• Journal of Advanced Marine Engineering and Technology
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• v.29 no.8
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• pp.891-898
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• 2005

Inertia welding is a solid-state welding process in which butt welds in materials are made in bar and in ring form at the joint race, and energy required lot welding is obtained from a rotating flywheel. The stored energy is converted to frictional heat at the interface under axial load. The quality of the welded joint depends on many parameters, including axial force, initial revolution speed and energy amount of upset. working time, and residual stresses in the joint. Inertia welding was conducted to make the large exhaust valve spindle for low speed marine diesel engine. superalloy Nimonic 80A for valve head of 540mm and high alloy SNCrW for valve stem of 115mm. Due to different material characteristics such as, thermal conductivity and flow stress. on the two sides of the weld interface, modeling is crucial in determining the optimal weld geometry and Parameters. FE simulation was performed by the commercial code DEFORM-2D. A good agreement between the Predicted and actual welded shape is observed. It is expected that modeling will significantly reduce the number of experimental trials needed to determine the weld parameters. especially for welds for which are very expensive materials or large shaft. Many kinds of tests, including macro and microstructure observation, chemical composition tensile , hardness and fatigue test , are conducted to evaluate the qualify of welded joints. Based on the results of the tests it can be concluded that the inertia welding joints of the superalloy exhaust valve spindle are better properties than the material specification of SNCrW.

• Journal of the Korean Society for Nondestructive Testing
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• v.24 no.2
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• pp.158-162
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• 2004

Reliability of welded structures in power plant facilities is very important, and their reliability evaluation requires exact materials properties. But, the conventional PQR (Procedure Qualification Record) can hardly reflect the real material properties in the field because the test is only done on specimens with simulated welding. Therefore, a continuous indentation technique is proposed in this study for simple and non-destructive testing of in-field structures. This test measures the indentation load-depth curve during indentation and analyzes the mechanical properties such as the yield strength, tensile strength and work hardening index. This technique has been applied to evaluate the tensile properties of the weldment in the main steam pipe and hot reheater pipe in power plants under construction and in operation.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.266-272
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• 2002

This study reviews the factors controlling the weld metal cracking and shows the difference from those of HAZ cracking. It further reviews the recent progresses made in consumable design for improving the crack resistance in the high strength weld metal. Previously the controlling factors for weld metal cracking were regarded as weld metal strength, diffusible hydrogen and weld metal height. However an overall review presented in this article shows that the cold crack resistance can be improve significantly through the microstructural control and that an increase in tensile strength is not necessarily related to a decrease in the resistance to cold cracking.

• Proceedings of the KWS Conference
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• 2010.05a
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• pp.51-51
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• 2010

Recently just as in the automobile industry, shipbuilders also try to reduce material consumption and weight in order to keep operating costs as low as possible and improve the speed of production. Naturally industry is ever searching for welding techniques offering higher power, higher productivity and a better quality. Therefore it is important to have a details research based on the various welding process applied to steel and other materials, and to have the ability both to counsel interested companies and to evaluate the feasibility of implementation of this process. Submerged-arc welding (SAW) process is usually used about 20% of shipbuilding. Similar to gas metal arc welding(GMAW), SAW involves formation of an arc between a continuously-fed bare wire electrode and the work-piece. The process uses a flux to generate protective gases and slag, and to add alloying elements to the weld pool and a shielding gas is not required. Prior to welding, a thin layer of flux powder is placed on the work-piece surface. The arc moves along the joint line and as it does so, excess flux is recycled via a hopper. Remaining fused slag layers can be easily removed after welding. As the arc is completely covered by the flux layer, heat loss is extremely low. This produces a thermal efficiency as high as 60% (compared with 25% for manual metal arc). SAW process offers many advantages compared to conventional CO2 welding process. The main advantages of SAW are higher welding speed, facility of workers, less deformation and better than bead shape & strength of welded joint because there is no visible arc light, welding is spatter-free, fully-mechanized or automatic process, high travel speed, and depth of penetration and chemical composition of the deposited weld metal. However it is difficult to application of thin plate according to high heat input. So this paper has been focused on application of the field according to SAW process for thin plate in ship-structures. For this purpose, It has been decided to optimized welding condition by experiments, relationship between welding parameters and bead shapes, mechanical test such as tensile and bending. Also finite element(FE) based numerical comparison of thermal history and welding residual stress in A-grade 3.2 thickness steel of SAW been made in this study. From the result of this study, It makes substantial saving of time and manufacturing cost and raises the quality of product.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.3
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• pp.387-395
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• 2013

Recently, several circumferential cracks were found in the control rod drive mechanism (CRDM) nozzles of U.S. nuclear power plants. According to the accident analyses, coolant leaks were caused by primary water stress corrosion cracking (PWSCC). The tensile residual stresses caused by welding, corrosion sensitive materials, and boric acid solution cause PWSCC. Therefore, an exact estimation of the residual stress is important for reliable operation. In this study, finite element simulations were conducted to investigate the effects of the tube geometry (thickness and radius) on the residual stresses in a J-groove weld for different CRDM tube locations. Two different tube locations were considered (center-hole and steepest side hill tube), and the tube radius and thickness variables ($r_o/t$=2, 3, 4) included two different reference values ($r_o$=51.6, t=16.9mm).

• Transactions of the Korean Society of Mechanical Engineers A
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• v.41 no.4
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• pp.263-270
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• 2017

The shipbuilding industry uses large stationary tanks to store low-pressure air, which is used to open and close large shut-off valves. However, when supplying air from the tank to a distant valve, there are problems related to the need for supplementary pipes and the pressure drop during transportation. In this study, a portable welded vessel for storing high-pressure nitrogen (11 kg, 10 L, and 50 bar) was designed to prevent air leakage and improve the convenience of workers. This pressure vessel was elliptical to reduce the number of welded parts, which are structurally weak. The thickness and ratio of the major and minor axes of the pressure vessel were calculated to verify its structure stability at the working pressure (50 bar), and that the proposed weight and capacity were satisfactory. The residual stress caused by the welding process was calculated by performing a transient thermal-structural coupled field analysis using the ANSYS parametric design language (APDL), and the fatigue life of the vessel was verified based on the Goodman criterion.

• Journal of the Society of Naval Architects of Korea
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• v.38 no.1
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• pp.99-107
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• 2001

Manufacture of fishing vessel is needed the effective material for light, strength, fire and corrosion of water in order to improve durability by high-speed and fishing. These fishing vessel can be divided into FRP and AI alloys fishing vessel. FRP fishing vessel is light and effective for strength but highly ignited and susceptible to heat during the manufacturing ship by-produce noxious component for human. In the case of a scrapped ship, it cause environmental pollution. On the other hand, aluminum is a material in return for FRP and has merit of high-strength and lightness. It's more heat proof and durable than FRP and superior to prevent from corrosion. Al alloys fishing vessel development is rising as an urgent matter. But, al alloy has some defect of bad weldability, welding transformation, cracks and overcost of construction. Therefore this study is to develop the new welding joint shape solving aluminum defects and mechanical behavior. First of all, strength was compared and reviewed by analysis of plate, stiffen plate, new model simplified by using plate theory. On the base of this result, plate and new model of temperature distribution, weld residual stress and strength of tensile, compressive force were compared and reviewed by finite element computer program has been developed to deal with heat conduction and thermal elasto plastic problem. Also, new model is proved application possibility and excellent mechanic by strength comparison is established to tensile testing result.