• Journal of the Korea Academia-Industrial cooperation Society
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• v.7 no.4
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• pp.738-742
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• 2006

In this study we developed the electrical heating mold core by applying three different heating methods. In order to find out the optimal heating method, we observed the temperature profiles with time. We also injection-molded the parts by the heating methods and investigated the shrinkage ratio, density, surface roughness and weld-lines. The temperature rise time and cycle time showed the promising results for commercial applications(the rise time is $130^{\circ}C$/14sec, the cycle time is 55sec). By comparing with the conventional and gas flame heating method, the parts by this method were proven to have good qualities. The shrinkage ratio reduced by 5.1%, the density increase by 2.66%, the smoothness increased about 3 times, and the weld-line did not observed by naked eyes.

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.6
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• pp.158-165
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• 2002

This study was to evaluate mechanical properties and toughness of the Al5083-O aluminum alloy welding zone according to the mixing shield gas ratio and heat input change. The GMA(Gas Metal Arc) welding of the base metal was carried out with four different mixing shield gas ratios(Ar100%+He0%, Ar67%+He33%, Ar50%+He50%, and Ar33%+He67%) and three different heat inputs(low, medium, and high). To investigate the Charpy absorbed energy of the weld zone, the specimens were divided base metal, weld metal, fusion line, and HAZ notched specimen according to the worked notch position. The different gas ratio and heat input had little effect upon the tensile strength. But Ar33%+He67% mixture had the greatest mechanical properties considering that the more He gas ratio concentrations, the higher yield strength and elongation. The maximum load and displacement of the weld metal notche specimen was so much low more than that of the base metal, but fusion line and HAZ notched specimens showed almost same regardless of the mixing shield gas ratio and heat input. The Charpy absorbed energy was lowest in weld metal notched specimen, and increased in the fusion line, and HAZ notche specimen in order. Ar33%+He67% mixture had the greatest toughness considering that the more He gas ratio, the higher absorption energy.

• Journal of Welding and Joining
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• v.32 no.6
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• pp.1-7
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• 2014

For the resistance spot welds of CR1180 and GA1180 TRIP steels, the weld quality evaluation method using the digitalized X-ray transmission imaging apparatus was investigated in comparison with the crosssectional examination method. In the case of the resistance spot welding of CR1180, three circular regions, such as WZ(white zone), GZ(grey zone) and DZ(dark zone), appeared on X-ray image and they corresponded to the diameters of indentation mark, nugget and corona bond, respectively. The variation of X-ray transmission thickness due to the thickness variation of the weld seemed to be mainly responsible for the formation of those contrasts. The X-ray image contrast formed from the variation of transmission thickness at the outer border line of DZ could also enable the inspections of the notch shape, nonuniformity of the welding pressure and spatter from its sharpness, concentricity and the normal straight line, respectively. The X-ray image of the resistance spot weld of galvannealed GA1180 TRIP steel was very similar to that of CR1180 TRIP steel except the crown shaped outer border line of DZ which was considered to be due to the melting behavior of zinc having the boiling temperature even lower than the melting temperature of steel.

• Proceedings of the KWS Conference
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• 1996.10a
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• pp.139-141
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• 1996

Among various welding parameters, the welding current which is inversely proportional to the tip-to-workpiece distance in GMAW is an essential parameter to monitor the GMAW process of horizontal fillet joints. For the case of weld defect such as overlap in horizontal fillet welding, therefore, the signal processing for process monitoring or automatic seam tracking should be modified by considering the weld pool surface geometry including the corresponding weld defect. In other words, the adequate signal processing algorithm is indispensible to improve the performance of the arc sensor. However, arc sensor algorithm already developed usually focus on weld seam tracing but do not considering the weld qualities. In this paper, various experiments were carried out to investigate the tendencies of the weld defects when weaving motion is added, and the experimental method based on 2$^n$ factorial design was proposed for deriving the mathematical model between the leg length and the various welding conditions. Moreover, a signal processing method based on the artificial neural network(Adaptive Resonance Theory) was proposed far discriminating the current signal of sound weld beads from that of weld beads with overlap. Finally, the algorithm for weld seam tracking combined with the mathematical modeling and the signal processing method was carried out to track the weld line in conjunction with the improvement of the weld qualities. The reliability of the proposed algorithms were evaluated through various experiments, which showed that the proposed algorithms could be effectively used for arc welding automation.

• Journal of Welding and Joining
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• v.27 no.4
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• pp.38-43
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• 2009

As it has been well appreciated, the weld-induced deformation control is one of the most important issues from view point of efficiency in ship production. The weld-induced deformation is more serious in the case of thin plate block than in the case of relatively thick plate block, since, for example, heat affect zone of thin plates is wider than that of thick plates for the same heat input. Among weld-induced deformation, buckling deformation due to shrinkage and residual stress in weld line direction is one of the most serious deformation type. This paper is concerned with the controling the buckling deformation of thin plate fillet weld by applying the tensioning method. Weld experiments have been carried out for specimens with varying the magnitude and direction of tension load. The results are graphically represented to show the effect of tensioning method upon reducing the weld-induced deformation. From the present findings, its has been seen that tensioning method is one of the useful ways to control the weld-induced deformation of fillet weld of thin plates.

• Journal of Welding and Joining
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• v.14 no.4
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• pp.79-88
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• 1996

For improvement in productivity and weld quality, weld seam tracking and welding parameter control are very essential in the welding of a structure which can not be cxactly fit-up due to mismatch, discontinous gap, deflection, etc.. In this study, an automatic weld seam tracking system is developed for I-butt joint structure, and the system consists of XYZ working table, vision sensor and user interface program. In the developed vision sensor system, an image projection algorithm for weld-line detection and an adaptive current control algorithm for gap variation were implemented. The user interface program developed in this study by basing on the objct oriented concept could provide very convenient way to utilize the tracking system with the pull-down menu driven structure. The developed system showed a good seam tracking and weld quality control capability corresponding to deflected weld lines and gap variations.

• Proceedings of the Korean Society of Marine Engineers Conference
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• 2002.05a
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• pp.113-199
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• 2002

In this study, the toughness was evaluated by using the instrumented Charpy impact testing procedures for A15083-O aluminum alloy used in the LNG carrying and storing tank. The specimens were GMAW welded with four different mixing shield gas ratios (Ar100%+He0%, Ar67%+He33%, Ar50%+He50%, and Ar33%+He67%), and tested at four different temperatures(+25, -30, -85, and -196$^{\circ}C$ ) in order to investigate the influence of the mixing shield gas ratio and the low temperature. The specimens were divided into base metal, weld metal, fusion line, and HAZ specimen according to the worked notch position. From experiment, the maximum load increased a little up to -85$^{\circ}C$, and the maximum load and maximum displacement were shown the highest and the lowest at -196$^{\circ}C$ than the other test temperatures. The absorption energy of weld metal notched specimens was not nearly depends on test temperature and mixing shield gas ratio because the casting structure was formed in weld metal zone. In the other hand, the others specimens was shown that the lower temperature, the higher absorption energy slightly up to -85$^{\circ}C$ but the energy was decreased so mush at -196$^{\circ}C$

• Journal of the Korean Society for Heat Treatment
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• v.16 no.3
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• pp.141-147
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• 2003

The effects of heat treatment on the fatigue life and welding residual stress of welded plates were investigated in this study. The plates were welded by flux cored arc welding process, and post weld heat treated at $600^{\circ}C$ for 1 hour. The residual stresses of welded plates before and after post weld heat treatment were measured by hole drilling method. To measure the fatigue life of welded plates, low cycle fatigue tests under strain control and high cycle fatigue tests under load control were performed respectively, by using cylindrical specimens containing weld metal and heat affected zone. The obtained result shows that the post weld heat treatment reduces the residual stress, and resultantly changes the fatigue life of welded plate. Goodman diagrammatic analysis has also been performed to study the effect of post weld heat treatment on the high cycle fatigue life.

• Proceedings of the KAIS Fall Conference
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• 2003.06a
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• pp.122-124
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• 2003

본 연구는 사출성형공정 후 조립공정에서 발생하고 있는 사출성형물의 Weld line에 의한 사출성형물의 파괴현상을 해석하고 개선된 품질을 얻기 위한 시도이다. 사출성형 관련 설계는 사출금형설계 전문가의 축적된 지식과 경험을 활용하여 수행되어 왔으며, 설계에 필요한 설계자의 경험이 전무한 경우 많은 시행 오차를 유발하고 있는 실정이다. 본 연구에서는 글라스 홀더 플레이트를 사출성형하고 조립공정을 수행함에 있어 생산 중 발생되고 있는 Weld line에 의한 제품의 강도 문제를 수치해석을 통하여 시뮬레이션함으로써 제품 품질을 향상 하고자 해석과 평가를 시도 하였다.

• Proceedings of the KAIS Fall Conference
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• 2003.06a
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• pp.133-135
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• 2003

본 연구는 사출성형공정상에서 발생하고 있는 사출성형물의 Weld line에 의한 외관 불량을 해석하고 개선된 품질을 얻기 위한 시도이다. 사출성형 관련 설계는 사출금형설계 전문가의 축적된 지식과 경험을 활용하여 수행되어 왔으며, 설계에 필요한 설계자의 경험이 전무한 경우 많은 시행 오차를 유발하고 있는 실정이다. 본 연구에서는 Window Panel의 사출성형을 수행함에 있어 생산 중 발생되고 있는 Weld line에 의한 제품 외관의 문제를 수치해석을 통하여 시뮬레이션함으로써 제품 품질을 향상 하고자 해석을 시도하였다.