• Journal of Welding and Joining
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• 제33권4호
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• pp.24-29
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• 2015

The current waveform was analysed to monitor the weld quality in real time process. The acquired current waveform was discretely analysed for the top and bottom limits of peaks as well as the pulse frequency measurement. Fast Fourier Transform was implemented in the program to monitor the pulse frequency in real time. The developed algorithm or program was tested for the validation purpose. The cross-section of weld profile was compared to the current waveform profile to correlate the monitored signal and the actual parts. Pulse frequency was also used as auxiliary tool for the quality monitoring. Based on the results, it was possible to evaluate the quality of welding by measure the current waveform profile and frequency measurement.

• Journal of Welding and Joining
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• 제16권4호
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• pp.125-135
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• 1998

The shielded metal arc welding (SMAW) by AC power source was performed to evaluate the arc stability by arc monitoring and analysing. In this study, the arc stability index was evaluated quantitatively by using he coefficient of resistance variation for welding time. This coefficient was obtained for the long time (20sec.) by analysing the waveforms of welding current, voltage and resistance. The coefficient was applied to indicate numerically the variation level of arc length and the degree of arc extinction. Using the coefficient of resistance variation in practical welding, the arc stability of the high titanium oxide electrode (KS E4313) turned out to be better than that of the low hydrogen electrode (KS E4316). In evaluating the skill level of welders by the coefficient, the horizontal fillet weaving welding became clear to be very discriminating because the higher level welder could weave in keeping constant arc length, but the lower level welder showed the characteristics of weaving with the unstable arc length. And it was confirmed that the welding defects as blow holes was formed when the arc stability index were high.

• 한국산업융합학회 논문집
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• 제5권2호
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• pp.111-118
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• 2002

In GMAW(Gas Metal Arc Welding) processes, bead geometry (penetration, bead width and height) is a criterion to estimate welding quality, Bead geometry is affected by welding current, arc voltage and travel speed, shielding gas, CTWD (contact-tip to workpiece distance) and so on. In this paper, welding process variables were selected as welding current, arc voltage and travel speed. And bead geometry was reasoned from the chosen welding process variables using neuro-fuzzy algorithm. Neural networks was applied to design FLC(fuzzy logic control), The parameters of input membership functions and those of consequence functions in FLC were tuned through the method of learning by backpropagation algorithm, Bead geometry could he reasoned from welding current, arc voltage, travel speed on FLC using the results learned by neural networks. On the developed inference system of bead geometry using neuo-fuzzy algorithm, the inference error percent of bead width was within ${\pm}4%$, that of bead height was within ${\pm}3%$, and that of penetration was within ${\pm}8%$, Neural networks came into effect to find the parameters of input membership functions and those of consequence in FLC. Therefore the inference system of welding quality expects to be developed through proposed algorithm.

• Journal of Welding and Joining
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• 제13권4호
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• pp.75-84
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• 1995

In GMA welding of sheet metal, the short circuit metal transfer mdoe is preferred because of its low heat input and capability of bridging the root gap. The molten electrode is transferred to the workpiece during repectitive short circuit in the model. The waveform of welding current or voltage and the frequency of short circuiting are affected by a number of factors including: magnitude of welding current and voltage, root gap, electrode extension, power supply characteristics, and so on. In this study experimental models were proposed, which are able to determine the relationship between the root gap and short circuit frequency and the relationship between the root gap and appropriate welding speed that produces the good quality of back bead without burn through. Using the experimental models, the root gap can be obtained from measuring the short circuit frequency, and then the appropriate weldig speed to the root gap can be determined. Thus a back bead control system was constructed by controlling the welding speed for maintaining the quality of back bead. The developed system has shown the successful capability of back bead control.

• Journal of Welding and Joining
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• 제31권6호
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• pp.90-95
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• 2013

Pipe inside clad welding is mainly used to the flow pipe of sub-sea or chemical plant. For the inside clad welding to the medium pipe with the diameter of about 12", TIG welding is frequently applied with filler metal. In this case, the clad welding has the very broad weld area over $10m^2$. And, the non-destructive test (NDT) such as ultrasonic test (UT) or radiographic testing (RT) should be conducted on the broad weld area, and it costs very high due to the time-consuming work. Therefore, the present study investigated the variation of arc voltage to develop the in-line quality monitoring system for the pipe inside TIG cladding. The 4 experimental parameters (current, arc length, wire feed position, and shield gas flow rate) varied to observe the change of arc voltage and to establish the model for the monitoring. The arc voltage was decreased when the wire was fed to the backward eccentric position(over 2mm), and the shield gas flow rate was insufficient under 10L/min. In the case of the backward eccentric position over 2mm, the bead appearance was not good and the dilution ratio was increased due to deep penetration. When the shield gas flow rate was lower than 10L/min, the bead surface was oxidized.

• International Journal of Advanced Culture Technology
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• 제3권1호
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• pp.169-178
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• 2015

This research aims to study the effects of various welding parameters in gas metal arc welding (GMAW) process on welding penetration, microstructure and hardness of AS3578-A350 high strength steel with the thickness of 10 mm. The welding process parameters were a welding current of 100-200A, an arc voltage of 20-30V, a welding speed of 20-60 cm/min and a gas shielding type of Ar and $Ar+CO_2$. The summarized experimental results are as follows. An increase of the welding current and voltage affected to increase the penetration depth of the joint. However, when the welding speed was decreased, it increased the penetration depth of the joint. Using the Ar gas for shielding the weld area, produced the higher penetration depth and the less narrow weld bead than the joint that was shielded by the mix gas of $Ar+CO_2$. The variation of the welding process parameters affected to produce the various microstructures of weld metal and heat affected zone and also showed the various kind of hardness along the weld joint.

• Journal of Welding and Joining
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• 제6권2호
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• pp.47-55
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• 1988

This paper reports on a study of the influence of welding variables on the weld shape of Al-7020 in pulse-GMA welding. Five variables, i.e., wire feed rate, peak pulse current, welding speed, welding votage, and pulse frequency were investigated for their effects on the weld shape. From the results of the 2$^{n-1}$ fractional factorial design, quantitative effects of each variable and the interaction of two variables were obtained, and consequently wire feed rate, welding voltage, and welding speed were determined as the main welding variables. Supplementary experiment was performed for ivestigating the detailed relationship between the main variables nd the seld shape. In this experiment, the penetation of the seldment increased when the wire feed rate was raised, nad the bead width increased when the welding voltage was raised or the welding speed was reduced.d.

• Journal of Welding and Joining
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• 제21권1호
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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.

• 한국해양공학회지
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• 제25권6호
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• pp.1-8
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• 2011

This paper describes a new method for a digital gas metal arc welding (GMAW) system. The GMAW system is an arc welding process that incorporates the GMAW power source (PS-GMAW) with a wire feed unit (WFU). The PS-GMAW requires an electric power of constant voltage. A constant magnitude is maintained for the arc current by controlling the wire-feed speed of the WFU. A mathematical model is derived, and a self-tuning fuzzy proportional-integral-derivative (PID) controller is designed and applied to control the welding current. The electrode wire feeding mechanism with this controller is driven by a DC motor, which can compensate for both the molten part of the electrode and undesirable fluctuations in the arc length during the welding process. By accurately maintaining the output welding current and welding voltage at constant values during the welding process, excellent welding results can be obtained. Simulation and experimental results are shown to prove the effectiveness of the proposed controller.

• Journal of Electrical Engineering and Technology
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• 제2권3호
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• pp.366-372
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• 2007

Joining thin aluminum alloy is difficult using most welding techniques. Many of the problems are associated with bum-through by the high heat input. Common welding techniques are TIG (Tungsten Inert Gas), MIG (Metal Inert Gas), and PULSE-MIG welding. The method provides more control of the heat balance in the welding arc by taking advantage of the different arc characteristics obtained with each of the two polarities. In this paper, we proposed a new welding method by control DSP 320C32, and the characteristic and experiment result-voltage, current, welding bead, and penetrations by this method are presented.