• Transactions of the Korean Society of Automotive Engineers
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• v.2 no.1
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• pp.73-83
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• 1994

Press formabilities of aluminum sheets for automobile body were investigated. Plane strain stretching test (called RIST-PSST), cupping test and U bending test were performed to assess the press formability of aluminum sheets respectively. The results showed that aluminum sheets are generally inferior to cold-rolled steel sheet of deep drawing quality (CSP3N) in press formability. The limiting punch height (LPH) and limiting plane strain (FLCo) of aluminum sheets are 50%-70% level compared to that of CSP3N. Moreover, the limiting drawing ratios(LDR) of aluminum sheets are ranged between 1.95 and 2.1. The poor press formability of aluminum sheets is responsible for low values of total elongation and plastic anisotropy parameter in tensile characteristic. The shape fixability of aluminum sheets evaluated in U bending test is very poor due to its low elastic modulus compared to CSP3N.

• Journal of Welding and Joining
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• v.14 no.3
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• pp.41-47
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• 1996

The spot weldability of coated steels for automobile has been investigated. Coated steels of SPC-Zn DC, SPC Zn-Ni SC, SPC Zn-Ni DC, SPC Zn-Fe DC and OCCS were welded under different conditions of welding current, force and time. Coating thickness at the welded surface was reduced as increased welding current. Tensile shear strength(TSS) and cross tensile strength (CTS) were increased up to expulsion began, then dropped as increased current. Optimum conditions of welding force and time were different, however 200~250kgf and 15~20cycle were optimum for coated SPC (Steel Plate Cold). Weldability lobes were measured for each coated steel and they showed narrow range of working welding current. The organic composite coated steel (OCCS) had the highest current to get $\sqrt5{t}$ nugget size and narrowest working welding current range.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.195-198
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• 2009

In this study, in order to get the forming limit of AHSS sheet in the negative minor strain region, the shapes of die corner and drawbead are redesigned by employing the Taguchi's design of experiment method and the FEM forming simulation. With the redesigned FLD tool, the forming limit tests of automotive multi-phase(Dual Phase and Complex Phase) steel sheets which induce the normal fractures on the blank are performed.

• Journal of Welding and Joining
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• v.20 no.4
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• pp.510-516
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• 2002

Recently the laser welding technology has been applied increasingly for the automotive bodies. But the lap joint laser welding for 3 dimensional automotive body is new while the butt joint laser welding is well known as the tailored blank technology. In this study, the process window was found for the full penetration welding of the lap joint of the 1mm-thick high strength steel sheets. The limit curves and characteristic curves were suggested to define the boundaries and the contour lines in a space of the welding speed and the gap size. The characteristics of the weld sectional geometry were used to determine the limit curves. They are bead width, penetration depth and sectional area. After the observed data was analysed carefully, it was noticed that there was a transition point at which the sectional shape was changed and the bead area jumped as the welding speed was increased. Also a new concept of 'input energy Per volume' was suggested to distinguish the difference at the transition Point. The difference of sectional areas at the transition point can be related to the dynamic keyhole phenomena.

• Proceedings of the KWS Conference
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• 1996.05a
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• pp.46-50
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• 1996

Continuous wave $CO_2$ laser beam welding and formability of zinc coated steel sheets were investigated. First, optimal welding condition could be obtained in butt welding by using the data for heat input and welding velocity. The highest value of Erichsen test is 79.3% compare to that of base metal. Secondly, Formability of laser welds was investigated by using ball punch tester. Finally, the forming results of butt-welded sheets showed that the joining design was important to apply the laser welded blank in the automotive production.

• Corrosion Science and Technology
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• v.10 no.6
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• pp.199-204
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• 2011

Hot dip metallic coated steels like as galvanized (GI), zinc-aluminium (GL) and aluminium coated steels are mostly used where corrosion resistance is needed. There are two kinds (type 1 and type 2) of aluminium coated steel being commercially used among them. Type 1 aluminium coated steel is coated with an Al-5~11 wt%Si alloy and Type 2 aluminium coated steel consists of commercially pure aluminium. Type 1 Al coated steel is generally used in automotive components and electrical appliances while type 2 aluminium coated steel is mainly used in construction applications such as building cladding panels, air conditioning and ventilation system. In this study, Type 1 aluminium coated steels have tested by accelerated conditions (salt spray or corrosive gas) and outdoor exposure condition in order to understand their corrosion behaviour. Due to the distinct corrosion mechanism of Al which exposes to the severe chloric condition, Salt Spray Test cannot predict the ordinary atmospheric corrosion of Al based coated materials. In addition, the test results and their corrosion feature of Al coated steel sheets will be discussed comparing with other metallic coated steel sheets of GI and GL.

• Transactions of Materials Processing
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• v.24 no.4
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• pp.256-263
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• 2015

Electric resistance spot welding has been used to join overlapped steel sheets in automotive bodies. Recently to reduce weight in automotive vehicles, non-ferrous metals are being used or considered in car bodies for hoods, trunk lids, doors parts, etc. Various welding processes such as laser welding, self-piercing rivet, friction stir welding are being used. In the current study, a new electric resistance heated friction stir spot welding is suggested for the spot welding of non-ferrous metals. The welding method can be characterized by three uses of heat -- electric resistance heating, friction stir heating and conduction heating of steel electrodes -- for the fusion joining at the interfacial zone between the two sheets. The welding process has variables such as welding current, diameter of the steel electrodes, revolutions per minute (rpm) of the friction stir pin, and the insert depth of the stir pin. In order to obtain the optimal welding variables, which provide the best welding strength, many experiments were conducted. From the experiments, it was found that the welding strength could be reached to the required production value by using an electrode diameter of 10mm, a current of 7.6kA, a stirring speed of 400rpm, and an insert depth of 0.8mm for the electric resistance heated friction stir spot welding of 5052 aluminum 1.5mm sheets.

• Transactions of Materials Processing
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• v.26 no.1
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• pp.55-62
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• 2017

This paper proposes the process to develop a light-weighting automotive door assembly using high strength steel with low cost penalty. In recent years, the automotive industry is making an effort to reduce the vehicle weight. In this study, inner panels for automotive front door using thinner sheets and quenchable boron steel were designed to reduce the weight of conventional one. In order to evaluate the stiffness properties for the proposed door design, the several static tests were conducted using the finite element method. Based on the simulation results, geometry modifications of the inner panels were taken into account in terms of thickness changes and cost saving. Furthermore, a prototype based on the proposed design has been made, and then static stiffness test carried out. From the results, the proposed door is proved compatible and weight reduction of 11.8% was achieved. It could be a reference process for automotive industry to develop the similar products.

• Corrosion Science and Technology
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• v.23 no.4
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• pp.296-301
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• 2024

Steels have excellent mechanical properties and weldability. They are also economically producible. Thus, they are widely applied in various industries. However, they have a disadvantage in that rust can occur after a certain period of time. To compensate for this, Zn, which has excellent sacrificial corrosion resistance, can be coated on steels. With global zinc consumption increasing at the current rate, depletion is expected in the near future. Recently, POSCO has developed innovative Al-Zn-Si alloy coated steel sheets with better corrosion resistance than Zn coating. In this study, corrosion resistance, weldability, friction characteristics, and so on were evaluated compared to GI steel sheets to evaluate their applicability to automotive steel sheets. It showed excellent corrosion resistance even at a lower coating weight compared to GI steel sheet. It was also excellent in terms of galling and welding LME. Its spot welding life, electrodeposition coating, and bendability were equally excellent. This is presumed to be related to the formation of the Al-Zn-Si alloy phase at the interface of the coating layer.

• Transactions of Materials Processing
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• v.1 no.1
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• pp.75-86
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• 1992

Coated sheet steels have been increasingly used in automotive industry for improving corrosion resistance. One of the arised concerns is frictional behavior of coated sheet steel in stamping process. But analyses of the frictional behavior are complex and difficult. A tensile strip test has been developed for evaluating friction under the condition which simulate the stretching of sheet. Tests are conducted under different die radius and lubrication conditions. Electro-galvanized steel sheets show a lower coefficient of friction than bare steel sheets whose coated layers have been chemically removed. The coefficients of friction are independent of die radius.