• Journal of Welding and Joining
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• v.28 no.5
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• pp.99-105
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• 2010

Inverter DC resistance spot welding process has been very widely used for joining such as automotive body sheet metal. Because the lobe area of DC welding is larger than AC welding and DC welding has low electrode wear. So the use of Inverter DC resistance spot welding process has been further increased. And the application of high tensile steel is growing for light weight vehicle. To improve the weldability of high strength steel, the development of Inverter DC resistance spot welding system is more conducted. However, Inverter DC resistance spot welding system has a few problems. Current waveform is unstable and the expulsion has been occurred by characteristics of steel. In this study, inverter DC resistance spot welding system was made. And Fuzzy control algorithm was applied for constant current. The genetic algorithm was applied to optimize the fuzzy scaling factors, in order to optimize the fuzzy control.

• Proceedings of the KWS Conference
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• 2007.11a
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• pp.79-81
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• 2007

• The Transactions of the Korean Institute of Power Electronics
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• v.4 no.2
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• pp.128-137
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• 1999

Recently the pelionnance of CO2 arc welding machine has been advanced significantly through the adoption of i invelter circuit topology. which made it possible to improve welding perfonnances such as spatter generation and bead s state. But the conventional inverter arc welding machine generates constant output voltage which cause much spatter g generation dUling short-circuit and arc start time because it is unable to control output current instantaneously. So this p paper representes wavefCnm controlled inverter arc welding machine which control the wavefonn of welding current and t thus to suppress the spatter generation. And the system designed in this paper is the digital controller using single chip m microprocessor of 80C196KC. As a result of perfonnance test for this system, the spatter generation is reduced and s shOlt-circuit time period is stabilized compared to conventional one. And more by using switched mode rectifier for A AC/DC power convelter. unity power factor is maintained and low order halmonic spectrum is supressed.

• Proceedings of the KIPE Conference
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• 1997.07a
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• pp.45-48
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• 1997

The low frequency pulsed MIG welding process of new current waveform control to switch over unit pulse conditions (pulse current, pulse duration) in the fixed cycle was developed and its effect were investigated for aluminium and its alloy. By using this new welding process, the bead appearance having clear ripple pattern, such as TIG welding bead can be obtained and the gap tolerance of lap and butt welding joint can be expanded.

• Journal of Welding and Joining
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• v.17 no.4
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• pp.85-92
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• 1999

In GMAW, the spatter is generated because of the variation of the arc state. If the arc state is quantitatively assessed, the control method to make the spatter be reduced is able to develop. This study was attempted to develop the optimal model that could estimate the arc state quantitatively. To do this, the generated spatters was captured under the limited welding conditions, and the waveforms of the arc voltage and of the welding current were collected. From the collected waveforms, the waveform factors and their standard deviations were produced, and the linear and non-linear regression models constituted using the factors and their standard deviations are proposed to estimate the arc state. the performance test to the proposed models was practiced. Obtained results are as follow. From the results of correlation analysis between the factors and the amount of the generated spatters, the standard deviations of the waveform factors have more the multiple regression coefficients than the waveform factors. Because the correlation coefficient between T and {TEX}$T_{a}${/TEX}, and s[T] and s[{TEX}$T_{a}${/TEX}] was nearly one, it was found that these factors have the same effect to the spatter generation. In the regression models to estimate the arc state, it was fond that the linear and the non linear models were also consisted of similar factors. In addition, the linear regression model was assessed the optimal model for estimating the arc state because the variance of data was narrow and multiple regression coefficient was highest among the models. But in the welding conditions which the amount of the generated spatters were small, it was found that the non linear regression model had better the estimation performance for the spatter generation than the linear.

• Journal of Welding and Joining
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• v.25 no.5
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• pp.64-71
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• 2007

The aim of this paper is to investigate the effects of welding parameters on the weld shape in seal-welding of STS304L capsule for manufacturing a radioisotope source which is widely used in nondestructive testing of metal structures using gamma ray. Pulsed gas tungsten arc (Pulsed GTA) welding is performed for thin cross sectional area of the capsule. Seven welding parameters including current waveform parameters and arc length etc. are selected as main process parameters using design of experiment. The weld shape such as bead width, penetration depth, weld area, aspect ratio and area rate is investigated to assess the effects of welding parameters. As results, the combination of pulse duty/welding speed largely affects on bead width, penetration depth, area and aspect ratio. Finally, it is concluded that the key parameters are the combination of pulse duty/welding speed, base current and arc length, and their optimal conditions are 50%/1.77mm/s, 6.4A and 1 mm.

• Journal of Welding and Joining
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• v.13 no.4
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• pp.75-84
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• 1995

In GMA welding of sheet metal, the short circuit metal transfer mdoe is preferred because of its low heat input and capability of bridging the root gap. The molten electrode is transferred to the workpiece during repectitive short circuit in the model. The waveform of welding current or voltage and the frequency of short circuiting are affected by a number of factors including: magnitude of welding current and voltage, root gap, electrode extension, power supply characteristics, and so on. In this study experimental models were proposed, which are able to determine the relationship between the root gap and short circuit frequency and the relationship between the root gap and appropriate welding speed that produces the good quality of back bead without burn through. Using the experimental models, the root gap can be obtained from measuring the short circuit frequency, and then the appropriate weldig speed to the root gap can be determined. Thus a back bead control system was constructed by controlling the welding speed for maintaining the quality of back bead. The developed system has shown the successful capability of back bead control.

• Proceedings of the KWS Conference
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• 2010.05a
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• pp.39-39
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• 2010

최근 자동차 산업에서는 차체의 무게를 감소시켜 연비향상과 배기가스의 양을 줄이려는 목적으로 고강도 강재의 차체 적용이 증가하고 있다. 또한 다른 여러 산업에서도 두께 감소를 통한 경량화를 위해 고강도 강재가 사용되고 있다. 고강도 강재를 자동차 차체에 적용하면서 용접성에 대한 새로운 문제가 제기 되고 있으며 그 중 자동차 생산라인에서 차체의 조립공정의 대부분을 차지하는 저항 점 용접에 대한 연구가 중요한 이슈가 되고 있다. 이러한 고강도 강재의 저항 점 용접의 문제점으로는 잦은 날림발생을 들 수 있다. 이는 강도의 증가에 따른 비저항 증가와 필요 가압력의 증가로 인해 입열에 의한 가압부의 소성변형이 쉽게 발생하기 때문이다. 이를 방지하기 위해 현재 다단가압, 다단전류제어 등의 기법들이 시도되고 있다. 본 연구에서는 저항 점 용접의 펄스전류 파형설계를 통해 고강도강 용접의 날림발생을 저감하고자 하였다. 실험소재로는 Al-Si 도금의 1.5GPa 급 강재를 사용하였고 실험조건으로는 기존 로브곡선에서 날림이 발생하는 용접조건을 사용하였다. On/Off 방식의 펄스전류를 이용하여 On/Off 시간에 따른 용접성을 평가하여 이를 기존 용접성과 비교하였다. 또한 펄스전류 파형에 따른 입열과 냉각의 변화와 날림발생에 미치는 영향을 분석하였다.

• Proceedings of the KIPE Conference
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• 2001.07a
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• pp.556-559
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• 2001

In this paper, we proposed AC/DC boost converter to improve input current harmonic reduction in SMAW(shielded metal-arc welding). The proposed harmonic reduction with the boost converter design and the UC2854 integrated circuit which controls the converter, The topology of welding power supply is made of a pair of boost converter and welder half-bridge IGBT inverter. The voltage arc is modeled by a variable resistance in series with a voltage source. The results has been confirmed by PSIM simulation tool. The simulation results show that input at current is nearly sinusoidal with low harmonic contents and sinusoidal input current waveform at high power factor.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.361-365
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• 2002

Advancements in silicon phase control (SCR) technologies provide an arc welding power supply that has the capability to allow the alteration of the Alternating Current (AC) welding output. These technologies provide a square wave output involving sixteen frequency selections and multiple balance selections. While an AC out put is known to minimize magnetic disturbances associate with Direct Current (DC), the potentials of a non-sinusoidal waveform have not been explored. The focus of the paper is to determine the effects that the frequency and balance of an AC wave form output will have upon a high speed Submerge Arc (SAW) application. The test matrix of the project includes welding .250" steel plate. Joint type is square groove with a travel speed of 65 IPM. Each of the weld parameters was held constant, only the frequency and/or balance were altered between welds. Each frequency/balance combination involved three-gap spacing. Upon completion of the welds the bead profiles were measured and recorded. A relationships/trends were observed with various frequency and balance values. Optimum frequency and balance values were found for the .250" square groove application which permit consistent weld sizing, ease of slag removal, and minimal plate distortion.