Advanced
High-Strength Steel
Weld-Performance
Study for Autobody
Structural Components
An A/SP Joining Technologies
Committee Report
rc welding commonly is used in the
A manufacture of automotive struc-
tures. Due to the recent increase in
the use of advanced high-strength steels
(AHSS) in automotive designs, the A/SP
(Auto/Steel Partnership) Joining Tech-
nologies Committee decided to evaluate
the application of arc-welding process-
es for joining of AHSS. Specifically, the
project analyzed the application of gas-
metal-arc welding (GMAW), laser weld-
ing and hybrid welds made in several
combinations for use in AHSS auto-
body structural components.
Scope of Work
The project establishes suitable weld-
ing parameters for AHSS material iter-
Welding processes performed by RoMan
Engineering Services, Madison Heights,
MI, and supervised by the Auto/Steel
Partnership Joining Project.
40 METALFORMING / FEBRUARY 2007
ations (DP 600, DP 780, DP 800, DP 980 nominal material grades and coatings
and HSLA 350). Material section thick-
nesses ranged from 1.0 to 3.4 mm, weld-
ed using five arc-welding processes:
evaluated. All material grades are
expressed as ultimate tensile strength
(UTS) in MPa except for HSLA 350,
G M AW - p u l s e / A C ,
G M AW - p u l s e / D C ,
hybrid laser-GMAW,
Table1Material Grade, Gauge and Coating
laser and laser-plasma. Material Grade Purchased Gauge (mm) Coating Designation
Special consideration
was given to the accept- HSLA 350 (y) 3.2 None
ance criteria for the pro- HSLA 350 (Y) 1.38 GI (HDG)
jects welds. The stan-
dards of the three OEMs DP 600 3.4 None
were reviewed and a
DP 600 1.15 GI (HDG)
derivative acceptance
standard was established DP 780 1.17 GA
for the study. Results of
DP 780 1.87 GA
the investigation include
hardness/metallograph- DP 800 1 GA
ic, impact, and yield/ten-
sile properties of the DP 980 1.18 GA
resulting weldments. GA-galvanneal, GI-HDG (hot-dip galvanized)
2 2
Table 1 provides the Coating thickness: 40g/m for galvanneal, 60g/m for GI
www.metalformingmagazine.com
 Table 2Processes
purchased based on yield strength.
Process Process Detail
Materials were supplied to the test facil-
ities from A/SP steel partners sample GMAW GMAW-pulsed DC
inventory. (Tables published elsewhere
may show values slightly different that GMAW GMAW-pulsed AC
the nominal values shown in Table 1.) GMAWlaser assisted Hybrid YAG laser/GMAW-pulsed DC
The project aimed to, using the five
single-sided weld process variations, Laser YAG laser
determine suitable welding parameters Laserplasma assisted Hybrid YAG laser/plasma
for the supplied AHSS materials, and to
test a specified number of micro-hard-
ness/metallographic, impact and tensile-
shear sample weldments. The process-
m

37.8 mm
es and equipment selected represent 6m
45.
60
conventional robotically applied body-
shop welding practices as well as
advanced processes that potentially
could be used for single-side welding of 50 mm
the selected materials (see Table 2). 125 mm
200 mm
Sample Design
Samples of material were construct- Fig. 1Side view of typical impact test sample. Stock is 75 mm wide,
ed to the dimensions shown in Fig. 1, bend radius 6.5 mm.
with the welds centered between the
edges of the sample and robot travel of Table 3Quality Requirements for SWSG AHSS Welding
25 mm total. This produced a weld with
Criterion Source Document Derivative SWSG Requirement
start and stop characteristics to be
included in all tensile shear and impact GM
testing. (Weld length was limited to 25 mm Cross-section25 percent limit
Porosity - internal
of total area
to allow use of existing impact-test GM 4490M, 1991
equipment from previous A/SP weld
GM
tests.) Porosity - surface <25 percent
Impact samples were fabricated from GM 4490M, 1991
blanks 75 mm wide; bend radius for the
Weld length A/SP SWSG 25.4 1.0 mm
ends, 6.5 mm.
>=75 percent of thinner metal,
Weld width at interface A/SP SWSG
Weld-Quality Measurement then 1.0 mm
Special consideration was given to Weld width at surface A/SP SWSG Report only, no requirement
quality acceptance of the welds for this
project. Several standards exist among Weld location A/SP SWSG As specified 1.0 mm
the OEMs that specify attribute and
GM
measurement requirements for con- Burnthrough (hole) Not allowed
ventional steel welding. Three standards GM 4490M, 1991
were reviewed and the quality-accept-
ance criteria were selected from the three Chrysler PS-9059
Undercut (maximum) 5 percent of thinnest metal
standards. Table 3 reports the derivative 2002, NOV 6, CHG B
requirements for the SWSG project and
source of the OEM document. Convexity Not addressed
The test plan specified five weld
Heat-affected zone Not addressed
processes for each of the stack-up com-
binations for testing for each process Chrysler PS-9059
evaluation. Five samples each were test- Penetration >=20 percent into second metal
ed for impact and tensile shear, and 2002, NOV 6, CHG B
one sample from each process was pre- Gap (under pressure) Not addressed
pared for micro-hardness testing.

www.metalformingmagazine.com METALFORMING / FEBRUARY 2007 41

Welding AHSS

Fatigue testing of each process required Results of Weld Tests related to the area of the weld joining
25 samples for spectrum analysis. All processes were capable of pro- the thinner of the two pieces. AHSS
(Fatigue data is reported under a sepa- ducing welds having useful engineering materials were successfully joined with
rate A/SP document.) properties. Joint strength is strongly the processes studied.

Table 4Parameter Values Obtained from Weld Tests

Process Parameter A B C D E F G H I J K L M N O P Q R
Process Matl
1 4.0 kW (-)2.0 mm Ar. 18 N/A N/A N/A N/A N/A N/A N/A 0 mm 16.66 mm/sec N/A N/A N/A N/A Normal Normal
2 4.0 kW 1.8 mm Ar. 18 N/A N/A N/A N/A N/A N/A N/A 0.1 mm 40.00 mm/sec N/A N/A N/A N/A Normal Normal
3 4.0 kW 1.5 mm Ar. 18 N/A N/A N/A N/A N/A N/A N/A 0.1 mm 31.66 mm/sec N/A N/A N/A N/A Normal Normal
Laser 4 4.0 kW 1.8 mm Ar. 18 N/A N/A N/A N/A N/A N/A N/A 0.1 mm 45.00 mm/sec N/A N/A N/A N/A Normal Normal
5 4.0 kW 1.8 mm Ar. 18 N/A N/A N/A N/A N/A N/A N/A 0.1 mm 55.00 mm/sec N/A N/A N/A N/A Normal Normal
8 4.0 kW 2.0 mm Ar. 18 N/A N/A N/A N/A N/A N/A N/A 0.1 mm 33.33 mm/sec N/A N/A N/A N/A Normal Normal
9 2.0 kW 1.5 mm Ar. 18 N/A N/A N/A N/A N/A N/A N/A 0.1 mm 43.33 mm/sec N/A N/A N/A N/A Normal Normal

1 4.0 kW 2.5 mm Ar. 20 1 ms 1335 ms 50 ms N/A 100 N/A N/A 0 mm 18.33 mm/sec Ar. 2.0 Ar. 20 CFH 5.0 3.0 mm 30 deg Normal
2 4.0 kW 2.5 mm Ar. 20 1 ms 560 ms 50 ms N/A 110 N/A N/A 0.1 mm 41.60 mm/sec Ar. 2.0 Ar. 20 CFH 5.0 3.0 mm 30 deg Normal
3 4.0 kW 2.5 mm Ar. 20 1 ms 560 ms 50 ms N/A 110 N/A N/A 0.1 mm 41.60 mm/sec Ar. 2.0 Ar. 20 CFH 5.0 3.0 mm 30 deg Normal
Laser-
4 4.0 kW 2.5 mm Ar. 20 1 ms 395 ms 53 ms N/A 75 N/A N/A 0.1 mm 56.60 mm/sec Ar. 2.0 Ar. 20 CFH 5.0 2.5 mm 30 deg Normal
Plasma
5 4.0 kW 2.5 mm Ar. 20 1 ms 350 ms 50 ms N/A 75 N/A N/A 0.1 mm 63.30 mm/sec Ar. 2.0 Ar. 20 CFH 5.0 2.5 mm 30 deg Normal
8 4.0 kW 2.5 mm Ar. 20 1 ms 560 ms 50 ms N/A 95 N/A N/A 0.1 mm 41.60 mm/sec Ar. 2.0 Ar. 20 CFH 5.0 3.0 mm 30 deg Normal
9 2.0 kW 2.5 mm Ar. 20 1 ms 450 ms 50 ms N/A 75 N/A N/A 0.1 mm 50.00 mm/sec Ar. 2.0 Ar. 20 CFH 5.0 3.0 mm 30 deg Normal

1 2.5 kW N/A Ar. 18 N/A N/A N/A 0.35/ER70S-6 219 10.6 m/min 19.2 0 mm 17.66 mm/sec N/A 92Ar/8CO2 16.0 1.0 mm 40 deg 30 deg
2 2.0 kW N/A Ar. 18 N/A N/A N/A 0.35/ER70S-6 132 8.7 m/min 14.6 0.1 mm 44.17 mm/sec N/A 92Ar/8CO2 16.0 1.0 mm 40 deg 30 deg
3 2.0 kW N/A Ar. 18 N/A N/A N/A 0.35/ER70S-6 219 8.9 m/min 14.2 0.1 mm 43.33 mm/sec N/A 92Ar/8CO2 16.0 1.0 mm 40 deg 30 deg
4 1.3 kW N/A Ar. 18 N/A N/A N/A 0.35/ER70S-6 110 8.7 m/min 13.3 0.1 mm 44.16 mm/sec N/A 92Ar/8CO2 16.0 1.0 mm 40 deg 30 deg
Laser- 92Ar/8CO2 16.0 1.0 mm 40 deg
5 1.3 kW N/A Ar. 18 N/A N/A N/A 0.35/ER70S-6 124 8.2 m/min 15.3 0.1 mm 44.16 mm/sec N/A 30 deg
GMAW
8-70 ksi 2.0 kW N/A Ar. 18 N/A N/A N/A 0.35/ER70S-6 136 8.9 m/min 15.2 0.1 mm 43.33 mm/sec N/A 92Ar/8CO2 16.0 1.0 mm 40 deg 30 deg
8-90 ksi 2.0 kW N/A Ar. 18 N/A N/A N/A 0.35/ER90SD2 136 8.9 m/min 15.2 0.1 mm 43.33 mm/sec N/A 92Ar/8CO2 16.0 1.0 mm 40 deg 30 deg
9-70 ksi 2.0 kW N/A Ar. 18 N/A N/A N/A 0.35/ER70S-6 110 8.6 m/min 16.8 0.1 mm 44.16 mm/sec N/A 92Ar/8CO2 16.0 1.0 mm 40 deg 30 deg
9-90 ksi 2.0 kW N/A Ar. 18 N/A N/A N/A 0.35/ER90SD2 118 8.6 m/min 16.8 0.1 mm 44.16 mm/sec N/A 92Ar/8CO2 16.0 1.0 mm 40 deg 30 deg

1 N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 195 12.2 m/min 22 0 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
2 N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 110 6.22 m/min 19.5 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
3 N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 115 7.11 m/min 19.5 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
4 N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 95 7.11 m/min 18.5 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
GMAW-AC 5 N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 85 6.22 m/min 18 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
8-70 ksi N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 120 7.37 m/min 21 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
8-90-ksi N/A N/A N/A N/A N/A N/A 0.35/ER90SD2 120 7.37 m/min 21 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
9-70 ksi N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 110 6.60 m/min 22 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
9-90 ksi N/A N/A N/A N/A N/A N/A 0.35/ER90SD2 110 6.60 m/min 22 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg

1 N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 240 13.5 m/min 28 0 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
2 N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 120 7.37 m/min 22 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
3 N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 140 8.38 m/min 21 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
4 N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 115 5.33 m/min 21 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
GMAW-DC 5 N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 85 4.78 m/min 19 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
8-70 ksi N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 150 7.62 m/min 22 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
8-90 ksi N/A N/A N/A N/A N/A N/A 0.35/ER90SD2 150 7.62 m/min 22 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
9-70 ksi N/A N/A N/A N/A N/A N/A 0.35/ER70S-6 125 6.73 m/min 21 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg
N/A 30 deg N/A N/A N/A N/A 0.35/ER70S-6 125 6.73 m/min 21 0.5 mm 12.7 mm/sec N/A 90Ar/10CO2 16.0 N/A 40 deg 30 deg

Process Parameter Key

A Laser Power D Ramp 1 G Wire Spec. J Weld Voltage (Volts) M PAW Gas P Trail Distance
B Focus Position E Ramp 2 H Arc Current (Amps) K Engineered Gap N Shield Gas Q Travel Angle
C Gas (Laser) (CFH) F Ramp 3 I Wire Feed Rate L Travel Speed O Tip/Work Dist. (mm) R Work Angle

42 METALFORMING / FEBRUARY 2007 www.metalformingmagazine.com

 Weld processes utilizing filler mate-
rial demonstrated better results than
processes with no filler material.
Laser-welded lap joints generally
failed in the weld metal, while GMAW
fillet joints generally failed in the heat-
affected zone.
Filler material/electrode strength
had no direct effect on weldment
strength.
Material strength and/or thickness
had no influence on laser-welded joint
strength.
Zinc-coated materials demonstrat-
ed high levels of porosity without a
controlled/engineered gap.
Since the tests include the start and
stop conditions of each process, some
variation in strength is expected as a
result of the non-equilibrium condi-
tions and less-than-ideal weld geometry
at ends of the welds. The actual UTS of
the sheet materials can differ substan-
tially from the nominal Grade/UTS.
This difference also can account for
some of the variation between expect-
ed tensile load and actual test values.
Similar results can be obtained for
laser welds using the weld width report-
ed in the section photographs to calcu-
late the area of the weld and multiply-
ing that by the UTS of the thinner sheet.
These weld tests provide nominal
parameter values (Table 4) that can be
used to establish a starting point for
making confirmation samples prior to
fabricating prototype parts. MF

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