Weldability of AHSS. Dr. Sree Harsha Lalam, CWEng. Mittal Steel Company. w w w. a u t o s t e e l. o r g

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1 Weldability of AHSS Dr. Sree Harsha Lalam, CWEng. Mittal Steel Company

2 Overview AHS Steels & Weld Joint Spot welding Spot Welding Window Effect of Coating AC vs. Mid-Frequency DC Weldmetal Hardness Mechanical Properties Fracture Mode Effect of Paint Baking Impact Testing at -20 o C and 20 o C Arc welding Laser welding Induction welding Summary

3 Summary The optimum resistance welding parameters of AHSS are different from the mild steel parameters. AHSS can be welded using Resistance, Arc, Laser, Induction welding processes.

4 Effect of cooling rate in a steel Ferrite Ac 3 Ac 1 Alloying elements effect Temperature 1% Bainite Pearlite 1 Martensite Time 2 3

5 Weld Microstructure Ferrite Ferrite + Martensite Martensite All weld joints including AHSS, will have similar microstructures. HSLA350 Arc weld The hardness of each region depends on the alloying elements.

6 Chemical composition of steels C (wt%) Mn (wt%) Si (wt%) S (wt%) P (wt%) DQSK CR HSLA350 CR DP500 CR DP600 CR DiForm140T CR (DP965) M220 CR (M1500) TRIP Steels : High C, Mn, Al/Si, etc.

7 SPOT WELDING

8 Mild Steel Influencing parameters on weldability AHSS Alloying Elements Low High Microstructure Simple Ferrite/DP/Martensite Resistivity Lower Higher Current Range Higher Lower Electrode Life Longer Shorter Fracture Location in HAZ in HAZ/ Nugget / Interface Electrode Force Lower Higher Current Higher Lower Using same welding parameters

9 DP500 EG DQSK EG BH210 EG DP600 CR DP600 HDG Material (Min. Button = 4 x t) HSLA 350 GA M900 CR HFT440 GA TRIP590 CR DP600 CR DiForm 140T (DP965) CR HSLA350 HDG Similar current range Gauge ( mm) Current range (ka) With optimum welding parameters the AHSS will produce current range similar to mild steel.

10 Effect of coating on weld time and current TRIP mm, Nugget Size 6.67mm TRIP590 CR TRIP590 GA Current (ka) CR GA Weld Time (Cycles, 60 Hz) Similar to mild steel the weld time, current depends on coating

11 Effect of current mode DP600 CR 1.4 mm DP965 CR 2.0 mm Button size (mm) MFDC AC Min. Button Size Elec. Force: 3.8 kn DP600 CR 1.4 mm Button Size (mm) DiForm140T(DP965) 2.0 mm, Dome Electrode MFDC AC Min. Button AC MFDC Current (ka) Current (ka) Mid-Frequency DC will increase the current range

12 Weld metal hardness depends on base material chemical composition, not on weld time. Weld metal hardness depends on steel chemical composition Vicker's Hardness (VHN) HSLA DP600HDG 1.4mm, 12 cycles DP600HDG 1.4mm, 26 cycles HSL350HDG 1.9mm, 28 cycles TRIP590GA 1.6 mm, 28 cycles TRIP590CR 1.6 mm, 18 cycles Base Material Indentation Distance (mm) Heat Affected Zone 191 HV Weld 355 HV 436 HV 469 HV Metal

13 Weld Time Vs Load Load (kn) TRIP590 CR 1.6 mm, Nugget Size 6.67 mm Weld Time (cycles, 60 Hz) TS- Tension Shear, CT-Cross Tension TRIP mm TS CT 28 Load (kn) TRIP590 GA 1.6 mm, nugget size 6.67 mm p 28 Weld Time (cycles, 60 Hz) TS CT 30 Optimum weld time depends on the type of coating Pulsing has little effect of tension shear load.

14 Below min. button Size Fracture mode may not be an indication of weldability Partial Interfacial Fracture Cross Tension Button Pullout 2258 lbf 2117 lbf DP965 CR 2267 lbf Tension Shear

15 Paint Baking improves the ductility Cycles, Flat Sample, Gray:As-welded, Pink: Baked DP590 GA, 1.1 mm 16 Cycles, Flat Sample, Gray:As-welded, Pink: Baked CT (lbf) Energy (J) Current (ka) Current (ka) Paint baking increases the cross tension load. Paint baking improves the weld ductility and energy.

16 Decreased hardness in baked weld 500 DP590 GA, 1.1 mm Vickers Hardness (VHN) Paint Baked, 350F 30min As-welded Distance (in) Paint baking decreases the coarse grain HAZ hardness and improves the fracture mode.

17 Shear Impact testing samples Teflon Thermocouple Sample at -20 o C before testing

18 AHSS higher impact load Impact Load (lbf) HSLA350 DP600 DiForm140T DP965 DP600 HSLA350 Cold Rolled 1.4 mm Button Size (mm) AHSS has higher impact load bearing capacity

19 Low-Temperature impact load Impact Energy (J) C -20C Spot weld performance under impact load depends on button size Button Size (mm) Shear Mixed Fracture Mode Button Button Shear Double Button 68.5 J 51.0 J J

20 ARC WELDING

21 Arc welding of AHSS mm Filler Wire: ER70-S3

22 AHSS has higher arc weld load 800 DP Weld Strength (MPa) M1300 DP600 HSLA Elongation (mm)

23 LASER WELDING Source: M. Gallagher, et. al., "Laser Welding of AHSS", to be presented at the International Automotive Body Congress (IABC), Sep., 2005.

24 Laser welding of AHSS WELD JOINT 30mm 100mm bottom shim top shim 500mm 25mm TRUMPF 4.5 kw Nd:YAG laser Power used: 3.8 kw Focal distance : 200mm No Purging Gas Shims : (0.1mm) Location of Shims: 1.5 long with 1.5 spacing between shims

25 Laser weld: Effect of penetration 90 Penetration (%) DP /2.0 DP / DP /1.2 M /1.5 HSLA / Weld Speed m/min

26 Laser weld: Failure locations Interfacial Failure HAZ Failure Base Metal Failure Interfacial failure usually occurs when penetration/weld width is small When HAZ failure occurs, almost always through bottom sheet. Weld rotation occurs

27 Effect of penetration on load 6000 DP600 2/ Load (lbs) DP /1.2 HSLA 1.9/1.9 M /1.5 DP600 2/2 DP /1.2 HSLA /1.9 M / % Penetration

28 Strength of laser weld Failed in Base material Stress (MPa) DP /1.2 DP /2.0 HSLA 1.9/1.9 M900- DP /2.0 DP600- M /1.5 Laser weld strength increases with base material strength

29 Summary AHSS need higher electrode force and optimized weld schedule. AHSS welds have higher load bearing capacity than mild steels. Paint baking increases the weld ductility. AHSS has higher impact load bearing capacity. Weld strength depends on the alloying elements and base material strength. The maximum strength in laser lap weld joints can be achieved at ~40% penetration.

30 Summary The optimum resistance welding parameters of AHSS are different from the mild steel parameters. AHSS can be welded using Resistance, Arc, Laser, Induction welding processes. Thank you

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