• Transactions of Materials Processing
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• v.22 no.4
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• pp.189-195
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• 2013

In this study, the weld strength of extru-rivet spot welding was investigated by simulation and experiment. In order to obtain hot plasticity flow bonding of the two plates by a single rivet, electrodes are used for heating of the two plates and the rivet by electric resistance. Because weld strength is influenced by the temperature in the weld zone, the diameter of the electrodes and the amount of current supplied to the electrodes are important variables. For the simulation, heat distribution and weld strength were calculated using DEFORM-3D. The weld strength in the weld zone was calculated for various values of the experimental parameters. The simulation results showed that the weld strength was the highest when the weld current was 37kA, the electrode diameter was 12mm, and the welding frequency was 90cycle. Aluminum 5052 was used for the experimental study. A total of three aluminum plates, two welding plates with 1mm thickness and one plate with 2mm thickness for the inserting rivet, were used for the experimental extru-rivet spot welding.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.98-103
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• 2008

This paper is to discuss distribution of welding residual stresses of a ferritic low alloy steel nozzle with dissimilar metal weld using Alloy 82/182. Two dimensional (2D) thermo-mechanical finite element analyses are carried out to simulate multi-pass welding process on the basis of the detailed and fabrication data. On performing the welding analysis generally, the characteristics on the heat input and heat transfer of weld are affected on the weld residual stress analyses. Thermal analyses in the welding heat cycle process is very important process in weld residual stress analyses. Therefore, heat is rapidly input to the weld pass material, using internal volumetric heat generation, at a rate which raises the peak weld metal temperature to $2200^{\circ}C$ and the base metal adjacent to the weld to about $1400^{\circ}C$. These are approximately the temperature that the weld metal and surrounding base materials reach during welding. Also, According to the various ways of appling the weld heat source, the predicted residual stress results are compared with measured axial, hoop and radial through-wall profiles in the heat affected zone of test component. Also, those results are compared with those of full 3-dimensional simulation.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.110-114
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• 2008

Determination of weld-induced residual stress has been an important issue in nuclear power industry because several failures were reported in dissimilar metal weld parts due to primary water stress corrosion cracking. In this context, a couple of remarkable round robin analyses were conducted to quantify the welding simulation variables and to establish optimized numerical analysis process. The purpose of the present research is to introduce welding simulation results for a safety and relief nozzle, which has a dissimilar metal weld part as well as a similar metal weld part. First, finite element analyses are carried out to calculate residual stresses at the inside of nozzle considering only dissimilar metal welding. Subsequently, residual stresses taking into account both the dissimilar and similar metal welding are computed. The similar metal weld effect is evaluated by compa

• Journal of Ocean Engineering and Technology
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• v.22 no.6
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• pp.27-34
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• 2008

The temperature distribution in the weldment is not uniform because a weldment is locally heated. Thermal plastic deformation results from the local expansion and shrinkage by the heating and cooling of metal. Therefore, residual stresses and distortion occur in the weldment. In this study, we had conducted on the weld thermal cycle simulation that is supposed as the HAZ on SS400 steel and STS304 steel. The residual stresses that were obtained from the drawing and the weld thermal cycle simulation were estimated by X-ray diffraction. We also carried out ultrasonic test for the weld thermal cycle simulated specimens, and then conducted on nondestructive evaluation by the ultrasonic parameters obtained ultrasonic test. From the results, residual stresses of weld thermal cycle simulated specimens after the residual stress removal heat treatment are lower than that of the drawing.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.458-461
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• 2009

Thermo-mechanical simulation of the Friction Stir Spot Welding (FSSW) processes was performed for the AA5083-H18 sheets, utilizing commercial Finite Element Method (FEM) and Finite Volume Method (FVM) which are based on Lagrangian and Eulerian formulations, respectively. The Lagrangian explicit dynamic FEM code, PAM-CRASH, and the Eulerian Computational Fluid Dynamics (CFD) FVM code, STAR-CD, were utilized to understand the effect of pin geometry on weld strength and material flow under the unsteady state condition. Using FVM code, material flow pattern near the tool boundary was analyzed to explain the weld strength difference between the weld by cylindrical pin and the weld by triangular pin, while the frictional energy concept using the FEM code had limitation to explain the weld strength difference.

• Journal of Ocean Engineering and Technology
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• v.19 no.6 s.67
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• pp.64-71
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• 2005

The welding methods have been applied to the most structural products used in the automobile, ship construction, and construction. The structure steel must have sufficient strength of structure; However, the mechanical properties of the welded part changes when it is welded. Therefore, the stability or life of the structure may be affected by the changed mechanical properties. The mechanical properties of the welded part must be examined in order to ensure the safety of structure. In this research, the SS400 steel and the STS304 steel were used to estimate the mechanical properties of the HAZ by weld thermal cycle simulation. In this study, the materials were used to examine the weld thermal cycle simulation characteristic, under two conditions: the drawing with diameter of $\Phi$10 and the residual stress removal treatment. To examine the mechanical properties by the weld thermal cycle simulation, the tensile test was carried out in room temperature. The crosshead speed was lmm/min.

• International Journal of Korean Welding Society
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• v.3 no.1
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• pp.8-16
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• 2003

A major concern in Gas Metal Arc (GMA) welding process is the determination of welding process variables such as wire diameter, gas flow rate, welding speed, arc current and welding voltage and their effects on the desired weld bead dimensions and shape. To successfully accomplish this objective, 81 welded samples from mild steel AS 1204 flats adopting the bead-on-plate technique were employed in the experiment. The experimental results were used to develop a mathematical model to predict the magnitude of bead geometry as follows; weld bead width, weld bead height, weld bead penetration depth, weld penetration shape factor, weld reinforcement shape factor, weld bead total area, weld bead penetration area, weld bead reinforcement area, weld bead dilution, length of weld bead penetration boundary and length of weld bead reinforcement boundary, and to establish the relationships between weld process parameters and bead geomery. Multiple regression analysis was employed for investigating and modeling the GMA process and significance test techniques were applied for the interpretation of the experimental data.

• Journal of Welding and Joining
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• v.15 no.3
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• pp.65-78
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• 1997

The effect of $O_2$and Al contents and the variation of welding parameters such as arc currents, welding speed on the weld penetration was investigated. Examination of weld penetration using GTAW was accomplished in the ferritic STS410L and austenitic STS304. Good penetration could be controlled by the variation of $O_2$ and Al contents in STS304. However, influences of $O_2$ and Al contents on the ferritic STS410L are far less than those on the austenitic STS304. Welding parameters should be considered first before controlling $O_2$ and Al contents for a good penetration in ferritic STS410L. In the simulation study under the stationary heat sources, the results of simulation and experiment have a similar tendency.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.3
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• pp.160-168
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• 2000

Hydroforming is a metal forming process that enables circular metal tubes to be formed in to the parts with the complex cross section along the curved axial direction. Recently this hydroforming process is largely used for the production of the automotive parts. This paper presents the results of tube bending and hydroforming simulations in cases of the varying weld line positions of the tube. Ten cases of prebending and hydroforming simulations are carried out to find the optiaml weld line position.

• 제어로봇시스템학회:학술대회논문집
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• 1992.10a
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• pp.531-536
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• 1992

In GMA welding processes, monitoring and control of weld quality are extremely difficult problems. This paper describes a neural network-based method for monitoring and control of weld pool sizes. First, weld pool sizes are estimated via a neural estimator using multi-point surface temperatures, which are strongly related to the formation of weld pool, and then controlled using the estimated pool sizes. Two types of controllers using the pool size estimator are designed and tested. To evaluate the performance of the designed controllers, a series of simulation studies was performed.