• The Transactions of the Korean Institute of Electrical Engineers B
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• v.48 no.5
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• pp.257-263
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• 1999

Recently the performance of CO2 arc welding machine has been advanced significantly through the adoption of inverter circuit topology which made it possible to control the waveform of welding current and thus to suppress the spatter generation. However, the optimum waveform is still uncertain. As a first step for figuring out the promising waveforms, this study was performed to set-up the experimental system for studying the effect of waveform variables, The system designed in this study is a digital controller using single chip microprocessor of 80C196KC. As a result of performance test of this system, it was demonstrated all of the waveform variables could be set individually and the resultant waveforms appeared to be pretty much the same as the intended one.

• 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 Welding and Joining
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• v.30 no.2
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• pp.54-58
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• 2012

Al-coated steel sheets with excellent heat and corrosion resistance are widely used in various applications. In welding of thin plate, some defects such as unmelted zone and metal-through occur easily in the beginning and ending of welding line. In the study, the welding defects in Al-coated steel sheets were investigated with respect to plasma arc current, height between Cu block and base metals, and using a roller to align the height of the base metal. Full penetration and voids free welds were obtained with a plasma arc current 52A and weld speed 2.3m/min. An unmelted zone increased and Ericshen rate decreased as the height between Cu block and base metal increased from 0 to 0.6mm. Using a roller moving ahead of the plasma arc, the length of unmelted zone decreased from 1.7mm to 0.5mm.

• Journal of the Korea Institute of Building Construction
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• v.8 no.6
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• pp.161-166
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• 2008

This study is focused on the welding performance of automatic gas pressure welding machine adapted to korean construction site by external appearance investigation. As gas pressure welding is more economical and has good performances compared with other steel bar jointing methods, as arc welding and mechanical joint etc, in Japan, the gas pressure welding is one of the typical connection of steel reinforcement when connecting the D29 and thicker steel bars, But in Korea, gas pressure welding joint method is not widely used caused by the shortage of skilled workers. so to activate the gas pressure welding in Korea, the automatic gas pressure welding machine is developed. In this study, the welding performances of gas pressure welding joint samples using korean automatic gas pressure welding machine are measured by external appearance investigation - blown diameters, blown length, welding face disagreement, central axis eccentric ratio, bending, sag and crack. The results of welding performances on the gas pressure welding joint samples show that samples are satisfied with the standard value regulated in KS D 0244 and JIS Z 3120.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.363-370
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• 2003

The object of this study is to investigate the effect of compounded welding by using an acoustic emission (AE) signals and doing a source location for weld heat affected zone (HAZ) through tensile testing. This study was carried out a SM 490A high tension steel for electronic shielded metal arc welding (SMAW), $CO_2$ gas arc welding and TIG welding. Data displays are based on the measured parameters of the AE signals, along with environmental variables such as time and load. These history plots are displays showing the chronological course of the test. Also, source location gives the X- and Y-coordinates of the AE source.

• The Transactions of the Korean Institute of Power Electronics
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• v.5 no.4
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• pp.358-369
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• 2000

Shielded metal arc welding machines with AC transformer have been widely used for thin-plate welding applications. Because of being bulky, heavy and of tap-changing property, so the SMAW's are changing to new power electronic circuits such as inverter circuit in order to reduce the system size and also to improve the welding performances at input output sides. The PWM inverter arc welding machine with diode rectifier has better output welding performances but it is has the plentiful harmonics and the lower input power factor. To solve these problems, input current-controlled scheme is considered for PWM inverter arc welding system, and then total input power factor is maintained to be more than 99%. Also a new combined control is proposed which can control both instantaeous welding output voltage and current under constant power condition, and as a result the variations of instantaneous current and voltage can be reduced to very narrow range in the V-I curve relationship, and hence the variance of welding current and voltage become so reduced. In addition the spatter generated during welding process is greatly reduced up to 70%. And the overall effiency can be improved up to 10%, which becomes higher when the load is lower.

• Journal of Welding and Joining
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• v.21 no.4
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• pp.56-62
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• 2003

MIG brazing is used for many parts without melting base metal because of high productivity. Pulsed MIG brazing can be used to further reduce heat input and to improve the process stability. However, a significant amount of zinc in galvanized sheet steel is burned off in the area of brazes. Therefore, the brazing method to reduce the heat input is needed. In the brazing for galvanized sheet steel, variable polarity AC pulse MIG arc brazing can be applied to more decrease the heat input by setting EN-ratio adequately. In this research, we studied for the variable polarity AC pulse MIG arc brazing to decrease the heat input by using ERCuSi-A wire. As the result of increasing EN-ratio, melting ratio of base metal and burning off of zinc were reduced in galvanized sheet steel.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.3
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• pp.81-87
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• 2007

It is important to investigate the relationship between weld process parameters and weld bead geometry for adaptive arc robot welding. However, it is difficult to predict an exact back-bead owing to gap in process of butt welding. In this paper, the quantitative prediction system to specify the relationship external weld conditions and weld bead geometry was developed to get suitable back-bead in butt welding which is widely applied on industrial field. Multiple regression analysis and artificial neural network were used as the research methods. And, the results of two prediction methods were compared and analyzed.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.1
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• pp.9-18
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• 2007

There have been continuous efforts for automation of joint tracking system. This automation process is mainly used to do in root pass of gas metal arc welding in the field of heavy industry and shipbuilding etc. For automation, it is important using of vision sensor. Welding robot with vision sensor is used for weld seam tracking on welding fabrication. Recently, it is used to on post-weld inspection for weld quality evaluation. For real time seam tracking, it is very important role in vision process technique. Vision process is included in filtering and thinning, segmentation processing, feature extraction and recognition. In this paper, it has shown performance comparison results of seam tracking for real time root pass on gas metal arc welding. It can be concluded better segment splitting method than iterative averaging technique in the performance results of seam tracking.

• Journal of the Korean Society for Precision Engineering
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• v.7 no.1
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• pp.63-73
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• 1990

Low cost automatic welding machine is developed for the purpose of welding process automation of automobile parts with two dimensional welding joints. Developed gantry type machine is equipped with X, Y and roll axis stepping motors, and dirive units units are designed by two phase on drive scheme using shift registers. Control system is constructed by single board microcomputer of Z80A CPU, and also it is equipped with parallel input output ports and counter-timer chips. Linear and circular interpolation of welding head movement is accomplished by employing software digital differential analyzers. It has been shown that contour error of develped system is withi ${\pm}1.0mm$, meaning that the machine is suitable for CO2 arc welding process of automoble parts and is expected it's application to industry.