• 한국기계가공학회지
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• 제19권11호
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• pp.102-108
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• 2020

The demand for lightweight materials and high-strength steel has rapidly increased to help reduce the weight of a vehicle body; it improves the fuel efficiency of automobiles and provides passenger safety. Additionally, as the material becomes thinner, the demand for its resistance against corrosion becomes higher. Hence, the application of the surface-treated steel sheet has surged rapidly. In this study, a weld bonding experiment using a delta spot welding machine is performed on a thin sheet of a different material (Al6061-T6/GA440). The thickness of the material was kept at 1 mm to reduce the weight of the automobile body parts. Additionally, the purpose of this study is to control the heat input by applying the welding conditions of a multi-stage pressure pattern to improve corrosion resistance shear strength. The analysis of nugget diameter measurement, shear tensile test, and salt spray test was performed to achieve the aim.

• Steel and Composite Structures
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• 제18권2호
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• pp.345-355
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• 2015

In this study, the effects of weld parameters on nugget size and tensile-shear strength of welding joint in electrical resistance spot welding of galvanized DP 600 steel sheets having 1.2 mm were investigated. Taguchi design method has been employed to examine the effects of five parameters of welding current, electrode pressure, welding time, clamping time and holding time by using the $L_{27}(5^3)$ orthogonal array. Results showed that the most effective parameters on tensile shear strength and the nugget size ratio (hn/dn) were found as welding current and welding time, whereas electrode pressure, clamping time and holding time were less effective factors. Max. 545 MPa strength was obtained through proposed optimum conditions by Taguchi technique.

• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2009년 추계학술발표대회
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• pp.239-242
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• 2009

Friction stir spot welding (FSSW), developed based on principle of friction stir welding, has been paid attention as a new solid-state spot welding process. Since FSSW can produce high-quality weld in Al alloys more easily than resistance spot welding, this process has been already used for construction of Al components in the automotive industries. Despite the large industrial interests in FSSW, fundamental knowledge on welding phenomena of this process has not been fully understood. In this study, FSSW phenomena, such as the consolidation mechanism, the microstructural evolution and the material flow, were examined in Al alloy 6061. This study clarified that the elliptical zone found in the vicinity of the pin hole on the cross section was characterized by the initially lapped surface of two sheets. Moreover, the following material flow was proposed; capture of the upper material with the threads on the pin surface, spiral flow along the tool rotation, and then release at the tip of the pin.

• International Journal of Korean Welding Society
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• 제5권1호
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• pp.53-59
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• 2005

Auto industry has employed resistance spot welding(RSW) to join steel sheets for structural rigidity of automobile body. Driven by the need to reduce weight and fuel consumption, car companies have been evaluating aluminum intensive vehicles(AIVs) as a way to reduce vehicle weight without downsizing. During the transition from all steel-construction vehicle body to aluminum intensive body, joining aluminum to steel sheets emerges as a serious contender in automobile body. This paper deals with application of transition material to RSW aluminum to steel. Placing transition material insert between the aluminum/steel interface was found very effective to overcome physical incompatibility between aluminum and steel. Use of transition insert allows for two separate weld nuggets to be formed in their respective aluminum/aluminum and steel/steel interfaces. This RSW processes was monitored with the aid of dynamic resistance sampling. Typical patterns in sampled dynamic resistance curves indicated formation of sound nugget. The growth of two separate nuggets was examined by micro-cross section test.

• 한국분말재료학회지
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• 제18권1호
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• pp.64-72
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• 2011

Nondestructive instrumented indentation test is the method to evaluate the mechanical properties by analyzing load - displacement curve when forming indentation on the surface of the specimen within hundreds of micro-indentation depth. Resistance spot welded samples are known to difficult to measure the local mechanical properties due to the combination of microstructural changes with heat input. Particularly, more difficulties arise to evaluate local mechanical properties of resistance spot welds because of having narrow HAZ, as well as dramatic changed in microstructure and hardness properties across the welds. In this study, evaluation of the local mechanical properties of resistance spot welds was carried out using the characterization of Instrumented Indentation testing. Resistance spot welding were performed for 590MPa DP (Dual Phase) steels and 780MPa TRIP (Transformation Induced Plasticity) steels following ISO 18278-2 condition. Mechanical properties of base metal using tensile test and Instrumented Indentation test showed similar results. Also it is possible to measure local mechanical properties of the center of fusion zone, edge of fusion zone, HAZ and base metal regions by using instrumented indentation test. Therefore, measurement of local mechanical properties using instrumented indentation test is efficient, reliable and relatively simple technique to evaluate the tensile strength, yield strength and hardening exponent.

• 한국산학기술학회논문지
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• 제11권9호
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• pp.3155-3160
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• 2010

최근 자동차 산업은 고효율 자동차의 개발에 박차를 가하고 있으며 이에 따라 차체 경량화 및 내식성 방지를 위한 고강도강 및 도금강의 사용이 증가하고 있다. 이에 따라 본 연구에서는 자동차 차체에 쓰이는 3종의 다른 강판에 대하여, 겹침 순서에 따른 용접 특성을 시뮬레이션 기법을 이용하여 분석하였다. 자동차 차체에 많이 사용되는 EDDQ 급의 도금강판 0.7t와 인장강도 440 MPa급의 440R 1.2t, 그리고 AHSS (Advanced High Strength Steel)인 DP 590 0.2t 판재에 대하여 겹치기 순서에 따른 용접 특성을 시뮬레이션 하였고, 너겟 성장 곡선 및 전류에 따른 너겟의 크기로 그 용접성을 분석하였다. 또한 용접 시 발생되는 각 접촉부의 접촉저항을 이용하여 겹침순서에 따른 너겟의 크기를 분석하였으며, 이를 통해 최적의 겹치기 순서를 제안할 수 있었다.

• 전력전자학회논문지
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• 제8권5호
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• pp.397-406
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• 2003

저항 스폿 용접은 자동 용접라인 등에서 널리 사용된다. 최근에는, 대량으로 생산하는 산업현장에서 좀 더 정교한 품질 제어가 필요하게 되었고 마이크로프로세서를 채용한 제어의 다양한 적용으로 높은 생산성과 더 나은 용접품질을 얻을 수 있게 되었다. 본 연구에서는 인버터 타입 파우어 소스와 용접 서보건을 개발하였다. 그 결과, 기존의 공압건에 비해 몇 가지 장점을 갖게 되었는데 그 중의 하나는 용접공정 중에 정밀한 가압력 제어가 가능하게 되었다. 또한, 작업시간도 줄고 경비도 절감되는 부가 효과를 얻을 수 있다고 판단된다.

• Journal of Welding and Joining
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• 제27권4호
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• pp.44-48
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• 2009

In automotive company, a lot of researchers have investigated for the spatterless welding process during last two decades. A spatter influences on the product quality such as strength and surface states. In this paper, a hollow tip is proposed for spatterless process. An optimal size of electrode hole is obtained from a weldability evaluation of each hole diameter. Through the cross section analysis, a phenomenon that molten metal moves in the hole which located between two workpiece is observed, and this makes spatterless welding process even though current is higher. Finally, widely acceptable weld area in lobe curve is obtained by using hollow tip as compare with conventional no hollow tip. In this paper, spatterless resistance spot welding with improvement weldability and productivity is proposed by using hollow tip.

• Journal of Welding and Joining
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• 제31권4호
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• pp.17-22
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• 2013

The excellent beam quality of high power fiber lasers are commonly used for remote welding applications in body job applications. The Welding speed and productivity is unmatched with any other welding technology including resistance spot welding or traditional laser welding. High tooling cost for clamping and bulky safety enclosures are obstacles which are limiting the use. With the newly developed Laser stitch welding gun we have an integrated clamping in the process tool and the laser welding is shielded in a way that no external enclosure is needed. Operation of this laser welding gun is comparable with resistance spot welding but 2-times faster. Laser stitch welding is faster than spot welding and slower than remote welding. It is a laser welding tool with all the laser benefits like welding of short flanges, weld ability of Ultra High Strength steel, 3 layers welding and Aluminium welding. Together with low energy consumption and minimum operation cost of IPG fiber laser it is a new and sharp tool for economic car body assembly.

• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2003년도 춘계학술발표대회 개요집
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• pp.143-145
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• 2003

The purpose of research is to measure power and dynamic resistance value through RMS module. Specially designed RMS-DC hardware module was tested. Its output which is obtained every half cycle was compared with that of commercial weld checker. The results show good agreement and the relative error in the measurement was found to be around 5%.