A Review on Optimizations of Welding Parameters in GMA Welding Process

Ill-Soo Kim,Min-Ho Park 대한용접·접합학회 2018 대한용접·접합학회지 Vol.36 No.1

With the increase of automatic welding system employed in the manufacturing industries, the selection of optimal welding parameters must be more specific to ensure that quality is obtained. Furthermore, it is necessary to have a suitable model that establishes the interrelationship between welding parameters and bead geometry to get the desired weld ability as quality since it is a complicated process, which involves interactions of thermal, mechanical, electrical and metallurgical phenomenon. Many researchers have reported theoretical, numerical, empirical and AI models to give the optimal welding conditions for GMA(Gas Metal Arc) welding process. In addition, controlling the welding parameters plays an important role in ensuring the quality of the weld. However, there is a need to comprehensively review the GMA welding process in terms of different independent and dependent welding parameters for the purpose of modeling and optimization of GMA process. In this paper, several experimental design and optimization methodologies are reviewed and discussed with current literature on experimental design, multiple regressions analysis, the neural network, fuzzy logic, and genetic algorithm to improve the quality of weldments. This review underlines the need of development of appropriate nature inspired algorithm for the optimization of such advanced manufacturing process.

빅 데이터(Big Data)를 이용한 용접품질에 연구

김일수(Ill Soo Kim),신윤덕(Yun-De Shen) 제어로봇시스템학회 2021 제어·로봇·시스템학회 논문지 Vol.27 No.12

Generally, in welding technology, big data refers to data that is too large, fast, or complex for processing using traditional methods. For the past years, the act of accessing and storing large amounts of information for welding has been utilized. Welding technology is a central component of numerous value creation chains and plays an important role in this development. In this study, gas metal arc (GMA) welding experiments were conducted to develop an algorithm for predicting welding defects in the GMA melting process of flat plates on SS400 materials using big data technology. The correlation between various welding parameters was analyzed using the real-time measured current and voltage data during welding. In addition, the welding quality related to the weld bead was analyzed using a 3D scanner. The optimal welding parameters were predicted using a CHMM model for the welShen Yun Deding current signal in the normal welding section, which is one of the machine learning technologies. By learning this, the similarity between the normal welding current signal and the weld defect was expressed as a probability, and the changed pattern of the Log-pdf value was used to predict the welding quality.

Al 5052, 6061합금에 대한 플라즈마-GMA 용접공정특성 평가

김철희,안영남,최진강,이세헌,Kim, Cheol-Hee,Ahn, Young-Nam,Choi, Jin-Kang,Rhee, Se-Hun 대한용접접합학회 2010 대한용접·접합학회지 Vol.28 No.6

In this study, the bead-on-plate welding were conducted by using GMA welding and plasma-GMA welding on Al 5052 and, Al 6061 plates. For these processes, the maximum welding speeds for full penetration were compared, and various weld qualities such as bead appearance, cross-section, cracks and porosities were examined. Faster welding speed, cleaner bead surface and more stable drop transfer could be achieved by plasma-GMA welding, compared with GMA welding.

GMA용접에서 비드단면형상을 예측하기 위한 실험적 모델의 개발

손준식,김일수,박창언,김인주,정호성,Son Joon-Sik,Kim Ill-Soo,Park Chang-Eun,Kim In-Ju,Jeong Ho-Seong 대한용접접합학회 2005 대한용접·접합학회지 Vol.23 No.4

Generally, the use of robots in manufacturing industry has been increased during the past decade. GMA(Gas Metal Arc) welding process is an actively Vowing area, and many new procedures have been developed for use with high strength alloys. One of the basic requirement for the automatic welding applications is to investigate relationships between process parameters and bead geometry. The objective of this paper is to develop a new approach involving the use of neural network and multiple regression methods in the prediction of bead geometry for GMA welding process and to develop an intelligent system that visualize bead geometry in order to employ the robotic GMA welding processes. Examples of the simulation for GMA welding process are supplied to demonstrate and verify the proposed system developed using MATLAB. The developed system could be effectively implemented not oかy for estimating bead geometry, but also employed to monitor and control the bead geometry in real time.

회전아크를 이용한 수평필릿 용접에 관한 연구 (II) - 고속용접공정의 개발 -

김철희,나석주,이현철,김세환 대한용접접합학회 2003 대한용접·접합학회지 Vol.21 No.3

The horizontal fillet joint is one of the most important weld joints in the shipbuilding industry. High-speed rotating arc welding, which can increase the leg length, is an effective way to improve the weld productivity and quality for the horizontal fillet welding. Based on the Taguchi method, the effects of welding parameters on bead characteristics - leg length, asymmetry, undercut, overlap - are investigated fur high-speed welding process. As a result, the adequate welding parameters are selected for the required leg length, symmetric bead and no undercut. Besides, considerably consistent leg length is observed for the horizontal fillet welding with gap variation up to 3mm.

A control system for uniform bead in fillet arc welding on tack welds

김재웅,이준영 대한기계학회 2008 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.22 No.8

Positioning a workpiece accurately and preventing weld distortion, tack welding is often adopted before main welding in the construction of welded structures. However, this tack weld deteriorates the final weld bead profile, so that the grinding process is usually performed for a uniform weld bead profile. In this study, a control system for uniform weld bead is proposed for the fillet arc welding on tack welds. The system consists of GMA welding machine, torch manipulator, laser vision sensor for measuring the tack weld size and the database for optimal welding conditions. Experiments have been performed for constructing the database and for evaluating the control capability of the system. It has been shown that the system has the capability to smooth the bead at the high level of quality.

GTA-GMA 하이브리드공정에 따른 자동차용 아연도금강판의 용접부 기공감소 (II)

안영남(Young-Nam Ahn),김철희(Cheolhee Kim) 대한용접·접합학회 2016 대한용접·접합학회지 Vol.34 No.4

The use of Zn coated steel has increased in the automotive industry due to its excellent corrosion resistance. Conventionally the BIW(body-in-white) structure and the hang-on parts have been made of Zn coated steel and more recently Zn coated steel began to be applied in the chassis parts. During gas metal arc (GMA) welding of the chassis part, lap fillet joint used to be adopted but spatter generation and porosities are most important concerns. In the industrial applications, an intentional joint gap was made to avoid the weld defects but it is not easy to control the size of joint gap. In this research, gas tungsten arc (GTA) is combined with GMA welding where GTA precedes GMA. As pulsed arc was adopted as GMA, GTA was oscillated along the longitudinal direction by pulsing GMA, but the arc oscillation did not disturb the molten droplet transfer of GMA welding. By increasing the distance between GTA and GMA, the length of weld pool increased and porosity could be reduced. Moreover porosity in the welds was fully removed when the distance between two arcs was 15 mm.

STACO 모델을 이용한 탄템 GMA 용접공정의 표면비드 폭 예측

이종표(Jong Pyo Lee),박민호(Min Ho Park),김도형(Do Hyeong Kim),진병주(Byeong Ju Jin),손준식(Joon Sik Son),강봉용(Bong Yong Kang),심지연(Ji Yeon Shim),김일수(Ill Soo Kim) 한국생산제조학회 2016 한국생산제조학회지 Vol.25 No.1

Tandem arc welding is a guarantor for high efficiency and cost saving since the quantity of wire which is deposited in the welding is approximated 30% greater that in conventional welding. The welding process is now being successfully applied in many industries. However, in the case of tandem arc welding, good quality and high productivity should depend on the welding parameters. Therefore, an intelligent algorithms for the automatic tandem arc welding process has been necessarily required. In this study, a predictive model based on the neural network by using the data acquired during tandem gas metal arc (GMA) welding process has been developed. To verify the reliability of the developed predictive model, a mutual comparison with the surface of the top-bead width obtained from actual experiments has been analyzed.

Optimization of weld bead geometry in the activated GMA welding process via a grey-based Taguchi method

Hsuan-Liang Lin,Jia-Ching Yan 대한기계학회 2014 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.28 No.8

We optimized the weld bead geometry of 6061 aluminum alloy welds pre-coated with activating flux before gas metal arc (GMA)welding. In this activated GMA welding process, there were five single component fluxes used in the initial experiment to evaluate thepenetration capability of bead-on-plate GMA welds. Based on the higher penetration of weld bead, two single component fluxes wereselected to create mixed component flux in next stage. The grey-based Taguchi method was employed to obtain the optimal weldingparameters that were considered with multiple quality characteristics such as penetration, depth-to-width ratio (DWR) and fusion area ofGMA welds. The experimental procedure of the proposed approach not only increases penetration of 6061 aluminum alloy welds, butalso improves the DWR and fusion area of GMA butt-joint welds simultaneously.

가스 메탈 아크 용접에서 단락현상 모델링 및 스패터 감소를 위한 전류파형 선정에 관한 연구

황주호,문형순,나석주,한광수 대한용접접합학회 1996 대한용접·접합학회지 Vol.14 No.1

With an expansion in automation of welding processes, emphasis has been shifted from other welding processes to the GMA welding. However, there is a problem with this process that the spatter occurs very frequently. In GMA welding, there are several types in the way of metal transfer from the electrode wire to the weld pool, which have a close relatonship with the spatter genetration. This study was concerned with the spatter occurring in the short-circuiting transfer. In welding with short-circuiting, the electromagnetic force formed by the welding current facilitatics the rupture of the metal bridge between the wire and workpiece and ensures the normal process of the welding process. However, the spatter can be genetrated from the droplet because of the upward magnetic force, when the droplet contacts with the weld pool. The passage of current through the bridge results in the accumulation of the thermal energy, which causes the bridge to explode in the final stage of short-circuiting, thus forming the spatter. Based on the above phenomena in conjunction with other experimental results published, the physical phenomenon related with the occurrence of spatter was modeled and the current waveform was investigated to reduce the spatter. Finally, the fuzzy rule based method was proposed to predict the time of short-circuiting and arcing in the metal transfer.