• Journal of the Korean Society for Nondestructive Testing
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• v.32 no.2
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• pp.162-169
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• 2012

This study detected SCC defects of dissimilar metal welded(STS304 and SA106 Gr. b) pipes using the ultrasonic infrared thermography method and the lock-in image treatment method among infrared thermography method. The infrared excitement equipment has 250 Watt of output and 20 kHz of frequency. By using the ultrasound infrared thermography method, the internal defects of dissimilar metal weld joints of pipes used at nuclear power plants could get detected. By an actual PT test, it was observed that the cracks inside the pipe existed not as a single crack but rather as a multiple cracks within a certain area and generated a hot spot image of a broad area on the thermography image. In addition, UT technology could not easily defects detected by the width of $10\;{\mu}m$ fine hair cracks. but, ultrasound infrared thermography technique was defect detected.

• Proceedings of the KWS Conference
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• 2010.05a
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• pp.51-51
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• 2010

Recently just as in the automobile industry, shipbuilders also try to reduce material consumption and weight in order to keep operating costs as low as possible and improve the speed of production. Naturally industry is ever searching for welding techniques offering higher power, higher productivity and a better quality. Therefore it is important to have a details research based on the various welding process applied to steel and other materials, and to have the ability both to counsel interested companies and to evaluate the feasibility of implementation of this process. Submerged-arc welding (SAW) process is usually used about 20% of shipbuilding. Similar to gas metal arc welding(GMAW), SAW involves formation of an arc between a continuously-fed bare wire electrode and the work-piece. The process uses a flux to generate protective gases and slag, and to add alloying elements to the weld pool and a shielding gas is not required. Prior to welding, a thin layer of flux powder is placed on the work-piece surface. The arc moves along the joint line and as it does so, excess flux is recycled via a hopper. Remaining fused slag layers can be easily removed after welding. As the arc is completely covered by the flux layer, heat loss is extremely low. This produces a thermal efficiency as high as 60% (compared with 25% for manual metal arc). SAW process offers many advantages compared to conventional CO2 welding process. The main advantages of SAW are higher welding speed, facility of workers, less deformation and better than bead shape & strength of welded joint because there is no visible arc light, welding is spatter-free, fully-mechanized or automatic process, high travel speed, and depth of penetration and chemical composition of the deposited weld metal. However it is difficult to application of thin plate according to high heat input. So this paper has been focused on application of the field according to SAW process for thin plate in ship-structures. For this purpose, It has been decided to optimized welding condition by experiments, relationship between welding parameters and bead shapes, mechanical test such as tensile and bending. Also finite element(FE) based numerical comparison of thermal history and welding residual stress in A-grade 3.2 thickness steel of SAW been made in this study. From the result of this study, It makes substantial saving of time and manufacturing cost and raises the quality of product.

• KSCE Journal of Civil and Environmental Engineering Research
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• v.8 no.2
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• pp.109-116
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• 1988

The strength and load of structure are varied with the Passage of time, and become a process of probability. It is possible to estimate the reliability from the relation between strength and load. Considering the safety, It is reasonable to estimate allowable stress from the safety factor based on the reliability. In this study, the method to estimate probability of fracture, which is index of reliability for rail subjeict to long term fatigue load were examined. In estimation of reliablity it is meaningless to evaluate numerical value especially this difficult case estimating parameter of random variable. To overcome this problem, conventional design method estimating relative reliability were proposed. In this study the Cornell method were examined. The uncertainity of random variale, ie coefficient of variation which is the index of variation of strength and load were considered. The effect of uncertainity related to probability of fracture, and safety factor based on reliability were examined. The results of this study are followed. The reliability of weld metal were influenced by variation of strength more then load, and base metal were influenced by load. It is confirmed that the allowable stress range calculating with factor of safety based an reliability is conservative.

• Journal of the Korean Society for Nondestructive Testing
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• v.36 no.6
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• pp.504-509
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• 2016

Defects in dissimilar metal welds are reported to be on the increase during the operating lifespan and aging of nuclear power plants. In Korea, reported cases of defects due to dissimilar metal welds include the drain nozzle of a steam generator and RCS hot tube sampling nozzles. Therefore, there is an urgent need to develop a reliable automated nondestructive inspection technique and a system for the inspection of dissimilar metal welds of small diameter nozzles in a high radiation area of a nuclear power plant. In this study, to ensure effective defect inspection of small diameter nozzles (RCS high-temperature tube sampling nozzle) of a nuclear power plant, three different methods were developed. These include: (1) optimum inspection probe design by beam simulation, (2) multi-directions UT optimum inspection technique for the inspection of small diameters of different welded parts, and (3) remote control automatic inspection system. The developed technique and systems have been verified to be suitable for use in the inspection of defects in smaller diameter nozzles in nuclear power plants.

• Journal of Korean Society of Steel Construction
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• v.10 no.3 s.36
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• pp.423-435
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• 1998

In this paper fatigue strength reduction of butt weld with penetration defect, which can be seen frequently in the steel bridge, was assessed quantitatively. S-N curves were derived and investigated through the constant amplitude fatigue test of fully or partially penetrated welded specimen made of SWS490 steel. The fracture mechanical method was applied in order to calculate the remaining fatigue life of the partially penetrated butt welds. The fatigue limit of the fully penetrated butt welds was higher than that of category A in AASHTO's fatigue design curves, and the slope of S-N curves with 5.57 was stiffer than that of other result for welded part generally accepted as 3. The fatigue strength of the partially Penetrated butt weld was strongly influenced by the size of lack of penetration, D. It decreased drastically with increasing D from 3.9 to 14.7mm. Fracture behaviour of the partially penetrated butt weld is able to be explained obviously from the beach mark test that a semi-elliptical surface crack with small a/c ratio initiates at a internal weld root and propagates through the weld metal. To estimate the fatigue life of the partially penetrated butt weld with fracture mechanics, stress intensity factors K of 3-dimensional semi-elliptical crack were calculated by appling finite elements method and fracture mechanics parameters such as C and m were derived through the fatigue test of CT-specimen. As a result, the fatigue lives obtained by using the fracture mechanical method agreed well with the experimental results. The results were applied to Sung-Su bridge collapsed due to penetration defects in butt weld of vertical member.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.7
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• pp.434-441
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• 2016

Friction Stir Welding (FSW) is a solid-state joining process involving the frictional heat between the materials and tools. The amount of heat conducted into the workpiece determines the quality of the welded zone. Excessive heat input is the cause of oxides and porosity defects, and insufficient heat input can cause problems, such as tunnel defects. Therefore, analyzing the temperature history and distribution at the center of the Friction Stir Welded zone is very important. In this study, the temperature distribution of the friction stir welding region of an AZ61 magnesium alloy was investigated. To achieve this goal, the temperature and metal flow was predicted using the finite element method. In FE analysis, the welding tool was simplified and the friction condition was optimized. Moreover, the temperature measuring test at the center of the welding region was performed to verify the FE results. In this study, the tool rotation speed was a more dominant factor than the welding speed. In addition, the predicted temperature at the center of the welding region showed good agreement with the measurement results within the error range of 5.4% - 7.7%.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.12
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• pp.2703-2714
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• 2002

In this work, energy absorption characteristics and optimal welding space of spot-welded square hat type tube are investigated via quasi-static crush experiments and finite element (FE) analyses. A FE model reflecting the crush characteristics is established based on the experimentally observed crush mechanisms of specimens with welding spaces (20, 30 & 45 mm) and (25,40 & 55 mm) respectively for two specimen widths (60, 75 mm). The established FE model is then applied to other crush models of widths (50, 60 & 75 mm) with various welding spaces (20, 25, 30, 40, 45, 55, 75, 150, 300 mm) respectively. We examine the energy absorption characteristics with respect to the welding space for each specimen width. The outcome suggests an optimal spot welding space of square hat type thin-walled tube. Energy absorption is also presented in terms of yield strength of base metal, specimen thickness, width, and mean crushing force of spot-welded square hat type thin-walled tube.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.20 no.12
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• pp.513-518
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• 2019

Friction Stir Welding is a welding technique for metal materials that utilizes the heat generated by friction between the material to be welded and the welding tool that rotates at high speed. In this study, a numerical analysis method was used to analyze the change in the internal temperature of the welded material during friction stir welding. As the welding target material, AZ31 magnesium alloy was applied and the welding phenomenon was considered a flow characteristic, in which a melting-pool was formed. FLUENT was used as the numerical tool to perform the flow analysis. For flow analysis of the welding process, the welding material was assumed to be a high viscosity Newtonian fluid, and the boundary condition of the welding tool and the material was considered to be the condition that friction and slippage occur simultaneously. Analyses were carried out for various rotational speeds and the translational moving speed of the welding tool as variables. The analysis results showed that the higher the rotational speed of the welding tool and the slower the welding tool movement speed, the higher the maximum temperature in the material increases. Moreover, the difference in the rotational speed of the welding tool has a greater effect on the temperature change.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.2
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• pp.1339-1347
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• 2015

This study discusses a remote control torch system equipped with a GMAW double wire reel. The welding machine is 30m away from the wire feeder at the industrial site and the feeder is three to five meters away from the torch. Accordingly, the welders cannot control the current and voltage that meets the welding condition during work when they are working at a place that prevents them from seeing the control panel, such as inside a vehicle or tank or at a far work site. They also have no choice but to stop working to change the wire reel when it is burned out completely. Such work suspension resulting from frequent moves to adjust the current and voltage as well as to replace the wire and subsequent cooling causes welding defects. This study produced a remote control torch equipped with a double wire reel by simplifying and streamlining the existing GMAW functions to reduce the troubling issue. The remote control torch equipped with a double wire reel and the existing $CO_2$ /MAG welding torch were applied as a V-groove butt in the vertical position using 6mm rolled steel for a SM50A welding structure. After welding, the condition of welded surface beads underwent a visual inspection and radiographic inspection to analyze the welding quality inside the welded part. This study also evaluated the reduction of welding defects, cost saving, the replacing performance against the existing commercial welders, and the effects on possible compatibility.

• Journal of the Korean Society for Railway
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• v.19 no.4
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• pp.417-426
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• 2016

In this study, the optimal welding condition of an extruded AZ61 magnesium alloy plate was investigated through evaluation of the mechanical properties and microstructure in the friction stir welding zones. The friction stir welding conditions considered in this study were the tool rotation speeds of 400, 600, and 800rpm and the welding speeds of 200, 300, and 400mm/min. To evaluate the welding strength, tensile and hardness tests were carried out. Microstructures of the welded regions were examined using optical microscopes. Under a tool rotation speed of 800rpm and welding speed of 200mm/min, the joint showed the best joining properties. The UTS, yield strength, and elongation of the welded region showed values of 79.0%, 65.4%, and 30.1%, respectively, of those of the base metal.