• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.2
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• pp.1339-1347
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• 2015

This study discusses a remote control torch system equipped with a GMAW double wire reel. The welding machine is 30m away from the wire feeder at the industrial site and the feeder is three to five meters away from the torch. Accordingly, the welders cannot control the current and voltage that meets the welding condition during work when they are working at a place that prevents them from seeing the control panel, such as inside a vehicle or tank or at a far work site. They also have no choice but to stop working to change the wire reel when it is burned out completely. Such work suspension resulting from frequent moves to adjust the current and voltage as well as to replace the wire and subsequent cooling causes welding defects. This study produced a remote control torch equipped with a double wire reel by simplifying and streamlining the existing GMAW functions to reduce the troubling issue. The remote control torch equipped with a double wire reel and the existing $CO_2$ /MAG welding torch were applied as a V-groove butt in the vertical position using 6mm rolled steel for a SM50A welding structure. After welding, the condition of welded surface beads underwent a visual inspection and radiographic inspection to analyze the welding quality inside the welded part. This study also evaluated the reduction of welding defects, cost saving, the replacing performance against the existing commercial welders, and the effects on possible compatibility.

• Journal of Welding and Joining
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• v.27 no.5
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• pp.88-93
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• 2009

While the pinch instability theory (PIT) has been widely employed to analyze the spray transfer mode in the gas metal arc welding (GMAW), it cannot predict the detaching drop size accurately. The PIT is modified in this work to increase the accuracy of prediction and to simulate the molten tip geometry to be more physically acceptable. Since the molten tip becomes a cone shape in the spray mode, the effective wire diameter is formulated that the effective diameter is inversely proportional to current square. Modifications are also made to consider the finite length of the liquid column and current leakage through the arc. While the effective diameter influences drop transfer significantly, the current leakage has negligible effects. The effects of modifications on drop transfer are analyzed, and the predicted drop diameters show good agreements with the experimental data of the steel wire.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.2
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• pp.209-217
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• 2015

Generally welding is one of the most important processes to have a strong influence on the quality and productivity from a manufacture-based industry such as shipbuilding, automotive and machinery. The GMA(Gas Metal Arc) welding process involves large number of interdependent welding parameters which may affect product quality, productivity and cost effectiveness. To solve such problems, mathematical models are required to select the welding parameters for GMA welding process. In this study, the GMA welding process was studied using the information generated during the welding. The statistical analysis of a generalized regression approach was conducted by the following three methods: Firstly using the mathematical model (linear regression, 2nd regression); Secondly GA(Genetic Algorithm) with intelligent models; And finally using response surface analysis of models to develop the relationships between welding parameters and bead width as welding quality.

• Proceedings of the KWS Conference
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• 2009.11a
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• pp.44-44
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• 2009

While the pinch instability theory (PIT) has been widely employed to analyze the spray transfer mode in the gas metal arc welding (GMAW), it cannot predict the detaching drop size accurately. The PIT is modified in this work to increase the accuracy of prediction and to simulate the molten tip geometry to be more physically acceptable. Since the molten tip becomes a cone shape in the spray mode, the effective wire diameter is formulated that the effective diameter is inversely proportional to current square. Modifications are also made to consider the finite length of the liquid column and current leakage through the arc. While the effective diameter influences drop transfer significantly, the current leakage has negligible effects. The effects of modifications on drop transfer are analyzed, and the predicted drop diameters show good agreements with the experimental data of the steel wire.

• Journal of Welding and Joining
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• v.34 no.1
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• pp.21-25
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• 2016

The automotive vehicle is made through the following processes such as press shop, welding shop, paint shop, and general assembly. Among them, the most important process to determine the quality of the car body is the welding process. Generally, more than 400 pressed panels are welded to make BIW (Body In White) by using the RSW (Resistance Spot Welding) and GMAW (Gas Metal Arc Welding). Recently, as the needs of light-weight material due to the $CO_2$ emission issue and fuel efficiency, new joining technologies for aluminum, CFRP (Carbon Fiber Reinforced Plastic) and etc. are needed. Aluminum parts are assembled by the spot welding, clinching, and SPR (Self Piercing Rivet) and friction stir welding process. Structural adhesive boning is another main joining method for light-weight materials. For example, one piece aluminum shock absorber housing part is made by die casting process and is assembled with conventional steel part by SPR and adhesive bond. Another way to reduce the amount of the car body weight is to use AHSS (Advanced High Strength Steel) panel including hot stamping boron alloyed steel. As the new materials are introduced to car body joining, productivity and quality have become more critical. Productivity improvement technology and adaptive welding control are essential technology for the future manufacturing environment.