• Journal of Welding and Joining
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• v.27 no.3
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• pp.67-72
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• 2009

The flux cored arc welding (FCAW) process is one of the most frequently employed and important welding process due to high productivity and excellent workability. The process is performed either as an automated process or as a semi-automatic process. In FCAW process, welding voltage has been considered as a qualitative indication of arc length. But it is necessary to let welding operators know, maintain and manage the arc length directly by estimating and displaying it. In this study, to develop arc length estimation technique, we measured a welding circuit resistance($R_sc$) and then we calculated welding circuit voltage drop($V_sc$). Also, we measured arc peak voltage($V_ap$). By subtracting $V_sc$ from $V_arc$, we can easily calculate net arc voltage drop($V_arc$). Consequently, we suggested arc length estimating equation and basic algorithm by regressive analyzing the relationship between net arc voltage drop($V_arc$) and real arc length(Larc) measured by high speed camera. Therefore, arc length can be predicted by just monitoring welding current and voltage.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.6
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• pp.128-133
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• 2011

In this study, the steel material for shipbuilding(LR-A class) was used, and FCAW was taken advantage of 3G attitude and they are welded by different welding ways. As a result of analyzing wave with welding monitoring system, the stable values are obtained which are the first floor(electronic current 164~182 A, voltage 24 V), the second floor(electronic current 174~190 A, voltage 22~25 V), the third floor(electronic current 158~188 A, voltage 22~25 V), and fourth floor(electronic current 172~184 A, voltage 22~25 V), at this time, the stable wave standard deviation and changing coefficient could be obtained. When the welding testing through nondestructive inspection was analyzed know defect of welding, there was no defect of welding in A, D, E, but some porosities in B, and slag conclusion near the surface in C, because the length of arc was not accurate, and the electronic current and voltage was not stable. After observing the change of heat affect zone through micro testing, each organization of floor formed as Grain Refinement, so welding part was fine, the distance of heat affect zone is getting wider up to change the values of the electronic current and voltage. As a result of degree of hardness testing, the hardness orders were the heat affect zone(HAZ), Welding Zone(WZ), and Base Metal(BM). When the distribution of degree of hardness is observed. B is the highest degree of hardness The reason why heat effect zone is higher than welding zone and base metal, welding zone is boiled over melting point($1539^{\circ}C$) and it starts to melt after the result of analysis through metal microscope, so we can know that delicate tissue is created at the welding zone. Therefore, in order to get the optimal conditions of the welding, the proper current of the welding and voltage is needed. Furthermore the precise work of welding is required.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.1
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• pp.112-117
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• 2017

The arc, generated by Tungsten Inert Gas(TIG) welding, is stable and provides excellent quality of the weld. Since automation is difficult, a lot of work is performed by hand. In addition, to obtain the uniform weld quality is difficult when using a base metal having a nonuniform welding line, or when welding inside a pipe. Generally, TIG welding power has the characteristic of constant-current. The welding voltage is changed in proportion to the arc length. Hence, the automatic voltage control equipment should be applied at the TIG welding system. The automatic voltage control equipment has been designed using LabVIEW software. It consists of a manufactured voltage divider circuit, and jig for moving the torch. The voltage measurements and driving of the motor were performed through the algorithm implementation in LabVIEW. Welding was conducted while increasing the arc length. In this process, it was confirmed that the automatic voltage control equipment kept the arc length constant.

• Journal of Welding and Joining
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• v.15 no.3
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• pp.79-87
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• 1997

This study was performed to evaluate basic characteristics of electron beam welding process for a 9% Ni steel plate. The principal welding process parameters, such as working distance, accelerating voltage, beam current and welding speed were investigated. The AB (Arata Beam) test method was also applied to characterize beam size and energy density of the electron beam welding process. The electron beam size was found to decrease with the increase of accelerating voltage and the decrease of working distance. So, in case of high voltage (150kV), spot size and energy density of electron beam were revealed to be 0.9mm and $6.5\times10^5W/\textrm{cm}^2$ respectively. The accelerating voltage among the welding parameters was found to be the most important factor governing the penetration depth. When the accelerating voltage of electron beam was low ($\leq$90kV), beam current and welding speed did not affect on the penetration depth significantly. However, in case of high voltage ($\geq$120kV), the depth of penetration increased very sensitively with the increase of beam current and the decrease of welding speed.

• Journal of Korea Society of Industrial Information Systems
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• v.21 no.2
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• pp.39-44
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• 2016

Using the welding current and voltage signal processing, we have studied the influence that the diameter of the welding wire to the welding quality detection. For the experiments, We have analyzed the signal with respect to large and small artificially a gap between base materials than the welding wire. In this experiment, the 1.2 mm diameter of the welding wire was used, and distance between the welding base materials was respectively 1.0 mm and 2.0 mm. In the welding with a large defect than the diameter of the welding wire it was able to detect a change in the welding current and welding voltage. But it could not detect a change in the welding current and welding voltage in the welding has a small defect than the welding wire diameter.

• Proceedings of the KWS Conference
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• 1999.10a
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• pp.47-50
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• 1999

The term adaptive control is often used to describe recent advances in welding process control but strictly this only applies to system which are able to cope with dynamic changes in system performance. In welding applications, the term adaptive control may not imply the conventional control theory definition but may be used in the more descriptive sense to explain the need for the process to adapt to the changing welding conditions. This paper proposed a methodology for obtaining a good bead appearance based on multi-torches welding system with the vision system in SAW. The methodologies for adaptive filling control used the welding current/voltage, arc voltage/welding current/wire feed speed combination and welding speed by using the vision sensor. It was shown that the algorithm for the welding current/voltage combination and welding speed revealed the sound weld bead appearance compared with that of the voltage/current combination.

• Journal of Korea Society of Industrial Information Systems
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• v.19 no.6
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• pp.25-31
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• 2014

Gas metal arc welding (GMAW) is currently the most widely used arc welding processes in the industry because of its high metal deposition rate, flexibility and low cost. It is attractive for high-productivity manufacturing applications and is well suited to automatic or robotic welding. Welding voltage and current have a significant impact on the weld bead. However, welding voltage and current are changed variously according to welding condition and user environment, and prediction is impossible. To determine the welding conditions, the welding current and voltage are applied to the appropriate data analysis techniques. In this paper, we used the moving average filter to the welding voltage and current data, and normal and abnormal welding waves were distinguished.

• Journal of Welding and Joining
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• v.17 no.6
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• pp.90-99
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• 1999

Significant portion of the total manufacturing time for a pipe fabrication process is spent on the welding following primary machining and fit-up processes. To achieve a reliable weld bead appearance, automatic seam tracking and adaptive control to fill the groove are urgently needed. For the seam tracking in welding processes, the vision sensors have been successfully applied. However, the adaptive filling control of the multi-torches system for the appropriate welded area has not been implemented in the area of SAW(submerged arc welding) by now. The term adaptive control is often used to describe recent advances in welding process control by strictly this only applies to a system which is able to cope with dynamic changes in system performance. In welding applications, the term adaptive control may not imply the conventional control theory definition but may be used in the more descriptive sense to explain the need for the process to adapt to the changing welding conditions. This paper proposed various types of methodologies for obtaining a good bead appearance based on multi-torches welding system with the vision system in SAW. The methodologies for adaptive filling control used welding current/voltage, arc voltage/welding current/wire feed speed combination and welding speed by using vision sensor. It was shown that the algorithm for welding current/voltage combination and welding speed revealed sound weld bead appearance compared with that of voltage/current combination.

• Journal of Welding and Joining
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• v.30 no.5
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• pp.46-50
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• 2012

This study was carried out to investigate the effect of welding parameters such as shielding gas compositions welding voltage and welding current on the pore formation in the weld beads of galvanized steel pipes produced with gas metal arc welding. The porosity was evaluated and rated by metallography and radiographic test in terms of weight percentage, number and distribution of pores in weld beads. The porosity increased with increasing welding voltage and current, in which Ar gas produced the most porosity while $Ar+5%O_2$ generated the least porosity. It was found that the porosity could be reduced by selection of the proper gas mixture composition such as $Ar+5%O_2$ and $Ar+10%CO_2$ and by using current (130~150A) and voltage(16~20V).

• The Transactions of the Korean Institute of Power Electronics
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• v.21 no.4
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• pp.351-355
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• 2016

Welding machines are high-capacity systems used in a low-frequency range using IGBT. As their system is similar to a large transformer, most welding machines suffer a great loss because of hard switching and vast leakage inductance. A voltage-balancing circuit is designed to overcome these shortcomings. This circuit can reduce the transformer size by making it into a high frequency and reducing the input voltage by half and by adopting a serial structure that connects two full-bridges in a series to use a MOSFET with a good property at high frequency. In addition, a Schottky diode is used in the primary rectifier to overcome the low efficiency of most welding machines. To use the Schottky diode with a reliably relatively low withstanding voltage, an active snubber is adopted to effectively limit the ringing voltage of the diode cut-off voltage.