• Journal of the Korean Society for Precision Engineering
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• v.14 no.3
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• pp.41-49
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• 1997

Laser spot welding offers a unique combination of high speed. precision and low heat distortion, compared with conventional resistance spot welding. This combinatin of advantages is especially attractive for the automotive industry. Until now automobile fabrication is widely used resistance spot welding, however, because of geometric and structural problem, spot welding is required many welding machine in that reason by substituting spot welding with laser welding, it save the equipment cost. In the present study we measured ultimate strength and observed bead cross section of laser welded specimen and compared with that of the resistance spot welding results in order to adapt laser welding in automobile industry. Also for strength esti- mation we calculated the residual stress of laser welded zone. All calculations are performed with the ABAQUS code on a workstation.

• Journal of Welding and Joining
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• v.32 no.3
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• pp.81-88
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• 2014

As the industrial technology has been developed, a dissimilar welding has been received huge attention in various engineering fields. To understand the mechanical properties and possibility of applications of dissimilar metals joining, the laser welding of Cu and Ni dissimilar metals was studied in this paper. Cu and Ni have differences in materials properties, and Cu and Ni make no intermetallic compounds according to typical binary phase of Cu and Ni system. In this study, lap welds of Cu and Ni dissimilar metals using single-mode fiber laser with high welding speed were tried, and mechanical properties of the welds zone were evaluated using a Vickers hardness test and a tensile shear test. To recognize the relation between hardness and tensile shear load, weld fusion zone of interface weld area were observed. And it was confirmed that the ultra-high welding speed could make good weld beads and higher hardness parts had higher tensile shear load under the all conditions.

• Journal of Advanced Marine Engineering and Technology
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• v.38 no.2
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• pp.133-139
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• 2014

Titanium (Ti) metal and its alloys are desirable materials for ship hulls and other ocean structures because of their high strength, corrosion-resistance and light weight properties. And light weight and corrosion-resistant aluminum (Al) is the ideal metal for shipbuilding. The joining of Ti and Al dissimilar metals is one of the effective methode to reduce weight of the structures. Ti and Al have great differences in materials properties, and intermetallic compounds such as $Ti_3Al$, TiAl, $TiAl_3$ are easily formed at the contacting surface between Ti and Al. Thus, dissimilar welding and joining of Ti and Al are considered to be very difficult. However, it was clarified that ultra-high speed welding could suppress the formation of intermetallic compounds in the previous study. Results of tensile shear strength increases with an increase in the welding speed, and therefore extremely high welding speed (50 m/min) is good to dissimilar weldability for Ti and Al. In this study, therefore, full penetration dissimilar lap welding of Ti (upper) - Al (lower) and Al (upper) - Ti (lower) with single-mode fiber laser was tried at ultra-high welding speed, and the microstructure of the interface zones in the dissimilar Al and Ti weld beads was investigated.

• Journal of Welding and Joining
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• v.31 no.5
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• pp.64-70
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• 2013

The joining of Ti and SUS304 dissimilar metals is one of the effective measures to save rare metal. But Ti and SUS304 have differences in materials properties, and Ti and Fe intermetallic compounds such as TiFe and $TiFe_2$ are easily formed in weld fusion zone between Ti and SUS304. Nevertheless, in this study, full penetration lap dissimilar welding of Ti and SUS304 using single-mode fiber laser with ultra-high welding speed was tried, and it was found out that ultra-high welding speed could control the generation of intermetallic compound. To recognize the formation of intermetallic phase in the weld fusion zone and the compound zone of interface weld area were observed and analyzed using energy dispersive X-ray spectroscopy (EDX). And it was confirmed that the ultra-high welding speed could reduce amount of intermetallic compounds, but the intermetallic compounds were existed in the weld fusion zone under the all conditions.

• International Journal of Korean Welding Society
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• v.3 no.1
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• pp.2-7
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• 2003

Laser welding application for car body manufacturing has many advantages in the stiffness and the lightness of vehicle, the productivity of assembly line, and the degree of freedom in design. This presentation will express the innovation of car body manufacturing including parameter optimization, process modeling, and system integration. In this application the investment for systems was cut down dramatically by real time switching over the laser path between two welding stations. Points of technical discussion are as follows; optimization of parameters such as laser power, robot speed and trajectory, compact and useful design of jig & fixture to assure welding quality for 3 sheet-layer zinc-coated steel, system integration between 4㎾ Nd:YAG laser device and the other systems, on-line real time welding quality monitoring system, perfect safety standards for high power laser, minimization of consumption costs such as arc lamp, protective glass for optic, etc. This application was successfully launched mass production line in 2001. The laser-welded line of side panel consists of 122 stitches totally. And the length is about 2.4m.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.35-36
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• 2006

In Nd:YAG laser welding, evaluation methods of welding flaw are various. But, the method due to fume shape is difficult to classification of welding flaw. The Nd:YAG laser process is known to have high speed and deep penetration capability to become one of the most advanced welding technologies. At the present time, some methods are studied for measurement of fume shape by using high-speed camera and photo diode. This paper describes the machining characteristics of SM45C carbon steel welding by use of an Nd:YAG laser. In spite of its good mechanical characteristics, SM45C carbon steel has a high carbon contents and suffers a limitation in the industrial application due to the poor welding properties. In this study, fume shape was measured by infrared thermal camera that is non-contact/non-destructive thermal measurement equipment through change of laser generating power, speed, focus. Weld was performed on bead-on method. Measurement results are compared as two equipments. Here, two results are composed of measurement results of fume quantities due to fume shape by infrared thermal camera and inspection results of weld bead include weld flaws by ultrasonic inspector.

• Journal of Advanced Marine Engineering and Technology
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• v.31 no.3
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• pp.282-292
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• 2007

The present paper describes the results of high speed photography, acoustic emission (AE) detection and plasma light emission (LE) measurement during $CO_2$ laser welding of 304 stainless steel in different processing conditions. Video images with high spatial and temporal resolution allowed to observe the melt dynamics and keyhole evolution. The existence of keyhole was confirmed by the slag motion on the weld pool. The characteristic frequencies of flow instability and keyhole fluctuations at different welding speed were measured and compared with the results of Fourier analyses of temporal AE and LE spectra. The experimental results were compared with the newly developed numerical model of keyhole dynamics. The model is based on the assumption that the propagation of front part of keyhole into material is due to the melt ejection driven by laser induced surface evaporation. The calculations predict that a high speed melt flow is induced at the front part of keyhole when the sample travel speed exceeds several 10 mm/s. The numerical analysis also shows the hump formation on the front keyhole wall surface. Experimentally observed melt behavior and transformation of the AE and LE spectra with variation of welding speed are qualitatively in good agreement with the model predictions.

• Laser Solutions
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• v.13 no.3
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• pp.7-12
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• 2010

In this study, laser welding of aluminum AA5182 with AA5356 filler wire was carried out and the formability of the weld joint was evaluated through Erichsen test according to laser power, welding speed and wire feed rate. Fracture was occurred in both directions, perpendicular and parallel to the weld line at 0.75 of Erichsen ratio. Second order Regression model to estimate Erichsen ratio with experimental variables was proposed and the performance of model was evaluated with F-test and average error rate.

• International Journal of Korean Welding Society
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• v.3 no.1
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• pp.45-50
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• 2003

Welding using lasers can be mass-produced in high speed. In the laser welding, performing real-time monitoring system of the welding quality is very important in enhancing the efficiency of welding. In this study, the plasma and molten metal which are generated during laser welding were measured using the UV sensor and IR sensors. The results of laser welding were classified into five categories such as optimal heat input, little low heat input, low heat input, partial joining due to gap mismatch, and nozzle deviation. Also, a system was formulated which uses the measured signals with a fuzzy pattern recognition method which is used to perform real-time evaluation of the welding quality and the defects which can occur in laser welding.

• Laser Solutions
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• v.5 no.1
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• pp.33-42
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• 2002

In order to investigate the characteristics of the plasma induced by lap-joint CO$_2$ laser welding of automotive steel sheets, the effects of welding speed, shield gas flow rate, gap size, and laser beam defocus to plasma intensity emitted from keyhole have been investigated. The plasma light is measured by fiber and photodiode. Also, the plasma images were captured by the high speed digital camera in 1000frames/sec in order to correlate the plasma light signal with plasma pattern. From the results, it is observed that the difference of the plasma intensity for between the deep penetration and partial penetration exists from 1.2 to 2 times. The plasma light intensity decreased in case of the deep penetration Is observed due to the exhausting of the plasma gas under the sheet. On the other hand, under the conditions of the deep penetration, the plasma intensity is significantly increased by controling the conditions decreasing the penetration depth. It was specially founded that the effect of 0.3mm gap size at partial penetration condition is approximately similar to deep penetration in 0mm gap. It is concluded that the plasma intensity is able to evaluate the penetration depth in lap-joint welding and appears to offer the most straightforward correlation to the welding process.