• Journal of Welding and Joining
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• v.34 no.5
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• pp.41-46
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• 2016

Welding is an absolutely essential component of industries such as the automotive industry, the construction industry and even the aviation industry. Although it is a widespread technology it is still characterized by lots of uncertainties. This still requires well experienced and highly skilled workforce to design and perform safe welding processes. The early knowledge of distortion and residual stresses is almost an issue which is influenced mainly by the welding parameters and the fixture design. But more and more engineers want to know as well final properties of the assembled components. With the beginning of the computer age in the 1970s and 1980s last century, the numerical prediction of manufacturing processes using FEM was gradually getting better and has established itself in the industry since the 1990s as a standard tool. Unlike in metal casting and forming industry, however, the everyday use of FEM- simulation tools for welding processes eked out a shadowy existence for a long time. This paper will give a short classification of welding simulation types and a structured overview on the technical questions. Selected case studies and the benefits achieved through simulations with the software Simufact welding are discussed. Finally an outlook on future developments will be given.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.589-594
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• 2002

In manufacturing of welded parts which require a proof on acceptance close observation of the process is mandatory. The manufacturer is obliged to document the welding process. An approach for monitoring and recording the process of laser beam welding combining theoretical knowledge, process monitoring and welding experience will be presented. The range of application of a device for co-axial process monitoring was extended up to 20 mm sheet thickness welded in one pass at beam powers of up to 20 kW. Crucial features of the process which refer to the formation of failures were observed. The results presented give rise to the general applicability of the approach for process monitoring and recording as well as failure management.

• Journal of Welding and Joining
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• v.26 no.1
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• pp.50-55
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• 2008

A low alloy-steel(2.25Cr-1.0Mo) has been widely used for boiler piping, header and tubes in high temperature and pressure conditions of the thermal power plant. It is common knowledge that the repair welding is permitted two or three times by customary practice rule, but there is no regulation to limit the number of repair welding base on the study heat-affected zone(HAZ), which is the weakest zone when repair welding is under taken, by experiments about the metallographic degradation and mechanical properties. Therefore, this study aims to verify the reliability of 5 times repair welding through conducting the experimental observation in the mechanical and the metallographic change on HAZ varying repair welding times. In results of the experiments, it is concluded that the reliability was kept in HAZ even up to the fifth repairs.

• Proceedings of the KWS Conference
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• 2009.11a
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• pp.239-242
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• 2009

Friction stir spot welding (FSSW), developed based on principle of friction stir welding, has been paid attention as a new solid-state spot welding process. Since FSSW can produce high-quality weld in Al alloys more easily than resistance spot welding, this process has been already used for construction of Al components in the automotive industries. Despite the large industrial interests in FSSW, fundamental knowledge on welding phenomena of this process has not been fully understood. In this study, FSSW phenomena, such as the consolidation mechanism, the microstructural evolution and the material flow, were examined in Al alloy 6061. This study clarified that the elliptical zone found in the vicinity of the pin hole on the cross section was characterized by the initially lapped surface of two sheets. Moreover, the following material flow was proposed; capture of the upper material with the threads on the pin surface, spiral flow along the tool rotation, and then release at the tip of the pin.

• Journal of Welding and Joining
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• v.32 no.6
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• pp.8-13
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• 2014

One of the main challenges of the automatic arc welding process which has been widely used in various constructions such as steel structures, bridges, autos, motorcycles, construction machinery, ships, offshore structures, pressure vessels, and pipelines is to create specific welding knowledge and techniques with high quality and productivity of the production-based industry. Commercially available automated arc welding systems use simple control techniques that focus on linear system models with a small subset of the larger set of welding parameters, thereby limiting the number of applications that can be automated. However, the correlations of welding parameters and bead geometry as welding quality have mostly been linked by a trial and error method to adjust the welding parameters. In addition, the systematic correlation between these parameters have not been identified yet. To solve such problems, a new or modified models to determine the welding parameters for tandem GMA (Gas Metal Arc) welding process is required. In this study, A new predictive model called STACO model, has been proposed. Based on the experimental results, STACO model was developed with the help of a standard statistical package program, MINITAB software and MATLAB software. Cross-comparative analysis has been applied to verify the reliability of the developed model.

• Journal of the Korean Society of Marine Environment & Safety
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• v.3 no.2
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• pp.13-21
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• 1997

This paper describes the effectiveness of laser pulse shaping in eliminating weld defects such as porosity, cracks and undercuts in pulsed Nd:YAG Laser welding. A large porosity was formed in a keyhole mode of deep penetration weld metal of any stainless steel. Solidification cracks were present in Type 303 with about 0.3%s. The conditions for the formation of porosity were determined in further detail in Type 316. With the objectives of obtaining a fundamental knowledge of formation and prevention of weld defects, the fusion and solidification behavior of a molten puddle was observed during laser spot welding of Type 310S. through high speed video photographing technique. It was deduced that cellular dendrite tips grew rapidly from the bottom to the surface, and consequently residual liquid remained at the grain boundaries in wide regions and enhanced the solidification cracking susceptibility. Several laser pulse shapes were investigated and optimum pulse shapes were proposed for the reduction and prevention of porosity and solidification cracking.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.1
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• pp.60-68
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• 2007

It has been conducted by laser vision sensor for weldability estimation of front-bead after doing high speed butt laser welding of any condition. It has been developed a real time GUI(Graphic User Interface) system for weldability application in the basis of texts and field qualify levels. In the reference of bead imperfections, defects absolute position and defects intensity index of front-bead in the basis of formability reference, it has been produced a weldability estimation and defects intensity index of back-bead by back propagation neural network. In the result of by comparing measuring data by laser vision sensor of back-bead and data by back propagation neural network of one, it has been shown the similar results. Finally, under knowledge of welding condition in production line, it has been conducted a weldability estimation of back-bead only in knowledge of informations of front-bead data without using laser vision sensor or welding inspection experts and furthermore it can be used data for final inspection results of back-bead.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.110-120
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• 1998

Tailor-welded blanks are made of two or more different blanks in thickness or material. So car body with tailor-welded blanks need not reinforcement panels. However in order to make stamping tools for tailor-welded blanks, die engineers should know about the exact position of the welding line after the part is drawn. The necessity of knowledge about the position of welding line needs forming simulation methodology as a prior step in tooling. Therefor some parts of the simulation methodology are proposed and compared with the experimental results.

• Journal of the Korean Society for Precision Engineering
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• v.8 no.1
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• pp.41-49
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• 1991

A knowledge of the resdual stress distribution at circumferential weldments can normally increase the accuracy of a fracture assessment in pipe line. In this paper, we present the measurements about the residual stress distributions at three kinds of circumferential butt welded pipes using the holl drilling strain gage method. By this experiment, we have obtined the following characteristics. At the inner surface of the pipe region near the center line of welding is under high tensile residual stress. However, as the distance from the center line of welding increases, the tensile component decreases and finally becomes compressive residual stress at region far away from the center line of welding. The longitudinal residual stress at the outer surface is compressive regardless of the diameter of pipe and the circumferential stress is changed from compressive to tensile as pipe diameter increases. The results also demonstrate that the residual stress is mainly caused by self-restraint bending force in the pipe welding.

• Proceedings of the KIPE Conference
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• 2001.10a
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• pp.731-736
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• 2001

Nowadays various simulation tools are widely used for the design and the analysis of power electronic converters. From the engineering point of view it is rather difficult to parameterize power semiconductor device models without the knowledge of basic physical parameters. In recent years some data sheet driven behavioral models or so called 'wizard' tools have been introduced to solve this problem. In this contribution some experiences with some user-friendly power semiconductor models will be discussed. Using special simulation test circuits it is possible to get information on the static and dynamic behavior of the parameterized models before they are applied in more complex schemes. These results can be compared with data sheets or with measurements. The application of these models for power loss analysis of inverter type arc welding power sources will be described.