Abstract
This study concerned laser welding replacing the traditional bolted connection of the ring gear and differential case in the power train of the automobile. Laser welding is necessary to reduce weight and manufacturing cost, since the bolted connection method requires additional parts and space. In the differential gear, however, it is difficult to control the welding processes because cast iron and carburized steel contain high carbon content. To solve these welding problems, laser welding using Ni-base filler metal was used in this work. The results of welding with Ni-base filler metal satisfied the torsional stiffness and durability, but compared to the bolted connection method, noise and hardness problems occurred. Therefore, to solve these problems, penetration depth was decrease from 5mm to 4mm and the carburized layer of the ring gear was cut with 1mm. As well, numerical method was used to evaluate welding deformation, torsional stiffness and fatigue.
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This paper was recommended for publication in revised form by Editor Sung-Lim Ko
Jiyoung Yu received his B.S. degree in Mechanical Engineering from Hanyang University, Korea, in 2007. He is currently in unified course of the M.S. and the Ph.D in Mechanical Engineering, Hanyang University, Korea. He is researching about development of resistance spot welding system for advanced high strength steel.
Taikmin Jung received the B.S. degree and M.S. degree in Mechanical Engineering from Hanyang University, Korea, in 2007 and 2010, respectively. He is currently a researcher in Hyundai Heavy Industries. His research interests are heat transfer and thermo-mechanical analysis for laser and spot welding.
Sulae Kim received B.S. degree in Mechanical Engineering from Suwon University, Korea, in 1997 and M.S. degree in Mechanical Engineering from Hanyang University, Korea, in 2001. He has worked for Hyundai-Dymos in Hyundai Motors Group as a principal research engineer from 2003 to 2011. His research interests are axle and welding design of 4 wheel drive mechanical system on an automotive.
Sehun Rhee received the B.S. degree in Mechanical Engineering from Hanyang University, Korea, in 1979, M.S. degree in Mechanical Engineering Design from Seoul National University, Korea, in 1981, and Ph.D degree in Mechanical Engineering from University of Michigan, USA, in 1990. He worked as a researcher in LG R&D Center from 1982 to 1983 and as a senior researcher in KITECH from 1991 to 1994. He has taught and researched at Mechanical Engineering, Hanyang University, Korea, since 1994. His research interests are focused on resistance spot welding and laser welding monitoring system.
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Yu, J., Jung, T., Kim, S. et al. Laser welding of cast iron and carburized steel for differential gear. J Mech Sci Technol 25, 2887–2893 (2011). https://doi.org/10.1007/s12206-011-0809-x
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DOI: https://doi.org/10.1007/s12206-011-0809-x