• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1560-1565
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• 2005

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 Powder Materials
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• v.22 no.3
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• pp.181-186
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• 2015

In this study, the effect of the friction stir welding (FSW) was compared with that of the gas tungsten arc welding (GTAW) on the microstructure and microhardness of Cu-Ni alloy weldment. The weldment of 10 mm thickness was fabricated by FSW and GTAW, respectively. Both weldments were compared with each other by optical microstructure, microhardness test and grain size measurement. Results of this study suggest that the microhardness decreased from the base metal (BM) to the heat affected zone (HAZ) and increased at fusion zone (FZ) of GTAW and stir zone (SZ) of FSW. the minimum Hv value of both weldment was obtained at HAZ, respectively, which represents the softening zone, whereas Hv value of FSW weldment was little higher than that of GTAW weldment. These phenomena can be explained by the grain size difference between HAZs of each weldment. Grain size was increased at the HAZ during FSW and GTAW. Because FSW is a solid-state joining process obtaining the lower heat-input generated by rotating shoulder than heat generated in the arc of GTAW.

• Journal of Welding and Joining
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• v.33 no.5
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• pp.35-40
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• 2015

Characterization of microstructures and mechanical properties of 83mm thickness EH36-TM welds produced by the combined flux cored arc (FCA) and electro gas (EG) welding processes has been studied with the two different groove conditions, single-V (SV) and double-V (DV) bevels. The welding consumables used for FCA and EG welding processes were ASME/AWS A5.29 (E81T1-K2) and A5.26 (EG72T), respectively. Experimental results showed that all the mechanical properties of welds such as tensile property, CVN toughness and Vickers hardness met IACS requirements. The tensile strength of EG welded plates were reduced by approximately 4% (DV: 3.8%, SV: 4.2%) compared to the base metal. The hardness value of SV-beveled weld metal was slightly lower than that of DV-beveled one. There were no significant differences as per welding groove conditions except for the weld metal. In addition, at the fusion line, the toughness of SV condition was 20J lower and the weld metal was 40J lower than DV condition, respectively. On the basis of microstructural analysis, grain boundary ferrite (GBF) structures for SV condition were 2 times higher volume fraction than for DV condition and their packet sizes were coarsened to almost double. It was thus suggested that the GBF volume fractions and packet sizes in the weld metal of EH36-TM steel plates are the most important factors affecting the mechanical properties of the combined FCA and EG welded joint. Nevertheless, all the results of welds with both DV and SV conditions were found to be excellent.

• 제어로봇시스템학회:학술대회논문집
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• 1996.10b
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• pp.1404-1407
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• 1996

A quality monitoring system in butt welding process is proposed to estimate weld pool sizes. The geometrical parameters of the weld pool such as the top bead width and the penetration depth plus half back width are utilized to prove the integrity of the weld quality. The monitoring variables used are the surface temperatures measured at three points on the top surface of the weldment. The temperature profile is assumed that it has a gaussian distribution in vertical direction of torch movement and verify this assumption through temperature analysis. A neural network estimator is designed to estimate weld pool size from temperature informations. The experimental results show that the proposed neural network estimator which used gaussian distribution as temperature information can estimate the weld pool sizes accurately than used three point temperatures as temperature information. Considering the change of gap size in butt welding, the experiment were performed on various gap size.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.05a
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• pp.111-116
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• 1999

Over the last few years, there has been a growing interest in quantitative representation of heat transfer and fluid flow phenomena in weld pools in order to relate the processing conditions to the quality of the weldment produced and to use this information for the optimization and robotization of the welding process. Normally, a theoretical model offers a powerful alternative to estimate the important input parameters and to calculate the effects of varying any of parameters. To solve this problem, a transient 2D(two-dimensional) heat conduction and a transient 2D axisymmetric heat and fluid model were developed for determining weld bead geometry and temperature distribution for the GMA(Gas Metal Arc) welding process. The equation was solved using a general thermofluid-mechanics computer program, PHOENICS code, which is based on the SIMPLE algorithm. The simulation results showed that the calculated bead geometry from two developed models reasonably agree with the experiment result.

• Journal of Welding and Joining
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• v.31 no.4
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• pp.73-79
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• 2013

Burr grinding, Tungsten Inert Gas (TIG) dressing, ultrasonic impact treatment, and peening are used to improve fatigue life in steel structures. These methods improve the fatigue life of weld joints by hardening the weld toe, by improving the bead shape, and by creating the compressive residual stress. In this study, a new post-weld treatment method improving the weld bead shape and metal structure at the welding zone using Friction Stir Processing (FSP), a welding process, is proposed to enhance fatigue life. For that, a pin-shaped tool and processing condition employing Friction Stir Processing (FSP) is established through experiments. Experimental results revealed that fatigue life is improved by around 50% compared to as-welded fatigue specimens by reducing the stress concentration at the weld toe and by generating a metal structure finer than that of flux-cored arc welding (FCAW).

• Journal of the Korea Institute of Information and Communication Engineering
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• v.10 no.7
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• pp.1326-1331
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• 2006

Weld root gap is a important fact of a falling-off weld quality in various kind of weld defect. The welding quality can be controlled by monitoring important parameters, such as, the Arc voltage, welding current and welding speed during the welding process. Welding systems use either a vision sensor or an Arc sensor, both of which are unable to control these parameters directly. Therefore, it is difficult to obtain necessary bead geometry without automatically controlling the welding parameters through the sensors. In this paper we propose a novel approach using neural networks for detecting and monitoring of weld root gap and bead shape. Through experiments we demonstrate that the proposed system can be used for real welding processes. The results demonstrate that the system can efficiently estimate the weld bead shape and detect the welding defects.

• Journal of Power System Engineering
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• v.15 no.6
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• pp.73-80
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• 2011

The experimental investigation focuses on an influence of artificial aging time in longitudinal butt welded Al 6013-T4 aluminum alloy on the fatigue crack growth resistance. The preferred welding processes for this alloy are frequently tungsten inert gas welding (TIG) process due to its comparatively easier applicability and better weldability than other gas metal arc welding. Fatigue crack growth tests were carried out on compact tension specimens (CT) in longitudinal butt TIG welded after T82 heat treatment was varied in three artificial aging times of 6 hours, 18 hours and 24 hours. Of the three artificial aging times, 24 hours of artificial aging time are offering better resistance against the growing fatigue cracks. The superior fatigue crack growth resistance preferred spatial variation of materials within each specimen in the Paris equation based on reliability theory and fatigue crack growth rate by crack length are found to be the reasons for superior fatigue resistance of 24 hours of artificial aging time was compared to other joints. The highest of crack propagation resistance occurs in artificial aging times of 24 hours due to the increase in grain size (fine grained microstructures).

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.6
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• pp.860-864
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• 2012

The contact tip is higher the wear of resistance and the longer life are demanded to GMA welding process. In this study, four different contact tips with three different compositions by two wires were evaluated their wear resistance by measuring in every one hour the area of enlarged hole at the exit side during actual wleding. Experimental results clearly showed that the Cr-containing tips strengthened by precipitation hardening have much better resistance to wear than those made by work hardening. In addition, flux cored wire is excellent abrasion resistance test results showed. Based on these results, the domestic industry, the life of the contact tip to know will be used as basic data.

• Journal of Preventive Medicine and Public Health
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• v.31 no.3 s.62
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• pp.414-423
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• 1998

Metal fume fever has been known as an occupational disease is induced by intense inhalation of fresh metal fume with a particle size smaller than $0.5{\mu}m\;to\;1{\mu}m$. The fumes originate from heating metals beyond their boiling point, as happens, for example, in welding operations. Oxidation usually accompanies this process. In most cases, this syndrome is due to exposure to zinc oxide fumes; however, other metals like copper, magnesium, cadmium, manganese, and antimony are also reported to produce such reactions. Authors report a case of metal fume fever suspected to be associated with copper fume inhalation. The patient was a 42-year-old male and was a smoker. He conducted inert gas tungsten arc welding on copper-coated materials without safety precautions such as a protective mask and adequate ventilation. Immediately after work, he felt metallic taste in his mouth. A few hours after welding, he developed headache, chilling sensation, and chest discomfort. He also complained of myalgia, arthralgia, feverish sensation, thirst, and general weakness. Symptoms worsened after repeated copper welding on the next day and subsided gradually following two weeks. Laboratory examination showed a transient increase of neutrophil count, eosinophilia, elevated erythrocyte sedimentation rate, and positive C-reactive proteinemia. Blood and urine copper level was also increased compared to his wife. Before this episode, he experienced above complaints several times after welding with copper materials but welding of other metals did not produce any symptoms. It was suggested that copper fume would have induced metal fume fever in this case. Further investigations are needed to clarify their pathogenic mechanisms.