MENSA TRE 13% B48, pp.9B~104, 1999. 11 on x 24a FZEQAS UALS A A439} AE A171 Qt fal a a aS a (90d 108 19d AP) Optimization of Friction Welding for Crank Shaft Steels and Its Real Time AE Evaluation Sae-Kyoo Oh’, Hei Young Choi”, Yu Sik Kong”” Key Words : Friction Welding(FRW, "}22), Optimization(31443}), Weld Strength(& AEE), Weld Tourhness(#42l-s), Acoustic Emission(AE, $302), Real-Time AE Evaluation(4l4]22 AEH) Abstract ‘The crank shafts need anti-corrosion materials. So STS 304 is the essential material to manufacture this shaft. However, it costs more to manufacture the shafts by using only STS 304 than welding of STS 304 to other carbon steels. And it has been difficult to weld this sort of dissimilar materials. They could be unstable in the quality by the conventional are welding. And also they have a lot of technical problems in manufacturing. But by the friction welding technique, it will be able to be made without such problems, ‘Then, this study aimed not only to develop the optimization of dissimilar friction welding of crank shafts steels of STS304, SM35C, but also to develop the application technique of the acoustic emission to accomplish in-process real-time quality(such as tensile) evaluation during friction welding of the shafts by the AE technique. LAM BE BPA. lee 71S9 Bu} Wate PUB OS HEE, AE, a SA} AM AoA AA Ha) Wale PIAS AS A) Lob as|z glee, ALMAS HS Ssh le EEE a PAE aS ARABS Balad wpe vA ASE ADE SE SUA oe FR ED ale? errr reer wala, aes ven Ashe eae aah -98—Aga AREAS) ote 31239} AE 42 B7b S4a ARES $4 HWS Hal Ay 44 ABS Ao] WaspA|et, Aelele|~ Bala Bo 24444) ste] otel UY ARS 71a) 7H AED Ye Agel. fee HE Atel Has Sdtoed Beyed aa UeAMS osha. HY SMIC HE Abas ol S}a) to] 7Ae abe] >} ahBH 2] Aaj) Ast 7eSr2] Ade 7Heabal UF ach. old Fe zeadoz weyedss} Sapol AU FY ste, ce WEtEe AF A4al Wt BYE, HASH Faso} Ye Yssae BUG Beads S RE dol Wel= tale] 4. old Yeas Head sso] Ababa & Vase Sessa. Be HA a els} Ade] she Sat lS $Y (acoustic emission:AE)4]@ & Basle] oes] Wash: AES Saat] el 4-g8l $ AESHtotal AE count)3} "Ht use 2 seals] AS TA stale. aso] 2 apap} ada ARES ae] AAAS Wt ol Sal aS) aast 71S WE AES 1% 24) AAlztel AaB We > We Sse 714 FAM 7) Ba} 7} sleeba Q7ie}. 2 NH os aeee 21 Ae & ate 44d age 24a AES aAN7E 7Ao} DE dst WBA, HAL ZB AS Fo Asstact. daagd STSIM4E 2 Seo] EA ArddlejzA Ble Heel ey A aya wats atel eke Yale 7alet7] Hai °]2tel Ni, Mo, SiBS WHe4]zl Boe 2 BE “Jol 18% Cr, 8% NEA WAGs AY DZ Ugo] Cra AddeAgwc} +patch. EV 18-8 See] Ate] Be] YERHE alae Al(boundary_corrosion)®|_ Bel STS304= GRES yale] EHS IRMA Hs AA & Aol, 2 Atel AHL STS304, SM35CS] Be} 2) 3} AA Jae A} Table 1 3 Table 22} 2c}. ‘Table 1 Chemical composition of STS304, ‘SM35C (wt?) Materia] C [si[mn] P| s [Nil cr [cu ‘STS304 [0.065 [0.62] 1.27 [0.024 [0015 [9.1 [1816 [0.23 sm35c | 0:32 [0.24] 0.75 [0.009 [0.017 [o07| 0:1 {os} Table 2 Mechanical properties of STS304, SM35C “Tensile | Reduction] Ye aa oe ee [i [cae | mete (Pa | 66 (Pa) stsau} mo | 2 | 2 | 30 [osc ssc} wo | ws | ze | m | 22 2 AF) HGS) ae 1 ee AL FA] Ae} Mesa (hiction welding, RW) AH82 A1GR9] Vpsh a] gM aleay 78) LEH WARIS, AR Bale 2p 2 Fig. lol Get ale. Fig. 12 SM35C (4 20)3+ STS304 (4 15)9] & OY SA HAS AE AWdes Halal Heh AUHE ARE aah ated (aye ohh AY ABAGR, (be I AMI a a a) $8 vole (a) Friction welding and AE test specimen of ¢ 15 bar to 420 bar (b) Tension test specimen of weld Fig. 1 Shape and dimension of test specimensLAF AMD SHA 22 MHA 8 Mee baeael Ae bale) 7lae Bate] a] AAR APRA] ASL $25e1D Se} SSS 94091 AGRE Belo]zA(continuous drive brake type)’ TOHO TH-25 "Hej 7i7ist ABZ|717} GH AES} ALAS] eh. #% Adel Ahead 4/Gael STS3049} SM35C A At 4B lSa atey aaeas As] Mal BVLEUNS ZA] PASE 7 AQ F AWM P), PAVA(PIS AVAD Table 33} Ze] VUE sed, 7H te)S ALS + AHS esha sla laa. S49] Bee US, Srl, dale F Sel 2Aad Fd WAS Asda aa 7HAAIZE (tS BA AE. ‘Table 3 Various condition of dissimilar friction welding of #15 bar-to- #20 bar Rotating] Heating | Forging | Heating | Forging Case| speed | pressure | pressure | time | time rrp) | Py (Mpa) | Pe (Mpa) | th (sec) | fy (sect @ 15, a 180 1} 2m [10 Ea 2 3 12 7 m | 20 2 | 0 [im | 2 [i-6| 3 23 So SOSA FASAAlS AE ANE SUAZE Sol eS ABA ASS AAsh 7 Mae SaAlaeel Ste Sol ASL 47| AE YAR SAF Y2i712b Sol Asa 47) AES) F717} AHA & Sled, & ae ae 47] AEBS} #472] AMIGA S S71 Hato} Arto Beho}a s}ajs}sice”, Haale Bathe AEBS Sasb7] Het of] 22S AA|RIS-150kHz sensor) °H4Hd lA] ea HA] 310mm) 4al2) Bz)4 (chuck)el +4}8}3431, acoustic couplant4] 2 eA AbHee} sensor mount® AAS 27YA} ney”, 3. aa 2 ae 31 AHS ABE SAS o/ Sal oS Ao} aaa 311 Saat] Ae o] Udell ALES hbase] UFEE sad + (n), “barbed ae (Pd), SE7T4 (Pp), OME 7HBAIZE (to), PAA (Sel, 91 Fall (STS304 - SM35C)9] Ht 84) 314} 71a rm LOD qASMSNOSC 2 Fa) = Siao bao 3 % = @ eB 2 8 8 BR BR Hearn cress, (4Pa) Fina ores.) Fig. 2. o: vs. P1, P2 in #15 bar-to- $20 bar friction welding of STS304 to SM35C Welding condition : as shown in Table 3 gr Bs i ‘ eatin tne, 80) 7 Fig. 3 Ur vs. tr in 615 bar-to- $20. bar friction welding of STS304 to SM35C Welding condition : as shown in Table 3Bt ARES] MERA alasts} AE 4142 37} Pt AA HEY Pee AAs] Ashe} el 7} a EUs ge aoe S awe dat PEA te 77} 2 sec, 3 seck Beta | Table 35} ate] "HB ZVS Wah Al7I Ay SaRRAS sheet. Fig. 2% Pi, Pee A987] Atte} nF} ty, eS BYt2 HAY 244s] Wages TA alzele}, 2eolal A + ghee] Pr, Port A 7 120, Z10MPal4] 7} @ lavrrs US BB tH. ele) SSVI Urimm)s} ebb 4\2b tt] BRVAS WYRE Ashe Fig. 35} ze. Fig. 32 haba lz ti(sech® Fe] 71S USA Sa eA ATE 615% At #204 (bar-to-bar)| "Hat 414s} LVS At StSYMS Urmm)s} 7}44]2b ti(sec)s} ARIS Uehaeh oleh Ute] A AA, 2 hat te] Ss art STS304 - SM35C dissimilar weld Ur = LA7tr - 0:72 , (RP = 0.95) @ Fig. 39] AF ue] S7b BFS Ur7t ABA 22 SRS YF Ud. HY, 1 Fal STS3O4 -SM35C2] "HERB oAA AU] Uy-t:9) BAR AAAS HAAS Asay He Wels) BWIS AY YWASAY FS AS AME a dae de] +Hepll ola + 31S 2lelet. 312 SNF BAZAAR Fig. 4& Table 35} 22 EAel4) 2b 2D 2 Bae g15% Y} $20% STS3042} SM35C olSal mae aie] da} oMPa)s} 7H AlZE t(sec)s}9| JRAS AYALE Fe As} & deh. oles] lt ABMS Fig. U(b)e419} Be] Be as B44] Segoe vlaeaddel Ste] LES HAT, 7104125 trlsecol HE 2] AVBAAYS ALASUS 91-841 HA HAG ah cs} Qe) SBs}aeh. 22.8817 + 169.35t) + 471, (R°=0.98) (2) 101 § a a E B & Tensie strength, (MPa) & | a * eatin tne (see) Fig. 4 a: vs. fr in 615 bar-to- $20 bar friction welding of STS304 to SM35C Welding condition : as shown in Table 3 Fig. 4914] OziZ(optimum t zone)o} AR 12} AAUAE o-3~Ssec14, olds] WEE o « 7162~T73MPa°| FURBL Ur-29~692 Hel de}. steht SM35CS Zale] ge i, olf RRe 100% oto] et. 313 4 ¥ Sal Heals] Aaa} STS304-SM35C9] 91a} "Hab-S-adale] alas} S Aa AAA tr UFE ste] UasEzt Ft 09 WHS ATs Ud. eH OnZert oe] 2A UF Bed At AEC oo7t Bolla, Bt leHse] Fz] Ge UY, OFZ tS AM 1L00%e] 42] SEE ES FA8 + slol 1S AR glel4} AER A AASHS Aad + ae Et, "HHS JASE Hal SHS] AE oh WISH, GIS, dA) BES Bet Va} ach Me} Table 32] & ASA Fe} ARS 2S T of obareayzt oof ARE Sate] Tolal, CISSH, dal Bats] 4D We Fig. 5% Beh. ©] 2Yol4] VB + YK] ella] HU OHZlAlS] VW, eR Ee zea 2 4 al dad UF yz] goes a 4d fas] @se IF Ue. lee BS Eb AT AsS} Oe daleicLARAMIE SHA Heat ue. sec) Fig. 5 Fvs. t, ¢ vs. 6, and Ey vs, é; in $15 bar-to- $20 bar friction welding of STS304 to SM35C Welding condition : as shown in Table 3 32 AWA AZES| OBUA AES Seah SHEUz Yad 3.2.1 SYS25+ AES) aduee sl4|zHe el S7Htel we} bat SAH AANMS] AS aa dehy) Fh ol ABE S7}ch. Fig. GE Table 33} Be PARAMS PS ABUSE TT ABZ ti] S7} cle] NE S7khe Whe Bel Se. 2A] t=Ssec o|4ba we Ne} aces AGS Bela le 7a2b] S7b mat g £ Z Total counts, W (courts) yg E a3 4 a aa Heating te, sec) Fig. 6 N vs. tr in 615 bar-to- #20 bar friction welding of STS304 to SM35C Welding condition : as shown in Table 3 ~102- oh HS dats] Aste} Bde] ket Bzhl Uh. Fig. 6°14 OtiZ(3~5sec) 42] AE S8(N)E 45819~56273(counts) 2% 3a) Saheb, ol} vhs] AES Mcount)3} ti(sec)Abo] 4} N-t WAALS est ah. N= -366681t/'+ 33901.57t - 22996, (R’=0.98) (3) 322 AE Ses} BASIS Yad Table 33} BE $4eA2= “HAT Fs ABE( 0) AE SB(N)2] AWA Fig. 7 3} Beh Bost ze] ONZE 45819~55273 counts 9] lad 762~773MPaZA] ©] Keo] Zahol 4] ef 100 %e]- FIs DUALS a ale > asic. oh} oN PANS e5} Zo] Falah. = 397% 10"N" + 0.0052N + 607, (R'=097) (4) ims a aa an fam SMR aos “Tensile srengih, o (MPa) $88 8 se 8 8 8 it anata aa Toll courts, Mounts) Fig. 7 a+ vs. N in 615 bar-to- $20 bar friction welding of STS304 to SM35C Welding condition : as shown in Table 3 714 abe] Sad & AE count7} 44) ONZAFS] oH BL&ol o]-SH& 100%0]449} 342} ASYVS v|s}3]4j2=2 Helo] VFaheh. o]= of aH Wz AEBS 4ytoe B44 t= AAS wspaoe Wyse USS E 4,4 4S Fe] ole aeaoe He Se Achaa ARE Dale) bale Aalstst AE 4l4)2b g7t Asal Sa) LEAL Fig. 7, AeA + QE] HSA AESS NS Sasha 34) Wate] 2 Bad] Wa ok FE + ala, obalel OnZasuls} ela) obdals AD $ Yo, BA GaZa 24] oh BAS 24 Molt $ Sle Ho] PS Nat + ale. ola Ashe 4 AFasbelAl= spell uh) ge) 323 844 4 RAls} ALRE ZAp BW aE vie] SEM 24h Fig. 8& AA PSY SAA AT AVIA BF AS PES tele}. eo] 2aqz S Wd SAR weld interface) BEAI7+ A Bele}, 2 ole Ba Fey PaaS % ast THY GR Ashe she} BxAl7} St 222 Aad}. wale) Bee STS3043} SM35C9) 3+ 44} W272, H2BIES4 ht Bz Ha AA WD Ate HMI = BAT STS3049] Ral EMC} Of 1996S AS g.2%), HAZ(heat affected zone} BAe a FF ImmBEleh. eae BEY peak FY AAA UWA + We Bele. 2. sMasc ‘STS304 8 x0 Bn * {. i @ am i. wi re re er [Distance from weld interface (en) Fig. 8 Hardness distribution near the weld interface of _ friction-welded-joint of STS304 to SM35C steel bars Welding cond. n=2,000rpm, P=120MPa, Pe210MPa, tr=4sec, te=3sec Fig. 9& Zale} @ dS (HAZ) @ HERA ae) 24¢ asia] Sa] Galo Ade St dell] obabe-aaRWD aH 6mm +2] BA) Apo. ARSE Ae] SM3ISC BA SoH, AW ES|ES HAZY WEES) AE Babe Ges Azadeh ANAL se Ale sorbite Fe = eht aleh. 2ejy sbbytalalzbs} wap) ap 2} HAZ¥S} WI Bae] Z2jo] Age olabey, Fig. 991] B= ¥}9} Bo) WI45} HAZHE BE sorbite &3]0]7) 3 W.PHE 4% 22}6] ¥| a3}, Wiel et UF WLS Fz Sy OLE #matal flow) & + get. de} HHS Salo val lala 2g YS 7H) 2422 Fo AAS OF FS & dela uct. Fig. 9 Micro-structures of B.M, HAZ and weld interface of friction welded joint of ‘STS304 to SM3SC steel bar (200) Welding cond. : 1=2,000 rpm, Pi=120(Mpa), P=210(Mpa), t1=4(sec), t3(sec) Fg 10 AQ co #a 2a Has 2000rpm, »Hi7Ha tt} Pi=120MPa, Fatt eA PeZT0MPa, "H7beA\ZE t=dsec, BS ALZE fe-3sec@ STS3049} SM35CH "Hab Be 2) la sheteol otal 349) abel a (SEM) 22 BA bo] 2s(microI2= SMIC 4 1 PERS 4000S abel Yepalsich, —103—LAT AME HEA Fig. 10 Fractograph of tensile fractured surface of dissimilar FRW joint (STS304- SM35C) by SEM, 400 Welding cond. : 1=2,000 ram, Pi=120(MPa), Pe-210(MPa), t7=4(sec), t2°3(sec) Abdel} SMISC sho] Lye a BAY + 92a, le Adal let sts ae e+ oleh. 4a 2 ada ALES AbEse 2Anoeq ~ Bleeds} 7 APB AZHSTS3-SM35C) } BH SOSA LARS Sehate] Haba ASS} AESD, SASAAMWTS), Ua >] ale U2 2 AESRS} apes} Gaal al @ apaste des} go] 2 @ + gd 1) 24a ARES 7ahel STS3049} SM35C9} la} Halo] 7s shat, D7} ABMS] a SA ade] 7Asehat, bed Alba & S77) 3 2daest chee] cys) AE7} aaletaeh. aaa Be Bales] Ae7t Be ‘SM35C( ¢-=690MPa)} SS HAZ) A BY AAA WDA) Abo spt eIz, a4) ab Bl SAMA BAF ol BE ee] 100% Olt SSA BARU Eghou, gayest eye Bat 44 Md 222 ches} ach 2,000 rpm, P/=120 MPa, P=270 MPa, t= 3~5 sec, t=3 sec 3) Salto] Sal ABS] 349] ONZ ol] "His ol gto] oh ES 24s (las, We US + Use} ayes, All| *HLA4) AES A}E¢2 28 AA) zh0H Sasa 87h eee Y + UA. 4) HRA BAe F 0] Saale] 7eysp7] E Uso] Asa 2UG 24e 27 Va, s AS M+ Sl debtor, Rage] Be FEU Adela. B2ae2ed 1) AWS, "Welding Handook”, Vol. 2. p. 747, pp. 672-763, 1991 2) MEPRRERTASC A, “AREER, 2O +i, p. 46, pp. 145-150, 184, 1976 3) BOR ARREARS, “MRARMRIR 204638", pp. 1-106, 1984 4) Vill, V.L, “Friction Welding of Metals”, pp. 2~21, 1962 5) Glennie, AMG. and J. Summerscales, "Acoustic Emission Source Location in Orthtropic Materials, British Journal of NDT, 28(1), pp.17~22, January, 1986 6) Beattie, AG. "Acoustic Emission Principles and Instrumentation", Journal of Acoustic Emission, Vol. 2, Nol/2, pp. 95~98, 1983 7) Arringtoon, M., "Acoustic Emission’, Speedtr ~onics Ltd, Huntingdon, pp. 25~89, 1988 8) QA, SU, MNS, “AbEAt wale] g AS] o]Sa H}SA2) 3713}9} AES) 2] eh RASA ANT 87h" US aAgs as, ‘Vol.12, No.4, pp.60~69, 1998 9) BA, Lal, ola, “LAYS RSals] Bole eleast AEB} BE UA” TE FA9S%2]2], Vol13, No2, pp66~73, 1999 10) Oh, Sae~Kyoo, Hyung-Dong Park, Bae~Sup Lee, “Friction Weld Quality Evaluation of Hydraulic Valve Spool Material by Acoustic Emission Technique,” Inter. J. of Ocean Engineering and Technology, Vol.2, No.1, pp.18~25, 1999