• Journal of Welding and Joining
• /
• v.35 no.2
• /
• pp.1-5
• /
• 2017

Many microelectronic devices are miniaturizing the capacitance density and the size of the capacitor. Along with this miniaturization of electronic circuits, tantalum (Ta) capacitors have been on the market due to its large demands worldwide and advantages such as high volumetric efficiency, low temperature coefficient of capacitance, high stability and reliability. During a tantalum capacitor manufacturing process, arc welding has been used to weld base frame and sub frame. This arc welding may have limitations since the downsizing of the weldment depends on the size of welding electrode and the contact time may prevent from improving productivity. Therefore, to solve these problems, this study applies laser spot welding to weld nickel (Ni) and Au-Sn-Ni alloy using CW IR fiber laser with lap joint geometry. All laser parameters are fixed and the only control variable is laser irradiance time. Four different shapes, such as no melting upper workpiece, asymmetric spherical-shaped weldment, symmetric weldment, and, excessive weldment, are observed. This shape may be due to different temperature distribution and flow pattern during the laser spot cutting.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.14 no.5
• /
• pp.81-87
• /
• 2015

In this paper, the finite element method was used for the flow and strength analysis of aluminum alloy under friction stir welding. The simulations were carried out using Sysweld s/w, and the modeling of the sheet was executed using Unigraphics NX6 s/w. The welding variables for the analysis were the shoulder diameter, rotating speed, and welding speed of the tool. Additionally, a three-way factorial design method was applied to confirm the effect of the welding variables on the flow and strength analysis with variance analysis. From these results, the rotating speed had the greatest influence on the maximum temperature, and the maximum temperature was $578.84{\pm}12.72$ at a confidence interval of 99%. The greater the rotating speed and shoulder diameter, the greater the difference between maximum and minimum temperature. Furthermore, the shoulder diameter had the largest influence on von Mises stress, and the von Mises stress was $184.54{\pm}12.62$ at a confidence interval of 99%. In addition to the increased shoulder diameter, welding speed, and rotating speed of the tool increased the von Mises stress.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2002.05a
• /
• pp.565-568
• /
• 2002

Welding variables and conditions in gas metal arc welding (GMAW) effect on the weld quality and productivity, extensive research efforts have been made to analyze the welding variables and conditions. In this study dynamic behavior of GMAW system is investigated using the characteristic equations of the power supply, wire and welding arc. Characteristic equation of wire is modified to include the effect of droplets attached at the electrode tip. The dynamic characteristics of arc length, current, voltage with respect to the step, ramp inputs of CTWD was simulated, seam tracking procedure using arc sensor was simulated with variable V-Groove geometries and weaving frequencies. From results of simulation, some predictions about dynamic characteristics of GMAW and welding process are available. The proposed simulator and results appear to be utilized to determine the proper welding conditions, to be improved by considering power supply dynamic characteristics.

• Journal of Welding and Joining
• /
• v.23 no.1
• /
• pp.69-76
• /
• 2005

Recently, application of arc welding to galvanized carbon steel sheet is on the increasing Ould in the fields of automobile and construction industries. In arc welding process, zinc is evaporated in weld pool, even under the appropriate welding condition and produce blowhole and/or pit. Zinc gas cause instability of arc and increase spatter and fume. This research is purposed to minimize the heat-input and the formation of porosities in the welded joint of the galvanized carbon steel sheet using variable polarity AC wave pulse MIG welding system. An appropriate welding condition which showed low spatter and good bead appearance was acquired by applying the AC pulse MIG welding machine to DC duplicated MIG welding with the solid wire. When oxygen gas was added to shield gas of MIG welding for galvanized steel sheet, arc length was increased and arc stability was improved. In the AC duplicated welding, the loss of galvanized layer was decreased as the amount of heat-input was decreased when the EN ratio was increased under the condition that average welding current was evenly set.

• Proceedings of the KWS Conference
• /
• 2002.10a
• /
• pp.384-389
• /
• 2002

This study was aimed to evaluate the weldability and optimize the welding conditions for flash butt welding of 780MPa grade steel applied to the automotive bumper reinforcement. And then the relationship between the welding conditions and the joint performance relating specifically to coil-joining steel would be established. The effect of welding conditions between flashing and upsetting process was elucidated. Microstructure observation of the joint indicated that the decarburized band was mainly changed with upsetting process. Width of HAZ was also related to the upsetting conditions rather than the flashing conditions. Generally maximum hardness at HAZ was correlated with $C_{eq}$ of steel and the empirical relationship was obtained to estimate the HAZ properties. Tensile elongation at the joint was usually decreased with increasing the initial clamping distance. Investigation of fracture surface after tensile and bending tests reveal that the origin of cracking at the joint was oxide inclusions composed of $SiO_2$, MnO, $Al_2$ $O_3$, and/or FeO. The amount of inclusions was dependent on the composition ratio of Mn/Si in steel. If this ratio was above 4, the amount of inclusions was low and then the resistance to cracking at the joint was enough to maintain the joint performance. It was obtained that the flashing process influenced the conditions for the energy input to establish uniform or non-uniform molten layer, while the upsetting conditions influenced the joint strength. Heat input variable during flashing process was also discussed with the joint properties.

• Proceedings of the Korean Society of Marine Engineers Conference
• /
• 2001.11a
• /
• pp.88-91
• /
• 2001

New type of vehicles made from thin aluminum alloy are under rapid development and some product are already on the market, but when welding sheet metal joint of aluminum alloy, the main problem are burn-through by the high heat input. The purpose of this study, it is to prevent the burn-through and to shallow penetration that AC pulse welding has diminish the penetration and to lower the droplet temperature at Al sheet metal welding. In this study, we observed the bead appearance and whether it was appeared burn through or not , as the variation of the root gap in the lap and butt-joint welding process.

• Special Issue of the Society of Naval Architects of Korea
• /
• 2007.09a
• /
• pp.22-25
• /
• 2007

Angular distortion in welding process is decided by the various variables. We can make the prediction of welding distortion in similar reality by the analysis of data through many specimen tests. However it is difficult that prediction of welding distortion applies to the ship building. We can establish that angular distortion varies directly as the specimen size. And, it makes clear distortion's difference between constraint and unconstraint, according to the change of a plate thickness.

• Journal of the Korean Society of Industry Convergence
• /
• v.5 no.2
• /
• pp.111-118
• /
• 2002

In GMAW(Gas Metal Arc Welding) processes, bead geometry (penetration, bead width and height) is a criterion to estimate welding quality, Bead geometry is affected by welding current, arc voltage and travel speed, shielding gas, CTWD (contact-tip to workpiece distance) and so on. In this paper, welding process variables were selected as welding current, arc voltage and travel speed. And bead geometry was reasoned from the chosen welding process variables using neuro-fuzzy algorithm. Neural networks was applied to design FLC(fuzzy logic control), The parameters of input membership functions and those of consequence functions in FLC were tuned through the method of learning by backpropagation algorithm, Bead geometry could he reasoned from welding current, arc voltage, travel speed on FLC using the results learned by neural networks. On the developed inference system of bead geometry using neuo-fuzzy algorithm, the inference error percent of bead width was within ${\pm}4%$, that of bead height was within ${\pm}3%$, and that of penetration was within ${\pm}8%$, Neural networks came into effect to find the parameters of input membership functions and those of consequence in FLC. Therefore the inference system of welding quality expects to be developed through proposed algorithm.

• Journal of Welding and Joining
• /
• v.34 no.2
• /
• pp.59-66
• /
• 2016

The Gas Metal Arc(GMA) welding, called Metal Inert Gas(MIG) welding, has been an important component in manufacturing industries. A key technology for robotic welding processes is seam tracking system, which is critical to improve the welding quality and welding capacities. The objectives of this study were to develop the intelligent and cost-effective algorithms for image processing in GMA welding which based on the laser vision sensor. Welding images were captured from the CCD camera and then processed by the proposed algorithm to track the weld joint location. The proposed algorithms that commonly used at the present stage were verified and compared to obtain the optimal one for each step in image processing. Finally, validity of the proposed algorithms was examined by using weld seam images obtained with different welding environments for image processing. The results proved that the proposed algorithm was quite excellent in getting rid of the variable noises to extract the feature points and centerline for seam tracking in GMA welding and could be employed for general industrial application.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2009.05a
• /
• pp.236-239
• /
• 2009

Cowl cross bar, a component of automotive cockpit module, has been manufactured by using welding processes of several tube parts with different diameters. However, in order to reduce costs and increase the quality, it is required to develop a new production method to manufacture the cowl cross bar as one-piece In this study, therefore, eliminating the welding process, tube drawing process which is one of metal forming processes was designed by using combined drawing technique. In addition, the selectable range of area reduction ratio was defined as a design guideline and the designed process sequence was verified by finite element analysis.