• Transactions of Materials Processing
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• v.26 no.4
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• pp.222-227
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• 2017

In order to respond to environmental regulations and increased demand for fuel economy, the demand for lightweight car bodies has grown. Hydroforming of aluminum is one possible solution as it eliminates the need for additional welding to develop closed cross-sectional parts. However, the low formability of aluminum is a limitation of its application. On the other hand, the ductility of materials can be improved at higher temperatures, and hot metal gas forming has been widely applied in the production of lightweight vehicle parts. In this study, aluminum alloy for pipe extrusion was developed by controlling the Mg:Cr:Mn ratio based on AA5083. Mechanical properties of the developed material were examined by tensile test and were applied to a forming simulation. Cold forming simulation for preforming and non-isothermal hot forming simulation for hot metal gas forming were carried out to validate process conditions. A prototype of the sidemember was manufactured under the given process condition. Finally, thickness distribution was compared with finite element analysis results.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.7
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• pp.116-123
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• 2008

In the fossil power plant, the reliability of the components which consist of the many welded parts depends on the quality of welding. The residual stress is occurred by the heat flux of high temperature during weld process. This decreases the mechanical properties as the strength of fatigue and fracture or causes the stress corrosion cracking and fatigue fracture. Especially, the accidents due to the residual stress occurred at the weld parts of high-temperature and high-pressure pipes and steam headers. Also, the residual stress of the welded part in the recently constructed power plants has been brought into relief as the cause of various accidents. The aim of this study is the measurement of the residual stress using the x-ray diffraction method. The merits of this are more accurate and applicable than other methods. The materials used for the study is P92 steel for the use of high temperature pipe on super critical condition. The variables of tests are the post-weld heat treatment, the surface roughness and the depth from the original surface. The test results were analyzed by the distributed characteristics of the full width at half maximum intensity (FWHM) in x-ray diffraction intensity curve and by the relation of hardness with FWHM.

• Journal of Ocean Engineering and Technology
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• v.19 no.5 s.66
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• pp.34-42
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• 2005

The cable connection zone of the cable-stayed bridge transfers deal-load, live-load, and second-load to the cables on the structural joint zone of the cables and the main girders are the most critical parts in which big cable tensile forces are generated by those loads. Therefore, it is necessary to thoroughly check the main girder, structurally to secure the required stability. Because of the heavy tensile force of cables linked in the connection zone of the cable-stayed bridge, locally concentrated stress, as well as the dispersion of stress, occurs in the structurally contacted point of cable and main girder thus, we need to make a thorough investigation through a detailed structural analysis. Directly delivering the tensile force to the connection zone of the cable, the consequently big effect in the tensile force fluctuation caused by the live-load will make it necessary to review the fatigue strength. As the connection zone of the cable is designed to resist the tensile force of the cable, which is applied to a connecting section as a concentrated force, thick plates are used. These plates are frequently made of welded structure, thus, the investigation of the welding workability is inevitable.

• The Transactions of the Korean Institute of Power Electronics
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• v.7 no.1
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• pp.48-54
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• 2002

This paper is described the indirect induction heated boiler and induction heated hot air producer using the voltage-fed series resonant high-frequency inverter which can operate in the frequency range from 20 kHz to 50 kHz. A specially designed induction heater is composed of laminated stainless plates, which have many tiny holes and are interconnected by spot welding. This heater is inserted into the ceramic type vessel with external working coil. This working coil is connected to the inverter and turbulence fluid through this induction heater to moving fluid generates in the vessel. The operating performances of this unique appliance in next generation and its effectiveness are evaluated and discussed from a practical point of view.

• Nuclear Engineering and Technology
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• v.48 no.6
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• pp.1412-1422
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• 2016

Austenitic stainless steels (ASSs) are widely used for nuclear pipes as they exhibit a good combination of mechanical properties and corrosion resistance. However, high tensile residual stresses may occur in ASS welds because postweld heat treatment is not generally conducted in order to avoid sensitization, which causes a stress corrosion crack. In this study, round robin analyses on stress intensity factors (SIFs) were carried out to examine the appropriateness of structural integrity assessment methods for ASS pipe welds with two types of circumferential cracks. Typical stress profiles were generated from finite element analyses by considering residual stresses and normal operating conditions. Then, SIFs of cracked ASS pipes were determined by analytical equations represented in fitness-for-service assessment codes as well as reference finite element analyses. The discrepancies of estimated SIFs among round robin participants were confirmed due to different assessment procedures and relevant considerations, as well as the mistakes of participants. The effects of uncertainty factors on SIFs were deducted from sensitivity analyses and, based on the similarity and conservatism compared with detailed finite element analysis results, the R6 code, taking into account the applied internal pressure and combination of stress components, was recommended as the optimum procedure for SIF estimation.

• Proceedings of the KWS Conference
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• 2009.11a
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• pp.100-100
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• 2009

This paper is concerned with numerical analyses of residual stresses in welds and material's susceptibility to stress corrosion cracking (SCC) for the primary piping system in nuclear power plants: Both the dissimilar metal weld (DMW) for stainless steel to low alloy steel joints and the similar metal weld (SMW) for forged stainless steel to cast stainless steel joints are considered. Thermal elasto-plastic analyses using the finite element method (FEM) are performed to predict residual stresses generated in fabrication welding and its related processes for both the DMW and SMW, including effects of quenching for cast stainless steel piping, machining of the DMW root, and grinding of the SMW root. As a result, the effect of quenching should be included in the evaluation of residual stresses in the SMW for the cast stainless steel piping. It is deemed that residual stresses in both the DMW and SMW would not affect the SCC susceptibility of the welds providing that the welding processes are completed without any weld repair on the inside wall of the joint. However, the grinding process if performed on the safe-end to piping weld, would produce a high level of residual stresses in the inner surface region and thus a stress improvement process (e.g. buffing) should be considered to reduce susceptibilities to SCC.

• Composites Research
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• v.36 no.1
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• pp.37-41
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• 2023

The treated water inside the ballast electrolytic cell creates a highly alkaline atmosphere due to hydroxide generated at the DSA(Dimension Stable Anode) electrode during electrolysis. In this study, a composite material that can replace the weakness of the PE-coated steel pipe used in the existing ballast pipe was prepared. The test samples are BRE(Basalt fiber reinforced epoxy), BRP(Basalt fiber reinforced unsaturated polyester), GRE(Glass fiber reinforced epoxy), and GRP(Glass fiber reinforced unsaturated polyester). And then it was immersed in NaOH for 720 hours. The friction test of each specimen was conducted. The Friction coefficient analysis according to material friction depth and interfacial adhesion behavior between resin and fiber were analyzed. As a result, the mechanism of interfacial separation between resin and fiber could be analyzed. In the case of the unsaturated polyester resin with low interfacial bonding strength the longer the immersion time in the alkaline solution, the faster the internal deterioration caused by the deterioration that started from the surface, resulting in a decrease in the friction coefficient. It is hoped that this study will help to understand the degradation behavior of composite materials immersed in various chemical solutions such as NaOH, acid, and sodium hypochlorite in the future.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.10
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• pp.121-127
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• 2018

A system for diagnosing surface defects of long and large pipe inner overlay welds, 1m in diameter and 6m in length, was developed using a Liquid Penetrant Test (PT). First, CATIA was used to model all major units and PT machines in 3-dimensions. They were used for structural strength analysis and strain analysis, and to check the motion interference phenomenon of each unit to produce two-dimensional production drawings. Structural strength analysis and deformation analysis using the ANSYS results in a maximum equivalent stress of 44.901 MPa, which is less than the yield tensile strength of SS400 (200 MPa), a material of the PT Machine. An examination of the performance of the developed equipment revealed a maximum travel speed of 7.2 m/min., maximum rotational speed of 9 rpm, repeatable position accuracy of 1.2 mm, and inspection speed of $1.65m^2/min$. The results of the automatic PT-inspection system developed to check for surface defects, such as cracks, porosity, and undercut, were in accordance with the method of ASME SEC. V&VIII. In addition, the results of corrosion testing of the overlay weld layer in accordance with the ferric chloride fitting test by the method of ASME G48-11 indicated that the weight loss was $0.3g/m^2$, and met the specifications. Furthermore, the chemical composition of the overlay welds was analyzed according to the method described in ASTM A375-14, and all components met the specifications.

• Corrosion Science and Technology
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• v.14 no.2
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• pp.47-53
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• 2015

Recently, the bending process is greatly applied to fabricate the pipe line. Bending process can reduce welding joints and then decrease the number of inspection. Thus, the maintenance cost will be reduced. Induction heat bending process is composed of bending deformation by repeated local heat and cooling. By this thermal process, corrosion properties and microstructure can be affected. This work focused on the effect of induction heating bending process on the properties of ASME SA106 Gr. C low carbon steel pipes. Microstructure analysis, hardness measurements, and immersion corrosion test were performed for base metal and bended area including extrados, intrados, crown up, and down parts. Microstructure was analyzed using an optical microscope and SEM. Hardness was measured using a Rockwell B scale. Induction heat bending process has influenced upon the size and distribution of ferrite and pearlite phases which were transformed into finer structure than those of base metal. Even though the fine microstructure, every bent area showed a little lower hardness than that of base metal. It is considered that softening by the bending process may be arisen. Except of I2, intrados area, the others showed a similar corrosion rate to that of base metal. But even relatively high rate of intrados area was very low and acceptable. Therefore, it is judged that induction heat bending process didn't affect boric acid corrosion behaviour of carbon steel.

• Laser Solutions
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• v.16 no.3
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• pp.1-10
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• 2013

In this study, Al-Si coated boron steel(1.2 mm) were laser welded by $CO_2$ laser and hot-stamping was applied to the laser joints. Tensile properties and microstructures of the joints were investigated before and after hot-stamping. Tensile and yield strengths of the as welded specimen similar with base metal and fracture occurred base metal of boron steel. Although, in case of heat treated specimen, fracture occurred fusion zone that Al segregated zone near the bond line. These could be explained by the existence of ferrite, in the Al segregated zone near the bond line and base metal of boron steel. Before hot-stamping, hardness of base metal is lower than fusion zone and heat affected zone in spite of exist Al segregation zone($Fe_3$(Al,Si)). So fracture occurred base metal. Although, after hot-stamping, microstructure of base metal and welds zone transformed to martensite and bainite except in Al segregation zone near the bond line that $Fe_3$(Al,Si) transformed to a-ferrite. So fracture occurred Al segregation zone near the bond line.