• 한국레이저가공학회지
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• 제5권1호
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• pp.13-21
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• 2002

Compared to conventional welding process, laser welding does not use additional filler wire generally. However, if laser welding uses the filler wire, the applicability of the method can be broaden. When laser welding uses the filler wire, it is possible to enhance gap bridging ability and to prevent cracking in weld pool by metallurgical control. In this study, we had optimal condition and experimented gap bridging capability for butt welding with 2㎜ Al5052 alloys using the filler wire feeder. As the experimental parameters, wire feed rate and wire diameter are considered and then the performance of wire feed is evaluated under various filler wire welding conditions.

• Journal of Welding and Joining
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• 제18권6호
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• pp.55-61
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• 2000

Dynamic monitoring of weld pool formation and seam deviations using infrared vision is described in this paper. Isothermal contours representing heat dissipation characteristics during the process of arc welding were analysed and processed using imaging techniques. Maximum bead width and penetration were recorded and the geometric position in relation to the welding seam was measured at each sampling point. Deviations from the desired bead geometry and welding path were sensed and their thermographic representations were digitised and welding path were sensed and their thermographic representations were digitised and subsequently identified. Evidence suggested that infrared thermography can be utilized to compensate for inaccuracies encountered in real-time during robotic arc welding.

• International Journal of Korean Welding Society
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• 제2권2호
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• pp.32-35
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• 2002

In this paper, an intelligent system to determine welding parameters for each pass and welding position in pipeline welding based on one database and FEM model, two BP neural network models and a C-NN model was developed and validated. The preliminary test of the system has indicated that the developed system could determine welding parameters fur pipeline welding quickly, from which good weldments can be produced without experienced welding personnel. Experiments using the predicted welding parameters from the developed system proved the feasibility of interface standards and intelligent control technology to increase productivity, improve quality, and reduce the cost of system integration.

• Journal of Welding and Joining
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• 제32권6호
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• pp.35-40
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• 2014

The contact tip for gas metal arc welding has important functions to transmit the welding current to the wire and to guide the wire to molten pool. If the contact tip is damaged, it is a cause of lowering the welding productivity due to removal of welding defects and replacement of contact tip. In case of the use of a contact tip for a long time the arc is unstable because the processed hole in the contact tip center is larger, and the variation of aiming position of the welding wire causes a seam tracking error. In this study, gas metal arc welding experiments using contact tip of three different materials were performed. The contact tips with Cu-P, Cu-Cr, and Cu-ODS were used at the experiments, and the welding characteristics by each contact tip were evaluated. After welding contact tip appearance, welding spatter adhesion amount of the nozzle, and weld bead appearance were evaluated. The welding current and welding voltage were measured to verify arc stability during arc welding.

• Journal of Advanced Marine Engineering and Technology
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• 제31권3호
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• pp.282-292
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• 2007

The present paper describes the results of high speed photography, acoustic emission (AE) detection and plasma light emission (LE) measurement during $CO_2$ laser welding of 304 stainless steel in different processing conditions. Video images with high spatial and temporal resolution allowed to observe the melt dynamics and keyhole evolution. The existence of keyhole was confirmed by the slag motion on the weld pool. The characteristic frequencies of flow instability and keyhole fluctuations at different welding speed were measured and compared with the results of Fourier analyses of temporal AE and LE spectra. The experimental results were compared with the newly developed numerical model of keyhole dynamics. The model is based on the assumption that the propagation of front part of keyhole into material is due to the melt ejection driven by laser induced surface evaporation. The calculations predict that a high speed melt flow is induced at the front part of keyhole when the sample travel speed exceeds several 10 mm/s. The numerical analysis also shows the hump formation on the front keyhole wall surface. Experimentally observed melt behavior and transformation of the AE and LE spectra with variation of welding speed are qualitatively in good agreement with the model predictions.

• Journal of Welding and Joining
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• 제27권2호
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• pp.44-50
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• 2009

The characteristics of arc pressure, current density and heat flux distribution are important factors in understanding physical arc phenomena, which will have a marked effect on the penetration, size and shape of a weld in TIG welding. The purpose of this study is to find out the effect of the heat flux on the melting efficiency and penetration shape in TIG welding using the results of the previous investigators. The conclusions obtained permit to draw a proper method which derived the heat flux distributions by arc pressure distribution measurements, but previous researchers calculated heat flux and current distribution with the heat intensity measurements by the calorimetry. Heat flux of Ar gas arc was concentrated at the central part and distributed low from the arc axis to the radial direction, that of He mixing arc was lower than that of Ar gas, and it was wide distributed to radial direction. That showed a similar characteristic with the Nestor's by calorimetry calculated values. Throughout heat flux drawn in this study was discussed melting efficiency and penetration shape on Ar gas and He mixing gas arc.

• 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.

• 한국레이저가공학회지
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• 제8권1호
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• pp.27-37
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• 2005

During laser spot welding of the braun tube electron gun, phenomena such as serious spattering and oxidative reaction, etc. were occurred. The spatter occurred from weld pool affects the braun tube, namely it blocks up a very small hole on the shadow mask and causes short circuit between two poles of the electron gun. We guessed that high power density and oxidative reaction are main sources of these problems. So, we studied to prevent and to reduce spatter occurring in spot welding of the braun tube electron gun using pulsed Nd:YAG laser. The characteristics of laser output power was estimated, and the loss of laser energy by optical parameter and spatter was measured by powermeter. The effects of welding parameters, laser defocused distance and incident angle, were investigated on the shape and penetration depth of the laser welded bead in flare and flange joints. From these results, the laser peak power was a major factor to control penetration depth and to occur spatter. It was found that the losses of laser energy by optic parameter and sticked spatter affect seriously laser weldability of thin sheets.

• 대한조선학회논문집
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• 제44권6호
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• pp.598-604
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• 2007

The purpose of this study is to establish the predictive method of welding distortion and residual stress for the channel I butt SA (submerged arc) weldment using FEA. In order to do it, the heat input model for the weldment was defined as the combined heat source with the surface heat flux of gaussian distribution and volumetric heat source uniformly distributed within weld groove by comparing the shapes of molten pool and temperature distribution obtained by FEA with those of experiments. The arc efficiency of SA welding for two-dimensional FE analysis was evaluated as 0.85. The welding distortion and residual stress of the weldment obtained by FEA and heat input model proposed have a good agreement with those obtained by experiment. Based on the results, it was suggested that the proper heat input model should be required to evaluate the welding distortion for weldment.

• Journal of Welding and Joining
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• 제18권6호
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• pp.102-107
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• 2000

It was attempted to improve the wear resistance of Al alloy under the load condition by making a formation of the thick surface hardening alloy layers. The thick surface hardening alloy layers were formed on 6061 Al alloys overlayed by MIG welding process with WC-12%Co powder addition. Effects of the dispersion of WE-12%Co powders on hardness and wear characteristics of alloys were investigated. The following results were obtained. Most of WE-12%Co powders are dispersed nearly uniform as unmelted particles in the matrix alloy. A part of WC-12%Co powders are melted in the molten pool, and during solidification {TEX}$Al_{9}Co_{2}${/TEX} appeared. With increasing addition of WC-12%Co powders, the hardness and specific wear resistance of the overlay weld alloys increased and reached Hv450 at WC-12%Co powder addition rate of 54g/min. It is considered that excellent wear resistance of the overlayed alloys was due to dispersed WC-12%Co powders and increased 10 times at WC-12%Co powder addition rate of 54 g/min than that of the WC-free overlaying layers.