• Journal of Welding and Joining
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• v.26 no.2
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• pp.92-97
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• 2008

In welding of thin plate, some defects such as melt through and unmelted zone occur easily at welding start, however there is a limited study on those problems. Therefore the effects of start block and arc length on melt through and unmelted zone at start were investigated in this study. When start block height was lower than base metal, there was melt through at start. And when the height was even with base metal, no unmelted zone existed. Unmelted zone was increased as start block height increased from 0mm to 0.5mm. However unmelted zone was not much changed as the height increasing from 0.5mm to 1.0mm. When gap existed between start block and base metal, melt through occurred. However, unmelted zone was increased as the contact force of start block on base metal was increased from 0kgf to 7.5kgf. And when arc length was decreased from 3.8mm to 3.0mm, unmelted zone was decreased. It was concluded that the optimum condition to prevent melt through and to minimize unmelted zone would be with start block height 0.25mm, contact force 3.0kgf, and arc length 3.4mm. This optimum condition was applied to the mass production line and resulted in satisfied outcome.

• Journal of Welding and Joining
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• v.19 no.1
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• pp.33-39
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• 2001

The welding quality by Gas Tungsten Arc Welding shows very high level, but the welding speed is lower than that of gas metal arc welding. Also, the welding quality by automatic GTAW is variable as the arc characteristics is changed by the consumption of electrode tip. The purpose of this study is to investigate the relation between the properties of tungsten electrode tip and the various arc characteristics at high current region. In this study, the high welding current 200A was applied to the repeated arc start test and long term arcing test using the $\phi$3.2 tungsten electrodes with cone angle 30$^{\circ}$, 45$^{\circ}$, 60$^{\circ}$sharp tip, and 60$^{\circ}$surface polished (S.P.) sharp tip. It was confirmed that the maximum arc pressure by the initial electrode condition was highest in 45$^{\circ}$sharp tip, and the next in 60$^{\circ}$sharp tip, the last was in 30$^{\circ}$sharp tip and 60$^{\circ}$S.P.. But, the maximum arc pressure after the repeated arc start test and long term arcing test was decreased considerably. But, the maximum arc pressure was highest also in 45$^{\circ}$ sharp tip after the tests, the next was in 30$^{\circ}$sharp tip, and the last was in 60$^{\circ}$sharp tip and 60$^{\circ}$S.P.. The arc start characteristics was the most excellent in 60$^{\circ}$S.P., By long term arcing test, the lanthania included in tungsten electrode was extinguished at tip surface preferentially, therefore the arc characteristics of electrode tip got worse.

• Journal of Welding and Joining
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• v.15 no.6
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• pp.41-48
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• 1997

For analyzing the characteristics of arc welding processes, an algorithm is necessary to determine the metal transfer mode, arc stability and weld quality. In this study, the weight of spatter during welding was selected for determining the arc stability, which is very relevant to the occurrence of spatter. Weld spatter occurs mainly at the moment when the short circuit is formed and also when it is broken causing the arc to restrike. Based on this fact, the arc stability can be determined by finding the suitable parameters of welding current and arc voltage which influence the weight of spatter. Through various welding experiments, the peak current, the arcing time, the short circuit time, the current and its slope at the start of short circuit were found mainly to influence the weight of spatter. For the convenient usage, an index was proposed by combining all these parameters. It was found that the index is very effective for determining the arc stability.

• Proceedings of the KIEE Conference
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• 1997.07f
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• pp.2155-2158
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• 1997

This paper describes the performance improvement of dc TIG (Tungsten Inert Gas) welder. The TIG welder consists of single phase full bridge IGBT inverter which incorporates the high frequency transformer, the boost converter for improving the input power factor, and the arc start system. The arc will be generated without fail even when the extension cable between the torch and the power source is 100m long. In addition, the arc start system with a short dc output voltage will generate less EMI noise than the traditional arc start system with a high frequency output voltage. To demonstrate the practical significance of the proposed methods, some simulation studies are presented.

• Proceedings of the Korean Society of Marine Engineers Conference
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• 2006.06a
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• pp.71-72
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• 2006

This paper introduces the results of the development of a new mobile Digital DC-arc Welding Machine (DDWM). A simple PI controller is applied to the DDWM to control the output welding current tracking the constant setting current. Furthermore, a hot-start function, an anti-stuck function, a standby mode and an intelligential circuit breaker (ICB) are included in the DDWM. The DDWM increases welding quality and saves more power energy than a conventional welding machine. Because the DDWM is changed from ready mode into the standby mode automatically after 2 minutes interval from this unload start. Then the DDWM is changed into ready mode automatically since it is reused to weld. Mover, the DDWM increases welding qualify, productivity and reduces costs of welding. So, the DDWM can have a great of contribution to the mobile welding industries. The effectiveness of the DDWM was proven by the experimental results and durable test.

• Journal of Ocean Engineering and Technology
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• v.20 no.6 s.73
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• pp.18-23
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• 2006

This paper introduces the results of the development of a new mobile digital DC-arc welding machine (DDWM). A simple PI controller is applied to the DDWM to control the output welding current that is tracking the constant setting current. Furthermore, a hot-start function, an anti-stuck function, a standby mode and an intelligential circuit breaker (ICB) are included in the DDWM. The DDWM increases welding quality and saves more power energy than a conventional welding machine. The DDWM is changed from ready mode into the standby mode, automatically, after 2-minute intervals from this unload start. Then, the DDWM is changed into ready mode, automatically, since it is reused for welding. Moreover, the DDWM increases welding quality, productivity and reduces costs of welding. So, the DDWM can make a considerable contribution to the mobile welding industries. The effectiveness of the DDWM was proven by the experimental results.

• Proceedings of the KWS Conference
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• v.43
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• pp.251-253
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• 2004

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.7
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• pp.1065-1070
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• 2003

In arc spot welding process, the arc is not moving and heat input is concentrated in one spot so that the heat input efficiency of arc is higher than that of GMAW. In other words, the heat input efficiency of arc change during weld time because arc start is done in spot and weld metal is filled. Therefore, the heat input model of arc spot welding should be different from that of general GMAW. In present study, the calculating model of heat input efficiency in arc spot welding was suggested by temperature monitoring near spot in arc spot welding of copper plate. The result showed that the heat input efficiency of arc was changed three times during weld time. The accuracy of calculating method of heat input efficiency was verified by heat transfer analysis of arc spot welding process using finite element method.

• Journal of Welding and Joining
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• v.23 no.3
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• pp.54-60
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• 2005

Tungsten Inert Gas(TIG) welding is today one of the most popular arc welding process because of its high quality welds and low equipment costs. Even if welding productivity increases with welding speed and current, this strategy is limited by the appearance of defects such as undercut and humping bead due to the depressed molten metal. The purpose of this study investigates the effect of He mixing ratio on the characteristics with high current and speed in TIG welding. The conclusions obtained permit to explain the arc start characteristics quantitatively and the maximum welding speed on stable bead formation with He mixing ratio for high current and speed TIG welding observed in experiments. Also through the relation of the maximum arc pressure and surface depression depth at high current and speed TIG welding, it made clear the mechanism of unstable bead formation.

• Journal of the Korean Institute of Illuminating and Electrical Installation Engineers
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• v.15 no.6
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• pp.8-14
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• 2001

MetalHalid lamps have good efficiency, good color rendition and good focusing capability. But the shortcoming of metalhalid lamps is blown as acoustic resonance phenomena in the arc tube. Such acoustic resonance produce annoying fluctuations in the intensity and distribution of the emitted light, they can raise the voltage to the point where the arc is extinguished and they can move the arc close enough to the wall to cause local overheating and tube cracking. The objective of this research is to reduce acoustic resonance in the arc tube of the Pulse Start MetaIHaide lamp(MH200[W]). To reduce the acoustic resonance phenomena the electronic ballast was designed for high frequency operation with the constant frequency sinusoidal wave of 89[kHz] in the 84.6[kHz]∼94.2[kHz] range. Experimental results show that the acoustic resonance phenomena are not in the arc tube of Pulse Start MetalHalide lamp (MH200[W]) .