• Transactions of the Korean Society of Automotive Engineers
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• v.11 no.6
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• pp.101-107
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• 2003

Since stainless steel sheets have good mechanical properties, weldability, appearance and corrosion resistance, they are commonly used as one of the structural materials of the railroad cars or the commercial vehicles which are manufactured by the spat welding. Among the many kinds of spot welded lap joints, it can be found that multi-lap joints are employed in their body structure. But, fatigue strength of these joints is lower than that of base metal due to high stress concentration at the nugget edge of spot weld and is considerably influenced by welding conditions as well as the mechanical and geometrical factors. Thus, it is necessary to establish a reasonable and systematic design criterion for the long life design of the spot-welded body structures. In this paper, the stress distribution and deformation around the spot-welded multi-lap joints subjected to tensile shear load was numerically analyzed. Also, the $\Delta$P-Nf curve was obtained by fatigue tests. Using these results, $\Delta$P-Nf curves were rearranged in to the ${\Delta}{\sigma}$-Nf relation with the maximum stress at nugget edge of spot weld.

• Transactions of the Korean Society of Automotive Engineers
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• v.16 no.4
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• pp.179-185
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• 2008

The purpose of this paper is to propose a systematic method on the weld pitch design of a vehicle sub-frame considering the fatigue life of spot welding points. The input data, which perform the fatigue analysis on the spot welding nuggets, are obtained by both the dynamic analysis of the multi-body vehicle model passing through the virtual proving ground of a typical Belgian road and the quasi-static analysis with the finite element model of the vehicle sub-frame. By utilizing the life cycle data obtained from the fatigue analysis, the welding points to perform the pitch change are determined. The sensitivity analysis on the fatigue life of the welding points is carried out by using the three-level orthogonal array design, and through the results of the sensitivity analysis, the best combination on the welding pitch is determined. This study shows that as compared with the baseline design, the sub-frame redesigned by the proposed technique improves the fatigue life about 7 percent while reducing the number of welding points about 19 percent.

• Proceedings of the KSME Conference
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• 2001.11a
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• pp.55-60
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• 2001

The automobile is made up of thousands of parts. Some parts are formed by pressing and combined by spot welding. To find weldability conditions of spot welding, clearance between two welding plates was made and after spot welding, weldability is evaluated by means of tensile shear load, nugget size and shape. Specimen used in this study was a steel plate of 1.2mm thickness and electrode was Cu-Cr alloy of 6mm diameter. When spot welding started, the clearance of two specimens was changed 0mm, 3mm and 5mm and distance from vise to measure influence of bending moment 25mm, 45mm, 65mm step by step. The fractured surface of specimen after this test was observed by Optical Microscope to measure microstructure and nugget shape. When clearance of two specimen was 3mm and 5mm, strength and nugget size was decreased and nugget shape was not clear. The much bending moment and crosshead speed are the much tensile shear load is.

• Transactions of the Korean Society of Mechanical Engineers
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• v.7 no.3
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• pp.313-318
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• 1983

It is required in designing a spot welding to get in advance an estimated figure of nugget diameter. A method of estimating nugget diameter of low carbon steel sheets is suggested in tesms of utilizing elastic calculation in theory and of making a sectional observation of specimen of spot welding in experiment. The resultant findings are summarized as follows: 1) A contact diameter of sheet, 2.gamma.$_{o}$=d sub e/+(1.1)t, wheer de is the electrode tip diameter and t is the thickness of sheets. 2) The practical measurement of the nugget diameter reveals that $d_{n}$=(1.05) $d_{e}$+(0.9)t, and $d_{b}$ is less by 0.8-4.3% than 2.gamma.$_{o}$. 3) The more $d_{n}$ is as compared with t, the less the difference between a theoretical value and an experimental value is. 4) In the spot welding of thin steel sheets less than 3mm in thickness that are commonly used in sheet metal works, the contact diameter equals the nugget diameter. In this case, either the theoretical or experimental approach can be used for estimating the nugget diameter.meter.ter.r.

• Journal of Welding and Joining
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• v.19 no.6
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• pp.622-629
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• 2001

The aim of this experiment is to establish the method that obtains symmetrically two nuggets in microresistance series spot welding. The sheets of austenite stainless steel STS304 applied to various electronic parts were experimented by the inverter welding power source of polarity controllable type and by the twin head for left and right electrode force to be controlled separately. The experimental results were obtained as follows : 1) When series spot welding was carried out by DC 1 pulse as welding current with same electrode force at left and right, the asymmetry of nuggets was resulted from the larger nugget of the (-) pole because of the Peltier effect. The dynamic resistance of weld spot at left and right was appeared differently according to the growth of nuggets. 2) When AC 1 cycle by welding power source of polarity controllable type was applied, the nuggets were almost symmetrically formed. 3) In a twin head, if the electrode force of (-) pole was larger than that of (+) pole, the diameters of two nuggets became to same. It was confirmed that the dynamic resistance of (-) pole was decreased to the same level as it of (+) pole. 4) Although the forces of left and right electrode were same, and only DC 1 pulse was applied, symmetric nuggets were obtained if the conductivity of (+) pole was lower than it of (-) pole.

• Proceedings of the KWS Conference
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• 2010.05a
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• pp.48-48
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• 2010

소형 공조장치용 냉매 압축기 부품인 기계식 제어 밸브는 에어컨 컴프레서의 핵심부품이고 년간 수백만 개가 국내에 수입된다. 이를 국산화 하기 위하여 진공로 속에서의 브레이징 공정이 수반되는 외국제품의 제조공정을 탈피하여 진공 속에서 DC 프로젝션 용접을 수행하는 기법을 개발하였다. 실린더 형상의 캡과 케이스를 맞대고 그 사이에 박판을 삽입한 상태에서 butt welding 방식으로 진행되는 본 공정에서는, 생산성이 높고 서보가압 장치를 사용하여 soft touch 를 구현하므로 프로젝션이 손상되지 않은 상태에서 통전이 시작되고 2 단 가압 및 프로파일 가압이 가능하므로 링(ring)형상의 너깃이 축대칭으로 안정적으로 형성되기 때문에 실린더 내부의 밀봉성능이 우수함을 확인하였다. 진공로 속에서 본 가압장치를 설치하여 간편한 방법으로 실린더 내부의 진공상태를 유지할 수 있기 때문에 진공로 속에서의 브레이징 공정이 적용되는 외국제품보다 생산성이 월등함을 알 수 있다. 본 연구에서 개발된 링 프로젝션(ring projection) 용접기법은 초소형 및 소형 실린더 형상의 부품 내부를 진공으로 유지해야 하는 산업현장에서 당장 적용될 수 있는 혁신적인 용접공정이라 판단된다.

• Transactions of the Korean Society of Mechanical Engineers
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• v.8 no.3
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• pp.224-231
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• 1984

Having found by means of a tension-shear test an optimal spot welding condition under which the maximum weld strength is to be brought forth, this study made an examination of behavior of fracture concerned with behavior of stress distribution, observed around the nugget periphery of the specimens prepared under the optimal conditions, with one point spot welded mild steel sheets. The resultant findings are as follows: (1)There remarkably exists an optimal spot welding condition to indicate the maximum weld strength, and fracture of the specimens spot welded under that condition occurs outside the nugget boundary. (2)An experiment on the basis of a photoelastic model reveals that the maximum stress is distributed along the center line of the steel plate width but occurs on the region corresponding to heat affected zone of spot welds. (3)Heat affected zone of spot welds consists of coarse grains with considerably low micro Vickers hardness value and of fine grains of high micro Vickers hardness value, and in this unbalanced structure weak region are represented in coarse grain region, where fracture is initiated and continues its propagation.

• Transactions of the Korean Society of Automotive Engineers
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• v.13 no.5
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• pp.42-49
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• 2005

In general, multi-lap spot weld joints are frequently present in automobile. Most research, however, has been focused on the single-lap spot weld joints until now. In this paper, tensile-shear strength tests are performed to examine the weldability of 3-lap spot joint welded by using the high strength steel sheet and the zinc coated steel sheet. The indentation depth and nugget diameter are used to propose the optimum welding conditions. The weldability is affected by the welding current and welding time for 3-lap spot joint. Meanwhile the expulsions is round to decrease with the increase of electrode force. The optimum welding conditions are presented for 3-lap spot joints of high strength steel sheet and zinc coated steel sheet.

• Journal of Welding and Joining
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• v.29 no.5
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• pp.99-105
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• 2011

In this study, effect of Si content on nugget diameter in electric resistance spot welded dual-phase(DP) steel was investigated. The cold rolled DP steels with different Si content (0.5, 1.0, 1.5, 2.0 wt.%) were used and thickness of those sheet was 1.2mm. With increasing Si content, nugget diameter was increased at the same welding current. This is attributed to increase of heat input result from high resistivity. Also, nugget diameter was increased with an increase in Si content for the same heat input. For this reason, the melting point of DP steel is lowered with an increase in the Si content. And solid DP steel can easily be transformed to a liquid phase because the low melting point. Finally, a prediction formula for the nugget diameter(N.D.) could be obtained in terms of heat input(Q) and melting point(M.P) as follows: N.D.(mm) = 0.11Q(J) - 0.0031 M.P.($^{\circ}C$) + 0.32.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.5
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• pp.58-63
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• 2008

Cold rolled and high strength steel were used for vehicle bodys to satisfy environmental regulation and improve fuel ratio. This paper presented a method far determining the fatigue life of cold rolled steel sheet EZNCEN and high strength steel sheet HS40R spot weldment used in vehicles. We can estimate the fatigue life of the spot weldments from the MSC/FATIGUE using the finite element method. The maximum load is found in the nugget part of both surfaces. The cold rolled steel and the high strength steel showed the maximum stress 746MPa and 730MPa in the effective nugget part when the weld current was 8KA and 7KA, respectively. Also the some weld current of the cold rolled steel and high strength steel is applied, the fatigue life of high strength steel is obtained about four times longer than the cold rolled steel.