• 한국생산제조학회지
• /
• 제20권2호
• /
• pp.145-150
• /
• 2011

There is problem to reduce the car body weight for improving fuel consumption and $CO_2$ generation. As one of the solution, the multi material car body concept using aluminum alloys and high strength steels is proposed recently. Therefore, new welding processes by which these dissimilar material can be joined in high reliability and productivity are demanded. Laser spot welding was developed for joining of dissimilar metals. In the present work, Laser spot welding of zinc coated steel and aluminum alloy was investigated, and the process parameters were studied. Otherwise, the influences of process parameters on the weldability, the formation of intermetallic compound layer and the mechanical properties have been investigated. When intermetallic compound layer thickness was more than 1mm, specimen was failure in the interface.

• 한국기계기술학회지
• /
• 제13권4호
• /
• pp.131-136
• /
• 2011

In commercial vehicle, sub-frame which equipped in main frame supporting dump deck and oil tanker. This is the main structure for all equipment which including joint function. Sub-frame is made by welding process, this susceptible to deform and crack by its longitudinal size. Also various kind of sub-frame make it difficult to standardization in manufacturing process and exclusive jig is not adapted yet. Frame size is over 6~8m and weight is more than 300kg this make re-work more difficult. If manufacturing company made precise sub-frame, this is not only convenient for customers but also save the company money by reducing the working time. In this study manufacture the sub-frame be suitable for its main function and develop exclusive welding jig for obtain checking fixture function as well.

• Safety and Health at Work
• /
• 제7권2호
• /
• pp.150-155
• /
• 2016

Background: Shipbuilding involves intensive welding activities, and welders are exposed to a variety of metal fumes, including manganese, that may be associated with neurological impairments. This study aimed to characterize total and size-fractionated manganese exposure resulting from welding operations in shipbuilding work areas. Methods: In this study, we characterized manganese-containing particulates with an emphasis on total mass (n = 86, closed-face 37-mm cassette samplers) and particle size-selective mass concentrations (n = 86, 8-stage cascade impactor samplers), particle size distributions, and a comparison of exposure levels determined using personal cassette and impactor samplers. Results: Our results suggest that 67.4% of all samples were above the current American Conference of Governmental Industrial Hygienists manganese threshold limit value of $100{\mu}g/m^3$ as inhalable mass. Furthermore, most of the particles containing manganese in the welding process were of the size of respirable particulates, and 90.7% of all samples exceeded the American Conference of Governmental Industrial Hygienists threshold limit value of $20{\mu}g/m^3$ for respirable manganese. Conclusion: The concentrations measured with the two sampler types (cassette: total mass; impactor: inhalable mass) were significantly correlated (r = 0.964, p < 0.001), but the total concentration obtained using cassette samplers was lower than the inhalable concentration of impactor samplers.

• Journal of Welding and Joining
• /
• 제15권4호
• /
• pp.166-177
• /
• 1997

The high strength AlZnMgCu0.5 alloy is a light metal with good age hardenability, and has a high tensile and yielding strength. Therefore, it can be used for structures requiring high speciple strength. Even though high strength AlZnMgCu alloy has good mechanical properties, it has a lot of problems in TIG and MIG welding processes. Since lots of high heat absorption is introduced into the weldment during TIG and MIG processes, the microstructural variation and hot cracks take place in heat affected zone. Therefore, the mechanical properties of high strength AlZnMgCu0.5 alloy can be degraded in weldment and heat affected zone. Welding process utilizing high density heat source such as electron beam should be developed to reduce pore and hot cracking, whichare usually accompanied by MIG and TIG welding processes. In this work, electron beam welding process were used with or without AlMg4.5Mn as filler material to avoid the degradation of mechanical properties. Mechanical and metallurgical characteristics were also studied in electron beam weldment and heat affected zone. Moreover hot cracking mechanism was also investigated.

• 대한산업공학회지
• /
• 제11권1호
• /
• pp.21-32
• /
• 1985

Presented in this paper is a procedure of developing graphical simulation software for planning robot welding processes. Welding is by far the highest application area for industrial robots, and it has been in great need of such a simulator in designing robot work cells, in justifying the economics of robot welding and in planning robotized welding operations. The model of a robot welding cell consists of four components: They are an welding structure which is a collection of plates to be welded, a positioner to hold the welding structure, a robot with a weld torch, and a set of welding lines (in case of arc welding). Welding structure is modeled by using the reference plane concept and is represented as boundary file which is widely used in solid modeling. Robot itself is modeled as a kinematic linkage system. Also included in the model are such technical constraints as weaving patterns and inclination allowances for each weld joint type. An interactive means is provided to input the welding structure and welding lines on a graphics terminal. Upon completion of input, the program displays the welding structure and welding lines and calculates the center of mass which is used in determining positioner configurations. For a given positioner and robot configuration, the welding line segments that can be covered by the robot are identified, enabling to calculate the robot weld ratio and cycle time. The program is written in FORTRAN for a VAX computer with a Tektronix 4114 graphic terminal.

• Journal of Welding and Joining
• /
• 제15권3호
• /
• pp.99-108
• /
• 1997

For the conventional welding method, the high heat transfer makes the crystallization of the work material unavoidable. Whereas the laser is able to weld the amorphous metal without a crystallized zone, because heat transfer is limited withn a very small restricted volume. In this paper, the possibilities and the limits of the laser welding in a deep frozen environment by liquid nitrogen were studied to utilize the advantageous properties of amorphous metal foils. The author investigated, after laser welding in a deep frozen environment with a solid state laser (Nd:YAG-laser), the achievable strengths and the influences of the laser beam parameters on the strengths.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 1991년도 춘계학술대회 논문집
• /
• pp.321-327
• /
• 1991

High power laser beams are used in a wide variety of materials processing applications such as cutting, welding, drilling and surface treatment. The CO$\sub$2/ laser is increasingly used in laser beam welding because of the highly potential advantages. High power laser welding is a high energy density, no filler metals and low heat input process to join metals. As the comparison with the conventiona welding, precision work and good fit-up to join the metals are required and maintenance is expensive at present. The principal variables of laser beam welding are the laser beam power, travel speed and bean spot size. The penetration depth during laser beam welding is directly related to the power density of the laser beam. Generally, for a constant beam size, the penetration depth increases with increasing laser beam power.

• 한국산학기술학회논문지
• /
• 제8권1호
• /
• pp.96-102
• /
• 2007

용접에 의해서 발생하는 변형은 강구조물의 치수를 변화시킬 뿐 아니라 역학적 강도를 저하시켜 강구조물의 제작공정과 공용중 심각한 문제를 발생시킬 수 있다. 특히 토목 강구조물의 경우 제작 및 조립공정에서 용접프로세스에 의해 불가피하게 발생하는 용접변형에 의한 설계치수의 변화를 검토하기 위해 넓은 장소에서 부분 또는 전체가 조립공정을 실시해야 한다. 이러한 가조립된 구조물은 현장에 설치되기 위해 해체하여 운반되어 현장에서 재조립하여 가설된다. 또한 높은 곳에서 작업해야 하므로 안전사고의 우려와 함께 크레인, 족장과 같은 부대장비를 사용해야 하므로 비경제적이다. 따라서 대형 강구조물의 제작시 발생하는 용접변형에 의한 부재오차를 검증하기 위한 가조립 공정을 생략하기 위해 용접변형 예측기법의 개발이 요구된다. 본 연구에서는 이를 위해 대형 강구조물의 용접변형 예측기법인 등가하중법을 이용한 용접부 수치모델링을 정립하고 이를 이용해 용접순서와 자중이 용접변형에 미치는 영향을 검토하였다.

• Journal of Welding and Joining
• /
• 제31권5호
• /
• pp.35-40
• /
• 2013

In this paper, we propose the Tangible Virtual Reality Representation Method to using haptic device and feature to morphology of created bead from Flux Cored Arc Welding. The virtual reality was started to rising for reduce to consumable materials and welding training risk. And, we will expected maximize virtual reality from virtual welding training. In this paper proposed method is get the database to changing the input factor such as work angle, travelling angle, speed, CTWD. And, it is visualization to bead from extract to optimal morphological feature information to using the Neural Network algorithm. The database was building without error to extract data from automatic robot welder. Also, the Neural Network algorithm was set a dataset of the highest accuracy from verification process in many times. The bead was created in virtual reality from extract to morphological feature information. We were implementation to final shape of bead and overlapped in process by time to using bead generation algorithm and calibration algorithm for generate to same bead shape to real database in process of generating bead. The best advantage of virtual welding training, it can be get the many data to training evaluation. In this paper, we were representation bead to similar shape from generated bead to Flux Cored Arc Welding. Therefore, we were reduce the gap to virtual welding training and real welding training. In addition, we were confirmed be able to maximize the performance of education from more effective evaluation system.

• 한국기계가공학회지
• /
• 제10권6호
• /
• pp.128-133
• /
• 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.