• Korean Journal of Metals and Materials
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• v.48 no.6
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• pp.533-542
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• 2010

The specific motivation for joining an Al alloy and Zn-coated steel arises from the need to save fuel consumption by weight reduction and to enhance the durability of vehicle structures in the automobile industry. In this study, the lap joining A6K31 Al alloy (top) and SGARC340 Zn-coated steel (bottom) sheets with a thickness of 1.0 mm and 0.8 mm, respectively, was carried out using the friction stir weld (FSW) technique. The probe of a tool did not contact the surface of the lower Zn-coated steel sheet. The friction stir welding was carried out at rotation speeds of 1500 rpm and travel speeds of 80~200 mm/min. The effects of tool geometry and welding speed on the mechanical properties and the structure of a joint were investigated. The tensile properties for the joints welded with a larger tool were better than those for the joints done with a smaller tool. A good correlation between the tensile load and area of the welded region were observed. The bond strength using a larger tool (M4 and M3) decreased with an increase in welding speed. Most fractures occurred along the interface between the Zn-coated steel and the Al alloy. However, in certain conditions with a lower welding speed, fractures occurred at the A6K31 Al alloy.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.10
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• pp.98-104
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• 2020

Recently, friction stir welding of dissimilar materials has become one of the biggest issues in lightweight and eco-friendly bonding technology. In this study, a lightweight torsion beam axle, which is an automobile chassis component, was used in the welding to cast aluminum material. The friction stir welding process of A357 cast aluminum and FB590 high-strength steel as well as the effects of the process parameters were investigated and optimized using a novel definitive screening design (DSD). ANOVA was used to predict the importance of the process parameters with 13 degradation experiments using the proposed DSD. Also, FSWed experiments were conducted using an optical microscope analysis to investigate the tensile strength behavior in the weld area. In addition to determining the interaction between the tool's rotational speed and the plunge speed, results indicate that the influence of the plunge depth was the most significant.

• Proceedings of the KWS Conference
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• 2005.11a
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• pp.189-191
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• 2005

Dissimilar joining of AI 6013-T4 alloys and austenite stainless steel was carried out using friction stir welding technique. Microstructures near the weld zone and mechanical properties of the joint have been investigated. Microstructures in the stainless steel side and AI alloy were depended on the thermo-mechanical condition which they received. TEM micrographs revealed that the interface region was composed of the mixed layers of elongated stainless steel and ultra-fine grained AI alloy and intermetallic compound layer which was identified as the $Al_{4}Fe$ with hexagonal close packed structure. Mechanical properties were lower than those of 6013 AI alloy base metal, because tool inserting location was deviated to AI alloy from the butt line, which resulted in the lack of the stirring.

• Transactions of Materials Processing
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• v.18 no.1
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• pp.73-79
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• 2009

In order to investigate the formability of friction stir welded(FSW) tailor welded blanks(TWB) with respect to the base material's directional combination, aluminum alloy AA6111-T4 sheets were welded with three different conjoining types: RD-RD, TD-RD and TD-TD. Here, RD and TD represent rolling and transverse directions, respectively. For experimental formability study, three tests with gradual complexity were performed: the simple tension test with various weld line directions for uni-axial elongation, the hemisphere dome stretching test for biaxial stretching and the cylindrical cup deep drawing test. As a result, all three forming tests showed that RD-RD type samples exhibited the best formability, while TD-TD type sheets showed the least formability performance.

• Proceedings of the KSR Conference
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• 2004.10a
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• pp.668-673
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• 2004

The Friction Stir Weld (FSW) has been prevailing in the rolling stock manufacturers now a day especially in Europe and Japan, that will be an inevitable welding method in Korean domestic railway industry in the near future. The Welding Institute (TWI) in United Kingdom (UK), who has the right of international patents, invented FSW. To meet the recommendation of Cullen's Report for Ladbroke Grove Rail Inquiry (LGRI) in UK, the FSW is considering for the only alternative welding method to improve the aluminium welding quality, i.e. for improve unzipping defect and crashworthiness on car body in Europe Railways within Railway Safety Research Program.

• Steel and Composite Structures
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• v.28 no.6
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• pp.759-766
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• 2018

Friction Stir Welding (FSW) is a solid-state process, where the objects are joined together without reaching their melting point. It has been shown that this method is a suitable way to join dissimilar aluminium alloys. The current article employed hole drilling technique to measure the residual stress distribution experimentally in different zones of dissimilar aluminium alloys AA6061-T6 and AA7075-T6 Butt welded using FSW. Results are compared with those of similar AA6061-T6 plates joined using a conventional fusion welding method called tungsten inert gas (TIG). Also, the evolution of the residual stresses in the thickness direction was investigated, and it was found that the maximum residual stresses are below the yield strength of the material in the shoulder region. It was also revealed that the longitudinal residual stresses in the joint were much larger than the transverse residual stresses. Meanwhile, Vickers micro hardness measurements were performed in the cross-section of the samples. The largest hardness values were observed in the stir zone (SZ) adjacent to the advancing side whereas low hardness values were measured at the HAZ of both alloys and the SZ adjacent to the retreating side.

• Proceedings of the KWS Conference
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• 2004.05a
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• pp.156-158
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• 2004

The microstructural evolution in a 304 stainless steel weld during FSW was examined. The SZ and TMAZ showed typical dynamically recrystallized and recovered microstructures, respectively, The microstructural observation revealed that sigma phase was formed at the advancing side of the stir zone. A possibility was suggested that the rapid formation of the sigma phase is related to the transformation of austenite to delta-ferrite in the stir zone, from introduction of high strain and dynamic recrystallization during FSW.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.12
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• pp.679-684
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• 2017

Friction Stir Welding is a metal welding technique, in which friction heat between a welding tool and a welding material is used to weld parts at temperatures below the melting point of a material. In this study, the temperature and velocity changes in a magnesium alloy (AZ31) during the welding process were analyzed by computational flow dynamics technique while welding the material using a friction stir welding technique. For the analysis, the modeling and analysis were carried out using Fluent as a fluid analysis tool. First, the welding material was assumed to be a temperature-dependent Newtonian fluid with high viscosity, and the rotation region and the stationary region were simulated separately to consider the rotational flow generated by the rotation of the welding tool having a helical groove. The interface between the welding tool and welding material was given the friction and slip boundary conditions and the heat transfer effect to the welding tool was considered. Overall, the velocity and temperature characteristics of the welded material according to time can be understood from the results of transient analysis through the above flow analysis modeling.

• Proceedings of the KWS Conference
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• 2003.05a
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• pp.176-178
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• 2003

The weld zone of dissimilar formed Al alloy exhibited the complex structure of the two materials and mainly composed of the retreating side material. The mechanical properties were also depended on the dominant microstructure of the weld zone with welding conditions. The different mechanical properties of weld zone with welding conditions were related to the behavior of the precipitates of wrought Al alloy and Si particles of cast Al alloy. The higher mechanical properties of weld were acquired when relatively harder material, wrought Al alloy, was fixed at the retreating side.

• Corrosion Science and Technology
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• v.6 no.2
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• pp.74-76
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• 2007

The increasing interest in the corrosion properties of weld joints in the corrosive environment is placing stringent demands on the manufacturing techniques and performance requirements, and the manufacture employs the high quality and efficiency welding process to produce welds. Welding plays an important role in the fabrication of chemical plants, nuclear power plant, ship construction, and this has led to an increasing attention to the corrosion resistant weld joints. This paper covers a recent technical trends of welding technologies for corrosion resistance properties including the COMPENDEX DB analysis of welding materials, welding process, and welding fabrications.