ADVANCED HIGH STRENGTH STEEL (AHSS) WELD PERFORMANCE STUDY FOR AUTOBODY STRUCTURAL COMPONENTS
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- Edward Parker
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2 A/SP Joining Technologies Committee Report ADVANCED HIGH STRENGTH STEEL (AHSS) PERFORMANCE STUDY FOR AUTOBODY STRUCTURAL COMPONENTS Welding Processes Performed by RoMan Engineering Services Supervised by Auto/Steel Partnership Joining Project Structural Welding Sub Group Members
3 TABLE OF CONTENT Joining Team Members... 5 Project Background... 7 Sample Design... 8 Weld Quality Measurement... 9 Test Coupon Sample Coding...11 Test Matrix...12 Results of Weld Tests...13 Material Chemistry...13 Material Physical Properties...14 Summary Data for Each Process...14 Group Laser Welding (Material Combinations)...15 Group-1: Laser Welding (Material Combination 1)...16 Group-1: Laser Welding (Material Combination 3)...17 Group-1: Laser Welding (Material Combination 3)...18 Group-1: Laser Welding (Material Combination 4)...18 Group-1: Laser Welding (Material Combination 4)...19 Group-1: Laser Welding (Material Combination 5)...20 Group-1: Laser Welding (Material Combination 8)...20 Group-1: Laser Welding (Material Combination 8)...21 Group-1: Laser Welding (Material Combination 9)...22 Group-1: Laser Welding (Impact Strength at 15 MPH)...23 Group-1: Laser Welding (Tensile Shear Data)...23 Group-1: Laser Welding (Tensile Shear Data)...24 Group Laser-GMAW (Material Combinations)...25 Group-2: Laser GMAW (Material Combination 1)...26 Group-2: Laser GMAW (Material Combination 3)...27 Group-2: Laser GMAW (Material Combination 3)...28 Group-2: Laser GMAW (Material Combination 4)...28 Group-2: Laser GMAW (Material Combination 4)...29 Group-2: Laser GMAW (Material Combination 5)...29 Group-2: Laser GMAW (Material Combination 8) 70 KSI Filler...30 Group-2: Laser GMAW (Material Combination 8) 70 KSI Filler...31
4 Group-2: Laser GMAW (Material Combination 9) 90 ksi Filler...31 Group-2: Laser GMAW (Material Combination 9) 90 ksi Filler...32 Group-2: Laser GMAW(Material Combination 9) 70 ksi Filler...33 Group-2: Laser GMAW (Material Combination 9) 90 ksi Filler...34 Group-2: Laser GMAW (Impact Strength at 15 MPH)...35 Group-2: Laser GMAW (Tensile Shear Data)...36 Group Laser Plasma Welding (Material Combinations)...37 Group-3: Laser Plasma Welding (Material Combination 1)...38 Group-3: Laser Plasma Welding (Material Combination 3)...39 Group-3: Laser Plasma Welding (Material Combination 3)...40 Group-3: Laser Plasma Welding (Material Combination 4)...40 Group-3: Laser Plasma Welding (Material Combination 4)...41 Group-3: Laser Plasma Welding (Material Combination 8)...42 Group-3: Laser Plasma Welding (Material Combination 8)...43 Group-3: Laser Plasma Welding (Material Combination 9)...43 Group-3: Laser Plasma Welding (Material Combination 9)...44 Group-3: Laser Plasma Welding (Impact Strength at 15 MPH)...44 Group-3: Laser Plasma Welding (Impact Strength at 15 MPH)...45 Group-3: Laser Plasma Welding (Tensile Shear Data)...46 Group Group GMAW AC (Material Combinations)...47 Group-4: GMAW AC (Material Combination 1)...48 Group-4: GMAW AC (Material Combination 2)...48 Group-4: GMAW AC (Material Combination 2)...49 Group-4: GMAW AC (Material Combination 3)...49 Group-4: GMAW AC (Material Combination 3)...50 Group-4: GMAW AC (Material Combination 4)...50 Group-4: GMAW AC (Material Combination 4)...51 Group-4: GMAW AC (Material Combination 5)...51 Group-4: GMAW AC (Material Combination 5)...52 Group-4: GMAW AC (Material Combination 8) 70 KSI Filler...52 Group-4: GMAW AC (Material Combination 8) 70 KSI Filler...53 Group-4: GMAW AC (Material Combination 8) 90 ksi Filler...53
5 Group-4: GMAW AC (Material Combination 8) 90 ksi Filler...54 Group-4: GMAW AC (Material Combination 9) 90 ksi Filler...56 Group-4: GMAW AC (Impact Strength at 15 MPH)...56 Group-4: GMAW AC (Tensile Shear Data)...57 Group-4: GMAW AC (Tensile Shear Data)...58 Group Group GMAW DC (Material Combinations)...59 Group-5: GMAW DC (Material Combination 1)...60 Group-5: GMAW DC (Material Combination 2)...60 Group-5: GMAW DC (Material Combination 3)...61 Group-5: GMAW DC (Material Combination 3)...62 Group-5: GMAW DC (Material Combination 4)...62 Group-5: GMAW DC (Material Combination 4)...63 Group-5: GMAW DC (Material Combination 5)...63 Group-5: GMAW DC (Material Combination 5)...64 Group-5: GMAW DC (Material Combination 8) 70 KSI Filler...64 Group-5: GMAW DC (Material Combination 8) 70 KSI Filler...65 Group-5: GMAW DC (Material Combination 8) 90 ksi Filler...65 Group-5: GMAW DC (Material Combination 8) 90 ksi Filler...66 Group-5: GMAW DC (Material Combination 9) 70 ksi Filler...66 Group-5: GMAW DC (Material Combination 9) 90 ksi Filler...67 Group-5: GMAW DC (Material Combination 9) 90 ksi Filler...68 Group-5: GMAW DC (Impact Strength at 15 MPH)...69 Group-5: GMAW DC (Tensile Shear Data)...69 Group-5: GMAW DC (Tensile Shear Data)...70 Appendix A: Welding Equipment Photographs...70 Appendix A: Welding Equipment Photographs...71
6 Joining Team Members James Dolfi Chairman A/SP Consultant Arnon Wexler Chairman SWSG Ford Motor Company I. Accorsi Daimler Chrysler Corporation J. C. Bohr* General Motors Corporation Chris Chen General Motors Corporation T. Coon Ford Motor Company A. M. Joaquin* Ford Motor Company Min Kuo Mittal Steel USA S. Lalam Mittal Steel USA Andy Lee Dofasco Inc W. Marttila* Daimler Chrysler Corporation Eric Pakalnins Daimler Chrysler Corporation B. B Patel Daimler Chrysler Corporation M. Tumuluru United States Steel Corporation Jim F. Quinn General Motors Corporation A. Ray* General Motors Corporation Consultants M. D'Agostin RoMan Engineering Services Eric Young Warren Peterson Hongyan Zhang RoMan Engineering Services Edison Welding Institute University of Toledo * SWSG project sub team
7 Abstract The fusion welding processes have historically been, and are today, commonly used in the manufacture of automotive structures. Recent increased usage of Advanced High Strength Steels (AHSS) in automotive designs posed a desire to evaluate the application of fusion welding processes relative to the joining of AHSS. This project establishes suitable welding parameters for AHSS material iterations (DP600, DP780, DP800, DP980 and HSLA350). Material section thicknesses ranged from 1.0mm to 3.4mm. Five fusion welding processes (GMAW-Pulse/AC, GMAW- Pulse/DC, Laser-GMAW, Laser, and Laser-Plasma) were examined in this operation. Special consideration was given to the acceptance criteria for this project s welds. The standards of General Motors, Ford, and DaimlerChrysler were reviewed and a derivative acceptance standard was established for this study. Hardness/Metallographic, Impact, and Yield/Tensile properties related to the resulting weldments are presented as the results of this investigation. The primary conclusions of this study can be summarized as: AHSS materials were successfully joined with the processes studied. Weld processes utilizing filler material 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 the weldment strength. Material strength and/or thickness gauge had no influence on laser welded joint strength. Zinc coated materials demonstrated high levels of porosity without a controlled/ engineered gap. Page 6 of 75
8 Project Background This project was conducted to analyze the application of Gas Metal Arc Welding (GMAW) 1, Laser and Hybrid welds made in several combinations of Advanced High Strength Steels (AHSS) proposed by A/SP Focus groups for use in Auto body structural components. Four grades of steel selected for use in high performance structural components were tested. Table 1 shows the nominal material grades and coatings. All material grades are expressed as Ultimate Tensile Strength (UTS) in MPa except the HSLA 350 which is purchased based on Yield Strength (Y). Materials were supplied to the test facilities from A/SP steel partners sample inventory. Tables elsewhere may show values slightly different that the nominal values shown in table 1. For example, DP 590 shown in physical data tables supplied by test labs is test material DP 600 nominal. Table 1: Material Grades, Gage and Coating. Material Grade Purchased Gage (mm) Coating Designation HSLA 350 (Y) 3.2 None HSLA 350 (Y) 1.38 GI DP None DP GI DP GA DP GA DP GA DP GA DP GA GA = Galvanneal, GI = HDG ( HOT DIP GALVANIZED) Coating weight was 40g/m 2 for galvanneal, 60g/m 2 for GI The objective of this project was to, using five single sided weld process variations, determine suitable welding parameters for the supplied AHSS materials, and test a specified number of Micro-hardness/Metallographic, Impact, and Tensile-Shear sample weldments. Test specimens were prepared from the materials to collect data for static shear, micro-hardness, and impact energy. The sample preparation matrix is shown in Table 5. Processes and equipment were selected to represent both conventional robotically applied body shop welding practices used today and advanced processes that could potentially be used for single side welding of the selected materials. 1 GMAW is the AWS standard term for welding often referred to as MIG welding Page 7 of 75
9 GMAW, Laser and Plasma equipment used to for fabricating test samples was commercially available and considered qualified by prove-out in other production applications. Members of the A/SP joining team monitored all phases of sample fabrication and approved final process setup prior to proceeding with sample fabrication for testing. Table 2 reports processes that were used on selected combinations of the AHSS materials. Table 2: Processes utilized in this project. Process Process Detail GMAW (MIG) GMAW (MIG) GMAW Pulsed DC GMAW Pulsed AC GMAW Laser Assisted Hybrid YAG Laser/GMAW-Pulsed DC Laser Laser - Plasma Assisted YAG Laser Hybrid YAG Laser/Plasma Sample Design Samples of material were constructed to the dimensions shown in Figure 1. The weld location was centered between the edges of the sample and the robot travel distance was 25 mm total. This produced a weld with start and stop characteristics to be included in all tensile shear and impact testing. The length of the weld was limited to 25 mm to allow use of existing impact test equipment from previous A/SP weld tests. Impact samples, shown in Figure 2, were fabricated from blanks that were 75mm wide. Bend radius for the ends was approximately 6.5 mm. Special end treatments were applied by the University of Toledo that performed the final impact sample fitting and testing using a unique weld test impact machine. Page 8 of 75
10 mm mm mm mm Figure : Sample for tensile shear. Shims were placed at each end to keep the fatigue load applied along a line through the plane of the weld mm mm 50 mm 125 mm Figure 1: Side view of typical impact test sample. Sample is 75 mm wide, bend radius is approximately 6 mm. Weld Quality Measurement Special consideration was given to quality acceptance of the welds for this project. Several standards exist among the OEM s that specify attribute and measurement requirements for conventional steel welding. Three standards were reviewed and the quality acceptance criteria were selected from the three standards. Table 3 reports the derivative requirements for the SWSG project and source of the OEM document. Page 9 of 75
11 Table 3: Quality Requirements for SWSG AHSS Welding Criterion Source Document Derivative SWSG Requirement Porosity - Internal GM GM 4490M, 1991 Cross-section- 25% limit of total area Porosity - Surface GM GM 4490M, 1991 < 25% Weld Length A/SP SWSG /- 1.0mm Weld Width at Interface A/SP SWSG >= 75% of thinner metal, then 1.0 mm Weld Width at Surface A/SP SWSG Report only, no requirement Weld Location A/SP SWSG As specified +/- 1.0mm Burn-through (Hole) GM GM 4490M, 1991 Not allowed Under Cut (Maximum) Chrysler PS , NOV 6, CHG B 5% of thinnest metal Convexity Not addressed (Heat Affected Zone) Not addressed Penetration Chrysler PS , NOV 6, CHG B >= 20% into second metal Gap (under pressure) Not addressed Page 10 of 75
12 Test Coupon Sample Coding Samples were coded as shown in Table 4. The source files on the CD contain engineering test data that follows the reported process coding format. The CD is organized by process; therefore, the sample number is shown only if the process folder is accessed. A typical file structure for data organization is shown in table 4. Table 4: Sample Identification Codes Sample Number Test Type Stack-up Number 01 through 41 IM = Impact 01 through 05 TS= Tensile 08 through 09 MS = Metallographic ES = Extra Sample Example: 01-IM LM This would indicate sample number 01 for impact testing, stack-up combination 02, using filler wire with 90 ksi tensile strength, welded with a Laser assisted GMAW (MIG) process. Page 11 of 75
13 Test Matrix The test plan specified five weld samples for each of the stack up combinations for testing for each process evaluation. Five samples each were tested for impact, tensile shear and one sample form each process was prepared for micro hardness testing. Fatigue testing of each process required 25 samples for spectrum analysis. Fatigue data is reported under a separate A/SP document. Table 5: Material Test Matrix. Stack-up Combination Process MIG AC Number Top Sheet Bottom Sheet Evaluation MIG DC Filler 1 3.4mm DP600 Bare 3.4mm DP600 Bare AC, DC, LS, LM, PL 70 ksi (see each sheet) mm DP600 HDG 3.2mm HSLA Bare AC, DC, LS, LM, PL 70 ksi (see each sheet) mm HSLA 350 HDG 3.2mm HSLA Bare AC, DC, LS, LM, PL 70 ksi (see each sheet) mm DP980 GA 1.18mm DP980 GA AC, DC, LS, LM, PL 70 ksi (see each sheet) 5 1.0mm DP800 GA 1.0mm DP800 GA AC, DC, LS, LM, PL 70 ksi (see each sheet) mm DP 600 GA mm DP780GA 1.87mm DP 780 GA 1.87mm DP 780 GA AC, DC, LS, LM, PL AC, DC, LS, LM, PL 70 and 90 ksi (See each sheet) 70 and 90 ksi (See each sheet) Process Legend AC = AC GMAW DC = DC GMAW LS = Laser (No Filler Wire) LM = Laser Assisted GMAW PL = Plasma Assisted Laser (No Filler Wire) Page 12 of 75
14 Results of Weld Tests All processes were capable of producing weld joints having useful engineering properties. Joint strength is strongly related to the area of the weld joining the thinner of the two pieces. 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 conditions and less than ideal weld geometry at ends of the weld. Similar results can be obtained for laser welds using the weld width reported in the section photographs to calculate the area of the weld and multiply that by the UTS of the thinner sheet. These weld tests provide nominal parameter values that can be used to establish a starting point for making confirmation samples prior to fabricating prototype parts. Material Chemistry Table 6: Material Chemistry. Elements Materials C Mn P S Si Cr Mo Al N Ti Other 1.15mm DP 600 HDG 1.52mm DP 600 GN 3.4mm DP600 BARE 3.2mm HSLA 350 BARE 1.18mm DP 980 GN 1.87mm DP 780 GN 1.17mm DP 780 GN 1.0mm DP 800 GN 1.38mm HSLA 350 HDG < < < V=0.005 Cu=0.041 V=0.003 Cu=0.037 V=0.004 Cu=0.016 V=0.049 Cu=0.021 V=0.007 Cu=0.023 V=0.005 Cu=0.025 V=0.007 Cu=0.028 V=0.007 Cu=0.031 V=0.006 Cu=0. Page 13 of 75
15 Material Physical Properties Table 7: Material Physical Properties. Material Used in Stack Thickness Upper Yield Point Lower Yield Point Peak Load 0% Droop (mm) (ksi) (ksi) (ksi) (lb-in) 3.4mm DP 600 BARE mm HSLA 350 BARE 2, mm DP 800 GN mm DP 780 GN mm DP 600 GN mm DP 780 GN mm DP 980 GN mm DP 600 HDG mm HSLA 350 HDG Summary Data for Each Process A list of the grouping structure is provided below. Each process group includes; a list of material combinations, machine type travel description, combination parameters, and summary data (impact and tensile shear). Table 8: Grouping Summary Group Description Figures Tables 1 Laser Welding G1-1, G1-32 G1-1, G1-8 2 Laser GMAW G2-1, G2-31 G2-1, G Laser Plasma G3-1, G3-32 G3-1, G3-8 4 GMAW AC G4-1, G4-22 G4-1, G GMAW DC G5-1, G5-22 G5-1, G5-10 Page 14 of 75
16 Group-1 Laser Welding (Material Combinations) Table-G1-1: Parameters and Data Stack-up Combination Number Top Sheet Bottom Sheet 1 3.4mm DP600 Bare 3.4mm DP600 Bare mm DP600 HDG 3.2mm HSLA 350 Bare mm HSLA 350 HDG 3.2mm HSLA 350 Bare mm DP980 GA 1.18mm DP980 GA 5 1.0mm DP800 GA 1.0mm DP800 GA mm DP mm DP 780 GN mm DP780GA 1.87mm DP 780 GN Machines: Laser: Rofin NDI YAG Model DY kW Head: HighYAG with focal length of 150 mm Robot: Gantry type Machine Manufacture: EFD LIHM Note: Focus position is expressed as + for dimensions above the material surface. Fiber optic is 600 micron in diameter. Page 15 of 75
17 Group-1: Laser Welding (Material Combination 1) Figure G1-1: Top sheet: 3.4mm DP600 Bare, Bottom sheet: 3.4mm DP600 Bare. Figure G1-2: Hardness measurement path Table-G1-2: Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed 1.00 m/ min Min Focus Position -2.0 mm Average Gas (Laser) Ar Max Gap (engineered) 0 mm Shielding Gas Flow Ar, 18 CFH Impact Strength Load (kn) Energy (J) Min Average Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G1-4: Bottom Sheet Microhardness Traverse. Page 16 of 75
18 Group-1: Laser Welding (Material Combination 2) Figure G1-5: Top sheet: 1.15mm DP600 HDG, Bottom sheet: 3.2mm HSLA 350 Bare. Figure G1-6: Hardness measurement path Table-G1-3: Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed 2.40 m/ min Min Focus Position +1.8 mm Average Gas (Laser) Ar Max Gap (engineered) 0 mm Shielding Gas Flow Ar, 18 CFH Impact Strength Load (kn) Energy (J) Min Average Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G1-7: Top Sheet Microhardness Traverse. Figure G1-8: Bottom Sheet Microhardness Traverse. Page 17 of 75
19 Group-1: Laser Welding (Material Combination 3) Figure G1-9: Top sheet: 1.38mm HSLA 350 HDG, Bottom sheet: 3.2mm HSLA 350 Bare. Figure G1-10: Hardness measurement path Table-G1-4: Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed 1.90 m/ min Min Focus Position +1.5 mm Average Gas (Laser) Ar Max Gap (engineered) 0.1 mm Shielding Gas Flow Ar, 18 CFH Impact Strength Load (kn) Energy (J) Min Average Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G1-11: Top Sheet Microhardness Traverse. Figure G1-12: Bottom Sheet Microhardness Traverse. Page 18 of 75
20 Group-1: Laser Welding (Material Combination 4) Figure G1-13: Top sheet: 1.18mm DP980 GA, Bottom sheet: 1.18mm DP980 GA. Figure G1-14: Hardness measurement path Table-G1-5: Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed 2.70 m/ min Min Focus Position +1.8 mm Average Gas (Laser) Ar Max Gap (engineered) 0.1 mm Shielding Gas Flow Ar, 18 CFH Impact Strength Load (kn) Energy (J) Min Average Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G1-15: Top Sheet Microhardness Traverse. Figure G1-16: Bottom Sheet Microhardness Traverse. Page 19 of 75
21 Group-1: Laser Welding (Material Combination 5) Figure G1-17: Top sheet: 1.0mm DP800 GA, Bottom sheet: 1.0mm DP800 GA. Figure G1-18: Hardness measurement path Table-G1-6: Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed 3.25 m/ min Min Focus Position +1.8 mm Average Gas (Laser) Ar Max Gap (engineered) 0.1 mm Shielding Gas Flow Ar, 20 CFH Impact Strength Load (kn) Energy (J) Min Average Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G1-19: Top Sheet Microhardness Traverse. Figure G1-20: Bottom Sheet Microhardness Traverse. Page 20 of 75
22 Group-1: Laser Welding (Material Combination 8) Figure G1-21: Top sheet: 1.52mm DP 600 Bottom sheet: 1.87mm DP 780 GN. Figure G1-22: Hardness measurement path Table-G1-7: Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed 2.00 m/ min Min Focus Position +1.5 mm Average Gas (Laser) Ar Max Gap (engineered) 0.1 mm Shielding Gas Flow Ar, 18 CFH Impact Strength Load (kn) Energy (J) Min Average Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G1-23: Top Sheet Microhardness Traverse. Figure G1-24: Bottom Sheet Microhardness Traverse. Page 21 of 75
23 Group-1: Laser Welding (Material Combination 9) Figure G1-25: Top sheet: 1.17mm DP780 GA Bottom sheet: 1.87mm DP 780 GN. Figure G1-26: Hardness measurement path Table-G1-8: Parameters and Data Laser power 2.0 kw Load (kn) Energy (J) Weld speed 2.60 m/ min Min Focus Position +1.5 mm Average Gas (Laser) Ar Max Gap (engineered) Shielding Gas Flow 0.1 mm Ar, 20 CFH Impact Strength Load (kn) Energy (J) Min Average Max VICKERS HARDNESS (HV) VICKERS HARDNESSS (HV) Figure G1-27: Top Sheet Microhardness Traverse. Figure G1-28: Bottom Sheet Microhardness Traverse. Page 22 of 75
24 .00 Group-1: Laser Welding (Impact Strength at 15 MPH) LASER AVERAGE IMPACT PEAK LOAD (kn) IM-01 IM-02 IM-03 IM-04 IM-05 IM-08 IM-09 Figure G1-29: Impact Strength Peak Load. LASER AVERAGE IMPACT ENERGY (J) IM-01 IM-02 IM-03 IM-04 IM-05 IM-08 IM-09 Figure G1-30: Impact Strength Energy. Page 23 of 75
25 Group-1: Laser Welding (Tensile Shear Data) LASER AVERAGE PEAK LOAD (kn) TS TS TS TS TS TS TS-09 Figure G1-31: Tensile Shear Load. LASER AVERAGE ENERGY (J) TS TS TS TS TS TS TS-09 Figure G1-32: Tensile Shear Energy. Page 24 of 75
26 Group-2 Laser-GMAW (Material Combinations) Table G2-1: Stack-up Combination Stack-up Combination Number Top Sheet Bottom Sheet 1 3.4mm DP600 Bare 3.4mm DP600 Bare mm DP600 HDG 3.2mm HSLA 350 Bare mm HSLA 350 HDG 3.2mm HSLA 350 Bare mm DP980 GA 1.18mm DP980 GA 5 1.0mm DP800 GA 1.0mm DP800 GA mm DP mm DP 780 GN mm DP780GA 1.87mm DP 780 GN Machines: Laser: Rofin NDI YAG Model DY kW Head: HighYAG with focal length of 150 mm Power Source: Lincoln Electric Powerwave 455 Robot: Gantry type Machine Manufacture: EFD LIHM Note: Focus position is expressed as + for dimensions above the material surface. Fiber optic is 600 micron in diameter. Page 25 of 75
27 Group-2: Laser GMAW (Material Combination 1) Figure G2-1: Top sheet: 3.4mm DP600 Bare, Bottom sheet: 3.4mm DP600 Bare. Figure G2-2: Hardness measurement path Table-G2-2: Parameters and Data Laser power 2.5 kw Load (kn) Energy (J) Weld speed 10.6 m/ min Min Focus Position +1.0 mm Average Wire Spec. 1.14mm Dia. ER70S6 Max MIG Current Wire Feed Rate 219A 10.6m/ min Weld Volts 19.2V Impact Strength Gap (engineered) 0mm Load (kn) Energy (J) Shielding Gas Flow Ar, 18 CFH Min Shielding Gas 92% Ar/8% CO 2 Average Max VICKERS HARDNESS (HV) Figure G2-3: Microhardness Traverse. Page 26 of 75
28 Group-2: Laser GMAW (Material Combination 2) Figure G2-4: Top sheet: 1.15mm DP600 HDG, Bottom sheet: 3.2mm HSLA 350 Bare Figure G2-5: Hardness measurement path Table-G2-3: Parameters and Data Laser power 2.0 kw Load (kn) Energy (J) Weld speed 2.65 m/ min Min Focus Position +1.0 mm Average Wire Spec. 0.9mm Dia. ER70S6 Max MIG Current 132A Wire Feed Rate 8.7m/ min Weld Volts 14.6V Impact Strength Gap (engineered) 0mm Load (kn) Energy (J) Shielding Gas Flow Ar, 18 CFH Min Shielding Gas 92% Ar/8% CO 2 Average Max VICKERS HARDNESS (HV) Figure G2-6: Microhardness Traverse. Page 27 of 75
29 Group-2: Laser GMAW (Material Combination 3) Figure G2-7: Top sheet: 1.38mm HSLA 350 HDG, Bottom sheet: 3.2mm HSLA 350 Bare Figure G2-8: Hardness measurement path Table-G2-4: Parameters and Data Laser power 2.0 kw Load (kn) Energy (J) Weld speed 2.60 m/ min Min Focus Position +1.0 mm Average Wire Spec. 1.0mm Dia. ER70S6 Max MIG Current Wire Feed Rate 219A 8.9m/ min Weld Volts 14.2V Impact Strength Gap (engineered) 0mm Load (kn) Energy (J) Shielding Gas Flow Ar, 18 CFH Min Shielding Gas 92% Ar/8% CO 2 Average Max VICKERS HARDNESS (HV) Figure G2-9: Microhardness Traverse. Page 28 of 75
30 Group-2: Laser GMAW (Material Combination 4) Figure G2-10: Top sheet: 1.18mm DP980 GA, Bottom sheet: 1.18mm DP980 GA. Figure G2-11: Hardness measurement path Table-G2-5: Parameters and Data Laser power 1.3 kw Load (kn) Energy (J) Weld speed 2.65 m/ min Min Focus Position +1.0 mm Average Wire Spec. 0.9mm Dia. ER70S6 Max MIG Current 110A Wire Feed Rate 8.7m/ min Weld Volts 13.3V Impact Strength Gap (engineered) 0.1 mm Load (kn) Energy (J) Shielding Gas Flow Ar, 18 CFH Min Shielding Gas 92% Ar/8% CO 2 Average Max VICKERS HARDNESS (HV) Figure G2-12: Microhardness Traverse. Page 29 of 75
31 Group-2: Laser GMAW (Material Combination 5) Figure G2-13: Top sheet: 1.0mm DP800 GA, Bottom sheet: 1.0mm DP800 GA. Figure G2-14: Hardness measurement path Table-G2-6: Parameters and Data Laser power 1.3 kw Load (kn) Energy (J) Weld speed 2.65 m/ min Min Focus Position +1.0 mm Average Wire Spec. 0.9mm Dia. ER70S6 Max MIG Current 124A Wire Feed Rate 8.2m/ min Weld Volts 15.3V Impact Strength Gap (engineered) 0.1 mm Load (kn) Energy (J) Shielding Gas Flow Ar, 18 CFH Min Shielding Gas 92% Ar/8% CO 2 Average Max VICKERS HARDNESS (HV) Figure G2-15: Microhardness Traverse. Page 30 of 75
32 Group-2: Laser GMAW (Material Combination 8) 70 KSI Filler Figure G2-16: Top sheet: 1.52mm DP 600 Bottom sheet: 2.0mm DP 780 Figure G2-17: Hardness measurement path Table-G2-7: Parameters and Data Laser power 2.0 kw Load (kn) Energy (J) Weld speed 2.60 m/ min Min Focus Position +1.0 mm Average Wire Spec. 0.9mm Dia. ER70S6 Max MIG Current 136A Wire Feed Rate 8.9m/ min Weld Volts 15.2V Impact Strength Gap (engineered) 0.1 mm Load (kn) Energy (J) Shielding Gas Flow Ar, 18 CFH Min Shielding Gas 92% Ar/8% CO 2 Average Max VICKERS HARDNESS (HV) Figure G2-18: Microhardness Traverse. Page 31 of 75
33 Group-2: Laser GMAW (Material Combination 8) 90 ksi Filler Figure G2-19: Top sheet: 1.52mm DP 600 GA Bottom sheet: 2.0mm DP 780. Figure G2-20: Hardness measurement path Table-G2-8: Parameters and Data Laser power 2.0 kw Load (kn) Energy (J) Weld speed 2.60 m/ min Min Focus Position +1.0 mm Average Wire Spec. 0.9mm Dia. ER90SD2 Max MIG Current 136A Wire Feed Rate 8.9m/ min Weld Volts 15.2V Impact Strength Gap (engineered) 0.1 mm Load (kn) Energy (J) Shielding Gas Flow Ar, 18 CFH Min Shielding Gas 92% Ar/8% CO 2 Average Max VICKERS HARDNESS (HV) Figure G2-21: Microhardness Traverse. Page 32 of 75
34 Group-2: Laser GMAW(Material Combination 9) 70 ksi Filler Figure G2-22: Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780. Figure G2-23: Hardness measurement path Table-G2-9: Parameters and Data Laser power 2.0 kw Load (kn) Energy (J) Weld speed 2.65 m/ min Min Focus Position +1.0 mm Average Wire Spec. 0.9mm Dia. ER70S6 Max MIG Current 110A Wire Feed Rate 8.6m/ min Weld Volts 16.8V Impact Strength Gap (engineered) 0.1 mm Load (kn) Energy (J) Shielding Gas Flow Ar, 18 CFH Min Shielding Gas 92% Ar/8% CO 2 Average Max VICKERS HARDNESS (HV) Figure G2-24: Microhardness Traverse. Page 33 of 75
35 Group-2: Laser GMAW (Material Combination 9) 90 ksi Filler Figure G2-25: Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780. Figure G2-26: Hardness measurement path Table-G2-10: Parameters and Data Laser power 2.0 kw Load (kn) Energy (J) Weld speed 2.65 m/ min Min Focus Position +1.0 mm Average Wire Spec. 0.9mm Dia. ER90SD2 Max MIG Current 118A Wire Feed Rate 8.6m/ min Weld Volts 16.8V Impact Strength Gap (engineered) 0.1 mm Load (kn) Energy (J) Shielding Gas Flow Ar, 18 CFH Min Shielding Gas 92% Ar/8% CO 2 Average Max VICKERS HARDNESS (HV) Figure G2-27: Microhardness Traverse. Page 34 of 75
36 Group-2: Laser GMAW (Impact Strength at 15 MPH).00 LASER-GMAW AVERAGE IMPACT PEAK LOAD (kn) IM IM IM IM IM IM IM IM IM Figure G2-28: Impact Strength Peak Load. LASER-GMAW AVERAGE IMPACT ENERGY (J) IM IM IM IM IM IM IM IM IM Figure G2-29: Impact Strength Peak Energy. Page 35 of 75
37 Group-2: Laser GMAW (Tensile Shear Data) LASER-GMAW AVERAGE PEAK LOAD (kn) TS TS TS Figure G2-30: Tensile Shear Load. 06-TS TS TS TS TS TS LASER-GMAW AVERAGE ENERGY (J) TS TS TS Figure G2-31: Tensile Shear Energy. 06-TS TS TS TS TS TS Page 36 of 75
38 Group-3 Laser Plasma Welding (Material Combinations) Table G3-1: Stack-up Combination Stack-up Combination Number Top Sheet Bottom Sheet 1 3.4mm DP600 Bare 3.4mm DP600 Bare mm DP600 HDG 3.2mm HSLA 350 Bare mm HSLA 350 HDG 3.2mm HSLA 350 Bare mm DP980 GA 1.18mm DP980 GA 5 1.0mm DP800 GA 1.0mm DP800 GA mm DP mm DP 780 GN mm DP780GA 1.87mm DP 780 GN Machines: Laser: Rofin NDI YAG Model DY kW Head: HighYAG with focal length of 150 mm Robot: Gantry type Machine: Thermal Arc Ultima 150 with Manual Plasma Torch 3A Note: Focus position is expressed as + for dimensions above the material surface. Fiber optic is 600 micron in diameter. Page 37 of 75
39 Group-3: Laser Plasma Welding (Material Combination 1) Figure G3-1: Top sheet: 3.4mm DP600 Bare, Bottom sheet: 3.4mm DP600 Bare Figure G3-2: Hardness measurement path Table-G3-2: Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed mm/ sec Min Focus Position mm Average Gas (Laser) Ar, 20 CFH Max Ramp 1 (Laser) 1 ms Ramp 2 (Laser) 1335 ms Ramp 3 (Laser) 50 ms Plasma Current 100A Impact Strength Plasma Gas Flow Ar, 2.0 CFH Load (kn) Energy (J) Shielding Gas Flow Ar, 20 CFH Min Position of Plasma Tip Above Surface 5.0 mm Average Distance Between Laser and Plasma Spot 3.0 mm Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G3-3: Top Sheet Microhardness Traverse. Figure G3-4: Bottom Sheet Microhardness Traverse. Page 38 of 75
40 Group-3: Laser Plasma Welding (Material Combination 2) Figure G3-5: Top sheet: 1.15mm DP600 HDG, Bottom sheet: 3.2mm HSLA 350 Bare Figure G3-6: Hardness measurement path Table-G3-3 Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed mm/ sec Min Focus Position mm Average Gas (Laser) Ar, 20 CFH Max Ramp 1 (Laser) 1 ms Ramp 2 (Laser) 560 ms Ramp 3 (Laser) 50 ms Plasma Current 110A Impact Strength Plasma Gas Flow Ar, 2.0 CFH Load (kn) Energy (J) Shielding Gas Flow Ar, 20 CFH Min Position of Plasma Tip Above Surface 5.0 mm Average Distance Between Laser and Plasma Spot 3.0 mm Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G3-7: Top Sheet Microhardness Traverse. Figure G3-8: Bottom Sheet Microhardness Traverse. Page 39 of 75
41 Group-3: Laser Plasma Welding (Material Combination 3) Figure G3-9: Top sheet: 1.38mm HSLA 350 HDG, Bottom sheet: 3.2mm HSLA 350 Bare Figure G3-10: Hardness measurement path Table-G3-4 Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed mm/ sec Min Focus Position mm Average Gas (Laser) Ar, 20 CFH Max Ramp 1 (Laser) 1 ms Ramp 2 (Laser) 560 ms Ramp 3 (Laser) 50 ms Plasma Current 110A Impact Strength Plasma Gas Flow Ar, 2.0 CFH Load (kn) Energy (J) Shielding Gas Flow Ar, 20 CFH Min Position of Plasma Tip Above Surface 5.0 mm Average Distance Between Laser and Plasma Spot 3.0 mm Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G3-11: Top Sheet Microhardness Traverse. Figure G3-12: Bottom Sheet Microhardness Traverse. Page 40 of 75
42 Group-3: Laser Plasma Welding (Material Combination 4) Figure G3-13: Top sheet: 1.18mm DP980 GA, Bottom sheet: 1.18mm DP980 GA. Figure G3-14: Hardness measurement path Table-G3-5 Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed mm/ sec Min Focus Position mm Average Gas (Laser) Ar, 20 CFH Max Ramp 1 (Laser) 1 ms Ramp 2 (Laser) 395 ms Ramp 3 (Laser) 53 ms Plasma Current 75A Impact Strength Plasma Gas Flow Ar, 2.0 CFH Load (kn) Energy (J) Shielding Gas Flow Ar, 20 CFH Min Position of Plasma Tip Above Surface 5.0 mm Average Distance Between Laser and Plasma Spot 2.5 mm Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G3-15: Top Sheet Microhardness Traverse. Figure G3-16: Bottom Sheet Microhardness Traverse. Page 41 of 75
43 Group-3: Laser Plasma Welding (Material Combination 5) Figure G3-17: Top sheet: 1.0mm DP800 GA, Bottom sheet: 1.0mm DP800 GA. Figure G3-18: Hardness measurement path Table-G3-6 Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed mm/ sec Min Focus Position mm Average Gas (Laser) Ar, 20 CFH Max Ramp 1 (Laser) 1 ms Ramp 2 (Laser) 350 ms Ramp 3 (Laser) 50 ms Plasma Current 75A Impact Strength Plasma Gas Flow Ar, 2.0 CFH Load (kn) Energy (J) Shielding Gas Flow Ar, 20 CFH Min Position of Plasma Tip Above Surface 5.0 mm Average Distance Between Laser and Plasma Spot 2.5 mm Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G3-19: Top Sheet Microhardness Traverse. Figure G3-20: Bottom Sheet Microhardness Traverse. Page 42 of 75
44 Group-3: Laser Plasma Welding (Material Combination 8) Figure G3-21: Top sheet: 1.52mm DP 600 Bottom sheet: 1.87mm DP 780 Figure G3-22: Hardness measurement path Table-G3-7 Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed mm/ sec Min Focus Position mm Average Gas (Laser) Ar, 20 CFH Max Ramp 1 (Laser) 1 ms Ramp 2 (Laser) 560 ms Ramp 3 (Laser) 50 ms Plasma Current 95A Impact Strength Plasma Gas Flow Ar, 2.0 CFH Load (kn) Energy (J) Shielding Gas Flow Ar, 20 CFH Min Position of Plasma Tip Above Surface 5.0 mm Average Distance Between Laser and Plasma Spot 3.0 mm Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G3-23: Top Sheet Microhardness Traverse. Figure G3-24: Bottom Sheet Microhardness Traverse. Page 43 of 75
45 Group-3: Laser Plasma Welding (Material Combination 9) Figure G3-25: Top sheet: 1.17mm DP780 GA Bottom sheet: 1.87mm DP 780. Figure G3-26: Hardness measurement path Table-G3-8 Parameters and Data Laser power 4.0 kw Load (kn) Energy (J) Weld speed mm/ sec Min Focus Position mm Average Gas (Laser) Ar, 20 CFH Max Ramp 1 (Laser) 1 ms Ramp 2 (Laser) 450 ms Ramp 3 (Laser) 50 ms Plasma Current 75A Impact Strength Plasma Gas Flow Ar, 2.0 CFH Load (kn) Energy (J) Shielding Gas Flow Ar, 20 CFH Min Position of Plasma Tip Above Surface 5.0 mm Average Distance Between Laser and Plasma Spot 3.0 mm Max VICKERS HARDNESS (HV) VICKERS HARDNESS (HV) Figure G3-27: Top Sheet Microhardness Traverse. Figure G3-28: Bottom Sheet Microhardness Traverse. Page 44 of 75
46 Group-3: Laser Plasma Welding (Impact Strength at 15 MPH).00 LASER-PLASMA AVERAGE IMPACT PEAK LOAD (kn) IM-01 IM-02 IM-03 IM-04 IM-05 IM-08 IM-09 Figure G3-29: Impact Strength Peak Load LASER-PLASMA AVERAGE IMPACT ENERGY (J) IM-01 Figure G3-30: Impact Strength Energy. IM-02 IM-03 IM-04 IM-05 IM-08 IM-09 Page 45 of 75
47 Group-3: Laser Plasma Welding (Tensile Shear Data) LASER-PLASMA AVERAGE PEAK LOAD (kn) TS TS TS TS TS TS TS-09 Figure G3-31: Tensile Shear Load. LASER-PLASMA AVERAGE ENERGY (J) TS TS TS TS TS TS TS-09 Figure G3-32: Tensile Shear Energy. Page 46 of 75
48 Group-4 GMAW AC (Material Combinations) Table G4-1: Stack-up Combination. Stack-up Combination Number Top Sheet Bottom Sheet 1 3.4mm DP600 Bare 3.4mm DP600 Bare mm DP600 HDG 3.2mm HSLA 350 Bare mm HSLA 350 HDG 3.2mm HSLA 350 Bare mm DP980 GA 1.18mm DP980 GA 5 1.0mm DP800 GA 1.0mm DP800 GA mm DP mm DP 780 GN mm DP780GA 1.87mm DP 780 GN Machines: Power Source: OTC Daihen AC/MIG/ Robot: OTC Daihen Robot Dynamic 0 DR Page 47 of 75
49 Group-4: GMAW AC (Material Combination 1) Top sheet: 3.4mm DP600 Bare Bottom sheet: 3.4mm DP600 Bare. Figure G4-1: Cross-Section. Table-G4-2: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 195A Wire Feed Rate 480 in./min (12.2 m/min) Impact Strength Weld Volts 22.0V Load (kn) Energy (J) Gap (engineered) 0mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNE Figure G4-2: Microhardness Traverse. Page 48 of 75
50 Group-4: GMAW AC (Material Combination 2) Top sheet: 1.15mm DP600 HDG Bottom sheet: 3.2mm HSLA 350 Bare Table-G4-3: Parameters and Data Figure G4-3: Cross-Section. Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 110A Wire Feed Rate 245 in./min (6.22 m/min) Impact Strength Weld Volts 19.5V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( Figure G4-4: Microhardness Traverse. Page 49 of 75
51 Group-4: GMAW AC (Material Combination 3) Top sheet: 1.38mm HSLA 350 HDG Bottom sheet: 3.2mm HSLA350 Bare Figure G4-5: Cross-Section. Table-G4-4: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 115A Wire Feed Rate in./min (7.11 m/min) Impact Strength Weld Volts 19.5V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( Figure G4-6: Microhardness Traverse. Page 50 of 75
52 Group-4: GMAW AC (Material Combination 4) Top sheet: 1.18mm DP980 GA Bottom sheet: 1.18mm DP980 GA. Figure G4-7: Cross-Section. Table-G4-5 Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 95A Wire Feed Rate 202 in./min (7.11 m/min) Impact Strength Weld Volts 18.5V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( Figure G4-8: Microhardness Traverse. Page 51 of 75
53 Group-4: GMAW AC (Material Combination 5) Top sheet: 1.0mm DP800 GA Bottom sheet: 1.0mm DP800 GA. Figure G4-9: Cross-Section. Table-G4-6: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 85A Wire Feed Rate 198 in./min (6.22 m/min) Impact Strength Weld Volts 18V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( Figure G4-10: Microhardness Traverse. Page 52 of 75
54 Group-4: GMAW AC (Material Combination 8) 70 KSI Filler Top sheet: 1.52mm DP 600 Bottom sheet: 2.0mm DP 780 GN Figure G4-11: Cross-Section. Table-G4-7: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 120A Wire Feed Rate 290 in./min (7.37 m/min) Impact Strength Weld Volts 21V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( Figure G4-12: Microhardness Traverse. Page 53 of 75
55 Group-4: GMAW AC (Material Combination 8) 90 ksi Filler Top sheet: 1.52mm DP 600 GA Bottom sheet: 2.0mm DP 780 GN Table-G4-8: Parameters and Data Figure G4-13: Cross-Section. Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER90S-D2 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 120A Wire Feed Rate 290 in./min (7.37 m/min) Impact Strength Weld Volts 21V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( Figure G4-14: Microhardness Traverse. Page 54 of 75
56 Group-4: GMAW AC (Material Combination 9) 70 ksi Filler Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780 GN Figure G4-15: Cross-Section. Table-G4-9: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 110A Wire Feed Rate 260 in./min (6.60 m/min) Impact Strength Weld Volts 22V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( Figure G4-16: Microhardness Traverse. Page 55 of 75
57 Group-4: GMAW AC (Material Combination 9) 90 ksi Filler Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780 GN Figure G4-17: Cross-Section. Table-G4-10: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER90S-D2 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 110A Wire Feed Rate 260 in./min (6.60 m/min) Impact Strength Weld Volts 22V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( Figure G4-18: Microhardness Traverse. Page 56 of 75
58 Group-4: GMAW AC (Impact Strength at 15 MPH).00 GMAW-AC AVERAGE IMPACT PEAK LOAD (kn) IM IM IM IM IM IM IM IM IM Figure G4-19: Impact Strength Peak Load. GMAW-AC AVERAGE IMPACT ENERGY (J) IM IM IM IM IM IM IM IM IM Figure G4-20: Impact Strength Energy. Page 57 of 75
59 Group-4: GMAW AC (Tensile Shear Data) GMAW-AC AVERAGE PEAK LOAD (kn) TS TS TS TS TS TS TS TS TS Figure G4-21: Tensile Shear Load. GMAW-AC AVERAGE ENERGY (J) TS TS TS TS TS TS TS TS TS Figure G4-22: Tensile Shear Energy. Page 58 of 75
60 Group-5 GMAW DC (Material Combinations) Table G5-1: Stack-up Combination Stack-up Combination Number Top Sheet Bottom Sheet 1 3.4mm DP600 Bare 3.4mm DP600 Bare mm DP600 HDG 3.2mm HSLA 350 Bare mm HSLA 350 HDG 3.2mm HSLA 350 Bare mm DP980 GA 1.18mm DP980 GA 5 1.0mm DP800 GA 1.0mm DP800 GA mm DP mm DP 780 GN mm DP780GA 1.87mm DP 780 GN Machines: Unless otherwise specified GMAW DC MIG DC Power Source: OTC Daihen Turbo Pulse 350 Robot: OTC Daihen Robot Dynamic 0 DR Travel All MIG welding are done with a 30 degree Torch Angle and 40 degree Push Angle. The Travel Angle is 40 deg (push). The wire is tipped at 30 degree from normal to the metal surface. The gas cup is.625in. diameter. The cup is shown shortened for clarity. Cone represents heated area and gas coverage. Page 59 of 75
61 Group-5: GMAW DC (Material Combination 1) Top sheet: 3.4mm DP600 Bare Bottom sheet: 3.4mm DP600 Bare. Figure G5-1: Cross-Section Table-G5-2: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current A Wire Feed Rate 530 in./min 13.5 m/min) Impact Strength Weld Volts 28V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( (Base Metal) HZ () HV (Weld) HZ () (Base Metal) Figure G5-2: Microhardness Traverse. Page 60 of 75
62 Group-5: GMAW DC (Material Combination 2) Top sheet: 1.15mm DP600 HDG Bottom sheet: 3.2mm HSLA 350 Bare Figure G5-3: Cross-Section. Table-G5-3: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 120A Wire Feed Rate 290 in./min (7.37 m/min) Impact Strength Weld Volts 22V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( (Base Metal) HZ () HV (Weld) HZ () (Base Metal) Figure G5-4: Microhardness Traverse. Page 61 of 75
63 Group-5: GMAW DC (Material Combination 3) Top sheet: 1.38mm HSLA 350 HDG Bottom sheet: 3.2mm HSLA350 Bare Table-G5-4: Parameters and Data Figure G5-5: Cross-Section. Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 140A Wire Feed Rate 330 in./min (8.38 m/min) Impact Strength Weld Volts 21V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( (Base Metal) HZ () HV (Weld) HZ () (Base Metal) Figure G5-6: Microhardness Traverse. Page 62 of 75
64 Group-5: GMAW DC (Material Combination 4) Top sheet: 1.18mm DP980 GA Bottom sheet: 1.18mm DP980 GA. Figure G5-7: Cross-Section. Table-G5-5: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 115A Wire Feed Rate 210 in./min (5.33 m/min) Impact Strength Weld Volts 21V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max (Base Metal) HZ () HV (Weld) HZ () (Base Metal) VICKERS HARDNESS ( Figure G5-8: Microhardness Traverse. Page 63 of 75
65 Group-5: GMAW DC (Material Combination 5) Top sheet: 1.0mm DP800 GA Bottom sheet: 1.0mm DP800 GA. Figure G5-9: Cross-Section. Table-G5-6: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 85A Wire Feed Rate 188 in./min (4.78 m/min) Impact Strength Weld Volts 19V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( (Base Metal) HZ () HV (Weld) HZ () (Base Metal) Figure G5-10: Microhardness Traverse. Page 64 of 75
66 Group-5: GMAW DC (Material Combination 8) 70 KSI Filler Top sheet: 1.52mm DP 600 Bottom sheet: 2.0mm DP 780 GN Figure G5-11: Cross-Section. Table-G5-7: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 150A Wire Feed Rate 300 in./min (7.62 m/min) Impact Strength Weld Volts 22V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( (Base Metal) HZ () HV (Weld) HZ () (Base Metal) Figure G5-12: Microhardness Traverse. Page 65 of 75
67 Group-5: GMAW DC (Material Combination 8) 90 ksi Filler Top sheet: 1.52mm DP 600 GA Bottom sheet: 2.0mm DP 780 GN Figure G5-13: Cross-Section. Table-G5-8: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER90S-D2 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 150A Wire Feed Rate 300 in./min (7.62 m/min) Impact Strength Weld Volts 22V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( (Base Metal) 9.53 HZ () 9.91 HV (Weld) HZ () (Base Metal) Figure G5-14: Microhardness Traverse. Page 66 of 75
68 Group-5: GMAW DC (Material Combination 9) 70 ksi Filler Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780 GN Figure G5-15: Cross-Section. Table-G5-9: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER70S3 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 125A Wire Feed Rate 265 in./min (6.73 m/min) Impact Strength Weld Volts 21V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( (Base Metal) HZ () HV (Weld) HZ () (Base Metal) Figure G5-16: Microhardness Traverse. Page 67 of 75
69 Group-5: GMAW DC (Material Combination 9) 90 ksi Filler Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780 GN Figure G5-17: Cross-Section. Table-G5-10: Parameters and Data Travel Speed 30 in/min (762 mm/min) Load (kn) Energy (J) Wire Spec. ER90S-D2 Min Wire Diameter in. (0.9 mm) Average Gas Cup Size.625 in. (16 mm) Max Contact Tip to Work (Distance).625 in. (16 mm) Tip Recess/Extension.0625 in. (1.5 mm) Travel Angle 40 deg. Push Work Angle 30 deg. MIG Current 125A Wire Feed Rate 265 in./min (6.37 m/min) Impact Strength Weld Volts 21V Load (kn) Energy (J) Gap (engineered) 0.5 mm Min Shielding Gas Flow 35 CFH Average Shielding Gas 90% Ar / 10% CO 2 Max VICKERS HARDNESS ( (Base Metal) HZ () HV (Weld) HZ () (Base Metal) Figure G5-18: Microhardness Traverse. Page 68 of 75
70 Group-5: GMAW DC (Impact Strength at 15 MPH).00 GMAW-DC AVERAGE IMPACT PEAK LOAD (kn) IM IM IM IM Figure G5-19: Impact Strength Peak Load. IM IM IM IM IM GMAW-DC AVERAGE IMPACT ENERGY (J) IM IM IM Figure G5-20: Impact Strength Energy. IM IM IM IM IM IM Page 69 of 75
71 Group-5: GMAW DC (Tensile Shear Data) GMAW-DC AVERAGE PEAK LOAD (kn) TS TS TS TS TS TS TS TS TS Figure G5-21: Tensile Shear Load. GMAW-DC AVERAGE ENERGY (J) TS TS TS TS TS TS TS TS TS Figure G5-22: Tensile Shear Energy. Page 70 of 75
72 Appendix A: Welding Equipment Photographs Laser Head Figure A1: Laser system arrangement. Figure A2: Laser system arrangement. Page 71 of 75
73 Figure A3: Laser-GMAW system arrangement. GMAW Torch Figure A4: Laser-MIG system arrangement. Page 72 of 75
74 Plasma Torch Figure A5: Laser-Plasma-Hybrid system arrangement. Figure A6: Laser-Plasma-Hybrid robot system. Page 73 of 75
75 Filler Material Figure A7: GMAW torch. Travel right to left. Figure A8: Robot used for GMAW (AC and DC) welding. Page 74 of 75
76 Figure A9: AC and DC GMAW Power Supplies. Page 75 of 75
77 0 Town Center, Suite Southfield, Michigan Tel:
A COMPARISON OF AC TO INVERTER DC RESISTANCE SPOT WELDING AND THE EFFECTS ON DUAL-PHASE 600
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