High Efficient Welding Technology of the Car Bodies

Abstract
The trend of the fabrication technology of high strength, high toughness aluminum alloys by
the severe plastic deformation (SPD) process and the welding technology of lightweight
alloys has been studied. The lightweight aluminum alloys can reduce vehicle weight, while
stringently demanding high quality and efficient welding techniques, to produce the best
weldments. Among the production technologies, welding plays an important role in the
fabrication of lightweight vehicle structure.

This paper covers the application of the HPT, ECAP and rolling, and the 'welding technology
of the automobile' obtained from the web of Science, and deals with the details of the
background data of the HPT, ECAP, and rolling of lightweight alloys, and welding
technology of the automobile technology.

Key words : SPD , HPT , ECAP , Aluminum alloys , Friction stir welding , Laser-arc hybrid
welding , Scientometric analysis , Methologist and source of data
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1. Introduction

Recently, countries around the world are making efforts to improve environment and save
energy in order to improve human welfare and living standards. Especially, from the
viewpoint of energy saving, we are investing heavily in the development of steel deformation
processing technology and welding / bonding technology of aluminum alloy, which is a
lightweight material that is essential for automobile energy saving and environmental
protection. Currently, advanced technology nations such as the United States and Japan are
developing the ECAP (Equal Angle Compression Molding) method, which manufactures
ultra-fine and lightweight aluminum alloys with nanometer-scale dimensions by
introducing large deformation strains to improve the strength and toughness of automobile
structures and components. High-quality and high-efficiency laser welding, hybrid arc
welding, SHORT ARC, friction stir welding, etc., which improve the quality and reliability of
light-weight aluminum alloy welds, The state is actively developing advanced welding
technology. Therefore, it is important to analyze domestic and overseas research and
development trends and development trends of steel deformation processing technology,
welding and welding technology so as to improve the productivity of lightweight aluminum
alloys for automobiles with high added value and high value added and to improve the
quality of welded parts. Do.
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2. Processing and Welding Technology of Automobile Lightweight Materials

2.1 Aluminum alloy steel processing technology

Aluminum alloys suitable as lightweight structural materials for transportation equipment
such as automobiles have high specific strength compared to steel materials, and they are
suitable for the production of ultra-fine lightweight aluminum alloys with nanometer- ) 1 ) ,
and high-pressure twisting (HPT) 2 ) . On the other hand, aluminum alloys have
disadvantages in that they have lower plasticity than steel materials because of their low
ductility, high thermal conductivity, and high chemical activity. Therefore, in order to
increase the utilization of aluminum alloy, it is necessary to improve the machining limit of
aluminum alloy by improving the material by controlling the structure, improving the
moldability and lubricity by controlling the surface texture, and reducing friction by the
flexible lubrication method. it is important to 3 , 4 ) .

In the case of Al-Mg alloy, dynamic recrystallization is dominant in dynamic restoration

process because Mg content is high. The microstructures formed on the rolled plate after
high-speed pressure-rolling the Al5052 alloy in the warm state are shown in Fig. 1 , dynamic
recrystallization appears finely. That is, when the high workability of the material is
sufficiently secured in the high-Z rolling and the high-temperature rolling, the grain
refinement can be realized by maintaining the high pressure exceeding the critical strain for
recrystallization.

Fig. One
Effect of the reduction ratio on the aluminum alloy sheet
(rolling temperature 623K, rolling speed 1000m / min) 3 )

2.2 Automotive welding technology

The use of lightweight materials is most effective in lightening the weight of automobiles. In
order to maximize the characteristics of aluminum alloys, joining techniques with different
materials are important. The joining of aluminum alloy sheet press parts
is shown in Fig. 2 was inserted, and stirring the plastic flow in the aluminum plate placed
superimposing the rotary tool uses a low friction spot joining bridge energy to integrate the
upper and lower plates, such as 5 , 6 ) .

Fig. 2
Process of friction stir spot welding 4 )

In the case of high-temperature wire-fed gas tungsten arc welding, which preheats the
consumable material by using the resistance current generated by applying the AC current,
the arcing generated by the arc generated in the tungsten electrode is used to melt the arc-
wire) is fed a gas tungsten arc welding is a welding technique that addresses the problem
with a conventional high temperature wire fed gas tungsten arc welding having 7 ) .

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3. Analysis of academic information

3.1 Overview of academic information analysis

Using the Web of Science (Thomson Reuters) and SCI-Expanded (ISI Web of Knowledge),
we searched and analyzed the information on steel machining and high-efficiency welding
of automotive light alloy materials. SCI-Expanded is an academic index of scientific journal
articles containing data from 1899 to the present. It provides complete indexing of more
than 7,100 major magazines across 150 scientific disciplines, as well as citations for all of
the index articles .

3.2 Academic Information of Domestic and Foreign Steel Processing

Technology of Aluminum Alloy
Fig. 4 retrieval formula was used to search the scientific information on the aluminum alloy
steel processing technology published in the SCI-Expanded DB (since 2004, published on
September 30, 2014), and a total of 2257 articles By analyzing the abstracts, the trends of
technical literature release by year, country, and research institute were analyzed for only
1576 documents related to aluminum alloy steel deformation processing technology,
excluding academic information, which had a somewhat lower relevance.
 Fig. 4
Bibliographic search flow chart of severe plastic
deformation technologies of aluminum alloy

Fig. 3
Schmatic of arching-wire GTAW system 5 )

The number of published technical literatures by year ( see Fig. 5 ) increased from 2008,
with 178 in 2008, 177 in 2010, and 194 in 2012.

Fig. 5
Annual trend of the published papers in severe plastic
deformation technologies of aluminum alloy

The present status of the technical literature presentations by research institutes ( see Fig.
6 ) shows that 118 research institutes around the world conduct related research. Among
these institutions, Univ. South Calf published 73 technical articles (4.6%), and Russian
Acad. Sci. Published 69 papers (4.4%) and Kyushu Univ. Published 60 papers (3.8%).

Fig. 6
Comparison of the papers in severe plastic deformation
technologies of aluminum alloys (research institutes)

The level of technical literature in each country is determined by using the index level based
on the number of citations as the ratio of the average number of citations in a specific
national publication to the average number of citations for all technical literature in a
particular technology field. Respectively. It analyzed according to the national quality
assessment indicators to be published technical literature Fig. 7 . If the level index is 1.0, it
means that the average number of citations for the technical literature published by a
specific country is equal to the average number of citations for the technical literature in the
relevant field. If the index is 1.0 or higher, Means that the quality level is below the global
average. As a result of the index analysis of the level of technical literatures by country, the
highest value (2.9) was shown in the United States, and the highest quality level was pointed
out in the technical literature. 2.3. , Hungary (1.8), Britain (1.3), Russia (1.2) and Japan
(1.2). Meanwhile, the level index in Korea was 0.7.

Fig. 7
Index level / number of papers (countries)

3.3 Academic Information of Domestic and Foreign Automotive Welding

Technology
Using the search formula in Table 1 , we searched the academic information about the
automotive welding technology published in the SCI-Expanded DB (published since 2001,
as of June 16, 2015) And analyzed the trends of technical literature release by year, country,
and research institute for only 945 documents related to automobile welding technology,
excluding academic information, which has a somewhat lower relevance.

Table 1
Bibliographic search flow chart of automobile welding technologies

Search Query

162,403 Title: (automotive * OR automobile * OR car OR cars OR vehicle *) Index =

#One
SCI-EXPANDED Year = 2001-2015

#2 30,425 Title: (weld *) Index = SCI-EXPANDED Year = 2001-2015

#3 1,500 # 1 AND # 2 Index = SCI-EXPANDED Year = 2001-2015

The number of published technical literatures by year ( see Fig. 8 ) increased from 2006,
with 93 publications in 2012 and 2013, and 109 publications in 2014.

Fig. 8
Annual trend of papers in automobile welding technologies

In the overall trend of analyzing the authorship of technical literatures ( see Fig. 9 ), China
published 121 technical publications, accounting for 12.8% of the total 945 papers, (111,
11.75%), Korea (105, 8.5%), Germany (86, 9.10%), India (61, 6.46% , Followed by Japan (44,
4.66%).

Fig. 9
Comparison of the papers in automobile welding
technologies (countrries)

Fig. 10
Index level / number of papers (countries)

Canada has the highest value (2.59) in the index level ( see Fig. 4-4 ), and the quality level in
the technical literature is the highest (1.55), the United States (1.53), the United Kingdom
(1.15), and India (1.05). Meanwhile, the level index in Korea was 0.74.

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4. Conclusion

1) The importance of high-quality steel processing technology and automobile welding

technology of light-weight aluminum alloy materials in relation to securing the quality and
safety of environment-friendly cars including hybrid cars and fuel cell vehicles,
strengthening environmental protection, and improving energy- Welding technology such
as high-quality and high-efficiency steel processing technology for aluminum alloy, arc-
wire-supplied gas tungsten arc welding, and friction stir welding is growing as core
production technology.

2) Development of various devices and practical application of software application

technology for the practical use of friction stirrup point bonding, which has advantages of
controlling the structure of the aluminum alloy surface layer by the steel deformation
processing, low power consumption and no spatter, .

3) Welding technology for high-tensile steels and aluminum alloys with different materials
is becoming more important in order to make high-strength automobile body. The use of
friction-stir spot bonding with low energy consumption for welding of aluminum alloy and
steel prevents weak intermetallic compound formation, improves the mechanical properties
of welds, and greatly improves the crash safety and running performance of automobiles. It
is necessary to apply the technique of friction stirrup point bonding for high strength and
high humanization. Therefore, it is important to develop the technology that improves the
bonding performance of the friction stir spot bonding method and to secure the quality of
the joint.

4) By searching and analyzing academic information about automobile welding technology,

Korea showed 105 (8.5%) announcements following China (121, 12.8%), USA (111,
11.75%). However, if we look at the index level based on the number of citations as the ratio
of the average number of citations for a specific national publication to the average number
of citations for all technical literature in a particular technology field, 0.74, which is lower
than that of Canada (2.59), Japan (1.55), the United States (1.53), the United Kingdom (1.15)
and India (1.652). Therefore, it is requested to improve the quality of automobile welding
technology, improve the quality of welding equipment including automobiles, and to
announce a lot of high-quality technical papers in order to secure competitiveness and
superiority in overseas export market. It is necessary to strengthen the active support of the
country in order to promote the development of high-efficiency automobile welding
technology.
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review

This technical commentary is the outcome of the ReSEAT program, which is supported by
the Future Creation Science and Technology Promotion Fund and Lottery Fund.

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