• Transactions of the Korean Society of Mechanical Engineers A
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• v.41 no.4
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• pp.321-327
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• 2017

In this study, to investigate the shape of the back bead as a weld quality parameter and to select the optimal condition of the root-pass TIG welding of a horizontal butt-joint, an experimental design and the response surface method (RSM) have been employed. Three parameters are used as input variables, which include the base current, peak current, and welding speed. The back bead width is selected as an output variable representing the weld quality, the target value of the width is 5.4 mm. Conducting the experiments according to the Box-Behnken experimental design, a $2^{nd}$ regression model for the back bead width was made, and the validation of the model was confirmed by using the F-test. The desirability function was designed through the nominal-the-best formula for the appropriate back bead width. Finally, the following optimal condition for welding was selected using the RSM: base current of 0.9204, peak current of 0.8676, and welding speed of 0.3776 in coded values. For verification, a test welding process under the optimal condition was executed and the result showed the back bead width of 5.38 mm that matched the target value well.

• Journal of Welding and Joining
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• v.20 no.3
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• pp.122-128
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• 2002

The laser welding in the automotive industries has been used widely for the butt joint of blank sheets rather than the lap joint of automotive body panels. But as a substitute far the spot welding of automotive body panels, the so called three dimensional laser welding will be important far the body panel engineers. Specially the laser welding of body panels with a smooth weld line is applied increasingly, for example, to the side panels. So far, some criteria of the laser weld quality was suggested by in-house regulations or national standards from experiences and/or rule of thumbs. In the manufacturing places, a go or no-go criterion is adopted because of the simplicity or a lack of rational criteria. It is true specially for the selection of the process parameters, which gives the basic causes for the good quality of laser welds. In this study, the effects of joint combination, gap and welding speed on the lap joint $CO_2$ laser welding of two mild steel sheets with different thicknesses are obtained through a $2{\times}3{\times}7$ factorial experiment. The results of the weld quality are statistically analysed using analysis of variance (ANOVA) and compared between two characteristic zones, which are separated by the type of sectional shapes and the level of input energy per volume. The thickness combinations are 0.8mm/1.2mm, 1.2mm/0.8mm of mild steel sheets. The welding speed covers from the deep penetration to the partial penetration. The gap size has three levels of no-gap, 0.16m, and 0.26mm. The bead width, penetration depth and input energy per volume are measured and used as the weld quality criteria.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.156-161
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• 2002

It depends on the joint configuration, dimensions and constraints on the joint whether the residual stress at the root of single-sided butt weld is tensile or not. Therefore, recommendation is generally made that high R ratio should be used in the fatigue test of this type of joint in order to prevent excessively long life caused by compressive residual stress. in this research, the residual stress profile in butt weld joint was obtained through compliance method, using successive extension of a slot and measurement of the variation of strain during the slot extension. The residual stress profile was firstly assumed to be the linear summation of Legendre polynomials up to 9th order excluding 0th and 1st order. Strain variation on the surface was measured while the slot was being extended by cutting to find out the 8 unknown coefficients of each polynomial tenn. The cut was made by the electric discharge machine. It was concluded that the residual stress near the surface stayed positive, however, it turned into the negative value as soon as it passed through 2 or 3 mm depth. Several fatigue tests were also carried out under zero stress ratio. Test results showed that fatigue life coincides well with the design cuive of butt joint in British Standards, which supports that it is tensile residual stress that exists near the weld root.

• Journal of Welding and Joining
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• v.16 no.2
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• pp.100-110
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• 1998

In this paper, the laser weldability of thin gage steels for automobile application is discussed. Welding was carried out with a high power carbon dioxide laser system, and the laser energy was concentrated through a plano-convex lens. Test results showed that the joint gap in the butt welding proved to be one of the critical conditions for an acceptable weld. In the case where the ratio of the gap clearance to the material thickness was slightly bigger than optimal value, the weld strength was reduced showing weld metal fracture. It was possible to obtained a weld penetration ratio of 0.91 when the vertical offset ratio was controlled to be 0.4 or smaller. Results also demonstrated that the weld strength of the lap joint was influenced by travel speed. At the travel speeds lower than 37 mm/s, the weld strength indicated higher value than that of class A recommendation strength of a resistance spot weld based on the KS code. It was clear that the complicated effect of specimen alignment should be considered so as to make a sound weld with high integrity when the laser process was applied to the long weld line.

• Journal of Welding and Joining
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• v.30 no.6
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• pp.120-125
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• 2012

Because ships and offshore structures have very large dimensions and complicated shapes, it is difficult to determine the deformation or internal stress in the structure by simple lab tests. Thus, a rigorous analysis by using the computer simulation technology is essential for obtaining their distortions by considering the entire production process characteristics. The rapid development of computer technology made it possible to analyze the heat transfer phenomena, deformation and phase transformation in the welded joint. For large shell structures, shell elements modeling contributed primarily to this development. But if a welding is done by multi-pass, shell elements whose thickness are unchangeable can hard to describe the local situation. Recently, it was researched how to introduce the imaginary temperature for V grooved multi-layer butt welding in strain-boundary method (a kind of shrinkage methodologies). In the present study, we formulated the imaginary temperature for the double bevel and double V groove by considering the thickness change of each pass through the bead and the thickness directions simultaneously and also demonstrated the feasibility of the formula by applying it to the thermal distortion analysis of the erection process of crane pedestal.

• Proceedings of the KWS Conference
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• 2003.11a
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• pp.18-20
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• 2003

Optimal processing and system to produce the laser welded tube for one body formed bumper beam are studied. The calculated size of tube is a thickness of 1.4mm, diameter of 105.4mm and length of 2000mm. The tube is shaped from cool rolled high strength steel sheet(tensile strength: 60kgf/$\textrm{mm}^2$ grade). Two roll bending method is the optimal tube shaping process compared to UO-bending, bending on press brake, multi-step continuous roll forming and 3 roll bending methods. Weld quality monitoring and seam tracking along the butt-joint lengthwise to the tube axis are also studied. The longitudinal butt-joint is welded by the $CO_2$ laser welding system equipped with a seam tracker and plasma sensor. The constructed $CO_2$ laser tube welding system can be used for the precision seam tracking and the real-time monitoring of weld quality. Finally, the obtained laser welded tube can be used for one-body formed automobile bumper beam.

• International Journal of Korean Welding Society
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• v.5 no.1
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• pp.60-65
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• 2005

In the field of welding the mechanical behavior of a welded structure under consideration may be predicted via heat transfer and welding residual stress analysis. Usually such numerical analyses are limited to small regular mesh models or test specimens. Nevertheless, there is very few strength assessment of the whole structure that includes the effect of welded residual stress. The present work is based on the specialized finite element codes for the calculation of nonlinear heat transfer details and residual stress including the external load on the welded RHS (Rectangular Hollow Section) T-joint connections of the whole structure. First the thermal history of the combined fillet and butt-welded T-joint equal width cold-formed RHS are calculated using nonlinear finite element analysis (FEA) considering the quarter model of the joint. Then using this thermal history the residual stress around the joints has been evaluated. To validity the FEA result, the calculated residual stresses were compared with the available experimental results. The residual stress obtained from the quarter model is mapped to the full model and then to the whole structure model using FEM codes. The results from the FEM codes were exported to the commercial package for visualization and further analysis applying loads and boundary conditions on the whole structure. The residual stress redistribution along with the external applied load is examined computationally.

• Journal of the Korean institute of surface engineering
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• v.42 no.6
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• pp.294-300
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• 2009

The Friction Stir Welding (FSW) has mainly been used for making butt joints in Al alloys. The development of Friction Stir Lap Welding (FSLW) would expand the number of applications. In this study, for effective application on thin aluminum alloy lap joint, non-heat treatment A5052 alloys were joined by FSLW with the length of probe 2.3 mm and 3.0 mm. Investigating the characteristics of joint area showed the results were as below ; When the length of probe was 2.3 mm, good joint area was formed at all welding condition except for 600 rpm-700 mm/min. In the case of 3.0 mm probe length, there was formed good joint area without defects at 1500 rpm-100 mm/min. The width of joint area, position and size of defects were very important factors for FSLW, due to heat input and stirring intensity.

• Journal of Advanced Marine Engineering and Technology
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• v.27 no.6
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• pp.728-735
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• 2003

This paper shows the possibility of performing Lap joint using the friction stir welding with $2mm^t$ aluminum alloy plate and the determination of tool-dimensions for FSW in milling machine. This research also is reported on obtaining the tensile-shear strength, 91.3 (MPa) and the energy absorption, 26.3 (J) for Lap jointed specimen. The optimal tool-dimensions and method for Lap joint using FSW is as follows; each diameter of shoulder and pin is $9\phi(mm) and 3\phi(mm)$, the length of pin is 3.6(mm), Pressing the shoulder of tool into original base metal is not reasonable.

• Proceedings of the Korean Society of Marine Engineers Conference
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• 2002.05a
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• pp.153-160
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• 2002

This paper shows the possibility of performing Lap joint using the friction stir welding and the determination of tool's dimensions for FSW in Milling machine. This research also is reported on obtaining the tensile-shear strength, 9.319 ( kgf/mm$^{2}$) and the energy absorption, 2,682 (kgf-mm) under this experiment. The optimal tool's dimensions and method for Lap joint in 2tmm aluminum alloy plate using FSW is as follows; The diameter of shoulder and pin are 9 $\phi$mm and 3$\phi$mm, the length of pin is 3.6mm. The conditions of shoulder of tool is not pressed into original base metal.