Development of Starting Weld

Schedules for AHSS

SORPAS Modeling of Starting Point Weld Schedules with
Experimental Evaluation and Validation

Michael L. Kuntz – University of Waterloo

Donald F. Maatz Jr. – RoMan Engineering Services
Eric Pakalnins - Chrysler
John C. Bohr – General Motors
Auto/Steel
Ted Coon & Armando Joaquin - Ford
Partnership www.a-sp.org
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 Background

Starting Point Weld Schedules

• Used by automotive manufacturers for “first welds” as
a basis for weld schedule development
• Schedules depend on the governing metal thickness
(GMT) and material coating
• Schedules currently in use for mild steel and HSLA
(IISI Groups 1 and 2) need to be adjusted for AHSS
(Groups 3 and 4) to produce acceptable weld quality
• Developing starting point weld schedules is potentially
tedious and material intensive due to the wide range of
material combinations.

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 Objectives

Phase I
• Verify starting point weld schedules for IISI Groups 3
and 4 AHSS using the SORPAS finite element
software, and
• Suggest schedule improvement if necessary because of
undersized welds or other observed defects.
Phase II
• Verify RSW Weld Schedule Effectiveness by:
– Peel Inspection
– Mechanical Evaluation
– Metallographic Analysis

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 Scope of Work

• Weld schedules developed with A/S-P member input

– AC & MFDC
– OEM production Cu-Zr electrode tips
• AC: AWS D8.6 ball nose, 4.8 mm contact face diameter
• MFDC: ISO 5821 B nose, 6/8 mm contact face diameter
• Thickness combinations:
– Test A: 2T stack-up, similar thickness
– Test B: 2T stack-up, thickness ratio 1:2.5
– Test C: 3T stack-up, mild and BH steels to group 3 and 4

AC electrode MFDC electrode

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 3T Stack-Up Thickness Combinations

3T Simulations with “thin” Mild Steel (140YS/270TS)

Stack-up Uncoated Gages(mm) Coated Gages

Description (mm)

#1 #2 #3 #4 #5 #6

Thin (mild) 1.08 0.92 0.76 0.64 0.76 0.64

Thick 2.70 2.30 1.90 1.60 1.90 1.60

Thick 2.70 2.30 1.90 1.60 1.90 1.60

3T Simulations with “thin” BH Steel

Stack-up Uncoated Gages(mm) Coated Gages

Description (mm)

#1 #2 #3 #4 #5 #6

Thin (mild) 1.08 0.92 0.76 0.64 0.76 0.64

Thick 2.70 2.30 1.90 1.60 1.90 1.60

Thick 2.70 2.30 1.90 1.60 1.90 1.60

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 Phase I - Simulation

Steels that were selected for simulation:

• Bare and Zn-coated IISI Groups 3 and 4
– TRIP 800 MPa
– DP 600 MPa
– DP 980 MPa
– Uncoated Hot Stamped Boron
• Bare and Zn-coated IISI Groups 1 and 2
– Mild 140 YS/270TS
– BH 210 MPa

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 Simulation Parameters

• SORPAS v.7 FEA software

• Squeeze time - 5 cycles
• Current specified by RMS with a constant current
control power supply
• 60 Hz AC with a conduction angle of 60%
• Axissymetric 2.5d model with 500 elements
• SORPAS interface condition parameter - 1.0
• 10°C water cooling
• HDGI coating weight of 75 g/m2 per side for coated
materials

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 AC Welding Simulation Results Summaries

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 AC - Uncoated Steel Schedules

AC Weld Schedules (For Squeeze Time Use 5 cycles)

Uncoated IISI Group 3 (High Strength >500-800 MPa) and Group 4 (Ultra High Strength >800 MPa)
Test GMT Weld Weld Cool Number Weld Hold Weld Electrode
Range (mm) Force Time Time of Sequence Time Current Shank Diameter
(lbs) (cycles) (cycles) Pulses (Cycles) (Cycles) (kA) (mm)
A, B 0.70 - 0.79 480 9 0 1 9 2 8.0 15.9
A, B 0.80 - 0.99 670 9 0 1 9 2 8.0 15.9
A, B 1.00 - 1.29 670 10 0 1 10 2 9.0 15.9
A 1.30 - 1.59 950 12 0 1 12 2 10.0 15.9
A,C 1.60 - 1.89 1200 7 1 2 7-1-7 5 10.5 19.0
A,C 1.90 - 2.29 1660 7 1 3 7-1-7-1-7 5 11.5 19.0
A,C 2.30 - 2.69 1660 8 2 3 8-2-8-2-8 10 12.0 19.0
A,C 2.70 - 3.00 1900 8 2 3 8-2-8-2-8 10 12.5 19.0

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 AC - Coated Steel Schedules

AC Weld Schedules (For Squeeze Time Use 5 cycles)

Coated IISI Group 3 (High Strength >500-800 MPa) and Group 4 (Ultra High Strength >800 MPa)
Test GMT Weld Weld Cool Number Weld Hold Weld Electrode
Range Force Time Time of Sequence Time Current Shank Diameter
(mm) (lbs) (cycles) (cycles) Pulses (Cycles) (Cycles) (kA) (mm)
A, B 0.70 - 0.79 480 14 0 1 14 2 9.0 15.9
A, B 0.80 - 0.99 670 14 0 1 14 2 9.5 15.9
A 1.00 - 1.29 670 16 0 1 16 2 10.0 15.9
A 1.30 - 1.59 950 7 1 3 7-1-7-1-7 5 11.0 15.9
A,C 1.60 - 1.89 1200 8 2 3 8-2-8-2-8 5 11.5 19.0
A,C 1.90 - 2.29 1660 8 2 4 8-2-8-2-8-2-8 5 12.5 19.0

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 Test A DP980 Results

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 Test B TRIP800 Results

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 Test C DP600-Mild Steel Results

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 Test C DP980-Mild Steel Results

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 Test C DP980-BH Results

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 DC Welding Simulation Results Summaries

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 DC - Uncoated Steel Schedules

Uncoated IISI Group 3 (High Strength >500-800 MPa) and Group 4 (Ultra High Strength >800 MPa)

Electrode
Electrode
GMT Range Weld Force Weld Time Weld Current Hold Time Face
Test Width
(mm) (N) (ms) (kA) (ms) Diameter
(d1)
(d2)

A, B 0.70 - 0.79 2800 210 6.5 105 6 16

A, B 0.80 - 0.99 3400 210 7.6 105 6 16
A, B 1.00 - 1.29 4400 270 9.3 135 6 16
A 1.30 - 1.59 5300 350 10.6 175 8 20
A,C 1.60 - 1.89 6400 440 11.2 220 8 20
A,C 1.90 - 2.29 7700 560 12.0 280 8 20
A,C 2.30 - 2.69 8500 670 12.5 335 8 20
A,C 2.70 - 3.00 10200 880 13.6 440 8 20

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 DC - Coated Steel Schedules

Coated IISI Group 3 (High Strength >500-800 MPa) and Group 4 (Ultra High Strength >800 MPa)

Electrode
Electrode
GMT Range Weld Force Weld Time Weld Current Face
Test Hold Time Width
(mm) (N) (ms) (kA) Diameter
(d1)
(d2)

A, B 0.70 - 0.79 2800 230 7.8 115 6 16

A, B 0.80 - 0.99 3400 250 8.5 125 6 16
A 1.00 - 1.29 4400 310 10.1 155 6 16
A 1.30 - 1.59 5300 400 11.5 200 8 20
A,C 1.60 - 1.89 6400 480 12.4 240 8 20
A,C 1.90 - 2.29 7700 600 13.2 300 8 20

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 Test A DP600 Results

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 Test A TRIP800 Results

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 Test B DP600 Results

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 Test C DP600-Mild Steel Results

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 Test C DP980-Mild Steel Results

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 Test C DP980-BH Results

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 Phase I - Conclusions

• Starting point RSW schedules were checked using the

commercially available SORPAS v.7 software
• Weld schedules for both AC and DC RSW of both coated and
bare AHSS were evaluated and found to give acceptable results
• The given starting point weld schedules can be used to ensure
acceptable weld size during the development of production RSW
schedules
• The schedules are intentionally ‘hot’ as they are designed to
produce large welds over a wide range of conditions
• Expulsion can be expected with these schedules and the
necessary safety precautions should be exercised
• These RSW schedules are not optimized for production
conditions

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 Phase II - Validation

• Evaluate the starting point weld schedules for various

combinations of steel grades and gauges
– 590R – 1.20, 1.40, 1.54
– DP600 – 1.20, 1.60, 1.97, 2.20
– DP750 – 1.50 (planned for DP780, substituted)
– DP780 – 1.15, 1.60
– TRIP800 – 1.00, 1.50
– DP980 – 1.40, 1.60, 1.92
• Weld sample coupons based on AWS D8.9M:2002
• Size and weld placement determined by material gauge
• All 3T assemblies produced with 2” x 6” coupons

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 Assembly and Inspection Procedure

• Peel samples (weld 5 samples, evaluate 3)

• Visual inspection per AWS D8.1M:2007, Section 5.1
• Peel inspection per AWS D8.1M:2007, Section 5.3
• Tensile-shear and cross-tension samples (weld 5 samples,
evaluate 3)
• Weld property determination per AWS D8.9M:2002, Section 11.6
– Static peak load
• Evaluate results per AWS D8.1M:2007, Section 5.4
• Metallographic (weld 2 samples, evaluate 1)
• Sample preparation per AWS D8.9M:2002, Section 11.5
– Micro-hardness and un-etched photo not required
• Evaluate results per AWS D8.1M:2007, Section 5.2

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 Peel Test Requirements

• Test inspection requirements - Peel Samples

– Visual inspection per AWS D8.1M:2007, Section 5.1
• Surface imperfection inspection without magnification
• Indentation measurement with depth gauge
– Peel inspection per AWS D8.1M:2007, Section 5.3
• Weld size requirements based on GMT and requirements of
Table-2
• Fracture mode

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 Tensile Test Requirements

• Test inspection requirements – mechanicals (TS & CT)

– Weld property determination per AWS D8.9M:2002, Section 11.6
• Static pull @ 10 mm/min
– Evaluate results per AWS D8.1M:2007, Section 5.4
• Weld size
• Fracture mode
• Peak load weld strength (per Equations Below)

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 Metallographic Test Requirements

• Test inspection requirements - metallographic

– Sample preparation per AWS D8.9M:2002, Section 11.5
• Micro-hardness and un-etched photo not required
• Etched photomicrograph at 10X
– Evaluate results per AWS D8.1M:2007, Section 5.2
• Fused nugget diameter
• Depth of penetration
• Welding discontinuities
– Porosity
– Voids
– Cracks
» Internal
» Surface

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 Results – Indentation AC

Weld Indentation

GMT
Material A Material B Material C Peel Sample Weld Indentation (mm) 30%
Test
(Top) (Middle) (Bottom) 2 - Top 2 - Bottom 4 - Top 4 - Bottom Limit
4165r1a 590R - 590R 1.20 0.45 0.42 0.41 0.36 0.36
4165r2a 590R (B) - 590R (B) 1.40 0.49 0.47 0.50 0.44 0.42
4165r3a 590R - 590R 1.54 0.64 0.61 0.53 0.45 0.46
4165r4a DP600 - DP600 1.20 0.29 0.42 0.37 0.52 0.36
4165r5a DP600 - DP600 1.60 0.48 0.49 0.44 0.50 0.48
4165r6a DP600 - DP600 1.97 0.77 0.83 0.69 0.68 0.59
4165r7a DP780 - DP780 1.15 0.39 0.38 0.45 0.41 0.35
4165r8a DP750 - DP750 1.50 0.59 0.41 0.47 0.42 0.45
4165r9a DP780 (B) - DP780 (B) 1.60 0.45 0.52 0.53 0.52 0.48
4165r10a TRIP800 - TRIP800 1.00 0.37 0.32 0.37 0.32 0.30
4165r11a TRIP800 - TRIP800 1.50 0.63 0.55 0.66 0.55 0.45
4165r12a DP980 - DP980 1.40 0.47 0.66 0.48 0.66 0.42
4165r13a DP980 (B) - DP980 (B) 1.60 0.41 0.37 0.41 0.42 0.48
4165r14a DP980 (B) - DP980 (B) 1.92 0.52 0.48 0.49 0.42 0.58
4165r15a DP600 - DP600 1.2/2.2 0.53 0.50 0.59 0.57 0.36 / 0.66
4165r16a DP780 - DP780 (B) 1.15/1.6 0.60 0.49 0.50 0.37 0.35 / 0.48
4165r17a TRIP800 - TRIP800 1.0/1.5 0.41 0.40 0.47 0.42 0.30 / 0.45
4165r18a DP980 - DP980 (B) 1.4/1.92 0.64 0.64 0.60 0.63 0.42 / 0.58
4165r19a Mild DP600 DP600 1.0/2.2 1.06 0.79 1.26 0.78 0.30 / 0.66
4165r20a Mild DP980 (B) DP980 (B) 1.0/1.92 1.05 0.67 1.11 0.73 0.30 / 0.58

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 Results – Indentation DC

Weld Indentation

GMT
Material A Material B Material C Peel Sample Weld Indentation (mm) 30%
Test
(Top) (Middle) (Bottom) 2 - Top 2 - Bottom 4 - Top 4 - Bottom Limit
4165r1d 590R - 590R 1.20 0.25 0.25 0.20 0.25 0.36
4165r2d 590R (B) - 590R (B) 1.40 0.17 0.17 0.16 0.19 0.42
4165r3d 590R - 590R 1.54 0.20 0.19 0.20 0.20 0.46
4165r4d DP600 - DP600 1.20 0.33 0.36 0.27 0.31 0.36
4165r5d DP600 - DP600 1.60 0.28 0.31 0.27 0.26 0.48
4165r6d DP600 - DP600 1.97 0.55 0.58 0.68 0.85 0.59
4165r7d DP780 - DP780 1.15 0.30 0.29 0.26 0.32 0.35
4165r8d DP750 - DP750 1.50 0.17 0.20 0.25 0.21 0.45
4165r9d DP780 (B) - DP780 (B) 1.60 0.31 0.27 0.31 0.32 0.48
4165r10d TRIP800 - TRIP800 1.00 0.31 0.31 0.48 0.47 0.30
4165r11d TRIP800 - TRIP800 1.50 0.18 0.20 0.21 0.22 0.45
4165r12d DP980 - DP980 1.40 0.15 0.18 0.13 0.16 0.42
4165r13d DP980 (B) - DP980 (B) 1.60 0.25 0.28 0.28 0.26 0.48
4165r14d DP980 (B) - DP980 (B) 1.92 0.51 0.44 0.45 0.42 0.58
4165r15d DP600 - DP600 1.2/2.2 0.54 0.62 0.45 0.45 0.36 / 0.66
4165r16d DP780 - DP780 (B) 1.15/1.6 0.43 0.40 0.46 0.43 0.35 / 0.48
4165r17d TRIP800 - TRIP800 1.0/1.5 0.68 0.66 0.44 0.44 0.30 / 0.45
4165r18d DP980 - DP980 (B) 1.4/1.92 0.19 0.18 0.20 0.21 0.42 / 0.58
4165r19d Mild DP600 DP600 1.0/2.2 0.60 0.42 0.92 0.74 0.30 / 0.66
4165r20d Mild DP980 (B) DP980 (B) 1.0/1.92 0.65 0.37 0.75 0.49 0.30 / 0.58

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 Results – Mechanical Testing AC

Mechanical Verification - AWS D8.1M:2007

GMT
Material A Material B Material C TS Average D8.1 CT Average D8.1
Test
(Top) (Middle) (Bottom) Peak Load TS Peak Load CT
4165r1a 590R - 590R 1.20 3419.2 1283.8 1196.8 419.7
4165r2a 590R (B) - 590R (B) 1.40 3349.2 1617.8 1871.0 589.1
4165r3a 590R - 590R 1.54 4785.0 1866.4 1250.0 726.5
4165r4a DP600 - DP600 1.20 3616.0 1304.8 1836.8 419.7
4165r5a DP600 - DP600 1.60 4897.8 2008.9 1912.7 790.3
4165r6a DP600 - DP600 1.97 5624.7 2744.6 1886.3 1248.9
4165r7a DP780 - DP780 1.15 4048.0 1557.2 1531.8 382.2
4165r8a DP750 - DP750 1.50 6204.0 2242.2 1818.5 685.7
4165r9a DP780 (B) - DP780 (B) 1.60 5053.7 2555.5 1659.7 790.3
4165r10a TRIP800 - TRIP800 1.00 3550.2 1290.1 1101.0 281.0
4165r11a TRIP800 - TRIP800 1.50 6042.0 2370.0 1461.7 685.7
4165r12a DP980 - DP980 1.40 5408.8 2493.3 1452.7 589.1
4165r13a DP980 (B) - DP980 (B) 1.60 5553.3 3046.2 2087.5 790.3
4165r14a DP980 (B) - DP980 (B) 1.92 6527.0 4004.3 3076.2 1180.2
4165r15a DP600 - DP600 1.20 3985.0 1304.8 1588.0 419.7
4165r16a DP780 - DP780 (B) 1.15 3921.3 1557.2 1184.0 382.2
4165r17a TRIP800 - TRIP800 1.00 4327.0 1290.1 1069.2 281.0
4165r18a DP980 - DP980 (B) 1.40 5838.3 2493.3 1687.7 589.1
4165r19a Mild DP600 DP600
4165r20a Mild DP980 (B) DP980 (B)

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 Results – Mechanical Testing DC

Mechanical Verification - AWS D8.1M:2007

GMT
Material A Material B Material C TS Average D8.1 CT Average D8.1
Test
(Top) (Middle) (Bottom) Peak Load TS Peak Load CT
4165r1d 590R - 590R 1.20 3232.8 1283.8 1085.8 419.7
4165r2d 590R (B) - 590R (B) 1.40 4647.5 1617.8 2780.3 589.1
4165r3d 590R - 590R 1.54 5755.7 1866.4 2010.0 726.5
4165r4d DP600 - DP600 1.20 3060.3 1304.8 1763.3 419.7
4165r5d DP600 - DP600 1.60 6226.7 2008.9 2676.3 790.3
4165r6d DP600 - DP600 1.97 7711.8 2744.6 2843.2 1248.9
4165r7d DP780 - DP780 1.15 4179.0 1557.2 1598.7 382.2
4165r8d DP750 - DP750 1.50 6906.3 2242.2 2976.2 685.7
4165r9d DP780 (B) - DP780 (B) 1.60 6668.2 2555.5 2760.8 790.3
4165r10d TRIP800 - TRIP800 1.00 4004.7 1290.1 959.8 281.0
4165r11d TRIP800 - TRIP800 1.50 6821.7 2370.0 1884.3 685.7
4165r12d DP980 - DP980 1.40 6326.0 2493.3 2668.0 589.1
4165r13d DP980 (B) - DP980 (B) 1.60 7995.7 3046.2 3022.3 790.3
4165r14d DP980 (B) - DP980 (B) 1.92 8193.7 4004.3 3422.2 1180.2
4165r15d DP600 - DP600 1.20 3813.7 1304.8 1802.2 419.7
4165r16d DP780 - DP780 (B) 1.15 4889.3 1557.2 1611.3 382.2
4165r17d TRIP800 - TRIP800 1.00 3606.3 1290.1 1280.2 281.0
4165r18d DP980 - DP980 (B) 1.40 7802.5 2493.3 2348.2 589.1
4165r19d Mild DP600 DP600
4165r20d Mild DP980 (B) DP980 (B)

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 Metallographic Inspection

AC – 7 DC – 7
1.15 mm DP780 Galvanized / 1.15 mm DP780 Galvanized

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 Metallographic Inspection

AC – 15 DC – 15
1.20 mm DP600 Galvanized / 2.20 mm DP600 Galvanized

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 Metallographic Inspection

AC – 18 DC – 18
1.40 mm DP980 Galvanized / 1.92 mm DP980 Bare

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 Phase II - Summary (1 of 2)

• Weld Schedules
– AC and DC schedules specify different electrodes
• Direct comparison of results difficult
– DC schedules had lower gauge transition to large electrodes
• AC @ 1.60 mm vs. DC @ 1.30 mm
• Affected amount of visible surfacing cracking and measurable
indentation in materials between the transition gauges
– Material between 1.30 and 1.60 mm (Trials #3 & #8)
– Longer hold times for DC
• Minor reduction in void formation (Trial #19)
– Nearly all schedules evaluated produced expulsion
– Indentation may predetermine peel weld size (Trials #11 & #19)

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 Phase II - Summary (2 of 2)

• Visual surface inspection

– No evidence of surface cracking
• Did not use magnification device
– Most indentation measurements in excess of 30% limit
• DC slightly better due to electrode geometry

• Mechanical evaluation
– All peak loads exceeded requirements of AWS D8.1
• Many results 2x or 3x greater than requirements

• Metallographic evaluation
– Over 50% of welds with surface cracks
• More evidence of AC surface cracks than DC

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 Acknowledgements

• Kevin Chan, Huys Industries – simulation work on DC

weld schedules

• Wenqi Zhang, SWANTEC Software and Engineering

ApS – technical support with SORPAS software

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 FOR MORE INFORMATION

• Contact:
Mike Bzdok, Project Manager
(248) 945-4778
mbzdok@a-sp.org

Eric Pakalnins
(248) 576-7454
ep18@chrysler.com

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