Abstract
This paper will discuss the experience from high volume production conditions, but also the overall performance
automotive production with a specific emphasis on the of the body structure.
welding of press-hardened steels and the quality
Table 1. Nominal chemical composition the Aluminium-Silicon
assurance of these welds. Different solutions about how
coated USIBOR 1500P.
to solve weld brittleness at resistance spot welding will
be described; including advanced welding schedules but C Si Mn P S Cr Al Ti B
also tailored tempering of the hot-formed components 0.23 0.2 1.1 0.01 0.00 0.1 0.03 0.03 0.002
themselves. 4 4 6 1 4 9 6 9 4
One section will exclusively describe the comprehensive
quality assurance procedures for the structural laser
welds in crucial crash protective components of the 2. The Press-Hardening Process
company's latest car models. Laser welding showed to be
superior to other alternative joining methods regarding Press-hardening or hot-stamping and die quenching is a
the fulfillment of crash related tests in early development method to produce ultra high strength components for the
phases of these car programmes, however such a welding automotive industry. It has been used since the mid-
method puts specific requirements on both equipment but 80ies, and typical components produced by the press-
also on parts accuracy and assembly tolerances. hardening process are e.g. A- and B-pillar
reinforcements, floor sills, cantrails, side impact door
Keywords: Automotive car body structures, Press- beams and bumper beams. To enable the Boron-alloyed
hardened steels, Resistance spot welding, Laser beam steel material to be formed and further on cooled down
welding, Weld quality assurance to a fully martensitic structure, the material first has to be
heated up to its austenitization temperature at around
1. Introduction 880-950C. To achieve a fully martensitic structure, the
cooling rate must exceed 25-30C/s. The small amount
Environmental aspects have become extremely important of Boron is used to facilitate the quenching process,
when engineering new passenger cars in order to reduce wherefore the material often is referred to as Boron steel
fuel consumption and toxic emissions. One step is to in colloquial terms.
decrease the weight of the vehicle, which for the car The hot forming process is mainly divided into two
body structure means down-gauging the components and different approaches, the indirect and the direct one,
introduce more advanced high strength steels (AHSS) to where the direct process is the most commonly used
be able to maintain a high performance in terms of among the automotive OEMs (Original Equipment
crashworthiness, durability etc. Manufacturers). These two processes offer different
One such steel is the ultra high strength (UHS) press- advantages for the final application in terms of design
hardened and hot-formed Boron-alloyed steel. Apart versus cost, and available choices for surface protection.
from a unique process technology, when manufacturing Making the first forming step(s) by conventional cold
automotive components in this material, it also contains forming, the indirect process offers the possibility for
specific alloy elements in order to guarantee a high more complex geometries and undercut designs before
ultimate strength (Tab. 1). The drawback is that due to the shaped components are heated, transferred to the
the alloy content these components become more oven and finally tempered (Fig. 1). This means that two
difficult to weld, regardless which welding method used. sets of tools are necessary, one for pressing and one for
At various loading conditions, these welds also present a cooling. One advantage however, with this process is that
different behaviour to what is common for welds applied it offers the possibility to use a conventional zinc-based
in lower strength steel grades. Therefore, the introduction coating for cathodic corrosion protection.
of press-hardened body components not only affects the
production, whereas Volvo Cars purchase all Boron
alloyed parts from external suppliers.
Figure 9. The spot welding gun of X-type used for the trials, with
additional technical information above.
Therefore different pulse sequences were investigated in 5.2. The effects of two different welding pulse
order to increase the elongation values for spot welded sequences
joints, and with the objective to avoid partial plug or
The two weld schedules and their effects can be
interfacial failures [3].
described as follows:
5.1. Widening of the soft zone Post pulse type A: A shorter pause time and high energy
input during the post pulse is creating a large nugget
To achieve a full button pullout failure the soft zone in
diameter as well as a wide soft zone. If the current is
the heat-affected zone (HAZ) must be wide enough to be
further increased the risk for expulsion will increase and
able to undergo the amount of plastic deformation
an extended post pulse time will not increase the nugget
involved with the rotation described above when the spot
size. These parameters, short pause time and high current
weld is loaded. The soft zone is here defined as the area
in the second welding pulse, are believed to generate the
with hardness below 400 HV. The area of the soft zone is
highest possible energy absorption during tensile shear
believed to be increased when increasing the heat input.
testing, due to that 100% full button pullout fracture is
This can be done by using a second welding pulse. The
achieved.
first pulse would in this case be the welding pulse which
Post pulse type B: A longer pause time and less energy
creates the nugget. After a pause time, the second pulse
input during the post pulse is used in this case in order to
is triggered and it could either re-melt the nugget,
International Congress on Advances in Welding Science and Technology for
Construction, Energy and Transportation Systems (AWST - 2011)
24-25 October 2011, Antalya, Turkey
AWST-11/04
maintain the nugget diameter. A second soft zone is of the steel sheet material. In such a case it would be
created by the post pulse. The pause time is optimized to detrimental to widen the soft zone as described above,
position this soft zone adjacent to the soft zone from the because this will serve as an initiator for cracks
initial weld pulse, thereby forming a wider soft zone. propagating from the spot welds and through the metal in
This alternative is more time consuming and might the weld flange. One solution to prevent such behaviour
require a total welding cycle time of about 2 seconds. is to manufacture the press-hardened part according to
The two different approaches of post pulsing, as well as a the tailored tempering methodology. This means that
reference weld carried out by conventional single pulse some areas in the component are not tempered to its full
welding, were tested by tensile shear loading of 10 strength, something that could be achieved either by
samples of each version. The fracture mode, energy different heating/cooling conditions during the hot-
absorption, elongation, maximum load and button forming process, but also through a subsequent operation
diameter were recorded (see Table 2). after forming by local tempering of such areas [4].
Regarding spot welding it is preferable to have not fully
Table 2. Results from tensile shear testing of spot welds made by hardened weld flanges, which will help overcome both
using various pulse programmes. the problem with brittle weldment behavior, but also to
prevent crack initiations around the spot welds.
Maximu Energy Full
m load absorption button Button size
There are two main techniques to obtain such soft areas.
pullout
Reference 32 kN 25 J 20 % 9.1 mm
In the first one a two-parted oven is being used meaning
Post pulse A 37 kN 82 J 90 % 11.1 mm that in the beginning the whole sheet is heated to the
Post pulse B 30 kN 60 J 100 % 9.0 mm austanization temperature. Later on the sheet reaches the
area with the split part of the oven where one section is
still kept around 920C, whereas the other one has a
The most promising parameter sets were also tested lower temperature (Fig. 10). This means that when the
using high speed tensile shear testing. The test equipment sheet is taken from the oven and put into the forming
is designed to perform tensile tests with a maximum tool, only a limited area will have the high
speed of 20 m/s, and the test specimen is positioned time/temperature cooling rate and result in the typical
between two grippers in the machine. A catapult, driven ultimate strength of around 1,500 MPa. The remaining
by an MTS hydraulic test machine, accelerates a drop part of the component will be much softer, and the
weight which hits the lower grip, initiating the test strength in this area can be tailored to in practice any
procedure. The maximum speed of the piston in the MTS strength wanted, but in general typical strength values are
machine is 1 m/s which, after a specially designed around 600 MPa.
hydraulic gear, generates a speed of 20 m/s for the
catapult. The improvements in ductility in terms of
energy absorption during regular tensile shear testing
created by the post pulses are also exhibited during high
speed testing.
The introduction of specific welding schedules and
optimized welding parameters have shown to be
successful for the enlargement of the softer HAZ around
the spot welds, which improves the ductility at spot weld
Figure 10. The principle of the two-parted oven in order to manufacture
failure and thereby the energy absorption. In general this
press-hardened components with locally softer areas. When lowering the
leads to longer welding cycles, which however might be oven temperature it will be possible to reformate the austenite in the
acceptable for a limited number of spot welds, which are ferritic microstructure.
crucial for the component behaviour in that respect that
they need to present a more ductile behavior when The other technique to achieve these uneven cooling
loaded. conditions are more sophisticated and therefore also
more expensive, but allows more than just one softer
area. Here the sheets are heated in the regular oven, but
6. Think Outside the Box Tailored the cooling channels in the forming tool are positioned at
Tempering for Increased Spot Weld different distances from the tool surface (Fig. 11).
Ductility Cooling channels close to the surface means a more rapid
cooling compared to those areas where the channels are
In the previous chapter it was described how to improve put deeper into the tool body.
the energy absorption at spot weld failure in press- Another advantage with this method is that the transition
hardened components, but for most applications the zone between the fully hardened area and the softer one
dimensioning criteria is that the weld shall stay intact. is very narrow, between 10-30 mm, whereas the
The spot welded joint shall guarantee a good backing and technique with the split oven normally results in a 100
allow the body components to deform just by plasticizing mm wide transition zone.
the desired behaviour of no spot weld failure indicating
that this technology seems to be very robust. The
recommendation is however to specify the weld flanges
to a hardness of 300 Hv (Fig. 13 and 14).
Figure 14. Drop weight testing of beams with soft flanges (300 Hv)
Figure 12. Drop weight testing of beams with fully hardened hat in the hat profiles; impact velocity 9.5 m/sec.
profiles; impact velocity 9.0 m/sec.
Another observation made was that if two press-hardened
The beams with the soft weld flanges could withstand parts are spot welded together it is important that both of
much larger deformations while the spot welds still them are manufactured with soft flanges, otherwise the
remained intact. Conventionally hardened Boron steel positive effects shown above will be lost (Fig. 15).
presents a Vickers hardness of more than 400 Hv. In the
tests, flanges softened to between 200-350 Hv all gave
International Congress on Advances in Welding Science and Technology for
Construction, Energy and Transportation Systems (AWST - 2011)
24-25 October 2011, Antalya, Turkey
AWST-11/04
Figure 15. Drop weight testing of beams with soft flanges (200 Hv)
in the hat profiles but fully hardened lids; impact velocity 7.9
m/sec.
Figure 17. A purpose developed tool for post-checking of laser
7. Extensive Quality Assurance Procedures weld quality by ultrasonic inspection.
References
[1] Fermr, M., Jergeus, J., Johansson, R., Larsson, J. K., "Hot-
Formed Steel in Car Body Structures", International Automotive
Body Conference (IABC), Munich, Germany, September 22-23,
2010
[2] Larsson, J.K., Lundgren, J, Asbjrnsson, E. and Andersson, H.,
"Extensive Introduction of Ultra High Strength Steels sets New
Standards for Welding in the Body Shop", Proceedings 61st
Annual Assembly of the International Institute of Welding (IIW),
Joint Workshop Commission III & SC-Auto, Graz, Austria, July
6-11, 2008