• Journal of Welding and Joining
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• 제26권2호
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• pp.62-68
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• 2008

Effects of gravitational orientation on gas tungsten arc welding (GTAW) for 304 stainless steel were studied to determine the critical factors for weld pool formation, such as weld surface deformation and weld pool shape. This study was accomplished through an analytical study of weld pool stability as a function of primary welding parameters (arc current and arc holding time), material properties (surface tension and density), and melting efficiency (cross-sectional area). The stability of weld pool shape and weld surface deformation was confirmed experimentally by changing the welding position. The arc current and translational velocity were the major factors in determining the weld pool stability as a function of the gravitational orientation. A 200A spot GTAW showed a significant variation of the weld pool formation as the arc held longer than 3 seconds, however the weld pool shape and surface morphology for a 165A spot GTAW were 'stable', i.e., constant regardless of the gravitational orientation. The cross-sectional area of the weld (CSA) was one of the critical factors in determining the weld pool stability. The measured CSA ($13.5mm^2$) for the 200A spot GTAW showed a good agreement with the calculated CSA ($14.9mm^2$).

• 한국정밀공학회지
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• 제16권10호
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• pp.141-151
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• 1999

The resistance Spot Welding is widely used in the field of assembling the plates. However we don't still have any satisfactory solution, which is non-destructive quality evaluation in real-time or on-line, against it. Moreover, even though the rate of welding under the condition of expulsion has been high until now, quality control of welding against expulsion hasn't still been established. In this paper, it was proposed on the quality assurance technique of resistance spot welding pieces using Neuro-Fuzzy algorithm. Four parameters from electrode separation signal in the case of non-expulsion, and dynamic resistance patterns in the case of expulsion are selected as fuzzy input parameters. The parameters consist of Fuzzy Inference System are determined through Neuro-Learning algorithm. And then, fuzzy Inference System is constructed. It was confirmed that the fuzzy inference values of strength have within ${\pm}$4% error specimen in comparison with real strength for the total strength range, and the specimen percent having within ${\pm}$1% error was 88.8%. According to KS(Korean Industrial Standard), tensile-shear strength limit for electric coated of zinc is 400kgf/mm2. Judging to the quality of welding is good or bad, according to this criterion and the results of inference, the probability of misjudgement that good quality is valuated into poor one was 0.43%, on contrary it was 2.59%. Finally, the proposed Neuro-Fuzzy Inference System can infer the tensile-shear strength of resistance spot welding pieces with high performance for all cases-non-expulsion and expulsion. And On-Line Welding Quality Inspection System will be realized sooner or later.

• Journal of Welding and Joining
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• 제20권2호
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• pp.102-108
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• 2002

Resistance spot welding of aluminum alloys is based upon Joule heating of the components by passing a large current in a short duration. Since aluminum alloys have the potential to replace steels fur automobile body assemblies, it is important to study the process robustness of aluminum spot welding process. In order to evaluate the effects of process parameters on the weld quality, major process variables and abnormal process conditions were selected and analyzed. A newly developed two-stage, sliding-level experiment was adopted fur effective parameter design and analysis. Suitable ranges of welding current and button diameters were obtained through the experiment. The effects of the factors and their levels on the variation of acceptable welding current were considered in terms of main effects. From the results, it is concluded that any abnormal process condition decreases the suitable current range in the weld lobe curve. Pareto analysis of variance was also introduced to estimate the significant factors on the signal-to-noise (S/N) ratio. Among the six factors studied, fit-up condition is found to be the most significant factor influencing the SM ratio. Using a Pareto diagram, the optimal condition is determined and the SM ratio is significantly improved using the optimal condition.

• 소성∙가공
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• 제19권8호
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• pp.460-467
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• 2010

It was studied that two plates of aluminum can be welded by extru-riveting experiments with extru-rivet welding dies, and that the welding strength and metal flow on the welding section were analyzed by computer simulation according to the welding variable such as the diameter of extrusion insert dies. It was known by computer simulation that welding strength on the welding section of plates could be influenced by the diameter of extrusion insert dies. And it was known by experiments that two plates of aluminum can be welded on a spot point on aluminum plate by extru-rivet welding process, and that welding strength is higher and higher if the diameter of extrusion insert die is smaller and smaller, and that welding strength is the highest when diameter of extrusion insert dies is ${\emptyset}4.2$mm in the case that the diameter of rivet is 5 mm, when aluminum 5052 two plates with 1.5 mm thickness and one plate with 3mm thickness for rivet plate are used as welding material.

• 전력전자학회논문지
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• 제15권3호
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• pp.218-225
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• 2010

본 논문은 인버터 AC 스폿용접시스템의 용접시간을 최소화하기 위한 방법에 관한 것이다. 기존의 SCR 회로방식을 이용한 스폿용접시스템의 경우 제어속도가 느리고 전류제어가 정밀하지 않다. 따라서 최근에는 인버터를 이용한 용접시스템이 점차 증가하고 있다. 2차전지의 전극과 같은 박판을 용접해야 하는 경우에는 용접시간이 수 [ms] 정도로 짧아야 한다. 수 [ms] 정도로 용접시간을 최소화하면서 수 천 [A]에 달하는 대전류를 흘리기 위해서 일반적으로 수십개의 스위칭 소자들을 병렬로 연결하여 사용하기도 한다. 본 논문에서는 단지 4개의 IGBT로 구성된 인버터와 60[Hz] 변압기만으로 수 [ms] 대의 용접이 가능한 비용절감형 용접시스템을 제안하고 특성을 분석하였다. 그리고 실험을 통하여 타당성과 효용성을 입증하였다.

• Journal of Welding and Joining
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• 제32권5호
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• pp.44-49
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• 2014

The effect of weldbond hybrid joining process on the mechanical behavior of single lap and L-tensile joints was investigated for the newly developed 1.2GPa grade ultra high strength TRIP(transformation induced plasticity) steel. In the case of single lap shear behavior, the weldbond joint of 1.2GPa TRIP steel showed lower maximum tensile load and elongation than that of the adhesive bonding only. It was considered to be due to the reduction of real adhesion area, which was caused by the degradation of adhesive near the spot weld, and the brittle fracture behavior of the spot weld joint. In the case of L-tensile behavior, however, the maximum tensile load of the weldbond joint of 1.2GPa TRIP steel was dramatically increased and the fracture mode was change to the base metal fracture which is desirable for the spot weld joint. These synergic effect of the weldbond hybrid joining process in 1.2GPa TRIP steel was considered to be due to the stress dissipation around the spot weld joint by the presence of adhesive which resulted in the change of crack propagation path.

• Journal of Welding and Joining
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• 제5권3호
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• pp.11-18
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• 1987

Effects of electrode tips shapes of spot welding on the galvannealed steel have been studied, and the results obtained from this studies are as follows. 1) Expulsion had no effect on the shear strength of the specimen but been observed on the tensile strength of the specimen. 2) Effect of holding time after welding was neglegible when the spot welding supplies enough heat input. 3) Depending on the sopt welding tip shape it has different weldbility. It has better weldability in the order of pointed shape, truncated shape and dome shape. But the effect of coolind was just the opposite of the above order.

• Journal of Welding and Joining
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• 제34권6호
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• pp.28-34
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• 2016

Galvannealed(GA) steels are now generally used in car body manufacturing for corrosion resistance. In this study, the weldability and joint mechanical behavior of a newly developed 1.2GPa grade GA ultra high strength TRIP(transformation induced plasticity) steel was investigated for three joining processes, such as adhesive bonding, resistance spot welding and weldbonding. Under both shear and peel stress conditions, the failure mode of the adhesive joints were the mixture of the adhesive cohesive failure, adhesive interface failure and coating layer failure. It means that the adhesion strength of GA coating onto the base metal was similar to that of adhesive bonding onto the GA coating. Under the shear stress condition, the weldbonding exerted to expand the optimal spot welding condition of 1.2GPa GA TRIP steel because the strength of adhesive bond overwhelmed that of the resistance spot weld. Under the peel stress condition, the weldbonding also exerted to expand the optimal spot welding condition of 1.2GPa GA TRIP steel by inducing the tear fracture mode rather than the partial plug fracture mode.

• 한국공작기계학회논문집
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• 제16권2호
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• pp.14-22
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• 2007

In this paper, the acoustic emission(AE) behaviors were investigated with single-and 2-spot resistance spot welded SPCC specimens. Test specimens were welded horizontally and/or vertically according to the rolling direction of base netal in 2-spot welding. In the case of 2-spot welding, when tensile-shear test has below amplitudes: crack initiation $50{\sim}60dB;$ tear fracture $40{\sim}50dB$. And when cross tensile test has below amplitudes: early stage $75{\sim}85dB;$ yielding point $65{\sim}75dB;$ post yielding $40{\sim}60dB;$ plug fracture $70{\sim}80dB\;or\;90{\sim}100dB$. Also, from the b-value that is slope of AE amplitude, we knew that there are lots of low amplitudes if b-value is big(i.e., tensile-shear $specimen{\rightarrow}tear$ fracture or shear fracture), and there are lots of high amplitudes if b-value is small(i.e.. cross tensile $specimen{\rightarrow}plug$ fracture). As the results of fiacture mechanism analyses through AE amplitude distributions, change of the b-value represented fracture patterns of materials. Correspondingly, low amplitude signals appeared in crack initiation, and high amplitude signals appeared in base metal fracture. We confirmed that these amplitude distributions represented the change or degradation of materials.

• Journal of Welding and Joining
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• 제30권2호
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• pp.76-80
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• 2012

In this study, the effect of the welding current on the hardness characteristics and microstructure in the resistance spot welding of 1GPa grade cold-rolled DP steel was investigated, Also, correlation between the hardness and microstructure was discussed. In spite of the change in the welding current, the hardness distributions near weld was similar. the hardness in the HAZ and the fusion zone was higher than that of the base metal and the hardness in the fusion zone was variated with the location. Especially, the hardness of HAZ adjacent to the base metal showed maximum value, and softening zone in the base metal adjacent to HAZ was found. With the increasing of welding current, there were no difference in maximum hardness and average hardness in the fusion zone were, but the hardness of the softening zone reduced. The difference in the hardness in each location of weld due to grain size of prior austenite. The softening of the base metal occurred by tempering of the martensite.