• Proceedings of the KWS Conference
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• 2002.10a
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• pp.289-294
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• 2002

This paper presents first results of an interdisciplinary research project for the development of an "intelligent" welding helmet. Contrary to conventional welding helmets the system allows a detailed observation both of the welding process and the environment. By methods of virtual and augmented reality additional information can be supplied to the welder. The system can be used for welding preparation, welding process observation and quality assurance.

• Journal of Korean Society of Occupational and Environmental Hygiene
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• v.8 no.2
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• pp.209-223
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• 1998

The aim of this study was to evaluate welders' exposure to hexavalent chromium (Cr(VI)) and nickel (Ni) during welding operations in a Korean shipyard. The airborne Cr(VI) and Ni concentrations were measured during metal inert gas (MIG) welding on mild and stainless steel, and manual metal arc (MMA) welding on mild steel. The geometric mean (GM) of Cr(VI) concentrations inside the welding helmet during MIG welding on mild steel were $0.0018mg/m^3$ inside a ship section, and $0.0015-0.0026mg/m^3$ at the welding shops. All of the personal breathing zone air samples were below the American Conference of Governmental Industrial Hygienists (ACGIH) Threshold Limit Value ($TLV^{(R)}$) of $0.01mg/m^3$. Conversely, eighty-eight percent(21 of 24) of the personal breathing zone air samples exceeded the National Institute for Occupational Safety and Health (NIOSH) recommended exposure limit of $0.001mg/m^3$. Ni was not detected on 20 of 23 air samples collected during MIG welding on mild steel. The three Ni samples above the limit of detection ranged from 0.015 to $0.044mg/m^3$. The GM of Cr(VI) concentrations during MMA welding on mild steel were $0.0013mg/m^3$, but Ni was not detected in the air samples during this operation. It is assumed that the airborne Cr(VI) and Ni during mild steel welding were derived from the base metals which contained about 0.03% Cr and 0.03% Ni. The GM of airborne total Cr, Cr(VI) and Ni concentrations during MIG welding on stainless steel were 4.02, 0.13 and $0.86mg/m^3$, respectively, and the levels of Cr(VI) and Ni were above the ACGIH-$TLV^{(R)}$. Cr(VI) comprised about 35.5% of the total chromium(Cr) from MIG welding on mild steel, and about 8.4% of total Cr from MIG welding on stainless steel. The ratios of Cr(VI) to total Cr were significantly different among welding shops. It was concluded that welders were exposed to high levels of Cr(VI) and Ni during welding on stainless steel, and were exposed to low levels of Cr(VI) even during welding on mild steel.

• Proceedings of the KWS Conference
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• 2010.05a
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• pp.51-51
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• 2010

Recently just as in the automobile industry, shipbuilders also try to reduce material consumption and weight in order to keep operating costs as low as possible and improve the speed of production. Naturally industry is ever searching for welding techniques offering higher power, higher productivity and a better quality. Therefore it is important to have a details research based on the various welding process applied to steel and other materials, and to have the ability both to counsel interested companies and to evaluate the feasibility of implementation of this process. Submerged-arc welding (SAW) process is usually used about 20% of shipbuilding. Similar to gas metal arc welding(GMAW), SAW involves formation of an arc between a continuously-fed bare wire electrode and the work-piece. The process uses a flux to generate protective gases and slag, and to add alloying elements to the weld pool and a shielding gas is not required. Prior to welding, a thin layer of flux powder is placed on the work-piece surface. The arc moves along the joint line and as it does so, excess flux is recycled via a hopper. Remaining fused slag layers can be easily removed after welding. As the arc is completely covered by the flux layer, heat loss is extremely low. This produces a thermal efficiency as high as 60% (compared with 25% for manual metal arc). SAW process offers many advantages compared to conventional CO2 welding process. The main advantages of SAW are higher welding speed, facility of workers, less deformation and better than bead shape & strength of welded joint because there is no visible arc light, welding is spatter-free, fully-mechanized or automatic process, high travel speed, and depth of penetration and chemical composition of the deposited weld metal. However it is difficult to application of thin plate according to high heat input. So this paper has been focused on application of the field according to SAW process for thin plate in ship-structures. For this purpose, It has been decided to optimized welding condition by experiments, relationship between welding parameters and bead shapes, mechanical test such as tensile and bending. Also finite element(FE) based numerical comparison of thermal history and welding residual stress in A-grade 3.2 thickness steel of SAW been made in this study. From the result of this study, It makes substantial saving of time and manufacturing cost and raises the quality of product.

• Advances in materials Research
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• v.6 no.3
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• pp.233-243
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• 2017

This paper describes an investigation on the effect of using three different filler metals on fatigue behavior of mechanical structures welded. The welding is carried out on the steel A510AP used for the manufacture of gas cisterns and pipes. The welding process used is manual welding with coated electrodes and automatic arc welding. Compact tension CT50 specimen has been used. The three zones of welded joint; filler metal FM, heat affected zone HAZ and base metal BM have been investigated. The results show that the crack growth rate CGR is decreasing respectively in BM, FM and HAZ; however, this variation decreases when stress intensity factor SIF increases. For low values of SIF, the CGR is inferior in the over-matched filler metal of which the value of mismatch M is near unity, but for high values of M the CGR is superior, and the effect of the over-matching on CGR becomes negative. No deviation of the crack growth path has been noticed.

• Corrosion Science and Technology
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• v.2 no.1
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• pp.36-40
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• 2003

An attractive combination of corrosion resistance and mechanical properties in the temperature range -50 to $250^{\circ}C$ is offered by duplex stainless steel. However, undesirable secondary precipitation phase such as $\sigma$, $\gamma_2$ and $Cr_2N$ may taken place at the cooling stage from the welding processes. Therefore, this paper describes the influence of different welding procedures such as manual metal arc welding (MMA), tungsten inert gas welding (TIG) and vacuum brazing on corrosion resistance of the welded joint for UNS S31803 duplex stainless steel. Microstructure and chemical compositions of the welded joint were examined. The weight loss of specimens immersed in 6% $FeCl_3$ solution at $47.5^{\circ}C$ for 24-hours was determined and used to evaluate the pitting resistance of duplex stainless steel and their welds. The region of heat-affected zone of specimen obtained by the MMA is much wider than that resulted from TIG, therefore, the weight loss of welds by MMA was larger than that of weld by TIG. The weight loss of brazed specimens cooled from slow cooling rate was larger than those of specimens cooled from high cooling rate, because the precipitation of $\sigma$ phase. Beside that, the weight loss of brazed specimen is greater than those of the welded specimens. The galvanic corrosion was observed in brazed duplex stainless steel joints in the chloride solution.