• Journal of Welding and Joining
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• v.34 no.3
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• pp.6-11
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• 2016

Joining Al/Fe dissimilar metals is becoming a subject of special interest in the assembly of automotive parts as a trade-off between the weight lightening and the cost reduction. Although various studies have been introduced to join Al alloy with the steel sheet by fusion welding, weak joint strength and galvanic corrosion still remained as problems to be solved. As a solid state welding, friction stir welding has been preferred to fusion welding processes in the dissimilar metal joints. This study investigated friction stir spot welding (FSSW) of Al alloy to the thin steel sheet with a thickness of 0.65 mm. The conventional FSSW is a stationary spot welding process but new approach adopted an additional circumferential movement in company with high speed tool rotation. A full factorial experimental design was implemented, and the main and interaction effects of parameters were analysed on the failure load in the tensile shear test. The direction and radius of rotation were statistically significant parameters and these two parameters affected the joint width and the shape of the hook.

• Journal of Power System Engineering
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• v.17 no.4
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• pp.64-71
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• 2013

In this paper, finite element method was used for flow and strength analysis of AZ31 magnesium alloy under friction stir welding. The simulations were carried out by SYSWELD s/w, and the modeling of sheet was doned by unigraphics NX3 s/w. Welding variables for analysis were rotating speed and welding speed of tool. Also two-way factorial design method was applied to confirm the effect of welding variables on maximum temperature and stress of material used. From these results, the increaser welding speed of tool the decreaser maximum temperature, but the increaser maximum stress. Also the increaser rotating speed of tool the increaser maximum temperature, but the decreaser maximum stress. In addition the increaser welding speed of tool and the decreaser rotating speed of tool, the narrower heat effect zone. Finally rotating speed of tool influenced on maximum temperature more than welding speed of tool, and welding speed of tool influenced on maximum stress more than rotating speed of tool from the variance analysis.

• Journal of the Korean Society of Propulsion Engineers
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• v.11 no.3
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• pp.7-12
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• 2007

Friction welding is a welding method to use frictional heat of a couple of materials. In this paper object is that design the welding part shape with the flow gallery part which there is no effect in flow. Decided the welding part design parameter and doing the friction welding analysis used the rigid-plastic FEM program DEFORM-2D. To do friction welding analysis must input necessary flow stress data, friction coefficient by temperature change, upset pressure and Revolution per minute etc. According to analysis result, it decided the optimal shape of welding part with no effect in flow.

• Journal of Welding and Joining
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• v.26 no.2
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• pp.85-91
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• 2008

In general, the quality of a welding process tends to vary with depending on the work environment or external disturbances. Hence, in order to achieve the desirable quality of welding, we should have the optimal welding condition that is not significantly affected by these changes in the environment or external disturbances. In this study, we used a dual response surface method in consideration of both the mean output variables and the standard deviation in order to optimize the V-groove arc welding process. The input variables for GMA welding process with the dual response surface are welding voltage, welding current and welding speed. The output variables are the welding quality function using the shape factor of bead geometry. First, we performed welding experiment on the interested area according to the central composite design. From the results obtained, we derived the regression model on the mean and standard deviation between the input and output variables of the welding process and then obtained the dual response surface. Finally, using the grid search method, we obtained the input variables that minimize the object function which led to the optimal V-groove arc welding process.

• Journal of Welding and Joining
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• v.33 no.2
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• pp.23-31
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• 2015

Stainless steel is used in automobile muffler and exhaust systems. However, in comparison with other steels it has a high thermal expansion rate and low thermal conductivity, and undergoes excessive thermal deformation after welding. To address this problem, we evaluated the use of arc brazing in place of welding for the processing of an exhaust system, and investigated the parameters that affect the joint characteristics. Muffler parts STS439 and hot-dipped Al coated steel were used as test specimens, and CuAl brazing wire was used as the filler metal for the cold metal transfer (CMT) welding machine, which is a low heat input arc welder. In addition, a Box-Behnken design of experiment was used, which is a response surface methodology. The main process parameters (current, speed, and torch angle) were used to determine the appropriate welding quality and the mechanical properties of the brazing part was evaluated at the optimal welding condition. The optimal processing condition for arc brazing was 135A current, 51cm/min speed and $74^{\circ}$ torch angle. The process was applied to an actual exhaust system muffler and the prototype was validated by thermal fatigue, thermal shock, and endurance limit tests.

• Journal of Computational Design and Engineering
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• v.1 no.4
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• pp.243-255
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• 2014

The present study describes the development of control hardware and software for a mobile welding robot. This robot is able to move and perform welding tasks in a double hull structure. The control hardware consists of a main controller and a welding machine controller. Control software consists of four layers. Each layer consists of modules. Suitable combinations of modules enable the control software to perform the required tasks. Control software is developed using C programming under QNX operating system. For the modularizing architecture of control software, we designed control software with four layers: Task Manager, Task Planner, Actions for Task, and Task Executer. The embedded controller and control software was applied to the mobile welding robot for successful execution of the required tasks. For evaluate this imbedded controller and control software, the field tests are conducted, it is confirmed that the developed imbedded controller of mobile welding robot for shipyard is well designed and implemented.

• Journal of Welding and Joining
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• v.27 no.5
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• pp.81-87
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• 2009

Recently, extruded aluminium-alloy panels have been used in the car bodies for the purpose of the light-weight of railway vehicles and FSW(Friction Stir Welding), which is superior to the arc weldings, has been applied in the railway vehicles. This paper presents the optimum design of the FSW process on A6005 extruded alloy for railway vehicles to improve its mechanical properties. Rotational speed, welding speed and tilting angle of the tool tip were chosen as design parameters. Three objective functions were determined; maximizing the tensile strength, minimizing the hardness and maximizing the difference between the normalized tensile strength and hardness. The tensile tests and the hardness tests for fifteen FSW experiments were carried out according to the central composite design table. Recursive model functions on three characteristic values, such as the tensile strength, the hardness difference(${\Delta}Hv$) and the difference of normalized tensile strength and ${\Delta}Hv$, were estimated according to the classical response surface analysis methodology. The reliability of each recursive function was verified by F-test using the analysis of variance table. Sensitivity analysis on each characteristic value was done. Finally, the optimum values of three design parameters were found using Sequential Quadratic Programming algorithm.

• International Journal of Korean Welding Society
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• v.1 no.1
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• pp.44-50
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• 2001

A genetic algorithm was applied to the arc welding process as to determine the near-optimal settings of welding process parameters that produce the good weld quality. This method searches for optimal settings of welding parameters through the systematic experiments without the need for a model between the input and output variables. It has an advantage of being capable to find the optimal conditions with a fewer number of experiments rather than conventional full factorial designs. A genetic algorithm was applied to the optimization of the weld bead geometry. In the optimization problem, the input variables were wire feed rate, welding voltage, and welding speed. The output variables were the bead height bead width, and penetration. The number of levels for each input variable is 16, 16, and 8, respectively. Therefore, according to the conventional full factorial design, in order to find the optimal welding conditions,2048 experiments must be performed. The genetic algorithm, however, found the near optimal welding conditions in less than 40 experiments.

• Proceedings of the KSME Conference
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• 2003.11a
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• pp.1425-1429
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• 2003

In this study, when structure which is combined by welding is receiving internal pressure, finite element analysis to confirm stability of structure and reliability of welding part is achieved. And we analyze the results. Also, if stability of the structure and reliability of the welding part are not defined, research that look for method to change design to receive stability and reliability is achieved.

• Journal of Welding and Joining
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• v.19 no.4
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• pp.391-398
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• 2001

MIAB welding method uses a rotating arc as its heat source and is known to be efficient in pipe butt welding. The arc is rotated around the weld line by the electro-magnetic force resulting from the interaction of arc current and magnetic field. This paper is concerned with the experiment of initial stage for process control, monitoring for weld quality, and the design of coil system which is efficient of flux generation and concentration. A coil system for the generation of magnetic flux was designed and constructed. Magnetic flux density and arc rotating behavior are important factors in MIAB welding, so the relations between these factors and process parameters were investigated. Various experiments were performed for the steel pipes(48.1mm O.D and 2.0mm thickness). The magnetic flux density is increased by increasing exciting current and decreasing gap size. The maximum of arc rotating frequency is affected by exciting current and gap size. However, the variations of arc rotating frequency during welding and then the melting process are mainly influenced by welding current. Thus, it is considered that the results of this study can be used as important data on the monitoring for weld quality and the design of efficient coil system.