Jim Dolfi Chairman A/SP JOINING TEAM

Transcription

1 Jim Dolfi Chairman T. D. Mackie ASP Project Manager Auto/Steel Partnership A/SP JOINING TEAM Great Designs In Steel Seminar February 19, 2003 (1) 5/12/2011

2 A/SP JOINING TEAM A/SP Welding The team consists of 21 members representing North American Steel and Automotive producers. DCX, Ford, GM, Bethlehem Steel, Dofasco, Ispat Inland, National, U.S.Steel We are an enabler team supporting other A/SP activities- Fatigue, Light Weight Front Structures, Special Process Development ( EWI ) (2) 5/12/2011

3 Project Team R. Bodner Bethlehem Steel M. Gentilcore Bethlehem Steel S. Kelley Bethlehem Steel A. P. Lee Dofasco, Inc. W. A. Peterson Edison Welding Institute P. Coduti Ispat Inland Inc. S. Lalam Ispat Inland B. Yan Ispat Inland L. Rado Stelco Inc. C. Jiang U.S. Steel Group M. Tumuluru U.S. Steel Group H. Zhang University of Toledo D. Biernat DaimlerChrysler Corp. E. Pakalnins DaimlerChrysler Corp. T. Morrissett DaimlerChrysler Corp. T. Brusadin Ford Motor Company T. Coon Ford Motor Company A. Wexler Ford Motor Company J. C. Bohr General Motors Corp. C. Horvath General Motors Corp A. C. Pollard General Motors Corp. A. Turley General Motors Corp. R. J. Roberts General Motors Corp. (3) 5/12/2011

4 Problem Statement European counterparts are aggressively incorporating AHSS into their designs. Euro standards are being developed. Need performance information and quality acceptance standards that will be uniform throughout the North American industry. (4) 5/12/2011

5 Welding Open Issues A/SP Welding No real-world data No published laboratory reference strength and performance data No material acceptance standards for welding No published in-process weld test standard (5) 5/12/2011

6 Welding Open Issues A/SP Welding Present standards based on low strength materials for resistance spot welds. Pulling buttons and distortion of metal Advanced High Strength Steel (AHSS) requires a new definition of a good weld. The concept of usefulness and suitability relative to intended use will dominate our focus for acceptance standards. (6) 5/12/2011

7 Approach Develop weld lobe for commercially viable welding schedules correlate to strength Explore physical characteristics of welded and weld-bonded joints tensile, fatigue, impact Develop quality acceptance guides for welded and weld-bonded joints. (7) 5/12/2011

8 Specific Deliverables Provide test criteria for acceptance of materials Publish test guidelines for AHSS Destructive tests - appearance standards Non-destructive test recommendations A/SP Welding (8) 5/12/2011

9 Progress Weld Lobe Development completed on DP, RA, MS. TRIP Steels in process. 13 material/coating combinations (see material list) Commercial application oriented using automotive production welding guns.(two types) (9) 5/12/2011

10 Materials Evaluated MATL BARE Galvanneal Galvanized HSLA 340 (baseline) X X DP 600 X X DP 800 X DP 980 X RA 830 X MS 1300 X TRIP 600 X TRIP 800 X (10) 5/12/2011

11 Parameter Development- Example A/SP Welding (11) 5/12/2011

12 Peel and Cross Sections A/SP Welding DP-600 Welds at 22 cycles, 1500 pounds force (12) 5/12/2011

13 Peel Test MS1300 Weld Profile of MS1300 Test , C Gun, High Tap Setting, WT: 16 Cycle SWS - #16 (13) 5/12/2011

14 Instrument equipment - test results (14) 5/12/2011

15 Equipment setup qualification Production welding guns Characteristics recorded Force build up Latent holding (clamping/ response) time Impact setup and sample qualification Some impact comparisons (15) 5/12/2011

16 Force sensor Voltage sensor Displ. sensor (16) 5/12/2011

17 8 Force stabilizing time 6 Δt(D-start) Data used for curve fitting Δt(F-start) Force Current Displacement Squeeze time Δt(F-end) -6-8 Time (ms) (17) 5/12/2011

18 Setup and measured squeeze time for C-gun I. Setup (cyc) Measured (ms) Measured (cyc) Stable (ms) Stable (cyc) Diff. in squeeze (ms) Diff. in squeeze (cyc) (18) 5/12/2011

19 Setup and measured hold time for C-gun I Setup (cyc) Δt (F-start, cyc) Δt (F-end, cyc) Δt (D-start, cyc) (19) 5/12/2011

20 Setup and measured squeeze time for C-gun II Setup (cyc) Measured (ms) Measured (cyc) Stable (ms) Stable (cyc) Diff. in squeeze (ms) Diff. in squeeze (cyc) (20) 5/12/2011

21 Setup and measured hold time for C-gun II Setup (cyc) Δt (F-start, cyc) Δt (F-end, cyc) Δt (D-start, cyc) (21) 5/12/2011

22 Impact Tester (22) 5/12/2011

23 Impact Specimen (23) 5/12/2011

24 IMPACT TEST RESULTS FOR MATERIAL 003A (DP600 GA) A/SP Welding Sample # Impact Energy (J) Nugget Width (mm) Type of Failure 3-29/SSD Shear failure 3-30/SSD Shear failure 3-31/SSD Shear failure 3-33/SSD Shear failure 3-34/SSD Shear failure 3-56/LFD Button pull-out 3-57/LFD Button pull-out 3-58/LFD Button pull-out 3-60/LFD Button pull-out 3-61/LFD Button pull-out (24) 5/12/2011

25 Impact Test - Comparison Impact Energy (J) Nugget Width (mm) SSD LFD SFD LSD DQ_0.8-3mm DP600 DQ Steel (25) 5/12/2011

26 Value A/SP Welding Supports design and crash performance assumptions. Develops industry acceptance for AHSS weld separation characteristics. Reduces experimental costs & launch timing (26) 5/12/2011

27 Others Working on AHSS EWI- weld process modification - tempering Battelle +NWNL testing design for CAE multimaterials, etc. INEEL- (Idaho National Engineering and Environmental Laboratory) - Hybrid welding investigating laser assisted MIG single side welding Ford N.A, Ford Europe, Honda, Nissan, Toyota, Volvo, others (27) 5/12/2011

28 Focus Project 2003 New Light Weight Front Structure Project. Focus on 12 material combinations. Various gage combinations. Resistance spot welding (RSW). (28) 5/12/2011

29 Destructive test for resistance weld inspection of side rail (29) 5/12/2011

30 Destructive test for resistance weld inspection of side rail (30) 5/12/2011

31 Questions (31) 5/12/2011