• Journal of Welding and Joining
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• v.17 no.3
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• pp.71-78
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• 1999

The welded metal bellows is commonly manufactured by welding pairs of washer-shaped discs of thin sheet metal stamped from strip stock in thickness from 0.025 to 0.254 mm. The discs, or diaphragms, are formed with mating circumferential corrugations. In this study, the diaphragms were welded by using a CW Nd: YAG laser to form metal bellows. The bellows was fixed on a jig and compressed axially, while Cu-rings were installed between belows edges for intimate contact of edges. The difference between the inner diameter of bellows and jig shaft causes an eccentricity, while the tolerance between motor shaft and jig shaft causes a wobble type motion. A vision sensor which is based on the optical triangulation was used for seam tracking. An image processing algorithm which can distinguish the image by bellows edge from that by Cu-ring was developed. The geometric relationship which describes the eccentricity and wobble type motion was modeled. The seam tracking using the image processing algorithm and the geometric modeling was performed successfully.

• Proceedings of the KWS Conference
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• 2005.06a
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• pp.370-376
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• 2005

Magnesium alloys are becoming important material for light weight car body, due to their low specific density but high specific strength. However they have a poor weldability, caused high oxidization tendency and low vapor temperature. In this study, the welding performance of magnesium alloys was investigated for automobile application. The materials were rolled magnesium alloy sheet contains Al and Zn such as AZ3l , AZ6l and AZ9l. Three types of welding process were studied, that were GTAW, Laser beam welding and FSW. To evaluate the weldability, we examined the appearance of welding bead. Also we checked bead shape and internal defects such as crack and porosity on cross section of welding bead. The mechanical property was measured for welded specimen by tensile test. For determination of the strength change by welding process, the hardness profile across the welding center was measured. For the results, the tensile properties of welded specimen were decreased obviously on all welding process. For the fusion welding process such as GTAW and laser beam welding, the surface of the welding bead was covered with oxidized magnesium dust but it was removed by simple cleaning work as wipe-out with tissue. Also under cut, that caused vaporization of base metal was occurred. for the friction stir welding, there was no oxidation, under-cut or internal defects. However it had poor weld performance, the reason was cleavage fracture occurred at plastic deformation zone. For welding of magnesium alloy, the laser beam welding process was recommended.

• Journal of Welding and Joining
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• v.34 no.6
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• pp.69-74
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• 2016

Because the pure titanium has superior corrosion resistance and formability compared with different material, it is widely used as material of welded heat exchanger. When the welding of heat exchanger is carried out, certain area in which welding start and end are overlapped occurs. The humping of back bead is formed in the overlap area due to partial penetration. Thus in this study, the experiments were carried out by changing the length and wave shape of overlap area, and then the weldabiliay was evaluated through the observation of microstructure, the measurement of hardness and tensile-shear strength test in the overlap area. When overlap length was 9.8mm, humping bead was suppressed. The microstructure of overlap area coarsened and its hardness increased due to remelting. As a result of tensile-shear strength test in the overlap area according to applying the wave shape control, it was confirmed that the overlap area applied wave shape control had more excellent yield strength and ductility.

• Journal of Welding and Joining
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• v.30 no.2
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• pp.59-64
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• 2012

Welding is an essential process in the automotive industry. Most welding processes that are used for auto body are spot welding and $CO_2$ welding are used in a small part. In production field, $CO_2$ welding process is decreased and spot welding process is increased due to welding quality is poor and defects are occurred in $CO_2$ welding process frequently. But $CO_2$ welding process should be used at robot interference parts and closed parts where spot welding couldn't. Because of the 0.65mm ~ 2.0mm thickness steel sheet were used in the automotive industry, poor quality of welding area such as burn through and under fill were happened frequently in $CO_2$ process. In this paper, we will study about the penetration depth which gives a huge impact on burn through changing a degree of base metal, welding position and torch angle. Voltage, current and welding speed were fixed but degree of base metal, welding position and torch angle were changed. And Cold- Rolled(CR) steel sheet was used. Penetration depth was analysed by multiple regression analysis to derive approximate calculations. And reliability of approximate calculations were confirmed through additional experiments. As the results of this research, we confirmed the effect of torch and plate angle to bead shape. And we present a possibility that can simulate more accurate to weld geometry, as deduced the verification equations that has tolerance of less than 21.69%.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.8
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• pp.25-31
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• 2018

Recently, research on the development of lightweight vehicle bodies is increasing continuously as a response to fuel economy regulations. To reduce the weight of a vehicle body, a conventional steel plate has been substituted by light weight material with high specific strength and the jointing of multi-materials is generally applied. On the other hand, the customer's demand for safety and emotional quality in NVH (Noise, Vibration and Harshness) is becoming increasingly important. Therefore, a light weight with proper strength and NVH quality is needed. In the view of light weighting and NVH quality, the application of a vibration proof steel plate can be an effective solution but the formability of a sandwich panel is different with a conventional steel sheet. Therefore, careful analysis of formability is required. This study aims to characterize the formability of a sandwich high-strength steel plate. The high-strength steel plates of different thicknesses with resistance spot welding and sealer bonding were analyzed using forming limits diagram through a cup drawing test.

• Proceedings of the KWS Conference
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• 2009.11a
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• pp.20-20
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• 2009

저항 점 용접은 1930년대에 Thomson에 의해 방법이 제안된 이후로 자동차, 전자, 항공기, 철도산업등에서 박판 금속(sheet metal)의 접합에 가장 널리 사용되고 있는 공정이다. 특히 자동차 차체와 같이 대부분 박판으로 구성되는 구조물에서는 저항 점 용접의 사용 범위가 매우 넓기 때문에 자동차 산업에서는 가장 기본적인 근본 기술 중의 하나로 인식되고 있다. 보통 자동차 한대를 생산하는데 소요되는 저항 점 용접 타점은 3000~4000개 정도로 자동차 차체 용접 공정의 대부분을 차지하고 있다. 또한 로봇과 연동된 자동화 공정으로 적용되고 있다. 최근의 자동차 차체를 구성하는 금속 재료가 자동차의 경량화, 친화경 소재의 사용자의 요구로 인해 새로운 강판이 사용된다. 자동차의 연비 향상을 위해서 다른 방법보다 자동차의 무게를 감소시키는 것이 가장 효율적이고, 쉽기 때문에 고장력 강판의 사용이 급속하게 증가하고 있다. 뿐만 아니라 차제의 부식성, 내마모성 향상을 위해 도금 처리된 강판의 사용도 활발하게 이루어지고 있다. 최근에 도장 공정 감소를 위해 도금 처리위에 도료 착색을 용이하게 하는 도료의 일부를 금속 표면에 처리된 강판의 개발도 진행되는 등 금속 소재의 변화가 다양하게 진행되고 있다. 이러한 새로운 강종은 기존의 AC 용접이나 DC 용접으로는 용접성 확보에 어려움을 가지고 있어, 새로운 저항 점 용접 공정의 연구 개발이 필요하다. 본 연구에서는 저항 점 용접 공정의 개선을 위해서 인버터 저항 점 용접기에서 용접 공정 중 전류를 제어하기 위한 효율적인 제어기 개발 방법과 개발된 제어기를 바탕으로 용접 중에 용접부의 품질을 예측하여, 용접 전류 및 가압력을 실시간 제어하여 안정적인 용접부의 품질을 갖질 수 있는 지능형 저항 점 용접기의 적응 제어기를 개발하는데 있다.

• Korean Journal of Materials Research
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• v.19 no.7
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• pp.369-375
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• 2009

The spot weldability of dissimilar metal joints between stainless steels (AISI316) and interstitial free (IF) steels were investigated. This study was aimed to determine the spot welding parameters for a dissimilar metal joint and to evaluate the dissimilar metal joint's weldability, including its welding nugget shape, tensileshear strength, hardness, and microstructure. The fracture surface was investigated by using a Scanning Electron Microscopy (SEM). The experimental results showed that the shape of nugget was asymmetric, in which the fusion zone of the STS316 sheet was larger due to the higher bulk-resistance. The microstructure of the fusion zone was fully martensite. In order to evaluate the microstructure further, dilution of stainless steels were calculated and imposed onto the Schaeffler diagram. The predicted microstructure from the Schaeffler diagram was martensite. In order to confirm the predicted microstructure, XRD measurements were carried out. The results showed that that initial weld nugget was composed of austenite and martensite.

• Korean Journal of Metals and Materials
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• v.48 no.6
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• pp.533-542
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• 2010

The specific motivation for joining an Al alloy and Zn-coated steel arises from the need to save fuel consumption by weight reduction and to enhance the durability of vehicle structures in the automobile industry. In this study, the lap joining A6K31 Al alloy (top) and SGARC340 Zn-coated steel (bottom) sheets with a thickness of 1.0 mm and 0.8 mm, respectively, was carried out using the friction stir weld (FSW) technique. The probe of a tool did not contact the surface of the lower Zn-coated steel sheet. The friction stir welding was carried out at rotation speeds of 1500 rpm and travel speeds of 80~200 mm/min. The effects of tool geometry and welding speed on the mechanical properties and the structure of a joint were investigated. The tensile properties for the joints welded with a larger tool were better than those for the joints done with a smaller tool. A good correlation between the tensile load and area of the welded region were observed. The bond strength using a larger tool (M4 and M3) decreased with an increase in welding speed. Most fractures occurred along the interface between the Zn-coated steel and the Al alloy. However, in certain conditions with a lower welding speed, fractures occurred at the A6K31 Al alloy.

• Corrosion Science and Technology
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• v.13 no.2
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• pp.70-80
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• 2014

Duplex stainless steels with nearly equal fraction of the ferrite(${\alpha}$) phase and austenite(${\gamma}$) phase have been increasingly used for various applications such as power plants, desalination facilities due to their high resistance to corrosion, good weldability, and excellent mechanical properties. Hyper duplex stainless steel (HDSS) is defined as the future duplex stainless steel with a pitting resistance equivalent (PRE=wt.%Cr+3.3(wt.%Mo+0.5wt.%W)+30wt.%N) of above 50. However, when HDSS is welded with gas tungsten arc (GTA), incorporation of nitrogen in the Ar shielding gas are very important because the volume fraction of ${\alpha}$-phase and ${\gamma}$-phase is changed and harmful secondary phases can be formed in the welded zone. In other words, the balance of corrosion resistance between two phases and reduction of $Cr_2N$ are the key points of this study. The primary results of this study are as follows. The addition of $N_2$ to the Ar shielding gas provides phase balance under weld-cooling conditions and increases the transformation temperature of the ${\alpha}$-phase to ${\gamma}$-phase, increasing the fraction of ${\gamma}$-phase as well as decreasing the precipitation of $Cr_2N$. In the anodic polarization test, the addition of nitrogen gas in the Ar shielding gas improved values of the electrochemical parameters, compared to the Pure Ar. Also, in the erosion-corrosion test, the HDSS welded with shielding gas containing $N_2$ decreased the weight loss, compared to HDSS welded with the Ar pure gas. This result showed the resistance of erosion-corrosion was increased due to increasing the fraction of ${\gamma}$-phase and the stability of passive film according to the addition $N_2$ gas to the Ar shielding gas. As a result, the addition of nitrogen gas to the shielding gas improved the resistance of erosion-corrosion.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.10
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• pp.1179-1185
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• 2011

Cold and hot-rolled carbon steel sheets are commonly used in railroad cars or commercial vehicles such as the automobile. The sheets used in these applications are mainly fabricated by spot welding, which is a type of electric resistance welding. However, the fatigue strength of a spot-welded joint is lower than that of the base metal because of high stress concentration at the nugget edge of the spot-welded part. In particular, the fatigue strength of the joint is influenced by not only geometrical and mechanical factors but also the welding conditions for the spot-welded joint. Therefore, there is a need for establishing a reasonable criterion for a long-life design for spot-welded structures. In this thesis, ${\Delta}P-N_f$ relation curves have been used to determine a long-life fatigue-design criterion for thin-sheet structures. However, as these curves vary under the influence of welding conditions, mechanical conditions, geometrical factors, etc. It is very difficult to systematically determine a fatigue-design criterion on the basis of these curves. Therefore, in order to eliminate such problems, the welding residual stresses generated during welding and the stress distributions around the weld generated by external forces were numerically and experimentally analyzed on the basis of the results, reassessed fatigue strength of gas welded joints.