• Journal of Welding and Joining
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• 제19권6호
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• pp.622-629
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• 2001

The aim of this experiment is to establish the method that obtains symmetrically two nuggets in microresistance series spot welding. The sheets of austenite stainless steel STS304 applied to various electronic parts were experimented by the inverter welding power source of polarity controllable type and by the twin head for left and right electrode force to be controlled separately. The experimental results were obtained as follows : 1) When series spot welding was carried out by DC 1 pulse as welding current with same electrode force at left and right, the asymmetry of nuggets was resulted from the larger nugget of the (-) pole because of the Peltier effect. The dynamic resistance of weld spot at left and right was appeared differently according to the growth of nuggets. 2) When AC 1 cycle by welding power source of polarity controllable type was applied, the nuggets were almost symmetrically formed. 3) In a twin head, if the electrode force of (-) pole was larger than that of (+) pole, the diameters of two nuggets became to same. It was confirmed that the dynamic resistance of (-) pole was decreased to the same level as it of (+) pole. 4) Although the forces of left and right electrode were same, and only DC 1 pulse was applied, symmetric nuggets were obtained if the conductivity of (+) pole was lower than it of (-) pole.

• International Journal of Korean Welding Society
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• 제1권1호
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• pp.23-30
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• 2001

Among the various welding conditions, the welding current that is inversely proportional to the tip-to-work-piece distance is an essential parameter as to monitor the GMAW process and to implement the welding automation. Considering the weld pool surface geometry including weld defects, it should modify the signal processing method for automatic seam tracking in horizontal fillet welding. To meet the above necessities, a mathematical model related with the weld pool geometry was proposed as in a conjunction with the two-dimensional heat flow analysis of the horizontal fillet welding. The signal processing method based on the artificial neural network (Adaptive Resonance Theory) was proposed for discriminating the sound weld pool surface from that with the weld defects. The reliability of the numerical model and the signal processing method proposed were evaluated through the experiments of which showed that they are effective for predicting the weld bead shape with or without the weld defects in a horizontal fillet welding.

• 대한기계학회논문집
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• 제7권3호
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• pp.263-269
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• 1983

Underwater welding by a gravity arc welding process was investigated by using six types of coated electrodes and SM41A steel plates of 10 mm thickness as base metal and it was ascertained that this process may be put to practical use. Main results obtained are summarized as follows: 1. Angle of electrode affects no influence on bead appearance and the proper range of welding current and diameter of electrode for the high titanium oxide type is relatively wider than that for the ilmenite type. And the lime titania type, high titanium oxide type and ilmenite type of domestic coated arc welding electrodes of .phi.4 mm could attain the soundest underwater welded joints which contain no welding imperfection. 2. According to macro-structure, micro-structure and hardness distribution inspectionson underwater welded joint, the area between the HAZ and the surface of the weld in neighbourhood of the bond has the maximum hardness value. The structure of these parts is martensite and bainite. Other parts contain mocro-ferrite, micro-pearlite structure, which contain soundness of welded joint free from weld imperfection. 3. On consideration of both tensile strength of more than 100% joint efficiency and sufficient impact value, the welding condition which can get optimal welding strength is heat input of 1,400-1,500 J/mm, current of 200-215 ampere (voltage of 32-33 volts) in the case of lime titania type electrode. 4. Underwater welding strength (tensile strength, impact strength) depends on heat input (or current) quantitatively and they have the relationship of parabolic function. Each experimental equation has a high reliability and its percent of mean error is 4.14%. 5. It is suggested that the optimal design of weld strength by welding condition (current, heat input) could be utilized for a quality control of underwater welding.

• 소성∙가공
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• 제28권3호
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• pp.135-144
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• 2019

Electromagnetic impulse welding (EMIW) is a type of solid state welding using the Lorentz force generated by interaction between the magnetic field of the coil and the current induced in the workpiece. Although many experimental studies have been investigated on the expansion and compression welding of tube using the EMIW process, studies on the EMIW process of lap joint between flat sheets are uncommon. Since the magnetic field enveloped inside the tube can be controlled with ease, the electromagnetic technique has been widely used for tube welding. Conversely, it is difficult to control the magnetic field in the flat sheet welding so as to obtain the required welding velocity. The current study analyzed the effects of coil shape on the impulse velocity for suitable flat one-turn coil for the EMIW of the flat sheets. The finite element (FE) multi-physics simulation involving magnetic and structural field of EMIW were conducted with the commercial software LS-DYNA to evaluate the several shape variables, viz., influence of various widths, thicknesses, gaps and standoff distances of the flat one-turn coil on the impulse velocity. To obtain maximum impulse velocity, the flat one-turn coil was designed based on the FE simulation results. The experiments were performed using an aluminum alloy 1050 sheets of 1.0mm thickness using the designed flat one-turn coil. Through the microscopic interfacial analysis of the welded specimens, the interfacial connectivity was observed to have no defects. In addition, the single lap joint tests were performed to evaluate the welding strength, and a fracture occurred in the base material. As a result, a flat one-turn coil was successfully designed to guarantee welding with bond strength equal to or greater than the base material strength.

• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2002년도 Proceedings of the International Welding/Joining Conference-Korea
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• pp.193-198
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• 2002

In 1his paper, applicability of laser welding to joining process of single crystal nickel base superalloy turbine blades was investigated. Because heat input of laser welding is more precisely controlled 1han TIG welding, it is possible to optimize solidification microstructure of the welds. Since in single crystal nickel base superalloy the crystal orientation have a significant effect on the strength, it is important to control the solidification microstructure in the fusion zone. A single crystal nickel base supera1loy, CMSX-4, plates were bead-on welded and butt welded using a $CO_2$ laser. The effects of microstructure and crystal orientation on properties of the weld joints were investigated. In bead-on weldling, welding directions were deviated from the base metal [100] direction by 0, 5, 15 and 30 degrees. The welds with deviation angles of 15 and 30 degrees showed fusion zone transverse cracks. As the deviation angles became larger, the fusion zone had more cracking. In the cross section microstructure, the fusion zone grains in 0 and 5 degrees welds grew epitaxially from the base metal spins except for the bead neck regions. The grains in the bead neck regions contained stray crystals. As deviation angles increased, number of the stray crystals increased. In butt welding, the declinations of the crystal orientation of the two base metals varied 0, 5 and 10 degrees. All beads had no cracks. In the 5 degrees bead, the cross section and surface microstructures showed that the fusion zone grains grew epitaxially from the base metal grains. However, the 10 degrees bead, the bead cross section and surface contained the stray crystals in the center of the welds. Orientations of the stray crystals accorded with the heat flow directions in the weld pool. When the welding direction was deviated from the base metal [100] direction, cracks appeared in the area including the stray crystals. The cracks developed along the grain boundaries of the stray crystals with high angles in the final solidification regions at the center of the welds. The fracture surfaces were covered with liquid film. The cracks, therefore, found to be solidification cracks due to the presence of low melting eutectic. As the results, in both bead-on welding and butt welding the deviation angles should be control within 5 degrees for preventing the fusion zone cracks. To investigate the mechanical properties of the weld joints, high temperature tensile tests for bead-on welds with deviation angles of 0 and 5 degrees and the butt welds with dec1ination angles of 0, 5 and 10 degrees were conducted at 1123K. The the tensile strength of all weld joints were more 1han 800MPa that is almost 80% of the tensile strength of the base metal. The strength of the laser weld joints were more than twice that of tue TIG weld joints with a filler metal of Inconel 625. The results reveals 1hat laser welding is more effective joining process for single crystal nickelbase superalloy turbine blades 1han TIG welding.

• 한국강구조학회 논문집
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• 제24권6호
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• pp.693-700
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• 2012

본 논문에서는 서로 다른 용접방법 및 용접재료를 사용하여 제작한 강구조물 용접부 및 열영향부에 대하여 샤르피 충격시험 (Charpy Impact Test) 및 조직검사를 통한 저온에서의 충격인성 평가를 실시하여, 극지 및 시베리아와 같은 저온환경에 노출된 강구조물 용접 접합부의 충격인성을 확보할 수 있는 용접방안에 대한 연구를 수행하였다. 사용된 용접방법은 강구조물 제작시 널리 쓰이는 SMAW (Shielded Metal Arc Welding)와 FCAW (Flux Cored Arc Welding)이며, 각 용접방법에 따른 저온강용 용접봉을 사용하여 시험판을 제작하였다. 서로 다른 용접방법으로 제작된 시험판의 용접부 및 열영향부에 대하여 샤르피 충격시험을 통한 저온에서의 충격흡수에너지 값과 미세조직 분석을 통하여 용접방법에 따른 구조용강 용접 접합부의 저온 충격인성을 평가하였다. 시험결과 극한지에 강구조물을 적용하기 위해서는 저입열 용접인 SMAW 용접방법 및 그에 따른 저온강용 용접봉을 사용하는 것이 충격인성 확보 측면에서 유리하다는 것을 알 수 있었다.

• Journal of Welding and Joining
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• 제8권3호
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• pp.60-69
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• 1990

Plasma arc cutting is a fusion cutting process in which a gas-constricted arc is employed to produce a high-temperature, high-velocity plasma jet on the workpiece. This process provides some advantages such as increased cutting velocity, excellent working accuracy and the ability to cut special materials (widely used stainless steels and Al-alloys, for example), when compared with iconventional oxyfuel gas cutting. From the view point of price and reliability of the power source, plasma arc cutting has also some distinct advantages over laser beam cutting. High-speed machines with NC or CNC systems are needed for the plasma arc or laser beam cutting process, while for oxyfuel gas cutting, low-speed machines with copying templates or optical-shape tracking sensors can be applied. The low price and high flexibility of the microprocessor arc contributing more and more the application of CNC system in the plasma arc cutting process, as in other manufacturing fields. From these points of view, a microprocessor-based plasma arc cutting system was developed by using a reference-pulse system, and its performance was tested. The interpolating routines were programmed in the assembly language for saving the memory volume and improving the compouting speed, which has an intimate relationship with the available cutting velocity.

• 전력전자학회논문지
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• 제5권4호
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• pp.358-369
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• 2000

얇은 판형 용접에 광범위하게 사용되는 피복아크 용접기는 용접전원으로 변압기를 사용하는 AC 아크용접기외 인버터를 사용하는 인버터 아크 용접기로 구분된다. AC아크용접기는 변압기를 사용하므로 전체시스템의 부피 및 무게가 커지며 변압기 탭조정으로 인한 최적 출력전압이 설정되지 않아 용접성는이 저하되는 단침이 있다. 이러한 단점올 개선히고 용접성능을 향상시키기 위하여 고속반도체 소자를 이용한 인버터 아크용접기가 많이 연구되고 있다. 인버터 피복아크 용집기시스템은 다이오드 정류기, 인버터, 고주파 변압기, 출력측 정류기 및 리엑터로 구성되어져 있는데, 입력전원측에 다아오두 정류기를 사용함으로서 고조파 다량 힘유 및 입력역률 저하등을 가져오며, 일정 듀티를 갖는 정전압제어방식을 이용하고 아크용접시스템 고유의 정전류특성은 변압기의 누설구조애 의해 실현하고 았다. 따라서 본 논문에서든 이상의 단점을 해결하기 위하여 PWM 컨버터를 적용하여 입력측의 고조파를 제거하고 입력역률 99% 유지할 수 있었으며, 또한 새로운 혼형제어기법을 적용하여 순시적인 용접 출력전압과 전류를 제어하여 용접 출럭전압과 전류를 일정하게 유지시킴으로서 AC아크용접기와 비교하여 스패터룹 70%감소시켰으며 무부하시 10%의 효율 상승을 가져왔다.

• 조명전기설비학회논문지
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• 제12권3호
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• pp.22-28
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• 1998

우리 나라 안경테 제조 산업은 대부분의 부품 조립과 용접 과정이 작업의 부정확성과 인력수급의 부족으로 자동화가 요구되고 있다. 이에 본 연구에서는 안경테의 Rim과 Lock의 전기 용접과정을 자통화하기 위해 Rim-Lock 전기 용접기를 설계하였다.Rim-Lock 전기 용접기는 Lock올 공급하기 위한 원형공급기와 직 진공급기. Rim과 Lock을 용접하기 위한 holder. 은납 공급장치 퉁으로 구성되고 주 컨트롤러는 확장성이 좋은 V55 마이크로 프로세서를 사용하였다. 제어프로그램은 C언어를 이용하였으며, 코딩과 프로그랭의 수정 및 보완이 편리하다. 본 연구에서 개발된 Rim-Lock 전기 용접기를 이용한 실제 용접시 Rim-Lock의 모양이 항상 일정하였고 계속적인 작업이 가능하므로 생산력이 향상된다.

• Journal of Welding and Joining
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• 제29권6호
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• pp.77-81
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• 2011

In most industry, manual GTAW welding is preferred for formation of stable back bead in root weld of butt joint. However, manual GTAW welding has low productivity as compared with GMAW, also it has unstable bead quality which depend on skilled workers. So it is necessary to develop process of root pass welding by using automation GMAW that have stable back bead formation and high productivity. In this paper, the design of U-groove with 3mm root face was applied to extend the tolerance of misalignment in condition of standard root gap 1.5mm. Consequently, for the formation of stable back bead in root pass of butt welding, in case of the narrow root gap(0.5mm) the large arc force was applied by increasing the current and voltage. In case of the large root gap(2.5mm), the small arc force was applied by decreasing the current and voltage. Considering the various root gap, the required deposited metal was controlled by welding speed only.