Hyo Sun Yu

Fatigue Analysis of Multi-Lap Spot Welding of High Strength Steel by Quasi Static Tensile- Shear Test

The welding quality of spot weldment is an important factor that significantly affects the strength, stiffness, safety, and other performance characteristics of vehicles. Therefore, quality control and fatigue life evaluation of spot weldment are necessary processes. This paper presents a method for determining the fatigue life of multi-lap spot weldment of a high strength steel sheet. In this method, the fatigue life is estimated by using the lethargy coefficient, which is the total defect coefficient according to rupture stress and time obtained by the quasi static tensile-shear test. Also, in this study, we modified the lethargy coefficient by using the welding current. And, we define a specific lapping constant, which is a characteristic constant of 2 or 3 lap weldments. The fatigue life obtained by the fatigue estimate equation, which contains a specific lapping constant was compared and verified with an experimental value. And we analyzed the relation of lap number, welding current and fatigue life. This method can save processing time and cost for predicting the life cycle of a structure.

A study on ultrasonic test for evaluation of spot weldability in automotive materials

The evaluation of spot weldability is very important in managing the quality of products and also in increasing the credibility in the automotive manufacturing processes. The purpose of this study is to investigate the applicability of ultrasonic techniques for the evaluation of weldability in spot weldment. Through test results, it is confirmed that the behavior of the average attenuation coefficient (αavg) shows a close relationship with the behavior of tensile-shear strength. The transit time of the ultrasonic pulse echo and nugget size also show a close interrelation. If a larger experimental database with various welding conditions can he collected, then it can he shown that the attenuation coefficient and the transit time of an ultrasonic wave can be effective parameters in the evaluation of spot weldability.

Fatigue Quality Index by Infrared Stress Measurement in Spot Weldment

Since the spot welding process was completed in a very short time and there were many factors affecting the generation of welding defects, it was difficult to control all experimental factors of welding. Additionally, it was hard to monitor the distribution of stress in practical cases such as vehicle bodies. The purpose of this study was to investigate the applicability of infrared thermography for the evaluation of spot weldability in the view of fatigue life. In this research, infrared(IR) stress analysis adopting an infrared thermography as nondestructive evaluation of spot weldability was investigated. Using temperature and IR stress distribution obtained by an infrared camera from adiabatic heat expansion under a repeated load of sinusoidal waves, we estimated the fatigue quality index(FQI) of spot welded specimens. We also evaluated in terms of FQI and corrected the S-N curve from the original fatigue life curve of base metals.

Fatigue Strength under Optimal Conditions of Spot Weldment Using GA and FEM

High tensile strength steel (HS40R) and galvanized steel (EZNCEN) are extensively used as components of vehicle bodies because they satisfy environmental standards and improve fuel economy. Because vehicle body sheets are becoming thinner and stronger, it is difficult to satisfy the design standards of spot welding joints. This research presents the optimization of the welding condition for various welding variables of a spot welding specimen by genetic algorithm (GA). When the welding condition optimization of spot weldment is performed using finite element method. The fatigue strength prediction method using FEM is useful for the prior evaluation technique that can predict the fatigue strength of spot weldment.

Shear Property of Pb-Free Solder Joint According to Temperature Condition by SP and FEM

The use of Pb-free solder alloys are just newly developed materials and their properties are not well established and documented yet. So, the research to substitute the critical problem of the Pb solder alloy are increasing widely. To evaluate the shear property of solder joints according to temperature condition was predicted through the Shear-Punch test and FEM. By using the database according to this, the reliability evaluation technology of the solder joints tries to be formulated. In this paper, the solder used the Sn37Pb, Sn-4Ag and the Sn4Ag0.5Cu. When solder melted in the copper interface, the solder joints according to reflow times, each modeling required for the Shear- Punch was made in consideration of the IMC layer thickness. And the micro shear punch test was performed to obtain material properties of solder according to temperature condition. The shear properties of specimen which was modeled was predicted through FEM. It compared with the test value in which it obtains from Shear-Punch. Also, a method which can obtain shear properties of Pb-free solder joints easily and quickly using FEM was proposed.

Fatigue Life of Multi-Lap Welding of Automotives Steel Sheet by QSTS

This paper shows how the number of lap of spot welded joints in automotive steel sheets changes the life -cycle transform of itself. There has been significant developments in the life extension of automotive steel sheets, as well as in passenger safety. We verified the validity of the S-N curve of materials by QSTS test. Moreover, we used EZNCEN and HS40R, which are commonly used as automotive steel sheets because of their excellence in increasing fuel efficiency. The purpose of research was to compare the fatigue life of multi - lap of spot welded joints to there. In addition s, we used the two different kinds of sheets together in the same welding under the same condition. Through this whole process, the hypothesis on the life cycle of lethargy coefficients was found to be in good agreement with the result of the experiment. That is, when using sheets of the same materials in one welding, the fatigue life of two laps of a spot welded joint was found to be much superior by EZNCEN 5~14%, HS40R 17~30%,and when using each sheet of different materials, we found the decrease in fatigue life by 6~16%. Finally, the best value from the data was chosen based on the experiment for the analysis of the fatigue life of each layer.

Characterization of Creep Resistance for Local Structure of Power Plant Weldment Using SP-Creep Technique

Power plant weldments are composed of various microstructures. Due to welding and PWHT processes, the microstructure of the base metal adjacent to fusion line is transformed into entirely different microstructures, collectively known as heat affected zone (HAZ). Creep, on the other hand, is considered as the most important deterioration mechanism of heat resistant components found in power plants. Therefore it is essential to evaluate creep properties of HAZ, which is considered to be very hazardous in weldment. Recently, most of the creep tests for HAZ are conducted using cross weld type specimen. However there are some problems with this type of creep test due to the results being largely varied according to the volume fraction of HAZ. In this paper, SP-Creep test, which has confirmed the availability for creep properties evaluation, has been conducted on each of the weldment microstructures. The results showed that each microstructure has a different creep behavior. The overall creep properties of HAZ are worse than those of the weld metal. Among the HAZ structures, fine grained HAZ has the worst creep properties.

Identification of Load Applying on T-Shape Joint with Inverse Problem

In the beginning of design, exact load data are actually necessary for the fatigue strength and life analysis to minimize the cost and time of designing. The procedure of practical load determination is developed by the combination of the principal stresses of F.E.Analysis and experiment. This paper conceives new procedure for the determination of load direction and magnitude applied on mechanical structures. New procedure is the combination of the analytical and empirical method with analyzed strain by F.E. Analysis under unit load and with measured principal stress by strain gages under driving load, respectively. In this paper, we theorize the procedure of practical load determination and make the validity and the practicality of the procedure with the application to T-shape jointed structure. F.E. Analysis is conducted to get the principal stress on arbitrary points in the F.E. model of T-shape joint under unit load. Then experiment is carried out to get the principal stress on the same points of F.E. model. To demonstrate the actual driving condition, the load conditions are bending and torsion. From these two data sets, the magnitude, the direction and the position of load can be obtained.

Cryogenic fracture toughness evaluation for austenitic stainless steels by means of unloading compliance method

Most research to date concerning the cryogenic toughness of austenitic stainless steels has concentrated on the base metal and weld metal in weldments. The most severe problem faced on the conventional austenitic stainless steel is the thermal aging degradation such as sensitization and carbide induced embrittlement. In this paper, we investigate the cryogenic toughness degradation which can be occurred for austenitic stainless in welding. The test materials are austenitic stainless JN1, JJ1 and JK2 steels, which are materials recently developed for use in nuclear fusion apparatus at cryogenic temperature. The small punch (SP) test was conducted to detect similar isothermally aging condition with material degradation occurred in service welding. The single-specimen unloading compliance method was used to determine toughness degradation caused by thermal aging for austenitic stainless steels. In addition, we have investigated size effect on fracture toughness by using 20% side-grooved 0.5TCT specimens.