• Journal of Welding and Joining
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• v.28 no.5
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• pp.75-79
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• 2010

The Remote welding system(RWS) using $CO_2$ laser equipment has focusable distance of laser beam longer than 800 mm from workpiece and can deflect the laser beam by the scanner mirrors very rapidly. In the case of normal welding system based on robot, there is a limit to move the shortest path in short time and this causes interference between robot and workpiece. On the other hand, RWS is the optimized equipment to get big merits with advanced sequence of welding and short cycle time. However, there is still a pending task such as the control of plasma in the welding process of thick sheets therefore, it requires high power laser beam because of the absence of assist gas equipment in itself. In this study, high-tensile steel plates were overlap welded with $CO_2$ RWS for the production of car body and the influence of penetration depth according to the existence of assist gas was analyzed. Excellent tensile strength with enough width of molten zone independent to penetration depth was observed under welding condition with 3.6 kW laser power and 2.8 m/min welding speed without assist gas. Finally, the proto-type automotive parts were produced by applying the deduced optimal welding condition.

• Journal of Welding and Joining
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• v.25 no.1
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• pp.49-56
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• 2007

Prediction and control of the thermal distortion is particularly important for the design and manufacture of welded thin plate panel. In this study, experiments and computations are performed to analyze effect of a hole configuration and a specimen size on distortion. In addition, this study aims to develop a thermal elasto-plastic simulation using finite element method to predict distortion, with particular emphasis on buckling deformation generated in plates welded around hole. From the experiments, the severe distortion appeared in the weldments by the laser welding process, in which the specimen size plays an important role on the distortion but the hole configuration showed little effect. And the results of numerical analysis were corresponded well with the experiment ones. Thus, a thermal elasto-plastic analysis model for predicting the weld distortion of thin plate panel was successfully developed through this study.

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

• Journal of Welding and Joining
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• v.28 no.5
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• pp.51-57
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• 2010

Brittle microstructure created in a heat affected zone (HAZ) during the welding of low alloy steel can be eliminated by post-weld heat treatment (PWHT). If the PWHT is not possible during a repair welding, the controlled bead depositions of multi-pass welding should be applied to obtain tempering effect on the HAZ without PWHT. In order to anticipate and control the tempering effect during the temper bead welding, the definition of temperature curve obtained from the analytical solution was suggested in this research. Because the analytical solution for heat flow is expressed as a mathematical equation of weld parameters, it may be effective in anticipating the effect of each weld parameter on the tempering in HAZ during the successive bead depositions. The reheating effect by the successive bead layer on the brittle coarse grained HAZ formed by earlier bead deposition was estimated by comparing the overlapped distance between the temperature curves in the HAZ. Three layered weld specimens of SA508 base metal with A52 filler were prepared by controlling heat input ratio between layers. The tempering effect anticipated by using the overlapped distance between the temperature curves was verified by measuring the micro-hardness distribution in the HAZ of prepared specimens. The temperature curve obtained from analytical solution was expected as a good tool to find optimal temper bead welding conditions.

• Journal of Welding and Joining
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• v.21 no.4
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• pp.56-62
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• 2003

MIG brazing is used for many parts without melting base metal because of high productivity. Pulsed MIG brazing can be used to further reduce heat input and to improve the process stability. However, a significant amount of zinc in galvanized sheet steel is burned off in the area of brazes. Therefore, the brazing method to reduce the heat input is needed. In the brazing for galvanized sheet steel, variable polarity AC pulse MIG arc brazing can be applied to more decrease the heat input by setting EN-ratio adequately. In this research, we studied for the variable polarity AC pulse MIG arc brazing to decrease the heat input by using ERCuSi-A wire. As the result of increasing EN-ratio, melting ratio of base metal and burning off of zinc were reduced in galvanized sheet steel.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.1105-1109
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• 1995

A CCD-camera, which is structured with vision system, was used to realize automatic seam-tracking system and 3-D information which is needed to generate torch path, was obtained by using laser-slip beam. To extract laser strip and obtain welding-specific point, Adaptive Hough-transformation was used. Although the basic Hough transformation takes too much time to process image on line, it has a tendency to be robust to the noises as like spatter. For that reson, it was complemented with Adaptive Hough transformation to have an on-line processing ability for scanning a welding-specific point. the dead zone,where the sensing of weld line is impossible, is eliminated by rotating the camera with its rotating axis centered at welding torch. The camera angle is controlled so as to get the minimum image data for the sensing of weld line, hence the image processing time is reduced. The fuzzy controller is adapted to control the camera angle.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.3
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• pp.243-251
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• 2015

In order to develop an automatic system for welding thin steel plates with curvature such as the corrugated membranes of an LNG storage tank, a rotating mechanism should be firstly designed for the torch to easily follow the weld seam with a constant distance and angle. In this study, a torch rotating mechanism consisting of three circular links, two square-type links and a torch link was proposed for automation of the welding process. A weld-seam tracking system with two axis slides and the proposed rotating mechanism was successfully simulated with a dynamic simulation software. A prototype tracking system was manufactured and a tracking test with the system was then carried out. The test results with tracking system showed that the rotating mechanism could be implemented and it was feasible to be used in automatic tracking of weld seam with curvature.

• Proceedings of the KWS Conference
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• 1998.05a
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• pp.150-154
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• 1998

The purpose of this paper is to investigate optimum welding conditions of STS 304 thin sheet by GTA welding and control 6 $\delta$--fenite which is harmful in mechanical processing, corrosion problem and can be formed brittle a phase in using long term at high temperature. One series of automatic welds was made using argon plus 10, 20, 30 % nitrogen to ensure a fully austenite deposit. Results obtained were summarized as follows: 1) 6 $\sigma$ferrite content in the weld metals is influenced largely by the nitrogen content. 2) Additions of nitrogen to the shielding gas can significantly reduce the amount of retained delta ferrite and result in an increase in hot cracking. 3) Bead width was increased when Ar + $N_2$ shielding gas was used and travel speed was increased. 4) Ar+$N_2$ shielding gas made weld metal ductile and reduce 6 -$\delta$-ferrite.

• Journal of Welding and Joining
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• v.30 no.5
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• pp.27-33
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• 2012

Friction stir processing (FSP), developed based on the basic principles of friction stir welding(FSW), a solid-state joining process originally developed for various metal alloys, is an emergingmetalworking technique that can provide localized modification and control of microstructures in near-surface layers of processed metallic components. The FSP causes intense plastic deformation, material mixing, and thermal exposure, resulting in significant microstructural refinement, densification, and homogeneity of the processed zone. The FSP technique has been successfully used for producing the fine-grained structure and surface composite, modifying the microstructure of materials, and synthesizing the composite and intermetallic compound in situ. In this review article, the current state of the understanding and development of FSP is addressed.

• 제어로봇시스템학회:학술대회논문집
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• 1993.10a
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• pp.672-678
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• 1993

The bead shape in high frequency electric resistance (HER) pipe welding gives important information ons judging current welding state. In most manufacturing process, the heat input is controlled by skilled operators observing color and bead shape. We proposed the bead shape monitoring system in HERW pipe process by using structured light beam. We reconstructs 3-D shape of bead from the measured data, and compare this shape with real 3-D shape obtained by coordinate-measuring machine. This experiment results show that the proposed system can monitor the bead shape with good accuracy.