• Proceedings of the KWS Conference
• /
• 2009.11a
• /
• pp.239-242
• /
• 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.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.7 no.5
• /
• pp.771-777
• /
• 2006

Recently regulations which make it mandatory to use the environment-friendly goods are increaing in automobiles. In this study the TIG autogenous welding process was developed by solving the problem of previous spot welding of side part and the ceramic protection Jig was developed for the welding of fragile glass ball. And the optimal process parameter was selected by complementing the demerit of the previous filler material welding to fill up the bottom part. Finally the lamp aging test and earthquake resistant test was done to check the reliability of welded brake lamp.

• Proceedings of the KWS Conference
• /
• 2009.11a
• /
• pp.96-96
• /
• 2009

The purpose of this study is to clarify the transitional behavior and main factor of excessive welding distortion caused by fabrication process of STS 304 vacuum vessel having double curvature for the efficient quality control of vacuum vessel. In order to do it, the predictive equations of the welding distortion in simple weldment of vacuum vessel were established by conventional finite element analysis. And the principal factor controlling the welding distortion was identified by evaluating the welding distortion of vacuum vessel in each fabrication process with FEA and simplified thermo elastic method. Based on the results, the principal factors of distortion of vacuum vessel were clarified as angular distortion and transverse shrinkage which are a source of excessive out-of plane distortion in the double curved vacuum vessel. It was expected that the FE analysis results of this study could contribute to establish the proper control method of welding distortion for double curved vacuum vessel.

• Coupled systems mechanics
• /
• v.11 no.3
• /
• pp.267-284
• /
• 2022

Due to the high usage of ABS in industries, such as aerospace, auto, recreational devices, boat, submarines, etc., the purpose of this project was to find a way to weld this material, which gives advantages, such as affordable, high speed, and good connection quality. In this experimental project, the friction welding method was applied with parameters such as numerical control (NC) machine with two different speeds and three cross-sections, including a flat surface, cone, and step. After the end of the welding process, samples were then applied for both tensile and bending tests of materials, and the results showed that, with increasing the machining velocity Considering of samples, the friction of the surface increased and then caused to increase in the surface temperature. Considering mentioned contents, the melting temperature of composite materials increased. This can give a chance to have a better combination of Nanomaterial to base melted materials. Thus, the result showed that, with increasing the weight percentage (wt %) of Nanomaterials contents, and machining velocity, the mechanical behavior of welded area for all three types of samples were just increased. This enhancement is due to the better melting process on the welded area of different Nano contents; also, the results showed that the shape of the welding area could play a significant role, and by changing the shape, the results also changed drastically.A better shape for the welding process was dedicated to the step surface.

• Proceedings of the KWS Conference
• /
• 2002.10a
• /
• pp.70-75
• /
• 2002

The penetration potential of TIG welding in one single run is limited, though the process itself generates high quality welds with good weld cosmetics. This is one of the main reasons, which has contributed to its development in high duty applications such as those encountered in aeronautical, aerospace, nuclear & power plant applications. For these applications, stainless steels, titanium k nickel based alloys are most often used. As these materials remain very sensible to weld heat input k atmospheric pollution, stringent processing conditions are imposed. For example welding of titanium alloys requires argon shielding of weld zone and for 5 mm thick plates multi-pass runs & filler additions are required. This multi-run operation not only raises the welding cost, but also increases defect risks. In recent years, extensive interest has been raised by the possibility to increase weld penetrations through flux applications & the process is designated ATIG-activated TIG, or FBTIG-flux bounded TIG. The improved welding performance of such flux assisted TIG is related to arc constriction and surface tension effects on weld pool. The research work by authors has lead to the formulation of welding fluxes for stainless steels k titanium alloys with TIG Process. These fluxes are now commercialized & some applications in industry have already been carried out. FBTIG for aluminum has been proposed with silica application for AC mode TIG welding. The paper highlights the fundamentals of flux role in TIG welding and illustrates some industrial applications.

• Journal of Welding and Joining
• /
• v.32 no.6
• /
• pp.8-13
• /
• 2014

One of the main challenges of the automatic arc welding process which has been widely used in various constructions such as steel structures, bridges, autos, motorcycles, construction machinery, ships, offshore structures, pressure vessels, and pipelines is to create specific welding knowledge and techniques with high quality and productivity of the production-based industry. Commercially available automated arc welding systems use simple control techniques that focus on linear system models with a small subset of the larger set of welding parameters, thereby limiting the number of applications that can be automated. However, the correlations of welding parameters and bead geometry as welding quality have mostly been linked by a trial and error method to adjust the welding parameters. In addition, the systematic correlation between these parameters have not been identified yet. To solve such problems, a new or modified models to determine the welding parameters for tandem GMA (Gas Metal Arc) welding process is required. In this study, A new predictive model called STACO model, has been proposed. Based on the experimental results, STACO model was developed with the help of a standard statistical package program, MINITAB software and MATLAB software. Cross-comparative analysis has been applied to verify the reliability of the developed model.

• Proceedings of the KWS Conference
• /
• 2002.10a
• /
• pp.94-100
• /
• 2002

During the last years, great progress has been made in the fields of welding power sources and filler materials for the MIG-welding of magnesium alloys. This advice resulted in a better welding process, md, therefore, in highly improved welding results. Furthermore the gap between short-circuiting- and spray-arc-trunsfer could be closed by the triggered short-circuiting- and the short-circuiting-arc with pulse overlay. A crucial contribution to the welding process is the energy input into the filler material. Many problems result from the physical properties of magnesium, for instance its narrow interval between melting point 600$^{\circ}C$ and vaporization point 1100$^{\circ}C$. The energy input into the filler material has to be regulated in such a way that the wire will melt but not vaporize. For th is reason, special characteristics of power sources hue been examined and optimized with the help of high-speed-photographs of the welding process with particular consideration of the drop detachment. An important improvement of the weld seam profile has been achieved by using filler material of only 1.2 mm in diameter. The experiments hue been made with 2.5 mm thick extruded profiles of AZ31 and AZ6l. The results of tensile testing showed strength values of 80 to 100% of the base metal. B ending angles up to 60$^{\circ}$ have been reached. The fatigue strength under reversed bending of the examined magnesium alloys after welding reaches 50% of the strength of the base metal. When the seam reinforcement is ground of the fatigue strength can be raised up to 75% of the base metal.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.28 no.2
• /
• pp.165-173
• /
• 2004

Laser beam welding is increasingly being used in welding of structural steels. The laser welding process is one of the most advanced manufacturing technologies owing to its high speed and deep penetration. The thermal cycles associated with laser welding are generally much faster than those involved in conventional arc welding processes, leading to a rather small weld zone. Experiments are performed for 304 stainless steel plates changing several process parameters such as laser power, welding speed, shielding gas flow rate, presence of surface pollution, with fixed or variable gap and misalignment between the similar and dissimilar plates, etc. The following conclusions can be drawn that laser power and welding speed have a pronounced effect on size and shape of the fusion zone. Increase in welding speed resulted in an increase in weld depth/ aspect ratio and hence a decrease in the fusion zone size. The penetration depth increased with the increase in laser power.

• Journal of the Korean Society of Manufacturing Technology Engineers
• /
• v.19 no.4
• /
• pp.511-520
• /
• 2010

In general, spot welding is used at no welding rod or flux for the process, low welding point temperature compared to arc welding, short heating time, less damage to the parent material, and low deformation and residual stress, relatively. Also, because of the pressurization effect, better mechanical qualities of the welding parts are obtained. Therefore, in various fields of industry its rapid operation speed can make mass production possible such as motor industry. In FEM analysis for the spot welding process, it is effective to use simple modeling rather than complicated one because of its numerous number of spots and reduction of analysis time. Therefore, this study provides with not only simplification of modeling analysis by using beam component composition of structure without re-compositing the spot welding point mesh but also modeling analysis of which property of fracture strength is reflected. In addition complete spot welding model is examined at rectangular post shape (hat shape) by impact test, compared the results, and verified its validity. As a result, it is possible to optimize the welding position and to recognize the strength of structure and the proposed equal distance model shows the effect of welding point reduction and improvement of stiffness.

• Journal of Welding and Joining
• /
• v.28 no.5
• /
• pp.99-105
• /
• 2010

Inverter DC resistance spot welding process has been very widely used for joining such as automotive body sheet metal. Because the lobe area of DC welding is larger than AC welding and DC welding has low electrode wear. So the use of Inverter DC resistance spot welding process has been further increased. And the application of high tensile steel is growing for light weight vehicle. To improve the weldability of high strength steel, the development of Inverter DC resistance spot welding system is more conducted. However, Inverter DC resistance spot welding system has a few problems. Current waveform is unstable and the expulsion has been occurred by characteristics of steel. In this study, inverter DC resistance spot welding system was made. And Fuzzy control algorithm was applied for constant current. The genetic algorithm was applied to optimize the fuzzy scaling factors, in order to optimize the fuzzy control.