• International Journal of Naval Architecture and Ocean Engineering
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• 제10권2호
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• pp.129-140
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• 2018

A residual stress generated in the steel structure is broadly categorized into initial residual stress during manufacturing steel material, welding residual stress caused by welding, and heat treatment residual stress by heat treatment. Initial residual stresses induced during the manufacturing process is combined with welding residual stress or heat treatment residual stress, and remained as a final residual stress. Because such final residual stress affects the safety and strength of the structure, it is of utmost importance to measure or predict the magnitude of residual stress, and to apply this point on the design of the structure. In this study, the initial residual stress of steel structures having thicknesses of 25 mm and 70 mm during manufacturing was measured in order to investigate initial residual stress (hereinafter, referred to as initial stress). In addition, thermal elastic plastic FEM analysis was performed with this initial condition, and the effect of initial stress on the welding residual stress was investigated. Further, the reliability of the FE analysis result, considering the initial stress and welding residual stress for the steel structures having two thicknesses, was validated by comparing it with the measured results. In the vicinity of the weld joint, the initial stress is released and finally controlled by the weld residual stress. On the other hand, the farther away from the weld joint, the greater the influence of the initial stress. The range in which the initial stress affects the weld residual stress was not changed by the initial stress. However, in the region where the initial stress occurs in the compressive stress, the magnitude of the weld residual compressive stress varies with the compression or tension of the initial stress. The effect of initial stress on the maximum compression residual stress was far larger when initial stress was considered in case of a thickness of 25 mm with a value of 180 MPa, while in case of thickness at 70 mm, it was 200 MPa. The increase in compressive residual stress is almost the same as the initial stress. However, if initial stress was tensile, there was no significant change in the maximum compression residual stress.

• Journal of Advanced Research in Ocean Engineering
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• 제1권2호
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• pp.106-114
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• 2015

In the fabrication of offshore oil and gas facilities, the significance of dimension control is growing continuously. But, it is difficult to determine the deformation of the structure during fabrication by simple lab tests due to the large size and the complicated shape. Strain-boundary method (a kind of shrinkage method) based on the shell element was proposed to predict the welding distortion of a structure effectively. Modeling of weld geometry in shell element is still a difficult task. In this paper, a concept of imaginary temperature pair is introduced to handle the effect of geometric factors such as groove shape, plate thickness and pass number, etc. Single pass imaginary temperature pair formula is derived from the relation between the groove area and the FE mesh size. By considering the contribution of each weld layer to the whole weldment, multi-pass imaginary temperature is also derived. Since the temperature difference represents the distortion increment, cumulative distortion curve can be drawn by integrating the temperature difference. This curve will be a useful solution when engineers meet some problems occurred in the shipyard. A typical example is shown about utilization of this curve. Several verifications are conducted to examine the validity of the proposed methodology. The applicability of the model is also demonstrated by applying it to the fabrication process of the heavy ship block. It is expected that the imaginary temperature model can effectively solve the modeling problem in shell element. It is also expected that the cumulative distortion curve derived from the imaginary temperature can offer useful qualitative information about angular distortion without FE analysis.

• International Journal of Korean Welding Society
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• 제1권2호
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• pp.12-17
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• 2001

With the advance of the robotic welding process, procedure optimization that selects the welding procedure and predicts bead width that will be deposited is increased. A major concern involving procedure optimization should define a welding procedure that can be shown to be the best with respect to some standard and chosen combination of process parameters, which give an acceptable balance between production rate and the scope of defects for a given situation. This paper presents a new algorithm to establish a mathematical model f3r predicting bead width through a neural network and multiple regression methods, to understand relationships between process parameters and bead width, and to predict process parameters on bead width for GMA welding process. Using a series of robotic arc welding, additional multi-pass butt welds were carried out in order to verify the performance of the neural network estimator and multiple regression methods as well as to select the most suitable model. The results show that not only the proposed models can predict the bead width with reasonable accuracy and guarantee the uniform weld quality, but also a neural network model could be better than the empirical models.

• 대한기계학회논문집A
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• 제32권9호
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• pp.770-781
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• 2008

In nuclear power plants, ferritic low alloy steel components were connected with austenitic stainless steel piping system through alloy 82/182 butt weld. There have been incidents recently where cracking has been observed in the dissimilar metal weld. Alloy 82/182 is susceptible to primary water stress corrosion cracking. Weld-induced residual stress is main factor for crack growth. Therefore exact estimation of residual stress is important for reliable operating. This paper presents residual stress computation performed by 6" safety & relief nozzle. Based on 2 dimensional and 3 dimensional finite element analyses, effect of welding variables on residual stress variation is estimated for sensitivity analysis.

• Journal of Welding and Joining
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• 제34권6호
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• pp.42-46
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• 2016

Hydrogen assisted cracking (HAC) is one of the most complicated problem in welding. Huge amount of studies have been done for decades. Based on them, various standards have been established to avoid HAC. But it is still a chronic problem in industrial field. It is well known that the main causes of the hydrogen crack are residual stress, crack susceptible micro structures and a certain critical level of hydrogen concentration. Even though the exact generating mechanism is unclear till today, it has been reported that the hydrogen level in the weld metal should be managed less than a certain amount to prevent it. Matsuda studied that the residual hydrogen level in the weld metal can be varied even if the initial hydrogen content is same. It is also insisted in this report that the residual hydrogen concentration is in stronger correlation with hydrogen crack than the initial hydrogen content. But, in practical point of view, the residual hydrogen is still hard to consider because measuring hydrogen level is time and cost consuming process. In this regard, numerical analysis is the only solution for considering the residual hydrogen content. Meanwhile, Takahashi showed the possibility of predicting the residual hydrogen by a rigorous FE analysis. But, few commercial software suitable for solving the weld metal hydrogen has been reported yet. In this study, two dimensional thermal - hydrogen coupled analysis was developed by using the commercial FE software MARC. Since the governing equation of the hydrogen diffusion is similar to the heat transfer, it is shown that the heat transfer FE analysis in association with hydrogen diffusion property can be used for hydrogen diffusion analysis. A series of simulation was performed to verify the accuracy of the model. For BOP (Bead-On-Plate) and the multi-pass butt welding simulations, remaining hydrogen contents in the weld metal is well matched with measurements which are referred from Kim and Masamitsu.

• 한국해양공학회지
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• 제17권4호
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• pp.52-58
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• 2003

Underwater wet arc welds were experimentally performed on the KR-RA steel plate as base metal by using four different types of flux coated electrodes: KT33, UWEE, UWCS, and TN20, UWEE, the individually designed flux coated underwater electrode, had good operability when compared with other domestic terrestrial electrodes, and imported goods. The hardness value and the portion of martensite of HAZ were increased, by using a rapid cooling rate, Mechanical properties were also examined experimentally with a multi-pass butt-welding specimen test. The individually designed flux coated electrode UWEE could be used in practice for underwater wet welds.

• International Journal of Ocean Engineering and Technology Speciallssue:Selected Papers
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• 제6권1호
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• pp.75-81
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• 2003

Underwater wet arc welds were experimentally performed on the KR-RA steel plate as base metal by using four different types of flux coated electrodes: KT33, UWEE, UWCS, and TN20. UWEE, the individually designed flux coated underwater electrode, had good operability when compared with other domestic terrestrial electrodes, and imported goods. The hardness value and the portion of martensite of HAZ were increased, by using a rapid cooling rate, Mechanical properties were also examined experimentally with a multi-pass butt-welding specimen test. The individually designed flux coated electrode UWEE could be used in practice for underwater wet welds.

• Journal of Welding and Joining
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• 제27권4호
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• pp.54-59
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• 2009

In the process to manufacture for metallic structures, control of welding deformation is one of an important problems connected with reliability of the manufactured structures so that welding deformation should be measured and controlled with quickly and actively. Also, welding parameters which have as lot of effects on welding deformation such as arc voltage, welding current and welding speed can also be controlled. The objectives for this study were to develop a simple 2-D FEM to calculate not only the transient thermal histories but also the sizes of fusion and heat-affected zone (HAZ) in multi pass arc welds including the butt and fillet weld type with dissimilar thickness, and to concentrate on a developed model for the finding the parameters of Godak's moving heat source model based on a GA. The developed model includes a GA program using MATLB and GA toolbox, and a batch mode thermal model using ANSYS software. Not only the thermal model was verified by comparison with Goldak's work but also the developed model was validated with molten zone section experimental data.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2001년도 춘계학술대회 논문집(한국공작기계학회)
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• pp.208-213
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• 2001

Objective of this paper is to develop a new approach involving the use of an Artificial Neural Network(ANN) and multiple regression methods in the prediction of process parameters on bead height for GMA welding process. Using a series of robotic are welding, multi-pass butt welds carried out in order to verify the performance of the neural network estimator and multiple regression methods. To verify the developed system, the design parameters of the neural network estimator are selected from an estimation error analysis. The experimental results show that the proposed models can predict the bead height with reasonable accuracy and guarantee the uniform weld quality.