• Journal of the Korean Society of Manufacturing Technology Engineers
• /
• 제21권2호
• /
• pp.290-296
• /
• 2012

Cold-rolled carbon steel sheets are commonly used in railroad car or commercial vehicles such as the automobile. These are mainly fabricated by spot welding which is a kind of electric resistance welding. But fatigue strength of spot welding joint is lower than that of base metal due to high stress concentration at nugget edge of the spot welded part. And fatigue strength of them is especially influenced by not only geometrical and mechanical factors but also welding conditions of the spot welded joint. So for fatigue design of gas welded joints such as TS-type joints, it is necessary to obtain design information on stress distribution at the weldment as well as fatigue strength of spot welded joints. And also, the influence of the geometrical parameters of spot welded joints on stress distribution and fatigue strength must be evaluated. And analysis approach for fatigue test using design of experiment are evaluated optimum factor in TS-type welded joint and geometrical parameters of materials. Using these results, that factors applied to fundamental information for automation of fatigue design.

• International Journal of Precision Engineering and Manufacturing
• /
• 제8권4호
• /
• pp.56-62
• /
• 2007

An analytical method to predict the post-weld deformation at the heat-affected zone (HAZ) is presented in this paper. The method was based on the assumption that the post-weld deformation is caused by external forces resulting from the inherent strain, which is defined as the irrecoverable strain after removing structural restraints and loadings. In general, the equivalent loading method can be used to analyze distortions in welding areas because it is efficient and effective. However, if additional loads are applied after welding, it is difficult to determine the final strain on a welded structure. To determine the final strain of a welded structure at the HAZ more accurately, we developed a modified equivalent loading method based on the inherent strain that incorporated hardening effects. The proposed method was applied to calculate the residual stress at the HAZ. Experiments were also conducted on welded plates to evaluate the validity of the proposed method.

• Journal of Adhesion and Interface
• /
• 제7권4호
• /
• pp.28-31
• /
• 2006

Due to the miniaturization of MEMS and microelectronics the joining techniques also have to be adjusted. The dosing technology with viscous adhesives does not permit reproducible adhesive volumes, which are clearly under a nano-liter. A nano-liter means however a diameter of bonding area within the range of several 100 micrometers. Additional, viscous adhesives need a certain time, until they are cross linked or cured. The problem especially in the MEMS is the initial strength, since it gives the time, which is needed for joining an individual adhesive joint. The time up to the initial strength is with viscous, also with fast curing systems, within the range of seconds until minutes. Until the reach of the initial strength, the micro part must be fixed/held. Without sufficient adjustment/clamping it can come to a shift of the micro parts. Also existing micro adhesive bonding processes are not batch able, i.e. the individual adhesive joints of a micro system must be processed successively. In the context of the WCARP III 2006 now an innovative method is to be presented, how it is possible to solve the existing problems with micro bonding. i.e. a method is presented, which is batch able, possess a minimum joining geometry with some micrometers and is so fast that no problems with the initial strength arise. It is a method, which could revolutionize the sticking technology in the micro system engineering.

• Transactions of the Korean Society for Noise and Vibration Engineering
• /
• 제14권5호
• /
• pp.370-376
• /
• 2004

The overall aim of this paper is to determine coupling loss factor of welding point between shell and cylinder using loss factor and structural loss factor. For this purpose, two kinds of loss factor were adopted. One is loss factor of each sub structure, another is structural loss factor based on the complex welded or assembled structure. Using these two parameters, it ispossible to derive the coupling loss factor which represent characteristic condition of SEA theory. Coupling loss factor of conjunction in complex structure was expressed as power balance equation. The derived equation for a coupling loss factor has been simplified on the assumption of one way (uni-directional) power flow between multi-sub structures. Using these conditions, it is possible to find the equation of coupling loss factor expressed as above two loss factors. To check the effectiveness of above equation, this paper used two-stage application. The first approach was application between simple cylinder and shell. The next was adopted rotary compressor. Rotary compressor has three main conjunctions between shell and internal vibration part. This equation was applied to find out the optimum welding point with respect to reduce the noise propagation. It shows the effective tool to evaluate the coupling loss factor in complex structure

• Journal of the Korean institute of surface engineering
• /
• 제41권4호
• /
• pp.156-162
• /
• 2008

Small FRP(fiber-reinforced polymer) fishing ships have numerous problems with the point of the environmental and recycling perspectives. In light of these aspects, aluminum can be used as a material for ship building. It is environmental friendly, easy to recycle, and provides a high added value to fishing boats. In this paper, we report on mechanical and electrochemical characteristics of welding parts for friction stir welded 5456-H116 Al alloy. In friction stir welded at various traveling speeds under the rotation speed of 500 RPM, the best characteristics presented in traveling speed of 15mm/min. The anodic polarizations of base metal and welding metal were observed tendency which current density from the open circuit potential suddenly increase. The cathodic polarization presented concentrated polarization caused by the dissolved oxygen reduction reaction and activation polarization caused by hydrogen generation. From result of Tafel analysis, the corrosion potential of 5456 alloy(Base metal) was lower than that of friction stir welded part, as were its corrosion current densities.

• Journal of the Korean institute of surface engineering
• /
• 제42권1호
• /
• pp.13-20
• /
• 2009

Friction stir welding(FSW) was developed as a new solid state welding technique by The Welding Institute (TWI). On the basis of FSW, a new processing technique, friction stir processing (FSP), has recently been developed. FSP has been applied to cast aluminum alloy to modify the microstructure to enhance mechanical characteristic. FSP is a new solid state processing technique for microstructural modification in metallic materials. FSP has been applied to aluminum alloy to modify the microstructure to enhance mechanical characteristic. In this study, we investigated optimum condition friction stir processing with the evaluation of mechanical characteristic for 5456-H116 Al alloy. The mechanical characteristics of base metal similar with in 15 mm/min, 250 RPM with full screw probe. This condition is concluded that optimum friction stir processing condition. The result of this investigation will be able to application for repair of welding part for aluminum ship.

• Transactions of Materials Processing
• /
• 제19권5호
• /
• pp.277-282
• /
• 2010

Magnesium alloy has been known as lightweight material in automobile and electronic industry with aluminum alloy, titanium alloy and plastic material. Friction welding is useful to join various metals and nonferrous metals that are difficult to join by such as gas welding, resistance welding and electronic beam welding. In this study, friction joining was performed to investigate mechanical properties of Mg alloy with 20mm diameter solid bar. Also the optimal joining conditions for its application were determined on the basis of tensile test, and hardness survey. The joining parameters were chosen as heating pressure, heating time, upsetting pressure, and upsetting time. Heating and upsetting pressure were executed under the range of 10~40MPa and 20~80MPa, respectively. From the experimental results, optimal joining conditions were determined as follows; rotating speed=2000rpm, heating pressure=35MPa, upsetting pressure=70MPa, heating time=1sec, upsetting time=5sec. Also the hardness of jointed boundary showed as HV50 which was similar to that of base metal at the optimal condition, and it was supposed that zone of HAZ was 8mm. Finally two materials were strongly mixed at interface part to show a well-combined microstructure without particle growth or any defect.

• Transactions of the Korean Society of Automotive Engineers
• /
• 제16권5호
• /
• pp.8-14
• /
• 2008

For nondestructive inspection of electron beam (EB) welding part in automotive power transmission assembly, a pulse-echo ultrasonic testing apparatus in water immersion has been applied using the ultrasonic waves with a frequency of 10MHz. However various problems have appeared during the ultrasonic inspection, which led to some significant mistakes in automatic quality evaluation of the welding parts. Experimental study showed that the state of water couplant medium containing some amount of contaminants, rusts and anti-corrosion agents had considerable influences on the reduction of ultrasonic amplitudes during wave propagation. The amplitude reduction depending on the coupling medium state could bring about some mis-diagnoses for defects in the welding parts. The results proposed that for a reliable inspection of defects in welds the state of water medium should be kept in about 15 volume fractions (vol.%) of anti-corrosion agents and in minimized contaminants.

• Proceedings of the Korean Society of Laser Processing Conference
• /
• 한국레이저가공학회 2005년도 추계학술발표대회 논문집
• /
• pp.50-56
• /
• 2005

The robot systems are widely used in the many industrial field as well as welding manufacturing. The essential tasks to operate the welding robot are the acquisition of the position and/or shape of the parent metal. For the seam tracking or the robot tracking, many kinds of contact and non-contact sensors are used. Recently, the vision is most popular. In this paper, the development of the system which measures the shape of the welding part is described. This system uses the line-type structured laser diode and the vision sensor. It includes the correction of radial distortion which is often found in the image taken by the camera with short focal length. The Direct Linear Transformation (DLT) method is used for the camera calibration. The three dimensional shape of the parent metal is obtained after simple linear transformation. Some demos are shown to describe the performance of the developed system.

• Journal of Welding and Joining
• /
• 제25권5호
• /
• pp.36-44
• /
• 2007

This paper is the first part of the study on the accuracy improvement of numerical analysis of steel welds. The aim of this paper is to raise the accuracy of thermal analysis results, such as the shape and size of the weld cross section and the hardness distribution in HAZ(Heat-Affected Zone). It is known that the factors affecting on the accuracy are thermal properties, metallurgical properties and welding heat source model. It was found that the arbitrary distributed heat source model should be used to predict practical weld cross section shape and size. Also, in order to improve the prediction accuracy of HAZ hardness distribution, it was essential to consider 2 CCT(Continuous Cooling Transformation) diagrams in calculating volume fraction of transformed phases. One is the peak temperature being around melting temperature. The other is the peak temperature being around metallurgical transformation temperature.