• Journal of Welding and Joining
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• v.33 no.1
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• pp.61-71
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• 2015

The effect of welding condition on microstructure and mechanical property of Plasma-MIG Hybrid Weld between Al 5083 plates(thickness : 10mm) was investigated. 1 pass weld without any defects such as puckering, undercut, and lack of fusion was obtained by 150~200A of plasma current and 5~7mm of welding speed. Gas porosities and shrinkage porosities were existed in the weld near fusion line. As welding speed and plasma current were decreasing, the area fraction of porosity was increasing. The hardness of the weld is increasing as welding speed. On the basis of microstructural analysis, Mg segregated region near dendrite boundaries tends to increase with the welding speed. In the result of hardness test, Distribution of hardness in fusion zone showed little change with the plasma current. However, when the welding speed increased, hardness in weld metal markdly increased. It could be considered that effect of heat input to growth of the dendritic solidification structures. Based on tensile test, tensile properties of weld metal was predominated by area fraction of porosities. Consequently, tensile properties can be controlled by formation site and area fraction of porosity.

• Journal of Welding and Joining
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• v.35 no.2
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• pp.43-51
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• 2017

The automatic welding systems, have received much attention in recent years, because they are highly suitable not only to increase the quality and productivity, but also to decrease manufacturing time and cost for a given product. Automatic welding work in semiconductor or space industry to be carried out in pipe line and butt joint mostly and plasma arc welding(PAW) is actively applied. To get the desired quality welds in automated welding system is challenging, a mathematical model is needed that has complete control over the relevant process parameters in order to obtain the required mechanical properties. However, In various industries the welding process mathematical model is not fully formulated for the process parameter and on the welding conditions, therefore only partial variables can be predicted. Therefore, this paper investigates the interaction between the welding parameters and mechanical properties for predicting the weld bead geometry by analyzing the S/N ratio.

• Journal of Welding and Joining
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• v.26 no.5
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• pp.29-35
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• 2008

In this paper concentrate on the comparison of the thermal and mechanical characteristics in Butt joint of ship structure AH32 steel by using hybrid welding and conventional SAW. For this purpose, fundamental welding phenomena of hybrid process using $CO_2$ Laser and MIG is investigated by the experiments and characteristics of thermal and welding residual stress distribution of welded joint in SAW and hybrid welding are understood from the result of FE numerical simulation and experimental values. From the result of this study, it is understood that Laser-MIG hybrid welding have high potential, make substantial saving of time and manufacturing cost and may proves its self robust in the butt joining of thick AH32 steel ship structural plate in the near future.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.5 no.2
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• pp.49-55
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• 2006

In the consideration of the problem occurred by certain return bender brazing welding works that depend only on handworks, the automatization of the whole production line is impossible due to the high dependency of skillful workers. In addition, it is difficult to establish a standardization due to the various heat exchanger model and irregular amount of orders, and the fault reduction is also impossible due to the severe difference in brazing conditions. It is necessary to develop a method, which quantitively analyzes the problem existed in this manual brazing welding of return benders and technically solves that problem, and to lead the improvement of the productivity and cost reduction in order to increase the business competitive power. Then, this will contribute the technical development of automatic welding for Korea's heat exchanger businesses. Thus, this study develops an automatic technology, which automatically controls the flame strength using digital control methods, for various models and produces a sample model. It is possible to increase the productivity and produce uniformed and qualified products by solving the problem existed in manual processes using the developed automatic return bender brazing system. In addition, the brazing condition can be automatically controlled according to the model and line speed, and such an economical operation can reduce the production cost. The developed system is expected to future applications not only heat exchangers in the field of refrigeration and air conditioning, but also other various industrial fields that apply heat exchangers, such as car and boiler industries.

• Journal of Welding and Joining
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• v.18 no.2
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• pp.86-94
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• 2000

This study was performed to investigate types and formation mechanism of cracks in two Al alloy welds, A5083 and A7N01 spot-welded by pulse Nd : YAG laser, using SEM, EPMA and Micro-XRD. In the weld zone, three types of crack were observed : center line crack({TEX}$C_{C}${/TEX}), diagonal crack({TEX}$C_{D}${/TEX}), and U shape crack({TEX}$C_{U}${/TEX}). Also, HAZ crack({TEX}$C_{H}${/TEX}) was observed in the HAZ region, furthermore, mixing crack({TEX}$C_{M}${/TEX}) consisting of diagonal crack and HAZ crack was observed. White film was formed at th hot crack region in the fractured surface after it was immersed to 10% NaOH water. In the case of A5083 alloy, white films in {TEX}$C_{C}${/TEX} crack and {TEX}$C_{D}${/TEX} crack region were composed of low melting phases, {TEX}$Fe_{2}SiAl_{8}${/TEX} and eutectic phases, $Mg_2$Al$_3$ and $Mg_2$Si. Such films observed $CuAl_2$, {TEX}$Mg_{32}(Al,Zn)_{3}${/TEX}, MgZn$_2$, $Al_2$CuMg and $Mg_2$Si were observed in the whitely etched films near {TEX}$C_{C}${/TEX} crack and {TEX}$C_{D}${/TEX} crack regions. The formation of liquid films was due to the segregation of Mg, Si, Fe in the case of A5083 alloy and Zn, Mg, Cu, Sim in the case of A7N01 alloy, respectively. The {TEX}$C_{C}${/TEX} and {TEX}$C_{D}${/TEX} cracks were regarded as a result of the occurrence of tensile strain during the welding process. The formation of {TEX}$C_{M}${/TEX} crack is likely to be due to the presence of liquid film at the grain boundary near the fusion line in the base metal as well as in the weld fusion zone during solidification. The {TEX}$C_{U}${/TEX} crack is considered a result of the collapsed keyhole through incomplete closure during rapid solidification.

• Proceedings of the KWS Conference
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• 2008.05a
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• pp.36-36
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• 2008

• 제어로봇시스템학회:학술대회논문집
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• 1988.10a
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• pp.370-373
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• 1988

Althouah there have been many attempts to control weld quality in resistance spot welding processes, design method for an on-line feedback controller based upon process dynamics has not been suggested. This is due to the fact that the resistance spot welding is a highly complicated process, whice involves the interaction of electrical, thermal, mechanical and metallurgical phenomena. In this paper, an optimal control method based on FDM model with shunt effect is presented, which can regulate the nugget size, at the same time minimizing the control heat input. Optimal PI gain of the controller were determined by numerical optimization. Simulation results show that, as a result of the proposed optimal control, the weld nugget can be made to approach a desired nugget size with less control heat input than that required for the conventional spot welding process in the face of the shunt effect.

• Journal of Power System Engineering
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• v.11 no.3
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• pp.41-46
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• 2007

The microstructure and electrochemical analysis of welds of electric resistance welding(ERW) pipe were investigated. The direction of metal flow line in HAZ of ERW pipe shifted to the inner(or outer) surface of pipe by plastic deformation during welding. The lowest heat input welds of ERW pipe was showed crack by liquid penetrant testing. Accelerated corrosion test by constant current density of 20mA/$cm^{2}$ developed groove at the welds of ERW pipe and the measured grooving factors were about $1.2{\sim}1.5$. Corrosion potential of base metal obtained by cyclic polarization in artificial sea water(3.5wt.% NaCl solution) was 100mV higher than that of weld metal of ERW pipe.

• Proceedings of the Korean Society of Laser Processing Conference
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• 1999.05a
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• pp.29-32
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• 1999

The material properties of laser welding zone such as strength coefficient, work-hardening exponent, and plastic anisotropic ratio are analytically obtained from those of base metals based on the tensile tests. . The finite element formulation is developed for predicting strain distributions and weld line movements in the forming processes of laser welded blank. The welding zone(WZ) is modelled with the several, narrow finite elements whose material characteristics are based on the experimental results and the analytical equations. In order to show an application of the developed weld element the stamping process of auto-body door inner panel is simulated. FEM predictions are compared and showed good agreements with experimental observations.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.08a
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• pp.240-248
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• 2004

Recently, the customer's demands for automotive steel sheet have been diversified and sterned more. Therefore, as the tendency of auto industry light-weight, one among these requirements is the trend for high strength together with the thinness of automotive steel sheet. Because Mn added essentially in producing high strength steel sheet is bonded strongly with oxygen, the Fine oxidation layer was created at the welding face after the flash butt welding operated in entry section of pickling line. Thereby it was caused the crack or breakage of welding part in process of cold rolling. At this research, in order to protect the contact Mn with oxygen in atomosphere it was considered to fire oxygen with LNG and the related researches have been gone forward with the find out concrete and to apply them to operation.