MECHANICAL PROPERTIES OF ALUMINUM WELDS FOR AUTOMOTIVE STRUCTURAL APPLICATIONS

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1 MECHANICAL PROPERTIES OF ALUMINUM WELDS FOR AUTOMOTIVE STRUCTURAL APPLICATIONS Jennifer Hyde Supervisor: Dr. McDermid MATLS 701 Seminar Feb 17, 2012

2 Outline 2 Motivation Background/Literature Review Project Outline Experimental Procedure Preliminary Results Summary Future Work Acknowledgements

3 Motivation 3 Increased use of aluminum for light weighting of vehicles due to its relatively high strength to weight ratio The Aluminum Association. Aluminum in Transportation (Accessed Feb 2012)

4 Background: GMAW 4 Gas Metal Arc Welding (GMAW) two metals are joined by heating from an arc between the metal and continuously fed filler wire electrode. This process uses a shielding gas (argon or helium) to protect the molten weld pool from oxidation. Popular welding technique for Al alloys Results in 3 distinct regions: weld; HAZ; base material S. Kou, Welding Metallurgy, 2 nd ed., Hoboken, New Jersey: John Wiley and Sons Inc., Microhardness Profile

5 Mechanical Properties of Welds 5 Problem One of the easiest ways to get the mechanical properties of a material is from uniaxial tensile testing This is a problem for welds since the mechanical properties of welded samples from tensile testing is limited to the instability of the weakest region of the welded joint How can we measure mechanical properties of each region of the weld?

6 Mechanical Properties of Welds 6 Solution: 1) Gleeble/thermal treatment apparatus costly time consuming Sensitive to variation of welding conditions 2) novel shear test; tensile testing combined with DIC modified ASTM B831 shear samples Mechanical behaviour up to large strains from shear test Gleeble 3180 Dynamic Systems Inc. (Accessed Feb 2012)

7 Modified Shear Samples 7 Machined using wire and sink EDM (Electric Discharge Machining) Pulled in a tensile testing machine

8 8 Digital Image Correlation (DIC): ARAMIS System Spray paint test sample to get random speckle pattern and using a CCD camera to take snapshots during testing. ARAMIS calculates displacement between each snapshot and a reference picture to get strain able to calculate strain within the shear zone and also localized strain during tensile test (i.e. strain in weld; HAZ and BM regions) Relate stress to strain by time. Facets in the undeformed and deformed state (Aramis v5.3 manual, GOM mbh, Braunschweig, Germany (2004))

9 Shear Test: Kang et al [1] 9 These modified samples first used on DC and CC 5754 sheet materials This geometry prevents end rotation of the shear zone as compared to the ASTM B831 samples Compared shear test to uniaxial tension tests They concluded that effective stress and strain for shear test only matched tensile results when using the Barlat-Lian yield function which incorporates planar anisotropy. [1] J. Kang et al, Journal of Engineering Materials and Technology, , 2008.

10 10 Yield Functions: For simple shear: Von Mises: Barlat-Lian: M=8 for FCC materials

11 Barlat-Lian Yield Function: r= plastic strain ratio Equal to 1 for an isotropic material 11

12 Effective stress, MPa [2] Kang J, McDermid, J.R., Bruhis, M., SAE Paper, (2012) Resistance Spot Welds 12 More recently this modified shear sample geometry has been extended to the investigation of AA5754-O RSW welds and AA6022 T4 RSW welds [2] Used Barlat-Lian equation on base materials to match tensile and shear effective stress-strain curves AA5754 Uniaxial tension AA6022-T4 Uniaxial tension AA5754 von Mises AA6022-T4 von Mises AA5754 Barlat-Lian AA6022-T4 Barlat-Lian Effective strain Uniaxial Tension and Shear effective stressstrain curves for the base materials: 5754 and 6022 T4

13 True stress, MPa RSW welds graph s = e R² = 0.99 s= e R 2 = s= e R 2 = s= e R 2 = AA5754-O T4 Case 8 Tensile Case 6 Tensile Case 8 Shear Case 6 Shear Case 6 Shear True strain Case 6: RSW 6022 T4 Case 8: RSW 5754-O

14 Research Objective 14 GM currently cannot accurately predict the failure location of gas metal arc welded aluminum structural components This research meant to provide the necessary mechanical property information for both the weld region and the HAZ so that their FE models are accurate

15 Project Outline 15 Weld Cases Case Material 1 Thickness Material 2 Thickness Weld wire 1 Aural 2 T7 3mm 6063 T4 4mm Aural 2 T7 3mm 6063 T6 4mm O 3mm 6063 T4 4mm O 3mm 6063 T6 4mm O 3mm 5754-O 3mm 4043 These are in a butt joint configuration for testing purposes Also testing base materials mechanical properties

16 Base Materials 16 AA 5754-O Main alloying element is Mg Non-heat treatable O temper fully annealed AA 6063 T4 and T6 Mg and Si are the main alloying elements heat treatable strengthening from metastable β'' precipitates (Mg 2 Si) T4 naturally aged; T6 optimally aged Aural-2 T7 Mg, Si and Mn are the main alloying elements die cast T7 stabilized

17 Weld Configuration 17 (A) (B) RD RD RD RD Cases 1 and 2 (C) Case 1 RD RD 5754 Cases 3 and 4

18 Paint Bake Cycle 18 Al alloys used for automotive applications undergo a paint bake cycle which may have an effect on the material s properties given that many Al alloys are artificially aged around this temperature Baking Conditions: 180 C for 20 mins then air cool, reheat to 180 C for 30 mins All base material samples with the exception of 5754-O tested in this condition All welds were tested in this condition which is meant to simulate the paint bake cycle.

19 Experimental Procedure 19 Mechanical Testing Tensile Tests Base Materials Welds Shear Tests Base Materials Welds HAZ Locating the HAZ to place shear zones Microhardness Profiles Microstructure OM (Electrolytic etching using Barker s and viewing under cross polarized light) Fractography SEM on fracture surfaces

20 Tensile Tests 20 Base Material: Tensile samples cut parallel (0 ), 45 and 90 to RD Extensometer as well as ARAMIS (DIC) for strain measurements Strain rate: 6.7 x 10-4 /s Welds: Weld in middle of tensile sample ARAMIS used for strain measurements Strain rate: 2.8 x 10-4 /s 10 KN Instron Testing Machine

21 6063 T4 Stress-Strain Curves T4 AR 6063 T4 B

22 Tensile Test of Welds: 1A:6063 T4 and Aural-2 T7 22 1A AR 1A B

23 Shear Test samples: welds 23 Welded Plate Shear Sample

24 24 Locating the HAZ for Shear Test

25 Shear Tests- Base Materials 25 Same machine as tensile test Testing base material samples parallel and transverse to RD (0 and 90 ) Strain rate: 2.6 x 10-3 /s Using Aramis/DIC to directly measure shear angle at each stage Shear stress and strain converted to effective stress and strain using von Mises criterion

26 Aural-2 T7 Shear Curves 26

27 Summary 27 Tensile tests on base materials were completed with general agreement between samples and some differences in sample orientation (i.e. 0, 45, 90 wrt RD) Tensile test on welds using ARAMIS (DIC) were able to show strain locally; in both the weld region and region where fracture occurs It has been found that only 6063 T6 has a noticeable HAZ Shear tests on base materials were completed. The effective stress-strain curves show differences for shear and tension.

28 Future Work 28 Locate the fusion zone of 6063 T4, 5754-O, Aural 2 T7 and then place the shear zone beside this region Shear tests on welds and HAZ SEM of fracture surfaces Possibly use Barlat-Lian yield function to incorporate material anisotropy

29 Acknowledgements 29 General Motors of Canada Ltd for financial support and experimental materials Initiative for Automotive Manufacturing Innovation (IAMI) for financial support Supervisor: Dr. McDermid Technical assistance: Jidong Kang; Mike Bruhis; and Doug Culley

30 QUESTIONS?

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