Ario Sunar Baskoro

Effect of Welding Current and Welding Time for Micro Resistance Spot Welding on Dissimilar Thin Thickness Materials of Al 1100 and KS 5 Spring Steel

In the dissimilar materials and dissimilar thin thickness sheets joining, welding current and welding time parameters of resistance spot welding (RSW) effect weld ability. RSW used for joining thin plate less than 1000 μm is called micro-resistance spot welding (μRSW). The objective of this article is to study the effect of welding current and welding time to the joining dissimilar thin thickness materials and the microstructure of a weld joint. The thickness of Al 1100 is 400 μm, and KS 5 Spring Steel is 200 μm. Welding parameters are Cycle Time 0.5, 1, 1.5, Welding Current 1kA and 2 kA, and holding time 10 second. Welding current 1kA, Cycle time of 0.5 produce maximum shear load of 227.4 N and fracture area of 6.644 mm2. Welding current 2 kA, cycle time of 1.5 affect maximum load of 222.7 N and fracture area of 10.559 mm2. Welding parameters lead to the majority fracture on aluminum material. The welding current and cycle time do not significantly affect maximum shear load and fracture area.

Improvement of Tungsten Inert Gas (TIG) Welding Penetration Using the Effect of Electromagnetic Field

Tungsten Inert Gas (TIG) welding is a process which an electric arc generated by the tungsten electrode to the workpiece and the welding area protected by a protective gas. Arc shape can be affected by electromagnetic force. In previous study, the use of some electromagnetic field around the arc has influenced the welding results. In this study, electromagnetic field generated from the solenoids was given to the welding arc. Welding process was conducted on Stainless Steel. The electromagnetic field made the arc becomes deflected. This deflection was controlled by the solenoid by activating it using a microcontroller. The results showed that the use of solenoid as a source of electromagnetic field has influenced the welding arc. Penetration produced by using a solenoid has deeper penetration than welding process without using solenoid. The increase of the welding power efficiency was 10.9% for arc current I = 80 A and 9.85% for arc current I = 90 A.

Development of interaction and orientation method in welding simulator for welding training using augmented reality

This paper presents a method of interaction and orientation that can be implemented in welding simulator and will be used for basic welding training. In welding process there are many factors that can affect the welding results. One of them is the orientation angle and interaction distance between plate and torch. Therefore, a method to find an angle and a distance between plate and welding torch so then it can be used as a part of the welding simulator was developed. The required components are webcam in laptop used as a video tracking device, two sets of marker, and ARToolKit as software library. After the interaction and orientation method was successfully built, a measurement for the interaction method to get a relation between actual distance and virtual distance was performed. The result will receive a comparison value from 27 to 28 pixels per centimeter with specified limitation. Then for orientation method, standard deviation and root mean square error (RMSE) of an angle was measured. This is the first stage of development in welding simulator. Further development is required to get a more advanced welding simulator.

Effects of High Speed Tool Rotation in Micro Friction Stir Spot Welding of Aluminum A1100

Technology of Friction Stir Welding (FSW) is a relatively new technique for joining metal. In some cases on Aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and less distortion. The purpose of this study is to analyze the parameters effect of high speed tool rotation on micro Friction Stir Spot Welding (μFSSW) to the shear strength of welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. The spindle speed was fixed at 30000 rpm. Tool shoulder diameter was 3 mm, and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of pin diameter (1.5 mm, 2.0 mm, and 2.5 mm), a variable of plunge speed (2 mm/min, 4 mm/min, 6 mm/min), and the variable of dwell time (2 seconds, 4 seconds, 6 seconds). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was the shear strength. Response Surface Methods (RSM) was used to analyze μFSSW parameters with the shear strength of welds. From the result of experiment and analysis, it is shown that the important welding parameters in high speed μFSSW process are pin diameter and plunge speed.

Effects of Welding Parameters in Micro Friction Stir Lap Welding of Aluminum A1100

Technology of Friction Stir Welding (FSW) as a technique for joining metal is relatively new. In some cases on Aluminum joining, FSW gives better results compared with the Arc Welding processes, including the quality of welds and less distortion. FSW can even use milling machine or drilling machine, by replacing the tools and the appropriate accessories. The purpose of this study is to analyze the effect of process parameters on micro Friction Stir Lap Welding to the tensile load of welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. Tool shoulder diameter was 3 mm, while the diameter pin was 2 mm and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of spindle speed (2300, 2600, and 2900 rpm), variable of tooltilt angle (0, 1, 2 degree) and a variable of Feed rate (50, 60, 70 mm/min). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was the tensile load. Analysis and optimization parameters between the micro FSLW parameters with the tensile load of welds, is used a Response Surface Methods (RSM). From the result of experiment and analysis, it is shown that the important welding parameter in Micro Friction Stir Lap welding process is tilt angle.

Effect of interlayer in dissimilar metal of stainless steel SS 301 and aluminum alloy AA 1100 using micro resistance spot welding

Each material has advantages and disadvantages properties, and two different metals, which have advantages properties, were welded to apply its advantages in a construction. Different thermal and electrical properties will influence to a welded joining performance. Aluminum and steel joining by welding process lead to decreasing lap shear strength of welded joint, due to thermal properties. The problem is more complex when the welding process uses thin metal. The objective of this study analyze peak load, elongation, and fracture area (fractographic) from a welded joint between SS301 and AA 1100 with ferro interlayer which was welded by Micro Resistance Spot Welding (RSW). Ferro sheet was inserted between stainless steel and aluminum sheet, RSW machine was used to weld three different plates. Tensile test machine used to measure load and elongation value, and teared plates effected by tensile tested were measured by digital microscope. The highest load value could be achieved by 8 kVA of welding power. Elongation of the highest peak loads was shorter than the lowest peak load. Welding time more than 8 CT tend to produce the elongation become shorter. Welding time affected to decrease fracture area, however welding power has also significantly effect.Each material has advantages and disadvantages properties, and two different metals, which have advantages properties, were welded to apply its advantages in a construction. Different thermal and electrical properties will influence to a welded joining performance. Aluminum and steel joining by welding process lead to decreasing lap shear strength of welded joint, due to thermal properties. The problem is more complex when the welding process uses thin metal. The objective of this study analyze peak load, elongation, and fracture area (fractographic) from a welded joint between SS301 and AA 1100 with ferro interlayer which was welded by Micro Resistance Spot Welding (RSW). Ferro sheet was inserted between stainless steel and aluminum sheet, RSW machine was used to weld three different plates. Tensile test machine used to measure load and elongation value, and teared plates effected by tensile tested were measured by digital microscope. The highest load value could be achieved by 8 kVA of welding power. El...

Design of humanoid robot stable walking using inverse kinematics and zero moment point

Main problem of humanoid locomotion is walking stability. Goal of this research is designing and standardize the stability of robot. Commonly, research of humanoid robot uses the method of static walking or dynamic walking for its stability. The usage of static walking on robots emphasize on stability pose while dynamic walking emphasizes on its mobility efficiency. The combination of both walking methods can achieve a stable and efficient humanoid robot movement, in which applies the rule of Zero Moment Point and Inverse Kinematic. Optimize centre of mass from humanoid robot with selection of combination material. This research will be done by simulation and real examiner to get a stability margin and also velocity of robot to ensure a quick and easy robot motion planning. The result of humanoid robot stability margin is 3.44 mm and its velocity 8.11cm/s.

Automatic Tungsten Inert Gas (TIG) welding using machine vision and neural network on material SS304

Welding is a process of joining two or more substances that are based on the principles of diffusion processes, resulting in unification on the materials to be joined. The strength of the weld joint is determined by several parameters, including the weld bead width and the penetration. The width of the weld bead especially the upper part can be determined by looking directly through the CCD (Charge-Coupled Device) camera. But it is difficult to observe the back bead width directly since in practice it is impossible to install the CCD camera at the bottom of specimen. In this paper, Tungsten Inert Gas (TIG) Welding with the welding speed is controlled by the microcontroller for the purpose of adjusting the back bead width has observed. The back bead width is estimated based on data of weld bead width obtained from machine vision, welding speed, and currents that used in this experimental. Its used to obtain a series of data which would have conducted as initial experiments to train and build the neural network system. Results showed that the back bead width is 3 mm on the current 55 A, 60 A, and 65 A have an average error of each current of 0.11 mm, 0.09 mm, and 0.12 mm.

Development of Photometric Stereo-Based 3 Dimensional Object Reconstruction for Welding Application

Photometric stereo works on recovering the shape and reflectance properties of an object using multiple images taken in variable lighting conditions. In this study, a system has been implemented to construct a height field from 12 images of an object. The algorithm which is able to calibrate the lighting direction, find the normals and color albedo at each pixel have been optimized to compute the surface which best fit the normals. This algorithm was also implemented to the welding product to reconstruct the shape of welding bead.

Development of travel speed detection method in welding simulator using augmented reality

This paper explains about travel speed detection method that can be applied as the welding simulator using augmented reality. In welding process, the travel speed is an important parameter that influences the welding quality. In the future, this simulator can be used in welder training with a relatively low cost. This method uses ARToolkit, OpenGL library, and Autodesk 3Ds Max software for building the simulator. This method is the development of welding simulator that will show the deviation and accuracy of moving marker detection. This method uses differences in distance of the coordinate per unit time algorithm, taken from the amount of frames per second (FPS) of a camera. After this method was successfully built, the measurement data is taken to analyze the accuracy and the number of error in speed detection by the simulator from the actual speed with different light intensity parameter. The result is that the error in speed detection is not too large, so this simulator was successfully built and it can be developed further to get more sophisticated features on welding process in the future.