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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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A/SP Welding
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