metals

Article
Resistance Spot Weldability of Galvanize Coated and
Uncoated TRIP Steels
Hayriye Ertek Emre * and Ramazan Kaçar
Department of Manufacturing Engineering, Karabük University, Karabük 78050, Turkey; rkacar@karabuk.edu.tr
* Correspondence: hayriyeertek@karabuk.edu.tr; Tel.: +90-370-433-8210 (ext. 1091)

Academic Editors: Halil Ibrahim Kurt, Adem Kurt and Necip Fazıl Yılmaz
Received: 27 October 2016; Accepted: 21 November 2016; Published: 28 November 2016

Abstract: In this study, the resistance spot weldabilty of zinc galvanize-coated and uncoated TRIP800
steels was investigated in detail. Depending on the welding parameters such as welding current
and welding time, the effects of zinc coating on the weld nugget geometry, the tensile shear strength,
the failure modes, the hardness, and the microstructure of the resistance spot-welded sample were
studied, and the results are compared with that of uncoated weldment. The coating on the surface of
the TRIP steel causes a decrease in the weld nugget size and tensile shear strength of the weldment,
and it changes to failure mode of the test sample from pullout to interfacial or partial interfacial
fracture. As compared with the uncoated sample, the galvanized TRIP800 steel weldment has
required a larger critical nugget size for achieving the desired pullout fracture mode and acceptable
tensile shear strength.

Keywords: TRIP800 steel; resistance spot welding; galvanized coating; failure mode

1. Introduction
One of the most important advanced high-strength steels (AHSS’s) widely used in the automotive
industry is TRIP (Transformation Induced Plasticity) steel because not only is it a good candidate to
facilitate gauge reduction, but it also attains an exceptional combination of strength and ductility [1,2].
TRIP steel is dominated by a ferrite matrix with retained austenite, bainite, and martensite as dispersed
phases, offering excellent mechanical properties due to the transformation of retained austenite into
martensite during plastic straining [3–5].
In recent years, car manufacturers have started using galvanized sheets in the automobile
industry [6,7]. Two types of coatings are generally applied to steel sheets used in the automotive
industry, galvanized and galvannealed coatings [8]. Pure zinc coating is called a galvanized coating,
and the zinc–iron alloy is called a galvannealed coating [9]. TRIP steel sheets can be galvanized for
automotive applications because of their improved corrosion resistance. Both galvanized and uncoated
steels are joined in automotive applications predominantly using the resistance spot welding (RSW)
process [8]. In resistance spot welding, the metal surfaces are joined by the heat obtained from the
resistance to the electric current. The metal parts around the interface are heated due to this heat
generation, resulting in melting and the formation of a weld pool. The weld pool solidifies and a joint
(weld nugget) is produced [10]. The welding current, the welding time, and the electrode force are
the most important parameters in spot welding [8]. The objective of the RSW process is to generate
heat rapidly in the joints of the material being welded while minimizing the conduction of heat to the
cooler adjacent material [11]. This heat generation (Q = I2 Rt) can be expressed, where Q is the heat
energy in joules, I is the current in amperes, R is the resistance in ohms, and t is the time in seconds [12].
According to this equation, in the course of RSW, the heat input is mainly controlled by the current,
time, and electrical resistance of the steel sheets. Compared to the welding of uncoated sheets, the
welding of galvanized sheets requires more accurate control of welding parameters, and the weldability

Metals 2016, 6, 299; doi:10.3390/met6120299 www.mdpi.com/journal/metals

Metals
Metals 2016,
2016, 6,
6, 299
299 22 of
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to the welding of uncoated sheets, the welding of galvanized sheets requires more accurate control
range
of must parameters,
welding be narrower andthan the
in the case of uncoated
weldability range mustsheets.
be Weldability
narrower than decreases
in theas the of
case thickness
uncoated of
the coating
sheets. increasesdecreases
Weldability [13]. Upon asheating, the coating
the thickness of theofcoating
the sample will melt
increases [13].first
Upon [14,15], andthe
heating, thecoating
molten
of the sample
coating at eachwill
of melt first [14,15],
the interfaces and the
serves the molten
contactcoating at each
resistances, asof the interfacesshown
schematically serves in
theFigure
contact1,
resistances,
as comparedastoschematically
the uncoatedshownsteels, in Figure
which 1, as
were compared
welded at thetosame
the uncoated
welding steels, which[15,16].
parameters were
welded at the
The molten same
zinc welding
at the fayingparameters
interface is[15,16].
pushedThe molten
to the zinc atofthe
periphery thefaying
contactinterface is pushed
area where to
it forms
the periphery
an annulus of the
that contact area
contributes where
to shunt it welding
the forms ancurrent
annulustothat contributes
further reduce to theshunt the welding
resistance of the
current to further reduce the resistance of the circuit [15,17].
circuit [15,17].

Figure 1. The
Figure 1. The resistance
resistance and
and resultant
resultant temperature
temperature profile
profile for (a) uncoated;
for (a) uncoated; (b)
(b) galvanize-coated
galvanize-coated
samples [15,16].
samples [15,16].

Generally, steel sheets were coated before RSW in the automotive industry. The optimum
Generally, steel sheets were coated before RSW in the automotive industry. The optimum
welding parameters can be changed by the coating the metal sheets. Thus, the automakers have to
welding parameters can be changed by the coating the metal sheets. Thus, the automakers have
decide the optimum welding parameters for uncoated and coated steel sheets. Since it has been
to decide the optimum welding parameters for uncoated and coated steel sheets. Since it has been
reported [13–17] that the zinc-galvanized coating affects the weldability of the steels negatively, it is
reported [13–17] that the zinc-galvanized coating affects the weldability of the steels negatively, it is
important to determine the effect of the process parameters on the weld quality of coated and
important to determine the effect of the process parameters on the weld quality of coated and uncoated
uncoated steels weldments. The extensive literature survey revealed that there has been limited
steels weldments. The extensive literature survey revealed that there has been limited research
research on the resistance spot weldability of uncoated and galvanize-coated TRIP steel sheets.
on the resistance spot weldability of uncoated and galvanize-coated TRIP steel sheets. Therefore,
Therefore, the effect of zinc coating on resistance spot weldability of TRIP800 steels was investigated
the effect of zinc coating on resistance spot weldability of TRIP800 steels was investigated in this study.
in this study. For this purpose, the effects of welding parameters (welding current and welding time)
For this purpose, the effects of welding parameters (welding current and welding time) on the nugget
on the nugget diameter, dn, and the nugget height, hn, of a weldment were investigated.
diameter, dn , and the nugget height, hn , of a weldment were investigated. Additionally, the tensile shear
Additionally, the tensile shear strength and failure mode associated with the weld nugget geometry
strength and failure mode associated with the weld nugget geometry of the spot-welded galvanized
of the spot-welded galvanized and uncoated TRIP800 steel sheets were examined under lap shear
and uncoated TRIP800 steel sheets were examined under lap shear loading conditions. Failure modes
loading conditions. Failure modes were determined by observing the weld fracture surfaces. The
were determined by observing the weld fracture surfaces. The hardness test was used to assess the
hardness test was used to assess the weldability of the steels.
weldability of the steels.
2.
2. Materials
Materials and
and Methods
Methods
Galvanize
Galvanize coated
coated and
and uncoated
uncoated TRIP800
TRIP800 steel
steel sheets
sheets 1.5
1.5 mm
mm inin thickness
thickness were
were used
used for
for the
the
experimental study. The chemical composition of the steel is given in Table 1. The coated samples
experimental study. The chemical composition of the steel is given in Table 1. The coated samples
were cleaned from
were cleaned galvanization under
from galvanization under laboratory
laboratory conditions
conditions with
with an
an emery
emery cloth
cloth and
and by
by rinsing
rinsing in
in
ethyl alcohol.
ethyl alcohol.
Metals 2016, 6, 299 3 of 10

Table 1. The chemical composition of the TRIP800 steel (% weight).

Base Metal C Si Mn P S Cr Mo Al Fe
Metals 2016, 6, 299 3 of 10
TRIP800 0.2 1.66 1.69 0.015 0.0002 0.006 0.011 0.43 Balance

Table 1. The chemical composition of the TRIP800 steel (% weight).

A timer, current-controlled AC resistance spot welding machine with a power capacity of 60 kVA,
Base Metal C Si Mn P S Cr Mo Al Fe
and various pneumatic
TRIP800
application mechanisms with a single lever were used for the experiments.
0.2 1.66 1.69 0.015 0.0002 0.006 0.011 0.43 Balance
The weld lobe diagram is one of the most powerful techniques that can be used to illustrate determining
optimumAwelding parameters [18,19].
timer, current-controlled A weld spot
AC resistance lobe welding
diagrammachine
divideswith
theawelding currentofand
power capacity 60 the
welding
kVA,timeanddomain,
various using two lines
pneumatic for themechanisms
application maximum and withminimum currents,
a single lever were into
usedthree regions
for the
experiments.
in terms of weld The weld undersized
quality: lobe diagramweldment,
is one of the most powerful
acceptable techniques
weldment, andthat can be used
expulsion [20].toThus,
illustrateparameters
the welding determiningselected
optimumassociate
welding with
parameters [18,19].
the weld lobeAdiagram,
weld lobe diagram
which wasdivides the for
developed
welding current and the welding time domain,
uncoated TRIP800 samples in a previous study [18]. using two lines for the maximum and minimum
currents, into three regions in terms of weld quality: undersized weldment, acceptable weldment,
The welding parameters are shown in Table 2.
and expulsion [20]. Thus, the welding parameters selected associate with the weld lobe diagram,
which was developed for uncoated TRIP800 samples in a previous study [18].
Table 2. Welding parameters.
The welding parameters are shown in Table 2.
Welding Squeeze Clamping Electrode
Electrode Weld Time Hold2.Time
Table Welding parameters. Electrode
Current Time Time Diameter
Force (kN) (Cycle) (Cycle) Type(F16)
(kA)
Welding Weld Hold (Cycle)
Squeeze (Cycle) (mm)
Electrode
Electrode Clamping Electrode
6 Current Time Time Time Diameter
Force (kN) 15 Time (Cycle) Type(F16)
7 (kA) (Cycle) (Cycle) (Cycle) 25 Spherical tip (mm)
6 20 15 15 5.5
8 6 (Cu–Cr–Zr)
25
9 15
7 Spherical tip
6 20 15
Note: 1 cycle25
= 0.02 s. 15 5.5
8 (Cu–Cr–Zr)
25
9
All series of welded joints were exposed to1acycle
Note: tensile shear
= 0.02 s. test in order to determine joint strength.
The information
All seriesabout the tensile
of welded shearexposed
joints were test sample is given
to a tensile in test
shear Figure 2a. Five
in order tensile shear
to determine joint test
samples were prepared and tested for each of the weld variables by using a Shimadzu testing
strength. The information about the tensile shear test sample is given in Figure 2a. Five tensile shear machine.
The Vickers microhardness
test samples were prepared (Shimadzu
and testedSanjo Works,
for each of the Kyoto, Japan) by
weld variables measurement across
using a Shimadzu the weld
testing
nugget, the heat
machine. The affected zone (HAZ),(Shimadzu
Vickers microhardness and the base Sanjometal
Works,was carried
Kyoto, Japan)outmeasurement
with a loadacrossof 500 g.
the weld nugget,
The transverse sections theof
heat
theaffected
weldmentzonepassing
(HAZ), and the base
through themetal
weldwas carried
nugget, asout with
well as aa load of 500
similar section
g. The transverse sections of the weldment passing through the weld nugget,
of the base plates, were prepared by a standard metallographic procedure. An optical examination as well as a similar
section ofwas
of specimens the carried
base plates, were aprepared
out using Nikon DIC by amicroscope
standard metallographic procedure.
(Nikon Instruments, An optical
Karfo-Karacasulu
examination of specimens was carried out using a Nikon DIC microscope (Nikon Instruments,
Dis. Tic. A.S., Istanbul, Turkey) Zeiss Ultra Plus type SEM microscope (Leibniz Institute for Solid State
Karfo-Karacasulu Dis. Tic. A.S., Istanbul, Turkey) Zeiss Ultra Plus type SEM microscope (Leibniz
and Materials Research, Helmholtzstraße, Dresden, Germany). Nugget diameters (dn ), the heights of
Institute for Solid State and Materials Research, Helmholtzstraße, Dresden, Germany). Nugget
the nugget (hn ) (d
diameters and the HAZ width were measured from the metallographic samples by an Optic and
n), the heights of the nugget (hn) and the HAZ width were measured from the
Stereometallographic
Microscope (Nikon samplesInstruments, Karfo-Karacasulu
by an Optic and Stereo Microscope Dis. Tic. A.S.,
(Nikon Istanbul,
Instruments, Turkey), as seen in
Karfo-Karacasulu
Figure 2b.Tic. A.S., Istanbul, Turkey), as seen in Figure 2b.
Dis.

Figure 2. (a) The tensile shear test sample; (b) the transverse sections of weldment.
Figure 2. (a) The tensile shear test sample; (b) the transverse sections of weldment.
Metals 2016, 6, 299 4 of 10

3. Results and Discussion

3. Results and Discussion
3.1. Microstructure and Nugget Geometry of the Weldment
3.1. Microstructure and Nugget Geometry of the Weldment
Figure 3 illustrates the macro and the microstructure of galvanized and uncoated welded
Figure 3 illustrates the macro and the microstructure of galvanized and uncoated welded samples,
samples, which were joined with the same welding parameters. The weldment consists of three
which were joined with the same welding parameters. The weldment consists of three distinct
distinct structural zones: (i) the weld nugget; (ii) the heat affected zone (HAZ); and (iii) the base
structural zones: (i) the weld nugget; (ii) the heat affected zone (HAZ); and (iii) the base metal.
metal.

Figure 3. Macro and microstructure of spot-welded samples: (a) uncoated; (b) galvanized; (c) HAZ;
Figure 3. Macro and microstructure of spot-welded samples: (a) uncoated; (b) galvanized; (c) HAZ;
(d) periphery of contact zone; (e) weld nugget.
(d) periphery of contact zone; (e) weld nugget.

As seen in Figure 3a,b, the weld nugget microstructure of the both galvanized and uncoated
As seen in Figure 3a,b, the weld nugget microstructure of the both galvanized and uncoated
samples is covered by martensite phases predominantly (Figure 3e), while the martensite, bainite,
samples is covered by martensite phases predominantly (Figure 3e), while the martensite, bainite,
and retained austenite phases present in the HAZ (Figure 3c). In Figure 3b, at the early stage of the
and retained austenite phases present in the HAZ (Figure 3c). In Figure 3b, at the early stage of the
welding, the expulsed molten zinc is evaluated on the periphery of the contact zone [21]. Li et al. [22]
welding, the expulsed molten zinc is evaluated on the periphery of the contact zone [21]. Li et al. [22]
investigated the behavior of the zinc liquid during the welding. The authors noticed that the molten
investigated the behavior of the zinc liquid during the welding. The authors noticed that the molten
zinc is expulsed towards the periphery of the contact area to form a zinc annulus that extends to the
zinc is expulsed towards the periphery of the contact area to form a zinc annulus that extends to the
electro-thermal contact surface during the welding stage, thereby reducing the current density
electro-thermal contact surface during the welding stage, thereby reducing the current density crossing
crossing the interfaces.
the interfaces.
The effects of the coating and welding parameters, such as the welding current and the welding
The effects of the coating and welding parameters, such as the welding current and the welding
time, on the nugget diameter and the nugget height were determined, and the findings are given
time, on the nugget diameter and the nugget height were determined, and the findings are given
graphically in Figure 4. It was confirmed that the nugget diameters of both weldments extend by
graphically in Figure 4. It was confirmed that the nugget diameters of both weldments extend by
increasing the heat input associate with the welding current and the welding time. Meanwhile, the
increasing the heat input associate with the welding current and the welding time. Meanwhile, the
nugget cross-section height decreases in high welding parameters. This might be due to the forging
nugget cross-section height decreases in high welding parameters. This might be due to the forging of
of the soft zone. In low welding currents achieved by increasing the welding time, the amount of
the soft zone. In low welding currents achieved by increasing the welding time, the amount of fused
fused metal to form a nucleus increase, so the nucleus diameter increases and the height of the
metal to form a nucleus increase, so the nucleus diameter increases and the height of the nucleus nearly
nucleus nearly reaches the sheet thickness [23]. Using a welding current greater than 6 kA causes
reaches the sheet thickness [23]. Using a welding current greater than 6 kA causes deeper electrode
deeper electrode indentation; thus, the weld nugget height decreases. As seen in Figure 4, a larger
indentation; thus, the weld nugget height decreases. As seen in Figure 4, a larger nugget diameter
nugget diameter and a thicker nugget cross-section height was determined for uncoated specimens,
and a thicker nugget cross-section height was determined for uncoated specimens, as compared with
as compared with galvanize-coated samples. Similar results have also been reported by other
researchers [7,22–25]. Since the resistance at the sheet interfaces has shifted due to the presence of
Metals 2016, 6, 299 5 of 10

Metals 2016, 6, 299

galvanize-coated samples. Similar results have also been reported by other researchers [7,22–25]. 5 of 10

Since the resistance at the sheet interfaces has shifted due to the presence of zinc, the thermal
zinc, the thermal gradient across the weld parallel to the electrode axis to the electrode may still be
gradient across the weld parallel to the electrode axis to the electrode may still be rather small [24,25].
rather small [24,25]. Raoelison et al. [21] reported that, in the case of the uncoated sample, 100% of
Raoelison et al. [21] reported that, in the case of the uncoated sample, 100% of the current crosses the
the current crosses the sheet-to-sheet contact inside a radius of 3 mm; however, only 80% of the weld
sheet-to-sheet contact inside a radius of 3 mm; however, only 80% of the weld current passes through
current passes through the zinc-coated weldment. According to the Joule rule, for the heat input
the zinc-coated weldment. According to the Joule rule, for the heat input occurring between electrodes
occurring between electrodes at an electric resistance Q (calorie) = I2Rt, the generated heat appears as
at an electric resistance Q (calorie) = I2 Rt, the generated heat appears as a function of the current
a function of the current intensity (I), the resistance of the materials (R), and the time (t). It is believed
intensity (I), the resistance of the materials (R), and the time (t). It is believed that a higher heat input
that a higher heat input is generated for uncoated samples than for galvanize-coated samples, which
is generated for uncoated samples than for galvanize-coated samples, which results in a larger melting
results in a larger melting area and thus an extension in nugget diameter. In the case of
area and thus an extension in nugget diameter. In the case of zinc-galvanized steel sheets, however,
zinc-galvanized steel sheets, however, higher welding currents are required to form a nugget with a
higher welding currents are required to form a nugget with a suitable size [22,25].
suitable size [22,25].

Figure 4.
Figure 4. Effect of welding
Effect of parameters on
welding parameters on the
the weld
weld nugget
nugget diameter
diameter and
and the
the nugget
nugget height
height of
of welded
welded
samples: (a,c)
samples: (a,c) uncoated;
uncoated; (b,d)
(b,d) galvanized.
galvanized.

Figure 5 indicates that the HAZ width of both weldments enlarge with increasing welding
Figure 5 indicates that the HAZ width of both weldments enlarge with increasing welding
parameters. It is worth noting that the zinc-galvanized welded sample has a larger HAZ. This could
parameters. It is worth noting that the zinc-galvanized welded sample has a larger HAZ. This could
be explained by the higher thermal conductivity of the galvanized steel and an enlargement of the
be explained by the higher thermal conductivity of the galvanized steel and an enlargement of the
electro-thermal contact radius, due to the zinc accumulation or uncertainties of the experiments and
electro-thermal contact radius, due to the zinc accumulation or uncertainties of the experiments and
the measurements (including the identification of the HAZ). Researchers [22] have also reported an
the measurements (including the identification of the HAZ). Researchers [22] have also reported
enlargement of the electro-thermal contact radius due to zinc accumulation. Therefore, during
an enlargement of the electro-thermal contact radius due to zinc accumulation. Therefore, during
resistance spot welding, an enlargement area of the contact surface to steel sheets causes a wider
resistance spot welding, an enlargement area of the contact surface to steel sheets causes a wider
heating zone, which indicates an extension in the HAZ for galvanized joints.
heating zone, which indicates an extension in the HAZ for galvanized joints.
Metals 2016, 6, 299 6 of 10
Metals 2016, 6, 299 6 of 10
Metals 2016, 6, 299 6 of 10

Figure 5. Effect of
Effect of welding
of welding parameters
welding parameters on
parameters on the
on the width
the width of
width of the HAZ:
of the
the HAZ: (a) uncoated;
uncoated; (b) galvanized.
galvanized.
Figure 5.
Figure 5. Effect HAZ: (a)
(a) uncoated; (b)
(b) galvanized.

3.2. Tensile
3.2. Shear Performance
Tensile Shear Performance of
of Weldment
Weldment
Weldment
The effects
The effects of
of the
the welding
welding parameters
parameters such
such as welding current
as welding and welding
current and welding time
time on the tensile
on the tensile
shear strength and failure types of both weldments were investigated, and the results are shown
shear strength and failure types of both weldments were investigated, and the results are shown
graphically in Figure 6a,b.
graphically in Figure 6a,b.

Figure 6. Effect of welding parameters on the tensile shear strength and failure types: (a) uncoated;
Figure
Figure 6. Effect
6. of welding
Effect of welding parameters
parameters on
on the
the tensile
tensile shear
shear strength
strength and
and failure
failure types:
types: (a)
(a) uncoated;
uncoated;
(b) galvanized.
(b) galvanized.
(b) galvanized.

As seen in Figure 6a,b, the tensile shear strength of all weldments improves by increasing the
As seen in Figure 6a,b, the tensile shear strength of all weldments improves by increasing the
heat As seen
input in Figurewith
associated 6a,b,the
thewelding
tensile shear
currentstrength
and theofwelding
all weldments improves
time, except 9 kA by increasing
in Figure the
6b. The
heat input associated with the welding current and the welding time, except 9 kA in Figure 6b. The
heat input tensile
maximum associated
shearwith the welding
strength current
for uncoated andand the welding
galvanized time,was
samples except 9 kA into
determined Figure 6b.
be 24.75
maximum tensile shear strength for uncoated and galvanized samples was determined to be 24.75
kN and
The 23.5 kN,tensile
maximum respectively. The strength
shear strength of the uncoated
for uncoated sample was
and galvanized found to
samples wasbe determined
about 1.25 kN to
kN and 23.5 kN, respectively. The strength of the uncoated sample was found to be about 1.25 kN
higher.
be 24.75ThekNzinc-galvanized coating causesThe
and 23.5 kN, respectively. a negative
strengtheffect on the
of the strength.
uncoated sample was found to be
higher. The zinc-galvanized coating causes a negative effect on the strength.
aboutThe1.25failure modeThe
kN higher. of the test samples was
zinc-galvanized examined.
coating causes aAs seen ineffect
negative Figureon 6,theanstrength.
interfacial failure
The failure mode of the test samples was examined. As seen in Figure 6, an interfacial failure
(IF) mode was evaluated
The failure mode of the fortest
galvanized
samples wassamples that were
examined. joined
As seen in at a 6 kA
Figure welding
6, an current
interfacial for(IF)
failure all
(IF) mode was evaluated for galvanized samples that were joined at a 6 kA welding current for all
welding
mode wastimes. The interfacial
evaluated fracture
for galvanized (IF) mode
samples can joined
that were be avoided
at a 6bykAeither
weldingreducing
currentthe
forfusion zone
all welding
welding times. The interfacial fracture (IF) mode can be avoided by either reducing the fusion zone
hardness
times. The or alternatively
interfacial fractureextending
(IF) mode the
can benugget
avoideddiameter
by eitherfor a given
reducing thesheet
fusionthickness [26,27].
zone hardness or
hardness or alternatively extending the nugget diameter for a given sheet thickness [26,27].
Increasing theextending
alternatively heat input theenabled a joining for
nugget diameter at aa larger area, thickness
given sheet which resulted
[26,27].inIncreasing
a desired thepullout
heat
Increasing the heat input enabled a joining at a larger area, which resulted in a desired pullout
failureenabled
input (PF) mode for both
a joining at a weldments. A partial
larger area, which interfacial
resulted failurepullout
in a desired (PIF) mode
failurewas(PF)observed
mode forinboth
the
failure (PF) mode for both weldments. A partial interfacial failure (PIF) mode was observed in the
uncoated sample
weldments. joinedinterfacial
A partial at 6 kA forfailure
all welding
(PIF) times
modedue wastoobserved
insufficientin heat input. Meanwhile,
the uncoated a PIF
sample joined
uncoated sample joined at 6 kA for all welding times due to insufficient heat input. Meanwhile, a PIF
mode
at 6 kAdueforto all
excessive
welding heat inputdue
times wastoalso observed heat
insufficient in theinput.
galvanized sample joined
Meanwhile, a PIF at 9 kAdue
mode for all
to
mode due to excessive heat input was also observed in the galvanized sample joined at 9 kA for all
welding times. These failure types indicate that the heat input related with the welding parameters
welding times. These failure types indicate that the heat input related with the welding parameters
passes through to a critical level that causes expulsion and results in a PIF type.
passes through to a critical level that causes expulsion and results in a PIF type.
Metals 2016, 6, 299 7 of 10

excessive heat input was also observed in the galvanized sample joined at 9 kA for all welding times.
These failure types indicate that the heat input related with the welding parameters passes through to
a critical level6, that
Metals 2016, 299 causes expulsion and results in a PIF type. 7 of 10
Studies have shown that zinc forms at the faying surface around the fusion zone during the spot
weldingStudies have shownsteel
of Zn-galvanized that zinc forms
(Figure 7).atResults
the faying surface
indicate around
that the fusion
the coating zone during
strongly affectsthe
thespot
failure
welding of Zn-galvanized steel (Figure 7). Results indicate that the coating strongly affects the
mode of the spot weldment of TRIP steels.
failure mode of the spot weldment of TRIP steels.

Figure 7. Failure modes: (a) IF mode. (b) Magnification view of IF mode (1 and 2 are point of EDS
Figure 7. Failure modes: (a) IF mode. (b) Magnification view of IF mode (1 and 2 are point of EDS
analysis). (c) PIF mode. (d) Magnification of PIF mode.
analysis). (c) PIF mode. (d) Magnification of PIF mode.

Figure 7 shows fracture surface of samples that were failed IF and PIF mode. They present
partly brittle fracture behavior due to a hard martensite structure or a zinc-enriched region. EDS
Metals 2016, 6, 299 8 of 10

Metals 2016, 6, 299 8 of 10

Figure 7 shows fracture surface of samples that were failed IF and PIF mode. They present partly
analysis
brittle was carried
fracture behavior out
dueontothe fracture
a hard surfacestructure
martensite of the samples. Results indicate
or a zinc-enriched region. theEDSzinc-enriched
analysis was
region (Figure
carried out on the 7b). The nature
fracture surface ofofthe
thespot welding
samples. and indicate
Results the subsequent rapid cooling
the zinc-enriched region resulted
(Figurein a
7b).
martensite
The nature structure
of the spotinwelding
the fusion andzonethe due to a high
subsequent amount
rapid of carbon
cooling resultedand
in alloying
a martensiteelements. The
structure
presence
in of the
the fusion zone hard
duemartensite
to a high amountphase essentially
of carbon andallows for anelements.
alloying easier propagation
The presence of of
cracks and
the hard
generates interface
martensite failures more
phase essentially allows easily
for an[27,28].
easier propagation of cracks and generates interface failures
more easily [27,28].
3.3. Hardness Measurement
3.3. Hardness Measurement
Figure 8a,b shows the hardness profiles of spot-welded galvanized and uncoated TRIP800
Figure
steels. 8a,b shows of
The hardnesses theboth
hardness profiles
galvanized of spot-welded
and uncoated base galvanized
and weldand uncoated
metals TRIP800 steels.
were determined for
The hardnesses of both galvanized and uncoated base and weld metals
similar welding conditions. The hardness of the base metal was found to be 250 HV0.5, and it were determined for similar
welding
increasedconditions.
up to 550–600 The HVhardness of weld
0.5 in the the base metal
nugget duewastofound to be 250
martensitic HV0.5 , and itThe
transformation. increased
hardness up to
in
550–600 HV in the weld nugget due to martensitic transformation. The hardness
the weld nugget and the HAZ was slightly affected due to increasing welding parameters (Figure 8).
0.5 in the weld nugget
and
Thisthe HAZ
result maywasbeslightly affected
explained due to increasing
by structural weldingduring
transformation parameters (Figure of
the cooling 8).the
This result mayThe
weldment. be
explained
HAZ hardness by structural transformation
in the galvanized weldmentduringwasthemeasured
cooling oftothe
be weldment. The HAZ
25 HV0.5, which hardness
is higher than thatin the
of
galvanized weldment was measured
the uncoated samples. This can be attributed 0.5 to be 25 HV , which is higher than that of the uncoated
to grain refinement and the increasing martensite samples.
This
volumecan fraction
be attributed
in thetoHAZ.
grainSince
refinement and the increasing
the galvanized coating has martensite volume
a faster heat fraction
transfer, theinmartensite
the HAZ.
Since
volume thefraction
galvanized coating has a faster heat transfer, the martensite volume fraction increased.
increased.

Figure 8.
Figure 8. Hardness
Hardness measurement
measurement of
of samples:
samples: (a)
(a) uncoated;
uncoated; (b)
(b) galvanized.
galvanized.

4. Conclusions
4. Conclusions
In this study, the effect of the welding parameters such as welding time and welding current on
In this study, the effect of the welding parameters such as welding time and welding current on the
the weld nugget geometry, the tensile shear strength, and the hardness of the resistance of
weld nugget geometry, the tensile shear strength, and the hardness of the resistance of spot-weldments
spot-weldments were investigated. From the results given above, the following conclusions can be
were investigated. From the results given above, the following conclusions can be drawn:
drawn:
Metals 2016, 6, 299 9 of 10

• The microstructure of both weldments was decorated by the predominantly martensite phases in
the weld nugget. Martensite, bainite, and retained austenitic phases were evaluated in the HAZ.
• It was found that the nugget diameter increased with increasing welding currents greater than
6 kA for all welding times (15, 20 and 25 cycles). Using a welding current greater than 6 kA causes
more forging of soft zones and decreases the nugget height. The galvanized coating on the surface
of the TRIP steel resulted in a smaller nugget diameter and a thicker nugget cross section.
• The HAZ of the galvanized TRIP800 weldment was found to be slightly larger due to the higher
thermal conductivity of the galvanized steel.
• The tensile shear strength of both weldments improves by increasing the heat input associated
with the welding current and the welding time, except 9 kA. The coating presents a negative effect
on the strength and failure mode.
• A partial interfacial failure (PIF) mode was observed in the uncoated sample joined at 6 kA for all
welding times due to insufficient heat input. Meanwhile, a PIF mode due to excessive heat input
was also observed in the galvanized sample joined at 9 kA for all welding times.
• The welding current and welding time range, to obtain indented weld nugget geometry and
a desired PF mode for the uncoated sample, should be higher. Increasing the heat input up to
expulsion enables joining at a larger area, which provides an extended nugget size and a desired
PF mode for both weldments.
• It was found that hardness increased in the fusion zone and the HAZ of both weldments due
to martensitic transformation. In addition, the HAZ hardness of the galvanized weldment was
found to be slightly higher. It is believed that coating leads to the conduction of heat faster, thus
preventing the coarsening of the grains in the HAZ, so fine grains cause high hardness.

Author Contributions: R.K. conceived and designed the experiments; H.E. performed the experiments; R.K.
analyzed the data; H.E. wrote the paper.
Conflicts of Interest: The authors declare no conflict of interest.

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