• Journal of Welding and Joining
• /
• v.23 no.1
• /
• pp.77-85
• /
• 2005

The structures and mechanical properties of friction stirred welds of oxygen free copper(OFC) sheet were investigated. Defect-free welds were obtained in a relatively wide range of the welding conditions from 1000 to 2000 rpm, and welding speed from 500 to 2000 mm/min. The microstructure of the stirred zone(SZ) showed recrystallized grains, and the gram size varied largely with the welding conditions. The SZ hardness values including those of all the optimum welding conditions were slightly lower than that of the base metal, and increased with decreasing heat input. The tensile strength of the all-SZ increased with increasing the hardness values. The Hall-Fetch relationship was confirmed between the yield strength of the all-52 and the recrystallized grain size of the SZ.

• Proceedings of the KWS Conference
• /
• 2007.11a
• /
• pp.53-56
• /
• 2007

Magnesium sheet used in electrical device due to mobility and EMF shielding characteristics. Magnesium case by press forming was advantageous compare with conventional die casting process, because of its thin gauge of wall and surface quality. But it need to makes the boss to fix inner part or assemble the case. CD stud welding was effective way for joining the boss to the thin gauge case of the electrical devices. In this study, we investigated the performances of the magnesium boss welder To measure the process parameters such as the force and the weld current, we design the monitoring system for CD stud welding. We test the characteristics of CD stud welding for AZ31 sheets at some variables. Finally we select the optimum welding range of magnesium sheets in CD stud welding process.

• Journal of Welding and Joining
• /
• v.16 no.1
• /
• pp.52-62
• /
• 1998

Laser beam welding of zinc-coated steel, especially lap joints, has a problem of zinc vapor produced during welding which has a low vaporization temperature of 906.deg. C. It is lower than the melting temperature of steel (1500.deg. C). The high pressure formed by vaporization of zinc during laser welding splatters the molten pool and creates porosities in weld. During laser lap welds of zinc-coated steel sheets with CW CO$_{2}$ laser the gap size has been analyzed and simulated using a FEM. The simulation has been carried out in the range of gap aetween 0 and 0.16 mm. The vaporized zinc gas has effected to prevent heat from conducting toward the bottom of sheets. In vaporized zinc gas has effected to prevent heat from conducting toward the bottom of sheets. In the case of too small gap size, zinc gas has not ejected and existed between two sheets. Therefore heat was difficult to conduct from the upper sheet to lower sheet and the upper sheet could over-melted. In the case of large gap size the zinc gas has been prefectly ejected but only a part of lower sheet has melted. The optimum range of gap size in the lap welds of zinc-coated steel sheets has been calculated to be between 0.08 and 0.12 mm. According to the comparison of experiment, the simulation is proved to be acceptable and applicable to laser lap welds.

• Journal of Welding and Joining
• /
• v.12 no.3
• /
• pp.71-81
• /
• 1994

Laser cutting is experiencing a rising worldwide acceptance in the industry. Expert systems are necessary for the systematic arrangement and searching of experimental data existing in journal papers, job handbooks, etc.. This paper proposes an expert system for the selection of the appropriate laser cutting variables from the available database. Optimum cutting conditions according to the given cutting velocity were searched and qualitative comments which are difficult to be used as database variables were shown at each velocity using the binary and fuzzy inference. These comments could be informative to unskilled operators of the laser cutting process. Typical cutting conditions of the mild steel and stainless steel were included and the working range and quality variations were displayed graphically. The proposed algorithm was implemented in an IBM compatible personal computer as an expert system for CO$_{2}$ laser cutting to derive the optimum cutting conditions by using the turbo prolog.

• Proceedings of the KWS Conference
• /
• 2002.10a
• /
• pp.511-515
• /
• 2002

Extruded and cast plates of AZ type magnesium alloys were successfully joined by friction stir welding (FSW). Effect of FSW conditions on the formation of the defect was revealed in relation to tool rotation speed and specimen travel speed. Magnesium alloy with higher aluminum content became difficult to be joined and the optimum condition without defect was restricted into narrow condition range. The structure of the stirred zone was a fine-grained recrystallized structure even in the case of cast AZ91D. FSW joint had better mechanical properties than those of GTA welded joint. Especially the toughness of the stirred zone increased more than that of the base metal.

• Proceedings of the KWS Conference
• /
• 2006.05a
• /
• pp.121-123
• /
• 2006

The aim of present study is to investigate the effect of welding parameters and heat treatment conditions on the formability of the laser welded silicon steel sheet. It was found that there is optimum range of the heat input ($0.6{\sim}0.7kJ/cm$) and gap distance ($0.125{\sim}0.150mm$) for the high tensile strength and the avoidance of the fracture in weld metal, Also, it was essential for the improvement of formability to perform pre- and post-welding heat treatment which cause the uniform mixture of base metal and welding consumable.

• Journal of the Society of Naval Architects of Korea
• /
• v.35 no.4
• /
• pp.65-75
• /
• 1998

The $CO_2$ welding with 100% $CO_2$ gas is commonly used because of its cost and efficiency. Arc phenomena and spattering ratio of the $CO_2$ welding are influenced by various factors such as chemical compositions of welding wire, shielding gas, welding condition and welding power source etc.. Spattering ratio is predominantly influenced by the welding condition which determines a droplet transfer rode. In this study, arc phenomena and spattering ratio are investigated by using two type of FCW(titania type, semi-metal type). Then, the welding quality and optimum welding condition can be selected. From this study, the following results ware obtained; 1) In low current range(140A), FCW up to welding voltage(22V) resulted in a typical short circuit transfer, increase of spattering ratio and growth of spatter diameter. 2) In high current range(320A), the arc stability in titania FCW of a typical globular transfer is better than that of semi-metal FCW.

• Special Issue of the Society of Naval Architects of Korea
• /
• 2007.09a
• /
• pp.118-127
• /
• 2007

SAW(Submerged Arc Welding) process is generally applied to a wide range of welding area in the fabrication of steel structure. This process has a good characteristic properties such as the high quality of welds and the high deposition rates, but in case of welding on a thick steel plate, it also has higher cold crack susceptibility than that of a thin steel plate. The purpose of this research is to find the main factor of crack generation and clarify the countermeasure for crack prevention, and then establish the optimum welding condition in a heavy thick steel plate. The results of this study are as follows, 1. The cause of crack generation is found the diffusible hydrogen penetrated into weld metal by decomposition of the remained moisture in SAW flux during welding. 2. For the removal of diffusible hydrogen, the raw materials of SAW flux are to be dehydrated at the high temperature in the initial manufacturing stage. 3. Mechanical properties of weld metal welded with the dehydrated SAW flux were evaluated very excellent, furthermore the weld metal has been proved to have low diffusible hydrogen content with 3.1ml /100g. 4. The weldability and quality welded with thick steel plates were improved by establishing the new optimum welding condition.

• Journal of Ocean Engineering and Technology
• /
• v.13 no.2 s.32
• /
• pp.83-89
• /
• 1999

In this paper an experimental study on the development of the shielded metal are welding(SMAW) optimization technique for the dissimilar materials SS41 and STS304 of Auto-Lifting Magnet core plate was carried out. It was confirmed that the optimum welding heat input range was 37.5 to 45 kj/cm by considering on the strength and fatigue life of the welded joints more than 100% joint efficiency. And the quantitative relationship empirical wquation between the strength toughness adn fatigue life and the weld heat input was obtained.

• Journal of Advanced Marine Engineering and Technology
• /
• v.17 no.4
• /
• pp.38-48
• /
• 1993

A study on friction welding of stainless steel bar(SUS431) to chrome molybdenum steel bar(SCM21) was accomplished experimentally through analysis for relations among friction welding conditions, tension test, hardness test, microstructure test and acoustic emission test. The results obtained are summarized as follows ; 1. Through friction welding of SUS431 bar to SCM21 bar, the optimum welding condition by considering on strength and toughness was found to be the range of heating time of 3-5 sec when the number of rotating speed of 2000rpm, heating pressure of 10kg/$mm^2$, and upsetting time of 4 sec. 2. Quantitative ralationship was identified between heating time($T_1$, sec) and tensile strength (${\sigma},\;kgf/mm^2$) of the friction welded joint and the relation equation is $\sigma$=52.62$T_1{^{0.06}}$. 3. Through AE test, quantitative relationship was confirmed between heating time($T_1$, sec) and total AE(N, counts) during welding, and the relation is computed as follows ; N=30413.6$e^{0.06T1}$. 4. It was confirmed that the quantitative ralationship exists between the tensile strength of the welded joints and AE cumulative counts. And the relation is computed as the following ; ${\sigma}$=16.37(ln N)- 116.4. 5. When ONZ=36500-41500 counts by $OT_1Z$=3~5sec, it was identified by experiment that the range of welded joint tensile strength is 55.6-57.7kgf/$mm^2$/ whose joint efficiency is more than 100%, and it was experimentally confirmed that the real-time nondestructive quality(strength) evaluation for the friction welded joints could be possible by acoustic emission technique.