• Journal of Welding and Joining
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• v.8 no.1
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• pp.31-42
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• 1990

Arc must be stable during welding first of all other factors for obtaining sound weldment, especially in the automation of welding process. Arc stability is somewhat sophisticated phenomenon which is not clearly defined yet. In consumable electrode welding, the voltage and current variation due to metal transfer enables to assess arc stability. Recently, statistical analyses of the voltage and current waveform factors are performed to assess the degress of arc stability which is assessed and controlled by operator's own experience by now. But, considering the increasing need and the trend of automation of welding process, it is necessary to monitor arc stability in real-time. In this sutdy, the modified stability index composed of two voltage and current wvaeform factors (arc time and short circuit time) reduced from four factors (arc time, short circuit time, average arc current and average short circuit current) in Mita's index by the welding electrical circuit modeling is proposed and verified by experiments to be well estimating arc stability in the static sense. Also, the recursive calculation form estimating present arc stability in the dynamic sense is developed for real-time estimation. The results of applying the recursive index during welding show good estimation of arc stability in real-time. Therefore, the results of this study offers the mean for real-time control arc stability.

• Proceedings of the KWS Conference
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• v.43
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• pp.58-60
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• 2004

In the field of welding the behavior of a welded structure under consideration may be predicted via heat transfer and residual stress analysis. In order to facilitate the industrial applications of welding, numerical modeling of heat transfer and residual stress in weldment has been carried out applying Finite Element Method (FEM) and the analysis with the external load including this residual stress due to welding has been done. The present work includes the specialized finite element codes for the calculation of nonlinear heat transfer details and residual stress redistributed along with the external load in the welded structures. A basic interface, which allows models, built in commercial preprocessing package access to the data necessary to build standard input decks for these specialized FEM codes, which are not supported by commercial package. The results from the FEM codes are imported back into commercial package for visualization. In addition the residual stress values are exported to commercial package (such as ANSYS, PATRAN etc.) for further analysis with the external loads, which make the FEM codes fully applicable to the industrial purpose.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.32 no.8
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• pp.668-677
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• 2008

In nuclear power plants, ferritic low alloy steel nozzle was connected with austenitic stainless steel piping system through alloy 82/182 butt weld. Accurate estimation of residual stress for weldment is important in the sense that alloy 82/182 is susceptible to stress corrosion cracking. There are many results which predict residual stress distribution for alloy 82/182 weld between nozzle and pipe. However, nozzle and piping system usually connected through safe end which has short length. In this paper, residual stress distribution for pressurizer nozzle of Kori nuclear power plant was predicted using FE analysis, which consideded safe end. As a result, existing residual stress profile was redistributed and residual stress of inner surface was decreased specially. It means that safe end should be considered to reduce conservatism when estimating the piping system.

• Journal of Ocean Engineering and Technology
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• v.6 no.2
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• pp.76-84
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• 1992

In this study, corrosion fatigue test of SAPH45 steel was performed by the use of plane behavior of base metal (BM) and heat affected zone (HAZ) of SAPH45. The main results obtained are as follows: 1) The more aspect ratio (b/t) of corner crack decreases, the more aspect ratio (b/a) takes greatly effect by corrosion. 2) The correlation between the stress intensity factor range ($\Delta$k) and crack growth rate (da/dN) for weldment in seawater is given by Paris rule as follow: da/dN=C($\Delta$K) super(m). Where m is constant, and the value is 3.82-3.84. 3) The accelerative factor ($\alpha$) of BM and HAZ under seawater is about 1.1-1.9, and ($\alpha$) of HAZ increases more and more under the low $\Delta$K region. 4) HAZ is more susceptible to corrowion than BM because of potential of electrode (E sub(c)) of HAZ becomes more less noble potential than that of BM.

• Journal of Ocean Engineering and Technology
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• v.8 no.1
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• pp.33-40
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• 1994

Welding of structure produces welding residual stresses which influence buckling strength, brittle fracture strength and cold crack on the weld parts. Therefore, it is very important to accurately analyze the residual stress before welding in order to guarantee the safety of weldment. If the weld length is long enough compared to the thickness and the breadth of plate, thermal and mechanical behaviors in the middle portion of the plate are assumed to be uniform along the thickness direction(z-axis). Thus, the following conditions(so-called plane deformation) can be assumed for the plate except near its end;1) distributions of stress and strain are independent on the z-axis;2) plane normal to z-axis before deformation remains plane during and after deformation. In this paper, plane-deformation thermal elasto-plastic problem is formulated by being based on the finite element method. Moreover special regards and paid to the fact that material properties in elastic and plastic region are temperature-dependence. And the method to solve the plane-deformation thermal elasto-plastic problem is shown by using the incremental technique. From the results of analysis, the characterisics of distribution of welding residual stress and plastic strain with the production mechanism are clarified.

• Journal of the Korean Society for Nondestructive Testing
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• v.31 no.4
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• pp.391-397
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• 2011

Conventional film radiographic test has been generally and widely used in the inspection on the weldment for quality assurance. On the other hand, since the analog RT is well known for typical time and cost consuming method with complex process of inspection, the industry has researched various ways how to improve radiographic test technology. In this study, we verified the fact that digital RT provides a lot more benefit in effectively detecting defects, ever film details, through digital processing of image enhancement, compared to film RT. As a result, we reached conclusion that digital RT is positively able to replace the film RT in industry in part or in whole.

• Proceedings of the KAIS Fall Conference
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• 2011.12b
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• pp.382-384
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• 2011

최근 오일샌드, 극지유전, 심해저자원 등 극한지 자원개발이 활발해짐에 따라 수요가 증대되고 있는 극한지용 내마식 소재는 내마식성과 함께 저온 인성이 요구되고 있다. 철계 합금에서 관찰되는 변형유기 마르텐사이트 상변태는 입자의 충돌에 의한 충격을 흡수하고 소재의 표면을 가공경화시켜 내마식성 향상 및 저온 인성에 기여할 수 있을 것으로 기대되고 있지만 합금조성의 정교한 제어가 필요하기 때문에 오버레이 용접에 적용하기 위해서는 모재와의 희석률을 제어하는 방안이 필요하다. 용접플럭스 설계기술은 용접시 금속이행모드, 용융풀 거동 등과 같은 용접현상 제어를 통해 오버레이 용접재료의 용접성과 용접비드형상, 용접부 희석률을 최적화할 수 있는 기술이다. 본 연구에서는 내마식 고인성 오버레이 용접재료의 개발을 위해 다양한 용접플럭스를 첨가한 메탈코어드 와이어를 제조하고 일정 송급속도에서 GMA 용접시 용접전압과 용접전류 간의 관계를 분석하여 용접플럭스가 아크현상 및 희석률에 미치는 영향을 조사하였다.

• Journal of Welding and Joining
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• v.22 no.6
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• pp.57-63
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• 2004

Fracture toughness is an important parameter in designing offshore structures to ensure resistance to fracture at various temperatures. In this study, a series of experiments is carried out to obtain fracture toughness values (CTOD) of API 2W Gr.50B, welded using FCAW(Flux Cored Arc Weld). In particular, a comparison of absorbed impact energy and CTOD values are made with respect to two different welding groove shapes; double-V-groove and double-bevel-groove. Charpy impact tests are performed for specimens sampled near the root gap, and CTOD tests are carried out for three point bending specimens having the notch at weld zone. While Charpy impact test result is determined to be a good qualitative measure of fracture toughness, no quantitative correspondence between impact absorbed energy and CTOD values was found. Based on the experiment, it is observed that double-V-groove welds give lower transition temperature than those of double-bevel-groove.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.694-699
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• 2002

In autobody assembly, thin-wall, tubular connections have been used for the frame structure. Recent interest in light materials, such as aluminum or magnesium alloys, has been rapidly growing for weight reduction and fuel efficiency. Due to higher thermal expansion coefficient, low stiffness/strength, and low softening temperature of aluminum and magnesium alloys, control of welding-induced distortion in these connections becomes a critical issue. In this study, the material sensitivity to welding distortion was investigated using a T-tubular connection of three types materials; low carbon steel (A500 Gr. A), aluminum alloy (5456-H116) and magnesium alloy (AZ91C-T6). An uncoupled thermal and mechanical finite element analysis scheme using the ABAQUS software program was developed to model and simulate the welding process, welding procedure and material behaviors. The predicted angular distortions were correlated to the cumulative plastic strains. A unique relationship between distortion and plastic strains exists for all three materials studied. The amount of distortion is proportional to the magnitude and distribution of the cumulative plastic strains in the weldment. The magnesium alloy has the highest distortion sensitivity, followed by the other two materials with the steel connection having the least distortion. Results from studies of thin-aluminum plates show that welding distortion can be minimized by reducing the cumulative plastic strains by preventing heat diffusion into the base metal using a strong heat sink placed directly beneath the weld. A rapid cooling method is recommended to reduce welding distortion of magnesium tubular connections.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.668-674
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• 2002

Structural integrity assessment is indispensable for preventing catastrophic failure of industrial structures/components/facilities. This diagnosis of operating components should be done periodically for safe maintenance and economical repair. However, conventional standard methods for mechanical properties have the problems of bulky specimen, destructive and complex procedure of specimen sampling. Especially, the mechanical properties at welded zone including weldment and heat affected zone could not be evaluated individually due to their size requirement problem. So, an advanced indentation technique has been developed as a potential method for non-destructive testing of in-field structures. This technique measures indentation load-depth curve during indentation and analyzes the mechanical properties related to deformation such as yield strength, tensile strength and work-hardening index. Also indentation technique can evaluate a residual stress based on the concept that indentation load-depth curves were shifted with the direction and the magnitude of residual stress applied to materials. In this study, we characterized the tensile properties and welding residual stress of various industrial facilities through the new techniques, and the results are introduced and discussed.