Joining
• /
• v.21 no.3
• /
• pp.40-45
• /
• 2003

The high-speed rotating arc process forms a flat bead surface with decreased penetration depth because the molten droplets are deflected by centrifugal force. Therefore the rotating arc welding for horizontal fillet welding increases the leg length with the increase of rotation frequency and prevents the deflection of weld bead and overlap. In this study, the relationship between the welding parameters and the weld bead shape - leg length and undercut - are investigated experimentally. Consequently, the weld quality could be improved by rotating arc welding, and sound weld bead was achieved when applied to horizontal fillet welding with 4mm gap by avoiding the undercut which is inevitable for the conventional GMA welding methods.

• Journal of the Society of Naval Architects of Korea
• /
• v.39 no.3
• /
• pp.81-88
• /
• 2002

The root joint in the welding structures are apt to failure by the stress concentration which is occurred by the external force. Therefore, in the safety and reliability of structure, the complete penetration joint welding which are obtained by the groove welding with edge preparation is generally required. Nevertheless, fillet T-joint welding without edge preparation is often carried out in the fields to reduce working time and consumption of welding electrode, however, this process is likely to produce inadequate joint penetration such as root gap. In this paper, the focus of research is to investigate distribution of welding residual stresses in the plate(or flange) and web of T-joint weld, and especially in the near of root gap notch that is due to incomplete joint penetration. For the analysis, we have chosen model of T-joint weld in the cases of single and multi-pass welding with submerged arc welding and analyzed model by using finite element programs considering the heat conduction and thermal elasto-plastic theory.

• Journal of Welding and Joining
• /
• v.34 no.4
• /
• pp.48-54
• /
• 2016

The use of Zn coated steel has increased in the automotive industry due to its excellent corrosion resistance. Conventionally the BIW(body-in-white) structure and the hang-on parts have been made of Zn coated steel and more recently Zn coated steel began to be applied in the chassis parts. During gas metal arc (GMA) welding of the chassis part, lap fillet joint used to be adopted but spatter generation and porosities are most important concerns. In the industrial applications, an intentional joint gap was made to avoid the weld defects but it is not easy to control the size of joint gap. In this research, gas tungsten arc (GTA) is combined with GMA welding where GTA precedes GMA. As pulsed arc was adopted as GMA, GTA was oscillated along the longitudinal direction by pulsing GMA, but the arc oscillation did not disturb the molten droplet transfer of GMA welding. By increasing the distance between GTA and GMA, the length of weld pool increased and porosity could be reduced. Moreover porosity in the welds was fully removed when the distance between two arcs was 15 mm.

• Journal of the Korean Society for Precision Engineering
• /
• v.18 no.12
• /
• pp.73-81
• /
• 2001

The MIAB welding uses a rotating arc as its heat source and is known as an efficient method fur pipe butt welding. The arc is rotated around the weld line by the electro-magnetic force resulting from the interaction of arc current and magnetic field. The electro-magnetic force is affected by magnetic flux density, arc current, and arc length. Especially, the magnetic flux density is an important factor on arc rotation and weld quality. This paper presents a 2D finite element model for the analysis of magnetic flux density in the actual welding conditions. The magnetic flux density is mainly dependent on gap between two pipes, the position of coil from gap center, exciting current, and relative permeability. Thus, the relations between magnetic flux density and main factors were investigated through experiment and analysis. Experiments were performed for the steel pipes(48.1mm O.D and 2.0mm thickness). The analysis results of magnetic flux density reveal that it increases with increasing exciting current, increasing relative permeability, decreasing distance from gap center to coil, and decreasing gap size. It is considered that the results of this study can be used as important data on the design of coil system and MIAB welding system.