• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2010년도 춘계학술발표대회 초록집
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• pp.72-72
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• 2010

최근 오일샌드, 극지유전, 심해저자원 등 극한지 자원개발이 활발해짐에 따라 수요가 증대되고 있는 극한지용 내마식 소재는 내마식성과 함께 저온 인성이 요구된다. 철계 합금에서 관찰되는 변형유기 마르텐사이트 상변태는 입자의 충돌에 의한 충격을 흡수하고 소재의 표면을 가공경화시켜 내마식성 향상 및 저온 인성에 기여할 수 있을 것으로 기대되고 있지만 합금조성의 정교한 제어가 필요하기 때문에 오버레이 용접에 적용하기 위해서는 모재와의 희석률을 제어하는 방안이 필요하다. 용접플럭스 설계기술은 용접시 금속이행모드, 용융지 유동거동 등과 같은 용접현상 제어를 통해 오버레이 용접재료의 용접성과 용접부 희석률을 최적화할 수 있는 기술이다. 본 연구에서는 내마식 고인성 오버레이 용접재료의 개발을 위해 Fe-12Cr-1.2C 합금조성을 갖는 메탈코어드 와이어에 대하여 아크안정제로 사용되는 Ca 함유 용접플럭스 첨가가 용착부 형상 및 희석률 변화에 미치는 영향을 조사하였다.

• 한국해양공학회지
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• 제11권1호
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• pp.10-15
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• 1997

Copper and its alloy had been used widely because of its pronouncing characteristics on their high thermal and electrical conductivity. Various fusion welding methods, such as SMAW, SAW, GTAW, GMAW, Electroslag welding amd so on are applied to weld copper and its alloy. But fusion welding of copper has so many welding problems. THe most serious problems were poor penetration amd high thermal contration stress due to its high thermal conductivity and porosity could be formed by rapid cooling rate of fusion welding. In order to avoid such fusion welding problems, preheating, peering and heat treatment must be applied to obtain sound weld joint of copper. But preheating induce another welding problem such as grain coarsening of weld heat affected zone. This grain coarsening reduces ductility and strength of weld joint. In this view of point, friction welding of copper is triedm to obtain sound weld joint of copper by reducing metallurgical problems. This study introduced new concept of heat input for evaluating the friction weldability of copper. As a result, weldability of copper could be evaluated by this new concept of heat input.

• 대한기계학회논문집A
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• 제27권2호
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• pp.310-316
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• 2003

One of the significant subject in the automatic arc welding is to establish control system of the welding parameters for controlling bead geometry as a criterion to evaluate the quality of arc welding. This paper proposes an inference algorithm for bead geometry in CMA Welding using Neuro-Fuzzy algorithm. The characteristic welding parameters are measured by the circuit composed of hall sensor, voltage divider tachometer, etc. and then the bead geometry of each weld pool is calculated and detected by an image processing with CCD camera and a measuring with microscope. The relationships between the characteristic welding parameters and the bead geometry have been arranged empirically. From the result of experiments, membership functions and fuzzy rules are tuned and determined by the learning of neural network, and then the relationship between actual bead geometry and inferred bead geometry are concluded by fuzzy logic controller. In the applied inference system of bead geometry using Neuro-Fuzzy algorithm, the inference error percent is within -5%∼+4% in case of bead width, -10%∼+10% in bead height, -5%∼+6% in bead area, -10%∼+10% in penetration. Use of the Neuro-Fuzzy algorithm allows the CMA Welding system to evaluate the quality in bead geometry in real time as the welding parameters change.

• Journal of Welding and Joining
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• 제17권5호
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• pp.98-106
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• 1999

In GMAW, the spatters are generated according to the variation of the arc. Of the arc is stable, Few spatters are generated. But if unstable, too many spatters are generated. So, this means the spatters are dependent on the arc state. The aim of this study is to accurately estimate the arc state. To do this, the generated spatters were captured under the some welding conditions, and the waveforms of the arc voltage and welding current were collected. From the collected signals, the waveform factors and their standard deviations were extracted. Using these factors as input parameters of multi-layer artificial neural network, the learning for the weight of the generated spatters is performed and the estimation results to the real spatter are assessed. Obtained results are as follow: the linear correlation coefficient between the estimated result and the real spatters was 0.9986. And although the average convergence error was set 0.002, the estimated error to the real spatter was within 0.1 gr/min at each welding condition. In the estimation for the weight generated spatters, the result with multi-layer neural network was far better than with multiple regression analysis. Especially, even though under the welding condition which the arc state is unstable (the spatter is generated much more), very excellent estimation performance was shown.

• International Journal of Korean Welding Society
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• 제1권1호
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• pp.23-30
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• 2001

Among the various welding conditions, the welding current that is inversely proportional to the tip-to-work-piece distance is an essential parameter as to monitor the GMAW process and to implement the welding automation. Considering the weld pool surface geometry including weld defects, it should modify the signal processing method for automatic seam tracking in horizontal fillet welding. To meet the above necessities, a mathematical model related with the weld pool geometry was proposed as in a conjunction with the two-dimensional heat flow analysis of the horizontal fillet welding. The signal processing method based on the artificial neural network (Adaptive Resonance Theory) was proposed for discriminating the sound weld pool surface from that with the weld defects. The reliability of the numerical model and the signal processing method proposed were evaluated through the experiments of which showed that they are effective for predicting the weld bead shape with or without the weld defects in a horizontal fillet welding.

• 한국정밀공학회지
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• 제32권2호
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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.

• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2009년 추계학술발표대회
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• pp.50-50
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• 2009

본 연구에서는 차체 부품의 경량소재 대체에 따른 Panel Assembly Rear Seat Back 부품 제작에 최신 저입열 미그용접공정을 적용한 TWB(Tailor Welded Blank) 공정기술을 확보하기 위해 최적 용접조건 도출에 관한 연구를 진행하였다. 용접 후 성형이 이뤄지는 제조공정의 특성 상 성형강도에 중점을 둔 실험을 진행하였으며, 이를 위해 각 와이어에 따른 용접부의 기계/금속학적 특성이 평가되었다. 대상 시편은 6천계열 열처리형 합금이며, 두께는 각각 1.6t, 1.4t로 이를 맞대기 용접 후 그 특성을 평가하였다. 용접은 저입열 GMA용접 공법 중 하나인 CMT 용접법(Cold Metal Transfer)을 사용하였으며, 평가 대상 와이어로는 4043, 4047, 5183 및 5356이 사용되었다. 특성평가는 마크로 및 마이크로 조직, 경도, 인장강도, 기공 및 결함, 성형강도 등에 대해 이뤄졌으며, 희석된 와이어의 조성이 용접부 특성에 미치는 영향에 대해서도 검토되었다. 실험 결과, 5천계열 와이어가 성형강도에 비교적 더 강인한 결과를 나타냈으며 성형강도는 용접조건 및 초기 갭에 대한 영향은 받았으나, 비드형상과 강도간의 연관성은 찾을 수 없었다. 이에 따라 TWB 적용을 위한 와이어로는 5356이 가장 우수한 것으로 판명되었다.

• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2009년 추계학술발표대회
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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.

• 대한기계학회논문집A
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• 제32권11호
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• pp.978-983
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• 2008

An application of innovative laser+GMA hybrid welding process is presented for reducing bead humping defects in high speed welding and increasing side wall fusion in narrow groove welding without torch or wire oscillation. In this hybrid process, the laser heat input is applied adjacent to the weld pool at a relatively low power density to produce a wider, flatter weld bead. In bead on plate in sheet metal gauges, the hybrid process was able to produce hump-free welds from 70ipm (${\sim}1780mm/min$) to over 150ipm (${\sim}3810mm/min$) of the travel speed compared to the un-assisted GMAW process. A square-butt joint in 15mm A572 Gr50 steel welds was investigated. A square butt joint with a gap of 3.2mm was filled with 6 passes. Liquid Nitrogen calorimetry and innovative $CO_2$ laser reflective optics were also developed to demonstrate the concept of hybrid welding.

• Journal of Welding and Joining
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• 제22권4호
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• pp.35-42
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• 2004

Contact tips are required to have a higher resistance to wear and thus to have an extended life time under the advanced GMAW welding process. Several requirements have been specified and employed by domestic industries for selecting their tips for such a purpose. However no attempt has been made to justify their requirements based on the experimental data of wear resistance or life time of contact tips. In this study, five different contact tips with three different compositions were employed for actual GMA welding up to 4 hours and were evaluated their wear resistance by measuring in every one hour the area of enlarged hole at the exit side. 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. It was further noticed that Cr is an excellent alloying element for improving the wear resistance of contact tips only when it is in an properly aged condition. Initial hardness may play some role in the early stage of wear but not in the later stage of welding because the microstructure of tip changes significantly by the prolonged exposure to welding arc heat. Based on these results, critical review has been made on the current requirements employed by domestic industries. Of importance is that a new guideline has been confirmed to be more reasonable.