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A/SP Welding

Jim Dolfi ChairmanT. D. Mackie – ASP Project Manager

Auto/Steel Partnership –

A/SP JOINING TEAMGreat Designs In Steel Seminar

February 19, 2003

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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 )

A/SP JOINING TEAM

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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.

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A/SP Welding

• 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.

Problem Statement

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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

Welding Open Issues

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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.

Welding Open Issues

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A/SP Welding

• 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.

Approach

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A/SP Welding

• Provide test criteria for acceptance of materials

• Publish test guidelines for AHSS– Destructive tests - appearance standards– Non-destructive test recommendations

Specific Deliverables

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A/SP Welding

• 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)

Progress

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A/SP Welding

XTRIP 800

XTRIP 600

XMS 1300

XRA 830

XDP 980

XDP 800

XXDP 600

XXHSLA 340 (baseline)

GalvanizedGalvannealBAREMATL

Materials Evaluated

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A/SP Welding

Parameter Development- Example

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A/SP Welding

DP-600 Welds at 22 cycles, 1500 pounds force

Peel and Cross Sections

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A/SP Welding

Weld Profile of MS1300 Test 2-11-1,

C Gun, High Tap Setting, WT: 16 Cycle SWS - #16

Peel Test – MS1300

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A/SP Welding

Instrument equipment - test results

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A/SP Welding

(15) 5/12/2011

• Equipment setup qualification – Production welding guns– Characteristics recorded

• Force build up• Latent holding (clamping/ response) time

– Impact setup and sample qualification– Some impact comparisons

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Force sensor Voltage sensor

Displ. sensor

A/SP Welding

(16) 5/12/2011

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-8

-6

-4

-2

0

2

4

6

8

0 1000 2000 3000 4000 5000 6000

Data used for curve fitting

Time (ms)

Squeeze time

Force stabilizing time

Δt(D-start)

Δt(F-start)

Δt(F-end)

Force

Current

Displacement

A/SP Welding

(17) 5/12/2011

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Setup (cyc)

Measured (ms)

Measured (cyc)

Stable (ms)

Stable (cyc)

Diff. in squeeze (ms)

Diff. in squeeze (cyc)

35 518.0 31.1 486.8 29.2 65.10 3.9

35 519.0 31.1 502.0 30.1 64.10 3.8

37 548.0 32.9 483.0 29.0 68.42 4.1

38 559.0 33.6 483.0 29.0 74.08 4.4

39 572.5 34.4 477.0 28.6 77.24 4.6

39 579.0 34.8 440.0 26.4 70.74 4.2

99 1573.0 94.4 491.0 29.5 76.34 4.6

Setup and measured squeeze time for C-gun I.

A/SP Welding

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Setup (cyc)Δt

(F-start, cyc)Δt

(F-end, cyc)Δt

(D-start, cyc)

0 3.12 6.72 6.88

1 2.60 5.95 6.35

9 2.29 5.64 5.96

9 2.32 5.56 5.83

12 2.26 5.62 5.96

40 2.32 5.22 5.70

50 2.69 5.55 6.22

100 2.34 6.08 6.12

150 2.52 6.66 6.24

180 3.66 7.92 7.38

198 2.46 6.78 6.12

Setup and measured hold time for C-gun I

A/SP Welding

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Setup (cyc)

Measured (ms)

Measured (cyc)

Stable (ms)

Stable (cyc)

Diff. in squeeze (ms)

Diff. in squeeze (cyc)

35 505.8 30.3 320.7 19.2 -77.30 -4.6

40 590.3 35.4 333.6 20.0 -76.10 -4.6

45 674.3 40.5 341.1 20.5 -75.40 -4.5

50 755.6 45.3 335.5 20.1 -77.40 -4.6

60 920.6 55.2 335.5 20.1 -79.00 -4.7

70 1091.0 65.5 362.6 21.8 -75.20 -4.5

80 1263.0 75.8 361.2 21.7 -69.80 -4.2

90 1422.0 85.3 357.2 21.5 -77.40 -4.6

99 1573.5 94.4 343.4 20.7 -75.84 -4.6

Setup and measured squeeze time for C-gun II

A/SP Welding

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Setup (cyc)Δt

(F-start, cyc)Δt

(F-end, cyc)Δt

(D-start, cyc)

1 2.1 4.7 5.5

10 1.4 4.7 4.9

20 1.4 4.6 5.1

30 1.5 4.7 5.1

40 1.5 4.6 5.2

60 1.3 4.7 5.3

80 1.5 4.8 5.2

99 1.6 4.9 5.3

Setup and measured hold time for C-gun II

A/SP Welding

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A/SP Welding

Impact Tester

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Impact Specimen

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Button pull-out6.418383.63-61/LFD6

Button pull-out7.12389.73-60/LFD5

Button pull-out7.406403.63-58/LFD3

Button pull-out7.437398.43-57/LFD2

Button pull-out6.758398.43-56/LFD1

Shear failure 6.4332.93-34/SSD6

Shear failure 5.992282.83-33/SSD5

Shear failure 5.785312.063-31/SSD3

Shear failure 6.44332.33-30/SSD2

Shear failure5.388313.423-29/SSD1

Type of FailureNugget Width (mm)Impact Energy (J)Sample #

IMPACT TEST RESULTS FOR MATERIAL 003A (DP600 GA)

A/SP Welding

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DP600

DQ Steel

A/SP WeldingImpact Test - Comparison

0.0

100.0

200.0

300.0

400.0

500.0

3.50 4.50 5.50 6.50 7.50

Nugget Width (mm)

Impa

ct E

nerg

y (J

)

SSD LFD SFD LSD DQ_0.8-3mm

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A/SP Welding

• Supports design and crash performance assumptions.

• Develops industry acceptance for AHSS weld separation characteristics.

• Reduces experimental costs & launch timing

Value

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A/SP Welding

• EWI- weld process modification - tempering • Battelle +NWNL testing design for CAE multi-

materials, 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

Others Working on AHSS

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A/SP Welding

Focus Project 2003• New Light Weight Front Structure Project.• Focus on 12 material combinations.

– Various gage combinations.• Resistance spot welding (RSW).

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A/SP Welding

Destructive test for resistance weld inspection of side rail

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A/SP Welding

Destructive test for resistance weld inspection of side rail

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A/SP Welding

Questions