• Journal of Welding and Joining
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• 제24권3호
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• pp.42-48
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• 2006

Since the voids occur at the CD stud welds, the mechanism of void formation and void reduction method are investigated in this work. It is speculated that the voids are formed because of high short-circuit current above 1000A. When the simple flow model is used to estimate the void trapping condition, the most voids are trapped at the weld mainly due to fast cooling rate of the CD stud weld. Since it is almost impossible to remove the voids completely, a method is proposed to reduce the void by decreasing the short-circuit current at the end of the arcing time. The experimental results show that the void is reduced by decreasing the short-circuit current to 1000A.

• Journal of Ship and Ocean Technology
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• 제7권4호
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• pp.41-49
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• 2003

Welding deformation reduces the accuracy of ship hull blocks and decreases productivity due to the need for correction work. Preparing an error-minimizing guide at the design stage will lead to higher quality as well as higher productivity. Therefore, developing a precise method to predict the weld deformation is an essential part of it. This paper proposes an efficient method for predicting the weld deformation of complicated structures based on the inherent strain theory combined with the finite element method. A simulation of a stiffened panel confirmed the applicability of this method to simple ship hull blocks.

• 대한전자공학회논문지
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• 제27권10호
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• pp.24-33
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• 1990

한 대의 자동차에는 많은 용접자들이 분포하므로 각 로보트에 할당되는 용접점의 수가 커지는데, 전체 공정에서 용접 작업이 차지하는 시간을 줄이기 위해서 용접 순서를 적절하게 계획할 필요성이 있다. 본 논문에서는 점 용접용 로보트의 효과적인 교시를 위한 오프라인 프로그래밍 방법을 제안한다. 이는 용접 로보트와 작업 대상물과의 충돌을 고려하여, 충돌 회피를 보장하며 최단 거리를 갖는 용접 순서를 계획하는데에 고전적인 TSP 알고리듬을 변형하여 적용한 것으로서 자동차 용접 작업에 응용한다. 또한 작업을 계획아는데에 필요한 모델 데이터로 기존의 일반적인 CAD 시스템과 그의 데이터를 이용할 수 있도록 하므로써, 데이터 베이스의 구축을 한층 용이하고 또 정교하게 할 수 있다록 한다. 자동차 생산 공정의 한 예에 본 교시 방식을 적용하므로써, 이의 효율성을 보인다.

• 한국정밀공학회지
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• 제30권2호
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• pp.154-163
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• 2013

Adhesive bonding and plastic welding have been widely used to join two plastic materials together. The goal of this paper is to determine a proper joining technology of a pair of flat panel (FP) photobioreactor (PBR) case. The material of the FP PBR case is polycarbonate (PC) plate. Two types of adhesion, including acryl adhesive and two-part epoxy adhesive, as well as two types of plastic welding technology, including ultrasonic welding and thermal welding, are employed for joining of PC plates. In order to influence of the adhesion and welding conditions on the joining characteristics of the PC plates in operational conditions of the FP PBR case, the morphology in the vicinity of the joined region as well as the water and pressure resistance characteristic are investigated. In addition, the variation of the bonding strength of the joined region and deformation behaviors in the vicinity of the joined region according to the adhesion and welding conditions is examined via the lap-shear test. From the results of basic experiments, proper joining technologies are chosen. Using the chosen joining technologies, the FP PBR case are fabricated to perform full-scale durability experiment. The results of the full-scale durability experiment have been shown that the chosen joining technologies can be applicable to fabricate the FP PBR case.

• Journal of Welding and Joining
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• 제15권3호
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• pp.88-98
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• 1997

Welding defects, such as porosity and spike, have sometimes occurred in deep penetration electron beam welds. These defects are known to be one of the serious problem in electron beam welds. So, effects of active parameters ($a_b$) on bead shape and occurrence of defects in electron beam welds of heavy section 9%Ni steel plates were investigated. Partial penetration welding in flat position, and deep penetration welding of 10 ~ 28mm depth were investigated in this study. It is desirable to select low accelerating voltage and above the surface focus position $a_b$$\geq$1.2 at which a wine-cup shaped bead is obtained to avoid the welding defects such as spike and root porosity. When the accelerating voltage of electron beam was low (90kV), active parameter ($a_b$) did not influence on the bead width, penetration depth and weld defects significantly. However, in case of high voltage ($\geq$120kV), active parameter ($a_b$) was sensitively associated with penetraton depth and weld defects, i.e. when the active parameter (($a_b$) was in the range of 0.6 to 1.0, the depth of penetration was always over the target (23mm), while the depth of penetration was dramatically decreased with further increase of active parameter ($a_b$). The weld defects were decreased with the increase of active parameter $a_b$ resulting in the decrease of energy density of the focused beam in the root part of fusion zone.

• Journal of Welding and Joining
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• 제26권4호
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• pp.79-84
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• 2008

Use of sheet metal structure is increased in various fields such as automobile, aerospace and communication equipment industry. When this structure is welded, welding distortion is generated due to the non-uniformity of temperature distribution. Recently welding distortion becomes a matter of great importance in the structure manufacture industry because it deteriorates the product's quality by bringing about shape error. Accordingly many studies for solving the problems by controlling the welding distortion are being performed. However, it is difficult to remove all kinds of distortion by welding process, though various kinds of methods for reducing distortion are applied to production. Consequently, straightening process is operated if the high precision quality is requested after welding. The local heating method induces compression plastic deformation by thermal expansion in the heating stage and then leaves constriction of length direction in the cooling stage. Accordingly, in the case of sheet metal structure, straightening effect is expected by heating for the part of distortion. This study includes numerical analysis of straightening effect by the local heating method in distortion comes from production of welded sheet metal structure. Particularly straightening effect followed by dimensions of heating area is analyzed according to the numerical analysis. The numerical analysis is performed by constructing 3-dimensional finite element model for 0.4mm stainless steel-sheet metal. Results of this study confirm that straightening effect changes as heating area increases and the optimum value of heating area that proves the maximum straightening effect exists.

• 한국재료학회지
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• 제29권2호
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• pp.97-105
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• 2019

In the current steel structures of high-rise buildings, high heat input welding techniques are used to improve productivity in the construction industry. Under the high heat input welding, however, the microstructures of the weld metal (WM) and heat-affected zone (HAZ) coarsen, resulting in the deterioration of impact toughness. This study focuses mainly on the effects of fine TiN precipitates dispersed in steel plates and B addition in welding materials on grain refinement of the HAZ microstructure under submerged arc welding (SAW) with a high heat input of 200 kJ/cm. The study reveals that, different from that in conventional steel, the ${\gamma}$ grain coarsening is notably retarded in the coarse grain HAZ (CGHAZ) of a newly developed steel with TiN precipitates below 70 nm in size even under the high heat input welding, and the refinement of HAZ microstructure is confirmed to have improved impact toughness. Furthermore, energy dispersive spectroscopy (EDS) and secondary-ion mass spectrometry (SIMS) analyses demonstrate that B is was identified at the interface of TiN in CGHAZ. It is likely that B atoms in the WM are diffused to CGHAZ and are segregated at the outer part of undissolved TiN, which contributes partly to a further grain refinement, and consequently, improved mechanical properties are achieved.

• 한국산학기술학회논문지
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• 제20권8호
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• pp.133-138
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• 2019

본 논문은 자동차 구조용 열간 압연 강재인 SAPH440을 GMAW 겹치기 용접을 하여 용접 변수인 용접 전류, 용접 전압, 이송 속도를 달리하여 인장 특성을 평가하였다. GMAW 공정의 접합 변수에 따라 인장 시험을 수행하기 위하여 겹치기 용접 하여 KS B ISO 9018에 따라 시험편을 제작하여 실험하였다. 각 조건에 따른 비드 외관을 관찰하였고 그에 따른 인장시험을 하여 용접성을 평가하였다. 평가 결과 용접전류가 높을수록 깊은 용입이 형성되는 것을 알 수 있었으나 인장강도 측면에서는 모재부 파단으로 인해 일정 변수 이상부터는 큰 차이는 없는 것으로 확인되었다. 용접 전류 200A, 용접 전압 17V의 조건에서와 같이 전압에 비해 전류가 높으면 다량의 스패터가 발생하며 용접이 불안정하고 이로 인해 용접부 파단이 일어나는 것을 확인 하였다. 전압이 높을수록 대체로 결함이 발생 되지 않을 정도의 비드외관을 관찰할 수 있었으며 너무 높은 전압 또한 용접성에 영향을 끼치는 것을 확인하였다. 너무 낮은 전류와 전압의 조건에서는 용접이 정상적으로 되지 않아 인장강도를 측정할 수 없었다. 그러나 용접이 가능한 용접 조건에서는 전류가 증가함에 따라 전압과 이송속도가 증가하더라도 인장강도에는 큰 영향을 미치지 않았다.

• 한국산학기술학회논문지
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• 제16권2호
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• pp.1339-1347
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• 2015

본 연구는 현장의 GMAW 용접기에 더블 와이어 릴을 겸비한 원격제어토치의 시스템에 관한 것이다. 산업현장 용접에서는 용접기 본체로부터 와이어 송급장치까지의 거리가 약 30m 떨어져 있고 송급장치로부터 토치까지의 거리는 약 3~5m 정도이다. 이에 따라 차량 및 탱크 내부의 용접에서 제어 패널을 볼 수 없는 곳이나 작업장이 먼 곳 등에서 용접사가 용접을 하면서 용접조건에 맞는 전류와 전압을 조절할 수가 없고 또한 용접와이어가 완전히 소모되면 용접을 중단하고 와이어 릴을 갈아 끼워야하는 번거로운 문제점이 있다. 이 때문에 전류와 전압 조절 및 와이어를 교체하기 위해 용접을 중단하고 잦은 이동으로 용접구조물의 순간적인 냉각에 의해 용접결함이 발생된다. 본 연구에서는 이러한 제반 문제를 감소하기 위해 기존의 GMAW 용접기의 제반기능을 토대로 간소화 및 합리화하여 더블 와이어 릴을 겸비한 원격제어토치를 자체 제작하였다. 실험은 SM50A 용접구조용 압연강재 6mm를 사용하여 와이어 더블 릴을 겸비한 원격제어 토치와 기존 $CO_2$ /MAG 용접토치를 V형 맞대기 수직자세로 용접을 실행하였다. 용접 완료 후 용접부의 표면비드 상태의 형상을 육안검사 관찰하고 또한 이를 방사선투과검사를 통해 용접부의 내부 용접품질에 대하여 용접현상을 분석하였다. 이 연구를 통해 용접결함 감소, 원가절감 및 기존 상용용접기에 교체사용에 대한 성능 및 호환성여부에 미치는 영향에 대해 평가하였다.

• 소성∙가공
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• 제17권7호
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• pp.523-527
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• 2008

In this study, mechanical properties of Alloy 718 welded after forgings for jet propulsion component was investigated. Hot-forged and machined work-pieces($230mm\times70mm\times15mm$) which have different grain sizes are welded by electron beam welding technique. After welding, the components were solution heat-treated and aged. Samples were sectioned to analyze the microstructural evolution and formation of micro-crack. It was found that HAZ grain boundary liquation crack generally initiates in the coarse grains rather than the fine grains. Needle-like phases with high Nb contents were found at the outer part near the base metal. Vickers hardness and tensile tests were carried out at room temperature and at $649^{\circ}C$. The tensile properties of electron beam welding specimens exhibited around 100MPa and 10% decrease in strength and elongation, respectively.