• Transactions of Materials Processing
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• v.19 no.8
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• pp.452-459
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• 2010

It was investigated that two plates of aluminum can be welded by hot extru-shear welding process with extru-shear welding dies, and that the welding strength and metal flow on the welding section were analyzed by computer simulation according to the welding variables such as inclined angle of cutter and overlapped length of plates and temperature of plates. It was known by computer simulation that welding strength on the welding section of plates could be influenced by the inclined angle of cutter and overlapped length of plates and temperature of plates. And it was known by experiments that two plates of aluminum can be welded on the end sections by hot extru-shear welding process using extru-shear welding dies, and that welding strength is the highest when inclined angle of dies is $70^{\circ}$, and overlapped length is 1.2 mm, and temperature is $520^{\circ}$, when aluminum 5052 two plates with 1.6 mm thickness are used as welding material.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.426-430
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• 2008

Hot shear-welding is a process of bonding two plates together by using shearing stress in a controlled manner. This study dealt with the hot shear-welding process of two aluminum plates. These two plates were piles up in the shear-welding mold. Due to the shearing stress, these two plates were cut off longitudinally, and meantime they were welded together. During this process the control of the surplus material flow is very important, and it can be realized by designing the overlapping length and the shape of the cavity. The commercial software Deform-3D was employed to predict the effect of these two factors. The overlapping length and the shape of the cavity that presents the optimum design was then developed to get a good shear-welding process.

• Journal of Welding and Joining
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• v.20 no.2
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• pp.95-101
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• 2002

After high power lasers are avaliable in the commercial market, the number of applications of the laser welding has been increased in manufacturing industries. Although the tailored blank laser welding of butt jointed steel sheets is well known recently in the automotive industries, the lap joint laser welding is a new technology to the automotive manufacturing people as well as the design people. But the deep penetration laser welding seems to be preferred to the partial penetration welding for the lap joint welding in the automotive manufacturers because the partial penetration is a serious deflect for the butt joint. In this study, the feasibility of partial penetration welding fur the lap joint $CO_2$ laser welding was studied fur the 1mm thick 390MPa high strength steel sheets for automotive bodies. The process window of the lap joint partial penetration welding was obtained from experiments with the gap size and the welding speed as process parameters. The partial penetration welding was found excellent on the basis of the tensile shear strength and sectional geometry. The bead width, input energy Per volume, tensile-shear strength, deformation energy and the sectional geometries after tensile-shear tests of partial penetration welded specimens are compared with those of full penetration welded specimens with a series of gaps and welding speeds.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.15 no.4
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• pp.98-104
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• 2006

In this paper, for the purpose of investigation the acoustic emission(AE) behaviors during resistance spot welding process and tension test of spec steels. As the results present the resistance spot welding method that can get suitable welding qualities or structural integrity estimating method. The resistance spot welding process consists of several stages: set-down of the electrodes; squeeze; current flow; forging; hold time; and lift-off. Various types of AE signals are produced during each of these stages. For tensile-shear test and cross tensile test in resistance spot welded specimens, fracture pa 야 ems are produced: tear fracture; shear fracture; and plug fracture. Tensile-shear specimens strength appeared higher than cross tensile specimens one. In case of tensile-shear specimen happened tear fracture that crack happens in most lower plate. Also, in case of cross tensile specimens, upper plate and lower plate are detached perfect fracture was exposed increases a little as acting force is lower than ordinary welding condition. Therefore, the structure which is combined by resistance spot welding confirmed that welding design must attain so that shear stress may can interact mainly.

• Transactions of Materials Processing
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• v.21 no.8
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• pp.467-472
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• 2012

Shaving shear-welding is a solid-state welding process, which utilizes plastic deformation of surplus material. The solid-state nature of this process contributes to high integrity and strength of the weld. The objective of this study was to investigate the effects of process variables on the material flow patterns and identify the process condition for obtaining the best weld. FEM simulations were carried out along with experimental characterizations. The results showed the importance of the cutter angles and the overlap lengths, and helped attain the optimum shaving shear-welding die and the best process condition.

• 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 Welding and Joining
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• v.31 no.6
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• pp.58-64
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• 2013

Several joining methods involving resistance welding, laser welding, ultrasonic welding and mechanical joining are currently applied in manufacturing lithium-ion batteries. Cu and Al alloys are used for tab and bus bar materials, and laser welding characteristics for these alloys were investigated with similar and dissimilar material combinations in this study. The base materials used were Al 1050 and oxygen-free Cu 1020P alloys, and a disk laser was used with a continuous wave mode. In bead-on-plate welding of both alloys, the joint strength was higher than the strength of O tempered base material. In overlap welding, the effect of welding parameters on the tensile shear strength and bead shape was evaluated. Tensile shear strength of overlap welded joint was affected by interfacial bead width and weld defect formation. The tensile-shear specimen was fractured at the heat affected zone by selecting proper laser welding parameters.

• Journal of Welding and Joining
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• v.18 no.1
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• pp.52-58
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• 2000

Spot welding, namely a kind of electric resisting welding has been used widely in field of automobile and aircraft industries because of easiness to apply. Specimens used in this study was a mild steel of 1.2mm thickness and the electrode was a Cu-Cr alloy of 6mm diameter. The surface sheared of specimens after testing of tensile shear was observed by SEM(scanning electron microscope) after ultrasonic cleaning for 10min., and microstructures and grain size of all specimens were measured with using of O.M.(Optical microscope). By the means of measurement and observations of tensile shear load, fatigue strength and share surface, the weldability of spot welding was evaluated. When tensile shearing testing, fracture starting point in all specimens was took place at the bond between HAZ(Heat affected zone) and nugget. With increasing in number of layers, fatigue strength was decreased. With increasing in electric current, grain size in the HAZ became more fine.

• Journal of Welding and Joining
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• v.21 no.2
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• pp.70-75
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• 2003

Spot welding is a process that sheet metals are joined in one or more spot by heating at the faying interface. In this process, the spatter is dispersed from melted area. It has been reported that spatter generation has adverse effects on weld quality. However, no systematic study has been carried out to find out its effect on weld quality in resistance spot welding processes. In this study, specially designed specimen are used to perform experimental investigation of spatter generation and its effect. Major finding of this study show trends in tensile-shear strength for various amounts of spatter generated during spot welding process. Thus, optimum welding conditions are proposed in view of spatter generation and tensile-shear strength. (Received December 11, 2002)

• Journal of Welding and Joining
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• v.25 no.4
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• pp.65-71
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• 2007

Laser weldability of the aluminized steel for the full penetration welding will be described in this paper. We focused on the effect of Al coating conditions on weld strength. For these objectives, aluminized steel sheets that have various thickness and coating weight were prepared for laser welding. And then, tensile-shear and hardness test were carried out. At the same time, Al contents in weld after laser welding were analyzed and their correlations with mechanical properties were investigated. Besides, as removing partially coating layer, weldability has been investigated according to the position of coating layer. As a result of this study, tensile-shear strength was decreased with increasing Al contents in weld, and Al of coating layer caused grain growth.