• Journal of Environmental Health Sciences
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• v.28 no.2
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• pp.117-129
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• 2002

Concentration of welding fumes and their components is known to be hazardous to welder and adjacent worker. To determine the generation rates of metals in fumes, $CO_2$ flux cored arc welding on stainless steel was performed in well designed fume collection chamber. Variables were different products of flux cored wire(2 domestic products and 4 foreign products) and input energy(low-, optimal- , high input energy). Mass of welding fumes was determined by gravimetric method(NIOSH 0500 method), and 17 metals were analysed by inductively coupled plasm-atomic emission spectroscopy(NIOSH 7300 method). Flux cored wire tube and flux were analysed by scanning electron microscopy to determine their metal composition. 17 metals were classified by their generation rates. Generation rates of iron, manganese, potassium and sodium were all above 50mg/min at optimal input energy level. Generation rates of chromium and amorphous silica were 25~50mg/min. At 1~25mg/min level, nickel, titanium, molybdenum, and aluminum were included. Copper, zinc, calcium, lead, magnesium, lithium, and cobalt were generated below 1 mg/min. Generation rates of metal components in fumes were influenced by input energy, types of flux cored wire. Flux cored wire was consisted of outer shell tube and inner flux. Iron, chromium, and nickel were the major components of outer tube. Flux contained iron, chromium, nickel, potassium, sodium, silica, and manganese. The use of flux cored wire can increase the hazards by increasing the amounts of fumes formed relative to that of solid wire. The reason might be the direct transfer of elements from the flux, since the flux is fine power. Ratio of metals to the fume of flux cored wire was lower than that of solid wire because non-metal components of flux were transferred. Total metal content of fumes in flux cored arc welding was 47.4(24.3~57.2) percent that is much lower than that of solid wire, 75.9 percent. We found that generation rates of iron, manganese, chromium and nickel, all well known to cause work related disease to welder, increased more rapidly with increasing input energy than those of fumes. To reduce worker exposure to fumes and hazardous component at source, further research is needed to develop new welding filler materials that decrease both the amount of fumes and hazardous components.

• Journal of the Korean Society for Precision Engineering
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• v.24 no.11
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• pp.44-51
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• 2007

Condenser tubes are mainly produced by precision extrusion with a porthole die and are used in the flow pass of refrigerant cooling systems in automobiles. The recent technical trend of condenser tube requires the tube to be of more multi cellizing, high strength and small size, and to increase the heat transfer area and heat efficiency. Hence, this paper is shown that the results of FE-simulation are in good agreement with the experimental ones. Finally, the extrusion die shape is proposed through analysis of FE-simulation and performance of trial extrusion. Chamber shape dimension and initial temperatures of die is adjusted analysis results. And the possibility of extrusion is estimated that forming load, welding pressure and stress analysis of die in this paper. The validity of simulated results was verified into extrusion experiments on the condenser tubes.

• Transactions of Materials Processing
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• v.13 no.8
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• pp.723-730
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• 2004

This paper describes the analysis of extrusion process and integrity for a condenser tube which is a component of the heat exchanger in automobile and all conditioning apparatus. Recently, according to the development of analysis method using the computer, the numerical simulation have been applied to the 3-dimensional hot extrusion process with complex section area of the non-steady statement and then results of the analysis have been applied to optimal die design and process design. In this paper, firstly, the die design was performed for a condenser tube with a multi-hole section and the rigid-plasticity FE analysis performed of extrusion process. Secondly, we estimated metal flow of billet, extrusion load, welding pressure in chamber etc. and evaluated the pressure and elastic strain of the die land and mandrel tooth profile through a stress analysis of the die. Finally, the extrusion test was performed to estimate the validity of FE analysis. This paper confirmed that the designed extrusion die of the research is satisfactorily designed fur integrity of condenser tube.

• Toxicological Research
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• v.24 no.2
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• pp.119-127
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• 2008

The objectives of this study were to examine the lung injury and inflammation caused by manual metal arc stainless steel(MMA-SS) welding fume inhalation and to evaluate the recovery process. Sprague-Dawley rats were exposed to MMA-SS welding fumes for 2 h per day in a whole-body exposure chamber, with a total suspended particulate(TSP) concentration of $51.4{\pm}2.8mg/m^3$(low dose) or $84.6{\pm}2.9mg/m^3$(high dose) for 30 days. The animals were sacrificed after 30 days of exposure as well as after a 30-day recovery period. To assess the inflammatory or injury responses, cellular and biochemical parameters as well as cytokines were assayed in the bronchoalveolar lavage fluid(BALF). MMA-SS welding fume exposure led to a significant elevation in the number of alveolar macrophages(AM) and polymorphonuclear cells(PMN). Additionary, the values of $\beta$-n-acetyl glucosaminidase($\beta$-NAG) and lactate dehydrogenase(LDH) in the BALF were increased in the exposed group when compared to controls. After 30 days of recovery from exposure, a significant reduction in inflammatory parameters of BALF was observed between the exposed and recovered groups. Slight, but significant elevations were noted in the number of AM and PMN in the recovered groups, and AM that had been ingested fume particles still remain in the lungs. In conclusion, these results indicated that welding fumes induced inflammatory responses and cytotoxicity in the lungs of exposed rats. Fume particles were not fully cleared from lungs even after a 30-day recovery period.

• Journal of Welding and Joining
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• v.27 no.3
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• pp.73-79
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• 2009

This present paper investigated the mechanical properties and the microstructures of each penetration shapes classifying the conduction shape area and the keyhole shape area about electron beam welded 120(T)mm thick plated aluminum 5052 112H. As a result the penetration depth is increased linearly according to the output power, but the aspect ratio is decreased after the regular output power. In the conduction shape area, the Heat affected zone is observed relatively wider than the keyhole shape area. In the material front surface of the welded specimen, the width is decreased but the width in the material rear surface is increased. After the measuring the Micro Vikers Hardness, it showed almost similar hardness range in all parts, and after testing the tensile strength, the ultimate tensile strength is similar to the ultimate tensile strength of the base material in all the specimens, also the fracture point was generated in the base materials of all the samples. In the result of the impact test, impact absorbed energy of the Keyhole shape area is turned up very high, and also shown up the effect about four times of fracture toughness comparing the base material. In the last result of observing the fractographs, typical ductile fraction is shown in each weld metal, and in the basic material, the dimple fraction is shown. The weld metals are shown that there are no other developments of any new chemical compound during the fastness melting and solidification.

• Transactions of Materials Processing
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• v.10 no.4
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• pp.311-318
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• 2001

Porthole die extrusion has a great advantage in the forming of long hollow section tubes. It is difficult to produce long hollow section tubes with complicated section by the conventional extrusion process with a mandrel on the stem Because of the limit of the length of mandrel and the complexity of cross section. Porthole die extrusion is affected by many parameters, such as extrusion ratio, extrusion speed, die geometry, porthole number, bearing length etc. Up to now, most of studies about porthole die extrusion have been investigated by experiments or steady state FE-analysis. However, in this paper, porthole die extrusion is analysed by the unsteady state 3D FE-simulation. And the result of unsteady state analysis is compared with the experimental result. Also, the surface state of extruded tubes are examined for the various process conditions.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.9 s.174
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• pp.49-59
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• 2005

This paper describes a development of the extrusion process and estimation of the weldability for multi cell tubes used to cooling system of automobiles. A study on extrusion process is performed through the 3D FE simulation in non-steady state and extrusion experimentation. Also, nano-indentation test is employed to estimate the weldability of tubes. Especially, An evaluation of the weldability using the nano-indentation is accomplished as compared with nano-hardness in welded part and in the others. Finally, the pattern of the mandrel defection is investigated according to shapes of the porthole and/or chamber.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.359-362
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• 2003

The bending phenomenon has been known to be occurred by the different of velocity at the die exit. The difference of velocity at the die exit section can be obtained by the different velocity of billets through the multi-hole container and by the cohesion of billet inside the porthole die chamber. The bending phenomenon can be controlled by the different hole diameter. The experiments using aluminium material for the curved tube product had been done. The results of the experiment show that the curved tube product can be formed by the extru-bending process without the defects such as the distortion of section and the thickness change of the wall of tube and the folding and wrinkling. It is known that the welding and extruding of each billet has done simultaneously although the curved tube is extruded with four billets.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.436-439
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• 2005

Condenser tube has been used as a component of heat exchanger in automobile and air conditioning apparatus. In this paper, porthole die extrusion that is advantageous to form long hollow section tube is analyzed by direct extrusion of condenser tube with 12 holes. A study on extrusion process is performed through the 3D FE simulation at non-steady state and extrusion experiments. Especially, weldability, extrusion load and die defects were estimated try FE-simulation. This study present the redesigned die of direct extrusion in consideration of the results obtained from FE-analysis.

• 제어로봇시스템학회:학술대회논문집
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• 2001.10a
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• pp.53.5-53
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• 2001

In continuous galvanizing process at steel making plant, coating weight on the surface of strip that pass through air knife is controlled by the pressure at the chamber of air knife and the gap between the nozzle of air knife and strip. The pressure can be easily measured and controlled. But it is difficult to measure the distance between Air knife nozzle and strip, and also difficult to decide how much distance air knife move. Because, the gap between nozzle and strip varies with the height of air knife, intermesh of stabilizing roll and welding of strips that have different thickness. In this research, we developed a gap sensor that can measure the relative distance between Air knife nozzle and strip. And several tests are performed to find optimal condition for application at real plant. We performed test in which the possibility of the sensor to apply ...