• Journal of Welding and Joining
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• v.14 no.1
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• pp.57-67
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• 1996

With an expansion in automation of welding processes, emphasis has been shifted from other welding processes to the GMA welding. However, there is a problem with this process that the spatter occurs very frequently. In GMA welding, there are several types in the way of metal transfer from the electrode wire to the weld pool, which have a close relatonship with the spatter genetration. This study was concerned with the spatter occurring in the short-circuiting transfer. In welding with short-circuiting, the electromagnetic force formed by the welding current facilitatics the rupture of the metal bridge between the wire and workpiece and ensures the normal process of the welding process. However, the spatter can be genetrated from the droplet because of the upward magnetic force, when the droplet contacts with the weld pool. The passage of current through the bridge results in the accumulation of the thermal energy, which causes the bridge to explode in the final stage of short-circuiting, thus forming the spatter. Based on the above phenomena in conjunction with other experimental results published, the physical phenomenon related with the occurrence of spatter was modeled and the current waveform was investigated to reduce the spatter. Finally, the fuzzy rule based method was proposed to predict the time of short-circuiting and arcing in the metal transfer.

• Journal of the Korean Society of Industry Convergence
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• v.11 no.2
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• pp.83-91
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• 2008

GMAW(Gas Metal Arc Welding) processes are usually used in industrial side in order to get its high productivity. But those are only adopted in the semi-automated welding equipment because of a lot of welding spatters. Many industrial robot actually percents from being engaged in the welding processes. The welding spatter problem of causes blocking them being a fully automated welding process.This study was carried out to investigate the optimal conditions for minimizing welding spatter generation at GMAW robot. The spatter can be significantly reduced below 2% of welding spatter generation at the following conditions ; First, below 18V at the wire-feed rate 2.0mm/min Second, below 23V at the wire-feed rate 3.6mm/min Third, below 24V at the wire-feed rate 5.5mm/min.

• Journal of Welding and Joining
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• v.21 no.2
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• pp.70-75
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• 2003

Spot welding is a process that sheet metals are joined in one or more spot by heating at the faying interface. In this process, the spatter is dispersed from melted area. It has been reported that spatter generation has adverse effects on weld quality. However, no systematic study has been carried out to find out its effect on weld quality in resistance spot welding processes. In this study, specially designed specimen are used to perform experimental investigation of spatter generation and its effect. Major finding of this study show trends in tensile-shear strength for various amounts of spatter generated during spot welding process. Thus, optimum welding conditions are proposed in view of spatter generation and tensile-shear strength. (Received December 11, 2002)

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.8 s.179
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• pp.1885-1898
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• 2000

Welding quality is closely related to the arc state. So, it is very important to estimate the arc state in real time. In the short circuit transfer region of CO2 are welding, the spatter , as it is well known, is mainly generated on an instance of short circuit or on an instance that the are is ignited after short circuit, or on the cases of an instantaneous short circuit. If the short circuit period or the arc time is irregular, the spatter is generated more than it is regular. Thus there is a close relationship of the amount of the spatter generation with the arc stability. In this paper, to develop the index for estimating the arc stability in short circuit transfer range Of CO2 arc welding, the welding current and are voltage waveforms were measured and the spatter generated was captured and measured. The correlation analysis of the measured amount of the spatter with the factors (the components and the standard deviations of the components) was performed, and the factors that have a considerable influence on the spatter generation among all factors were selected. And some cases of models consisted of the factors were presented, and a mathematical index model which can make an estimation the amount of the spatter from these models with multiple regression analysis. Also, it was compared how much the amount of the spatter generated under the selected welding conditions do these index models fit, and the index model to estimate the arc stability which represent the spatter generation most appropriately was developed

• Journal of Welding and Joining
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• v.15 no.2
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• pp.72-80
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• 1997

The spatter generation rate of GMA welding with $CO_2$ gas shielding was measured with the change of welding conditions such as wire feeding rate and welding voltage and then the results were analized with the accompanying changes in metal transfer mode and in bead geometry. The spatter generation rate (SGR) was relatively low not only wit the short circuit transfer but with the truely globular transfer mode. However, the SGR resulted with the mixed mode were consistantly high. The resultant wave pattern of mixed mode was due to the coexistance of short-circuit and globular transfer and characterized by the frequent appearance of instantaneous short circuit. Considering the result of SGR and that of bead geometry, it could be concluded that when the wire feeding rate (or welding current) was either low or high, the optimum bead shape could be obtained along with the low spatter generation. However, in the middle range of wire feeding rate, the optimum bead shape was only obtained in the mixed mode condition resulting in the high spatter generation.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.1
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• pp.110-115
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• 2016

The need for high-strength galvanized steel has recently increased because of the increased number of car consumers who want improved efficiency and exterior quality. High-strength galvanized steel with high corrosion resistance improves the durability of products and exterior quality. Furthermore, the gilt of zinc does not come off during machining because of the fine adhesive property of zinc. When these are welded, zinc has a lower melting temperature than iron, so zinc is more quickly vaporized than iron. Vaporized zinc can stick to electrodes, which increases spatter in welding transportation. Created spatter can enter the molten pool and develop into inner defects or blowholes and pits. Scattered spatter sticks to the product, which leads to the secondary cost of spatter removal. Therefore, in this study, comparisons of amounts of spatter generated are conducted according to the composition of shielding gas in the MIG and CMT processes to find optimal welding parameters.

• Journal of Welding and Joining
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• v.21 no.1
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• pp.48-53
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• 2003

The object of this study is to examine the effect of short circuit time ratio (SCTR) and current rise delay time (Td) on the spatter generation at low and medium current range in $CO_2$ welding. The spatter was evaluated by the weight generated in the welding of bead-on-plate for 30 seconds (3 times). Td was varied by order of 0, 0.4, 0.8 and 1.2 msec. At each Td, the short circuit time ratio was varied by the output voltage of the welding power source. In the low current range, it was found that the optimum SCTR was 20~25%, and the minimum spatter generation weight was obtained in the case of Td=0.4msec and SCTR=22% even though the remarkable difference was not showed by the application of Td. In the medium current range, it was confirmed that the arc was stable though the SCTR was increased from 20% to 40% by the control of current wave. Spatter generation weight depended on the variation of Td, and the lowest value of spatter generation weight occurred at Td=0.8~1.2msec.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.454-457
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• 1997

The purpose of this study is to develop an optimal model, using existing models, that is able to estimate the amount of spatter utilizing artificial neural network in the short circuit transfer mode of gas metal arc (GMA) welding. The amount of spatter generated during welding can become a barometer which represents the process stability of metal transfer in GMA welding, and it depends on some factors which constitute a periodic waveforms of welding current and arc voltage in short circuit GMA welding. So, the 12 factors, which could express the characteristics for the waveforms, and the amount of spatter are used as input and output variables of the neural network, respectively. Two neural network models to estimate the amount of spatter are proposed: A neural network model, where arc extinction is not considered, and a combined neural network model where it is considered. In order to reduce the calculation time it take to produce an output, the input vector and hidden layers for each model are optimized using the correlation coefficients between each factor and the amount of spattcr. The est~mation performance of each optimized model to the amount of spatter IS assessed and compared to the est~mation performance of the model proposed by Kang. Also, through the evaluation for the estimation performance of each optimized model, it is shown that the combined neural network model can almost perfectly predict the amount of spatter.

• Journal of Welding and Joining
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• v.17 no.5
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• pp.61-68
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• 1999

For the last two decades, waveform control techniques have been successively developed and applied for the inverter welding machines resulting in the substantial reduction of spatter generated in CO₂ welding. One of the constituents commonly involved in those techniques is to delay the instant of current increase to some extent after the initiation of short-circuiting. Although this technique has been known to be quite effective in reducing the spatter generation through the suppression of is instantaneous short circuiting, the delay time necessary for minimum spatter has not been clearly understood. In this study, the control system for varying the delay time was constructed so that the spatter generation rates could be measured over a wide range of delay time, 0.29-2.0 msec. As a result of this study, it was demonstrated that spatter generation rate(SGR) sharply decreased at delay time of 0.6 msec and longer accompanied with the change in characteristics of short circuit mode from the instantaneous short-circuiting(ISC) dominant to normal short-circuiting(NSC) dominant. Another feature that have been found in current waveform of over 0.6msec was the creation of current pulse right after the arc reignition stage. Because of this current pulses weld pool oscillated in wave-like fashion and it looks like to play an important role in developing short circuiting between electrode and weld pool.

• Journal of Welding and Joining
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• v.15 no.6
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• pp.41-48
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• 1997

For analyzing the characteristics of arc welding processes, an algorithm is necessary to determine the metal transfer mode, arc stability and weld quality. In this study, the weight of spatter during welding was selected for determining the arc stability, which is very relevant to the occurrence of spatter. Weld spatter occurs mainly at the moment when the short circuit is formed and also when it is broken causing the arc to restrike. Based on this fact, the arc stability can be determined by finding the suitable parameters of welding current and arc voltage which influence the weight of spatter. Through various welding experiments, the peak current, the arcing time, the short circuit time, the current and its slope at the start of short circuit were found mainly to influence the weight of spatter. For the convenient usage, an index was proposed by combining all these parameters. It was found that the index is very effective for determining the arc stability.