• Journal of Welding and Joining
• /
• v.8 no.3
• /
• pp.70-78
• /
• 1990

The harsh nature of welding environments makes welding a prime candidate for process automation. Among the variety of welding processes available, gas metal arc welding is one of the most frequently used methods, primarily because it is highly suited to a wide range of applications, and also to automation. Automatic seam tracking method is one of the most demanded techniques for automatic control of arc welding. In this study a seam tracking system has been developed by using the welding arc itself as a sensor. This paper described the principle and experimental result of the arc sensor system, as well as the development and application of the automatic CO_2$ welding for the horizontal fillet welding. A basic problem in horizontal fillet welding is the prevention of hanging bead formation such as undercut at the vertical plate and overlap at the horizontal plate. To produce the symmetric bead shape, the relationship of bead shape to welding parameters(welding velocity, weaving width, weaving speed, tip to workpiece distance) was also investigated.

• Journal of Welding and Joining
• /
• v.31 no.6
• /
• pp.84-89
• /
• 2013

The demand of LNG tank and the constituting material, i.e., the Al5083 thick plate, increased due to the rapid growth LNG market. To weld the Al5083 thick plate, the gas metal arc welding (GMAW) of high current is necessary to increase manufacturing productivity incurred by the multi pass welding. However, the arc welding vaporizes the volatile element such as magnesium (Mg). This phenomenon changes the Mg composition of the weld metal and the mechanical properties. The study investigated the weldability of Al5083 alloys after conducting high current GMAW. The Al5083 alloy was welded by using different size of welding wires and high current (800-950A). As the arc current increased from 800A to 950A, the mechanical strength decreased and the secondary dendrite arm spacing (SDAS) increased. Even though the arc current increased SDAS, the mechanical strength decreased due to the Mg loss in the weldment. The large diameter of welding wire decreased the dilution of the weld, therefore increasing the Mg content and the strength of the weld. For the reason, the content of Mg in welds was a major parameter to determine the mechanical property for the high current GMAW. For the arc current between 800A and 950A, the yield strength of the weldments showed a relationship with the weight percent of Mg content ($X_{Mg}$): Y.S = 27.9($X_{Mg}$)-11.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 1997.04a
• /
• pp.36-41
• /
• 1997

With the trend towards welding automation and robozation, mathematical models for studying the influence of various parameters on the weld bead geometry in Gas Metal Arc(GMA) welding process are required. The results of bead on plate welds deposited using the GMA welding process has enabled mathematical relationships to be developed that model the weld bead geometry. Experimental results were compared to outputs obtained using existing formulae that correlate process input variables to output parameters and subsequent modelling was performed in order to better predict the output of the GMA welding process. The aim of this work was to explain the relationships between GMA welding variables and weld bead geometry and thus, be able to predict input weld bead size. The relationships can be usefully employed for open loop process control and also for adaptive control provided that dynamic sensing of process output is performed.

• International Journal of Korean Welding Society
• /
• v.3 no.2
• /
• pp.1-6
• /
• 2003

The abrasion and impact wear resistance were investigated on the hardfacing weld dispersed with the recycled hard metal(HM). The HM was composed of the tungsten carbide(WC) reinforced metal matrix composite. The cored wire filled with the 35 wt.％ HM and 0­6 wt.％ of the alloying element, Fe­75Mn­7C(FeMnC), was used for the gas metal arc(GMA) welding. The FeMnC addition to the 35 wt.％ HM did not improve the abrasion wear property since the amount of the tungsten carbide formed was decreased with respect to the FeMnC amount. However, the 6 wt.％ FeMnC addition to the 35 wt.％ HM exhibited the better impact wear resistance than the hardfacing weld by the 40 wt.％ HM.

• Journal of Welding and Joining
• /
• v.25 no.5
• /
• pp.64-71
• /
• 2007

The aim of this paper is to investigate the effects of welding parameters on the weld shape in seal-welding of STS304L capsule for manufacturing a radioisotope source which is widely used in nondestructive testing of metal structures using gamma ray. Pulsed gas tungsten arc (Pulsed GTA) welding is performed for thin cross sectional area of the capsule. Seven welding parameters including current waveform parameters and arc length etc. are selected as main process parameters using design of experiment. The weld shape such as bead width, penetration depth, weld area, aspect ratio and area rate is investigated to assess the effects of welding parameters. As results, the combination of pulse duty/welding speed largely affects on bead width, penetration depth, area and aspect ratio. Finally, it is concluded that the key parameters are the combination of pulse duty/welding speed, base current and arc length, and their optimal conditions are 50%/1.77mm/s, 6.4A and 1 mm.

• International Journal of Korean Welding Society
• /
• v.1 no.2
• /
• pp.36-44
• /
• 2001

To get the appropriate welding process variables, mathematical modeling in conjunction with many experiments is necessary to predict the magnitude of weld bead shape. Even though the experimental results are reliable, it has a difficulty in accurately predicting welding process variables for the desired weld bead shape because of nonlinear and complex characteristics of welding processes. The welding condition determined for the desired weld bead shape may cause the weld defect if the welding current/voltage/speed combination is improperly selected. In this study, the $2^{n-1}$ fractional factorial design method and correlation parameter were used to investigate the effect of the welding process variables on the fillet joint shape, and the multiple non-linear regression analysis was used for modeling the gas metal arc welding(GMAW）parameters of the fillet joint. Finally, a fuzzy rule-based method and a neural network method were proposed so that the complexity and non-linearity of arc welding phenomena could be effectively overcome. The performance of the proposed neuro-fuzzy system was evaluated through various experiments. The experimental results showed that the proposed neuro-fuzzy system could effectively check the welding conditions as to whether or not weld defects would occur, and also adjust the welding conditions to avoid these weld defects.

• Journal of Welding and Joining
• /
• v.16 no.5
• /
• pp.119-133
• /
• 1998

To implement full automation in pipe welding, it si most important to develop special sensors and their related systems which act like human operator when detecting irregular groove conditions. In this study, an automatic pipe Gas Metal Arc Welding (GMAW) system was proposed to full control pipe welding procedure with intelligent sensor systems. A five-axes manipulator was proposed for welding torch to automatically access to exact welding position when pipe size and welding angle were given. Pool status and torch position were measured by using a weld-pool image monitoring and processing technique in root-pass welding for weld seam tracking and weld pool control. To overcome the intensive arc light, pool image was captured at the instance of short circuit of welding power loop. Captured image was processed to determine weld pool shape. For weld seam tracking, the relative distance of a torch position from the pool center was calculated in the extracted pool shape to move torch just onto the groove center. To control penetration of root pas, gap was calculated in the extracted pool image, and then weld conditions were controlled for obtaining appropriate penetration. welding speed was determined with a fuzzy logic, and welding current and voltage were determined from a data base to correspond to the gap. For automatic fill-pass welding, the function of human operator of real time weld seam control can be substituted by a sensor system. In this study, an arc sensor system was proposed based on a fuzzy control logic. Using the proposed automatic system, root-pass welding of pipe which had gap variation was assured to be appropriately controlled in welding conditions and in torch position by showing sound welding result and good seam tracking capability. Fill-pass welding by the proposed system also showed very successful result by tracking along the offset welding line without any control of human operator.

• Journal of Welding and Joining
• /
• v.28 no.5
• /
• pp.86-92
• /
• 2010

In GMAW processes, bead geometry is a criterion to estimate welding quality. Bead geometry is affected by welding current, arc voltage, welding speed, shielding gas and so on. Thus the welding condition has to be selected carefully. In this paper, an experimental method for the selection of optimal welding condition was proposed in the root pass welding which was done along the GMA V-grooved butt weld joint. This method uses the response surface analysis in which the width and height of back bead were chosen as the quality variables of the weld. The overall desirability function, which is the combined desirability function for the two quality variables, was used as the objective function for getting the optimal welding condition. Through the experiments, the target values of the back bead width and the height were chosen as 4mm and 1mm respectively for the V-grooved butt weld joint. From a series of welding test, it was revealed that a uniform weld bead can be obtained by adopting the optimal welding condition which was determined according to the method proposed.

• Journal of the Korean Society for Precision Engineering
• /
• v.16 no.12
• /
• pp.152-160
• /
• 1999

The weld quality of $CO_2$ arc welding is closely related to the arc stability. As the characteristics of the arc are excessively complex and nonlinear, it is not easy to make the arc model as mathematical form and to control the arc state to be stabilized. This paper was aimed to estimate the arc stability and to control for stabilizing the arc state in short circuit metal transfer mode of $CO_2$ arc welding. For these purposes, the behaviors of arc stability was investigated at different welding conditions using Mita's arc stability index, and the fuzzy control algorithm which uses the arc stability index as control imput and the arc voltage as control output was developed. In the control of the arc stability, the experiments of two cases were performed; the case of setting an initial welding voltage arbitrarily, the case of the step change in workpiece shape. Obtained results were as follows; Mita's arc stability index was able to be estimated qualitatively in the case of using the inverter type welding power source and the control performance for stabilizing the arc status was excellent in the case of existing step change disturbance.

• 제어로봇시스템학회:학술대회논문집
• /
• 1996.10b
• /
• pp.1404-1407
• /
• 1996

A quality monitoring system in butt welding process is proposed to estimate weld pool sizes. The geometrical parameters of the weld pool such as the top bead width and the penetration depth plus half back width are utilized to prove the integrity of the weld quality. The monitoring variables used are the surface temperatures measured at three points on the top surface of the weldment. The temperature profile is assumed that it has a gaussian distribution in vertical direction of torch movement and verify this assumption through temperature analysis. A neural network estimator is designed to estimate weld pool size from temperature informations. The experimental results show that the proposed neural network estimator which used gaussian distribution as temperature information can estimate the weld pool sizes accurately than used three point temperatures as temperature information. Considering the change of gap size in butt welding, the experiment were performed on various gap size.