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
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-1...15 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-2...25 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
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-3...37 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-4...46 Group-4...47 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
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-5...58 Group-5...59 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
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
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
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 600 3.4 None DP 600 1.15 GI DP 780 1.17 GA DP 780 1.87 GA DP 800 1 GA DP 980 1.18 GA DP 600 1.52 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
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
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. 45.6 mm 60 37.8 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
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 25.4 +/- 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-9059 2, NOV 6, CHG B 5% of thinnest metal Convexity Not addressed (Heat Affected Zone) Not addressed Penetration Chrysler PS-9059 2, NOV 6, CHG B >= 20% into second metal Gap (under pressure) Not addressed Page 10 of 75
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-02-90-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
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) 2 1.15mm DP600 HDG 3.2mm HSLA Bare AC, DC, LS, LM, PL 70 ksi (see each sheet) 3 1.38mm HSLA 350 HDG 3.2mm HSLA Bare AC, DC, LS, LM, PL 70 ksi (see each sheet) 4 1.18mm 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) 8 1.52mm DP 600 GA 9 1.17mm 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
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 0.092 1.79 0.017 0.0059 0.005 0.188 0.177 0.054 0.020 <.002 0.084 1.50 0.009 0.0073 0.010 0.032 0.315 0.054 0.017 <.002 0.080 1.17 0.016 0.0055 0.057 0.624 0.004 0.042 0.013 0.003 0.074 1.28 0.013 0.0077 0.026 0.023 0.003 0.041 0.010 0.002 0.131 2.62 0.012 0.0067 0.016 0.227 0.310 0.049 0.011 0.002 0.085 2.33 0.012 0.0059 0.006 0.238 0.291 0.055 0.013 <.002 0.124 2.10 0.017 0.0039 0.030 0.234 0.169 0.058 0.014 0.002 0.131 2.06 0.023 0.0050 0.020 0.234 0.179 0.076 0.015 0.002 0.067 0.629 0.010 0.0066 0.252 0.054 0.014 0.05 0.052 0.012 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
Material Physical Properties Table 7: Material Physical Properties. Material Used in Stack Thickness Upper Yield Point Lower Yield Point Peak Load Energy @ 0% Droop (mm) (ksi) (ksi) (ksi) (lb-in) 3.4mm DP 600 BARE 1 3.35 74.7-100.2 2262.53 3.2mm HSLA 350 BARE 2,3 3.24 73.0 70.6 83.3 1891.58 1.0mm DP 800 GN 5 1.19 66.0-133.3 735.98 1.17mm DP 780 GN 9 1.19 69.5-124.4 895.37 1.52mm DP 600 GN 8 1.59 53.5-88.4 1016.97 1.87mm DP 780 GN 8 2.1 81.5-131.6 1460.95 1.18mm DP 980 GN 4 1.19 94.7-157.4 903.69 1.15mm DP 600 HDG 2 1.42 61.8-103.8 876.04 1.38mm HSLA 350 HDG 3 1.19 60.7 57.8 72.1 860.55 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, G2-10 3 Laser Plasma G3-1, G3-32 G3-1, G3-8 4 GMAW AC G4-1, G4-22 G4-1, G4-10 5 GMAW DC G5-1, G5-22 G5-1, G5-10 Page 14 of 75
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 2 1.15mm DP600 HDG 3.2mm HSLA 350 Bare 3 1.38mm HSLA 350 HDG 3.2mm HSLA 350 Bare 4 1.18mm DP980 GA 1.18mm DP980 GA 5 1.0mm DP800 GA 1.0mm DP800 GA 8 1.52mm DP 600 1.87mm DP 780 GN 9 1.17mm DP780GA 1.87mm DP 780 GN Machines: Laser: Rofin NDI YAG Model DY044 4.4kW 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
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 12.66 16.11 Focus Position -2.0 mm Average 13.75 18.13 Gas (Laser) Ar Max 14.83 19.84 Gap (engineered) 0 mm Shielding Gas Flow Ar, 18 CFH Impact Strength Load (kn) Energy (J) Min 41.0 76.9 Average 47.4 116.2 Max 51.6 148.3 VICKERS HARDNESS (HV) 440 302 268 242 212 212 211 209213 210 334 321 309 303 308 310 310 291 291 298 287 286 261 210 212 208 202 0 1 2 3 4 5 6 7 VICKERS HARDNESS (HV) 440 307 295 290 294 300 287 263 274 260 217 210 215 211 207 214 215 213 212 214 211 216 209 204 195 199 212 0 1 2 3 4 5 6 7 Figure G1-4: Bottom Sheet Microhardness Traverse. Page 16 of 75
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 15.64 22.54 Focus Position +1.8 mm Average 16.44 24.55 Gas (Laser) Ar Max 17.59 26.46 Gap (engineered) 0 mm Shielding Gas Flow Ar, 18 CFH Impact Strength Load (kn) Energy (J) Min 18.6 88.9 Average 50.4 239.3 Max 120.2 323.3 VICKERS HARDNESS (HV) 440 307 295 290 294 287 300 263 274 260 217 210 215 211 207 214 215 213 212 214 211 216 209 204 195 199 212 0 1 2 3 4 5 6 7 VICKERS HARDNESS (HV) 440 386 363 367 355 254 225 191 192 207 205 195192 189 188 188 193193 194 0 1 2 3 4 5 6 Figure G1-7: Top Sheet Microhardness Traverse. Figure G1-8: Bottom Sheet Microhardness Traverse. Page 17 of 75
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 13.99 20.34 Focus Position +1.5 mm Average 15.73 23.63 Gas (Laser) Ar Max 17.59 27.08 Gap (engineered) 0.1 mm Shielding Gas Flow Ar, 18 CFH Impact Strength Load (kn) Energy (J) Min 28.5 95.8 Average 59.7 176.6 Max 117.6 303.6 VICKERS HARDNESS (HV) 440 322 311 297 288 278 276 295 264 267 238 212 197 192 180 166 168 169 173 165 0 1 2 3 4 5 6 VICKERS HARDNESS (HV) 440 326 321 300 323 304 255 243 194 199 204 214 199 191 211 195 194 189 191 195 0 1 2 3 4 5 Figure G1-11: Top Sheet Microhardness Traverse. Figure G1-12: Bottom Sheet Microhardness Traverse. Page 18 of 75
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 13.62 25.80 Focus Position +1.8 mm Average 15.87 30.49 Gas (Laser) Ar Max 18.72 37.19 Gap (engineered) 0.1 mm Shielding Gas Flow Ar, 18 CFH Impact Strength Load (kn) Energy (J) Min 50.5 58.9 Average 95.1 165.4 Max 154.1 308.3 VICKERS HARDNESS (HV) 440 409 402 395 397 386 390 388 385 383 388 392 386 297 308 294 287 283 283 289 281 258 256 273 0 1 2 3 4 5 6 VICKERS HARDNESS (HV) 440 402 395 387 390 390 399 383 378 292 285 288 287 293 271 265 258 290 288 290 282 261 263 267 0 1 2 3 4 5 6 Figure G1-15: Top Sheet Microhardness Traverse. Figure G1-16: Bottom Sheet Microhardness Traverse. Page 19 of 75
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 15.32 25.07 Focus Position +1.8 mm Average 16.78 29.08 Gas (Laser) Ar Max 18.31 34.04 Gap (engineered) 0.1 mm Shielding Gas Flow Ar, 20 CFH Impact Strength Load (kn) Energy (J) Min 10.5 220.3 Average 54.7 253.9 Max 88.1 312.8 VICKERS HARDNESS (HV) 440 275 420 417 416 404 409 398 418 405 405 404 404 313 277 263 256 255 263 244 255 248 0 1 2 3 4 5 6 VICKERS HARDNESS (HV) 440 423 415 422 391 402 402 384 261 255 257 257 247 248 254 248 250 256 238 239 0 1 2 3 4 5 6 Figure G1-19: Top Sheet Microhardness Traverse. Figure G1-20: Bottom Sheet Microhardness Traverse. Page 20 of 75
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 16.82 26.55 Focus Position +1.5 mm Average 19.21 32.02 Gas (Laser) Ar Max 21.58 37.91 Gap (engineered) 0.1 mm Shielding Gas Flow Ar, 18 CFH Impact Strength Load (kn) Energy (J) Min 8.6 63.2 Average 33.7 159.9 Max 54.4 348.2 VICKERS HARDNESS (HV) 440 364 352 348 346 357 334 355 356 343 346 326 264 264 234 230 196 196 196 201 191 193 193 195 0 1 2 3 4 5 6 VICKERS HARDNESS (HV) 440 358 361 350 357 351 341 253 256 248 267 251 252 237 248 262 246 254 257 257 237 243 0 1 2 3 4 5 6 Figure G1-23: Top Sheet Microhardness Traverse. Figure G1-24: Bottom Sheet Microhardness Traverse. Page 21 of 75
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 17.73 28.83 Focus Position +1.5 mm Average 18.67 31.61 Gas (Laser) Ar Max 19.72 34.03 Gap (engineered) Shielding Gas Flow 0.1 mm Ar, 20 CFH Impact Strength Load (kn) Energy (J) Min 48.8 133.2 Average 56.5 162.4 Max 65.7 192.6 VICKERS HARDNESS (HV) 402 405 395 396 399 410 394 388 390 398 403 390 395 380 310 246 260 246 251 246 210 262 245 232 244 228 230 215 0 1 2 3 4 5 6 VICKERS HARDNESSS (HV) 410 397 397 394 388 357 368 310 260 274 270 278 271 272 262 274 257 256 262 264 259 248 210 233 0 1 2 3 4 5 6 Figure G1-27: Top Sheet Microhardness Traverse. Figure G1-28: Bottom Sheet Microhardness Traverse. Page 22 of 75
.00 Group-1: Laser Welding (Impact Strength at 15 MPH) LASER AVERAGE IMPACT PEAK LOAD (kn) 180.00.00 140.00 120.00 100.00 95.11 80.00 60.00 47.36 50.39 59.73 54.65 56.47 40.00 33.72 20.00 0.00 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) 600.00 500.00.00 300.00 239.25 253.89.00 176.60 165.41 159.86 162.41 116.21 100.00 0.00 IM-01 IM-02 IM-03 IM-04 IM-05 IM-08 IM-09 Figure G1-30: Impact Strength Energy. Page 23 of 75
Group-1: Laser Welding (Tensile Shear Data) LASER AVERAGE PEAK LOAD (kn) 60.00 45.00 30.00 19.21 18.67 15.00 13.75 16.44 15.73 15.87 16.78 0.00 00-TS-01 00-TS-02 00-TS-03 00-TS-04 00-TS-05 00-TS-08 00-TS-09 Figure G1-31: Tensile Shear Load. LASER AVERAGE ENERGY (J) 250.00 225.00.00 175.00 150.00 125.00 100.00 75.00 50.00 25.00 18.13 24.55 23.63 30.49 29.08 32.02 31.61 0.00 00-TS-01 00-TS-02 00-TS-03 00-TS-04 00-TS-05 00-TS-08 00-TS-09 Figure G1-32: Tensile Shear Energy. Page 24 of 75
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 2 1.15mm DP600 HDG 3.2mm HSLA 350 Bare 3 1.38mm HSLA 350 HDG 3.2mm HSLA 350 Bare 4 1.18mm DP980 GA 1.18mm DP980 GA 5 1.0mm DP800 GA 1.0mm DP800 GA 8 1.52mm DP 600 1.87mm DP 780 GN 9 1.17mm DP780GA 1.87mm DP 780 GN Machines: Laser: Rofin NDI YAG Model DY044 4.4kW 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
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 23.24 64.52 Focus Position +1.0 mm Average 54.14 224.10 Wire Spec. 1.14mm Dia. ER70S6 Max 67.45 295.89 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 174.1 198.0 Shielding Gas 92% Ar/8% CO 2 Average 174.1 198.7 Max 174.0 198.7 VICKERS HARDNESS (HV) 440 263 250 267 256 265 233 254 256 235 246 235 214 243 236 239 203 211 221 196 199 193 198 192 190 0 2 4 6 8 10 12 Figure G2-3: Microhardness Traverse. Page 26 of 75
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 23.24 64.52 Focus Position +1.0 mm Average 54.14 224.10 Wire Spec. 0.9mm Dia. ER70S6 Max 67.45 295.89 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 23.8 197.0 Shielding Gas 92% Ar/8% CO 2 Average 53.1 301.3 Max 82.6 380.7 VICKERS HARDNESS (HV) 440 338 317 327 318 324 319 321 317 301 311 311 272 267 254 258 238 247 225 205 217 205 194 209 190 190 0 1 2 3 4 5 6 7 8 Figure G2-6: Microhardness Traverse. Page 27 of 75
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 22.14 56.75 Focus Position +1.0 mm Average 23.34 61.60 Wire Spec. 1.0mm Dia. ER70S6 Max 24.54 65.40 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 26.4 164.3 Shielding Gas 92% Ar/8% CO 2 Average 60.6 291.9 Max 102.2 347.4 VICKERS HARDNESS (HV) 430 390 350 318 310 295 295 289 283 293 293 288 272 270 281 260 265 267 221 235 223 230 209 204 198 190 190 190 166 159 173 163 188 150 0 2 4 6 8 10 Figure G2-9: Microhardness Traverse. Page 28 of 75
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 20.43 48.39 Focus Position +1.0 mm Average 22.48 59.04 Wire Spec. 0.9mm Dia. ER70S6 Max 25.04 69.19 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 22.4 186.1 Shielding Gas 92% Ar/8% CO 2 Average 39.1 284.9 Max 46.8 356.7 VICKERS HARDNESS (HV) 440 399 390 395 405 368 373 391 377 384 365 365 341 330 329 346 326 358 348 336 294 310 289 321 318 288 314 281 275 286 287 282 270 254 262 250 0 1 2 3 4 5 6 7 8 9 10 11 Figure G2-12: Microhardness Traverse. Page 29 of 75
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 18.01 37.64 Focus Position +1.0 mm Average 20.06 44.93 Wire Spec. 0.9mm Dia. ER70S6 Max 21.58 50.00 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 58.1 163.5 Shielding Gas 92% Ar/8% CO 2 Average 91.0 267.2 Max 129.2 326.4 VICKERS HARDNESS (HV) 440 388 391 386 394 380 354 377 347 344 350 346 344 356 345 339 347 339 313 326 332 308 286 246 264 234 229 238 237 228 226 223 0 1 2 3 4 5 6 7 8 9 Figure G2-15: Microhardness Traverse. Page 30 of 75
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 25.27 67.26 Focus Position +1.0 mm Average 27.20 76.72 Wire Spec. 0.9mm Dia. ER70S6 Max 29.42 85.82 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 37.5 190.1 Shielding Gas 92% Ar/8% CO 2 Average 52.9 398.2 Max 87.4 480.4 VICKERS HARDNESS (HV) 440 348 359 358 356 341 337 339 325 342 324 312 323 312 317 304 309 294 254 267 245 243 249 245 206 243 208 224 233 222 196 0 1 2 3 4 5 6 7 8 9 10 Figure G2-18: Microhardness Traverse. Page 31 of 75
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 25.50 75.56 Focus Position +1.0 mm Average 28.69 87.00 Wire Spec. 0.9mm Dia. ER90SD2 Max 31.72 105.10 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 60.1 268.9 Shielding Gas 92% Ar/8% CO 2 Average 63.8 415.7 Max 68.7 462.6 VICKERS HARDNESS (HV) 440 380 382 359 355 367 371 349 363 363 359 350 319 309 283 284 250 256 264 227 242 263 255 255 199 193 199 199 190 186 0 1 2 3 4 5 6 7 8 Figure G2-21: Microhardness Traverse. Page 32 of 75
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 24.82 59.9 Focus Position +1.0 mm Average 25.59 62.29 Wire Spec. 0.9mm Dia. ER70S6 Max 26.46 69.42 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 41.8 337.9 Shielding Gas 92% Ar/8% CO 2 Average 62.3 381.5 Max 94.0 451.3 VICKERS HARDNESS (HV) 440 393 377 375 367 363 353 349 346 334 337 349 357 346 341 340 329 327 319 317 293 261 262 266 262 238 248 260 227 235 223 237 0 2 4 6 8 10 Figure G2-24: Microhardness Traverse. Page 33 of 75
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 22.79 54.16 Focus Position +1.0 mm Average 24.68 61.21 Wire Spec. 0.9mm Dia. ER90SD2 Max 25.46 64.90 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 27.4 355.7 Shielding Gas 92% Ar/8% CO 2 Average 47.8 380.7 Max 100.9 406.9 VICKERS HARDNESS (HV) 440 392 386 388 378 385 384 365 369 379 358 369 364 353 348 316 306 300 292 252 242 244 237 228 229 236 230 214 232 234 221 0 2 4 6 8 10 Figure G2-27: Microhardness Traverse. Page 34 of 75
Group-2: Laser GMAW (Impact Strength at 15 MPH).00 LASER-GMAW AVERAGE IMPACT PEAK LOAD (kn) 180.00 174.14.00 140.00 120.00 100.00 90.96 80.00 60.61 63.78 62.31 60.00 53.06 52.88 47.76 40.00 39.07 20.00 0.00 IM-01-70 IM-02-70 IM-03-70 IM-04-70 IM-05-70 IM-08-70 IM-08-90 IM-09-70 IM-09-90 600.00 Figure G2-28: Impact Strength Peak Load. LASER-GMAW AVERAGE IMPACT ENERGY (J) 500.00.00 398.20 415.75 381.47 380.73 300.00 301.30 291.93 284.90 267.22.00 198.73 100.00 0.00 IM-01-70 IM-02-70 IM-03-70 IM-04-70 IM-05-70 IM-08-70 IM-08-90 IM-09-70 IM-09-90 Figure G2-29: Impact Strength Peak Energy. Page 35 of 75
Group-2: Laser GMAW (Tensile Shear Data) LASER-GMAW AVERAGE PEAK LOAD (kn) 60.00 54.14 45.00 30.00 24.78 23.34 22.48 20.06 27.20 28.69 25.59 24.68 15.00 0.00 06-TS-01-70 06-TS-02-70 06-TS-03-70 Figure G2-30: Tensile Shear Load. 06-TS-04-70 06-TS-05-70 06-TS-08-70 06-TS-08-90 06-TS-09-70 06-TS-09-90 LASER-GMAW AVERAGE ENERGY (J) 250.00 225.00 224.10.00 175.00 150.00 125.00 100.00 75.00 61.48 61.60 59.04 76.72 87.00 62.29 61.21 50.00 44.93 25.00 0.00 06-TS-01-70 06-TS-02-70 06-TS-03-70 Figure G2-31: Tensile Shear Energy. 06-TS-04-70 06-TS-05-70 06-TS-08-70 06-TS-08-90 06-TS-09-70 06-TS-09-90 Page 36 of 75
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 2 1.15mm DP600 HDG 3.2mm HSLA 350 Bare 3 1.38mm HSLA 350 HDG 3.2mm HSLA 350 Bare 4 1.18mm DP980 GA 1.18mm DP980 GA 5 1.0mm DP800 GA 1.0mm DP800 GA 8 1.52mm DP 600 1.87mm DP 780 GN 9 1.17mm DP780GA 1.87mm DP 780 GN Machines: Laser: Rofin NDI YAG Model DY044 4.4kW 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
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 18.33 mm/ sec Min 13.22 15.57 Focus Position +2.50 mm Average 14.29 17.27 Gas (Laser) Ar, 20 CFH Max 15.11 18.68 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 10.9 26.3 Position of Plasma Tip Above Surface 5.0 mm Average 36.8 55.0 Distance Between Laser and Plasma Spot 3.0 mm Max 49.7 71.7 VICKERS HARDNESS (HV) 440 349 327 291 283 264 266 220 198 207 204 195 197 191 190 193 0 1 2 3 4 5 6 7 8 VICKERS HARDNESS (HV) 440 343 343 359 339 311 283 236 204 227 199 214 210 197 185 197 218 191 191 205 193 185 189 186 0 1 2 3 4 5 6 7 Figure G3-3: Top Sheet Microhardness Traverse. Figure G3-4: Bottom Sheet Microhardness Traverse. Page 38 of 75
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 41.60 mm/ sec Min 17.05 27.37 Focus Position +2.50 mm Average 18.09 29.68 Gas (Laser) Ar, 20 CFH Max 19.04 31.76 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 25.5 25.5 Position of Plasma Tip Above Surface 5.0 mm Average 59.3 59.3 Distance Between Laser and Plasma Spot 3.0 mm Max 89.7 89.7 VICKERS HARDNESS (HV) 440 349 327 291 283 264 266 220 198 207 204 195 197 191 190 193 0 1 2 3 4 5 6 7 8 VICKERS HARDNESS (HV) 440 343 343 359 339 311 283 236 204 227 199 214 210 197 185 197 218 191 205 191 193 185 189 186 0 1 2 3 4 5 6 7 Figure G3-7: Top Sheet Microhardness Traverse. Figure G3-8: Bottom Sheet Microhardness Traverse. Page 39 of 75
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 41.60 mm/ sec Min 16.45 27.03 Focus Position +2.50 mm Average 17.61 29.11 Gas (Laser) Ar, 20 CFH Max 18.45 30.68 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 63.1 132.8 Position of Plasma Tip Above Surface 5.0 mm Average 78.5 189.6 Distance Between Laser and Plasma Spot 3.0 mm Max 96.1 308.7 VICKERS HARDNESS (HV) 430 390 350 328 321 315 310 286 286 299 270 234 236 230 205 225 196 191 186 209 206 192 190 181 163 168 163 175 183 183 171 150 0 1 2 3 4 5 6 7 8 VICKERS HARDNESS (HV) 440 312 308 297 306 307 239 238 203 213 205 193 193 183 184 215 207 191 185 186 191 196 194 192 0 1 2 3 4 5 6 7 Figure G3-11: Top Sheet Microhardness Traverse. Figure G3-12: Bottom Sheet Microhardness Traverse. Page 40 of 75
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 56.60 mm/ sec Min 11.23 20.16 Focus Position +2.50 mm Average 12.34 24.89 Gas (Laser) Ar, 20 CFH Max 13.65 28.19 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 12.4 36.3 Position of Plasma Tip Above Surface 5.0 mm Average 26.8 127.8 Distance Between Laser and Plasma Spot 2.5 mm Max 35.2 190.4 VICKERS HARDNESS (HV) 440 417 401 399 398 393 389 380 392 390 384 373 312 325 303 310 281 282 274 290 252 253 0 1 2 3 4 5 6 7 VICKERS HARDNESS (HV) 440 300 304 288 284 286 287 285 286 275 277 276 263 258 278 279 286 279 278 274 245 245 0 1 2 3 4 5 6 Figure G3-15: Top Sheet Microhardness Traverse. Figure G3-16: Bottom Sheet Microhardness Traverse. Page 41 of 75
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 63.30 mm/ sec Min 9.76 11.04 Focus Position +2.50 mm Average 10.61 12.72 Gas (Laser) Ar, 20 CFH Max 11.51 14.95 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 6.7 11.5 Position of Plasma Tip Above Surface 5.0 mm Average 22.7 28.4 Distance Between Laser and Plasma Spot 2.5 mm Max 47.7 56.5 VICKERS HARDNESS (HV) 440 416 399 407 406 395 386 399 416 399 390 389 294 248 247 268 246 232 251 242 232 244 231 0 1 2 3 4 5 6 7 VICKERS HARDNESS (HV) 440 272 281 247 249 243 245 244 243 244 238 239 234 224 223 227 242 251 235 233 236 230 0 1 2 3 4 5 6 Figure G3-19: Top Sheet Microhardness Traverse. Figure G3-20: Bottom Sheet Microhardness Traverse. Page 42 of 75
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 41.60 mm/ sec Min 13.90 20.79 Focus Position +2.50 mm Average 15.12 23.35 Gas (Laser) Ar, 20 CFH Max 16.68 26.48 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 26.8 190.4 Position of Plasma Tip Above Surface 5.0 mm Average 41.0 268.3 Distance Between Laser and Plasma Spot 3.0 mm Max 49.7 330.3 440 440 VICKERS HARDNESS (HV) 351 348 350 348 354 325 347 322 322 319 293 266 239 236 222 195 207 191 191 192 191 189 190 0 1 2 3 4 5 6 7 8 VICKERS HARDNESS (HV) 363 375 330 323 255 261 253 258 254 256 258 247 260 250 246 250 251 256 252 253 261 248 256 0 1 2 3 4 5 6 7 Figure G3-23: Top Sheet Microhardness Traverse. Figure G3-24: Bottom Sheet Microhardness Traverse. Page 43 of 75
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 50.00 mm/ sec Min 14.24 23.42 Focus Position +2.50 mm Average 16.49 27.57 Gas (Laser) Ar, 20 CFH Max 17.56 31.02 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 11.6 21.6 Position of Plasma Tip Above Surface 5.0 mm Average 26.1 37.9 Distance Between Laser and Plasma Spot 3.0 mm Max 39.5 46.4 VICKERS HARDNESS (HV) 440 392 395 404 398 397 391 389 388 380 371 385 375 382 343 349 265 233 235 224 234 227 222 229 219 0 1 2 3 4 5 6 7 VICKERS HARDNESS (HV) 440 385 393 361 370 361 370 328 258 263 253 248 250 255 254 254 253 255 256 254 253 252 247 249 0 1 2 3 4 5 6 Figure G3-27: Top Sheet Microhardness Traverse. Figure G3-28: Bottom Sheet Microhardness Traverse. Page 44 of 75
Group-3: Laser Plasma Welding (Impact Strength at 15 MPH).00 LASER-PLASMA AVERAGE IMPACT PEAK LOAD (kn) 180.00.00 140.00 120.00 100.00 80.00 78.46 60.00 59.25 40.00 36.83 40.99 26.84 22.67 26.06 20.00 0.00 IM-01 IM-02 IM-03 IM-04 IM-05 IM-08 IM-09 Figure G3-29: Impact Strength Peak Load. 600.00 LASER-PLASMA AVERAGE IMPACT ENERGY (J) 500.00.00 300.00 268.28.00 203.94 189.64 127.83 100.00 55.02 28.40 37.90 0.00 IM-01 Figure G3-30: Impact Strength Energy. IM-02 IM-03 IM-04 IM-05 IM-08 IM-09 Page 45 of 75
Group-3: Laser Plasma Welding (Tensile Shear Data) LASER-PLASMA AVERAGE PEAK LOAD (kn) 60.00 45.00 30.00 15.00 14.29 18.09 17.61 12.34 10.61 15.12 16.49 0.00 00-TS-01 00-TS-02 00-TS-03 00-TS-04 00-TS-05 00-TS-08 00-TS-09 Figure G3-31: Tensile Shear Load. LASER-PLASMA AVERAGE ENERGY (J) 250.00 225.00.00 175.00 150.00 125.00 100.00 75.00 50.00 25.00 17.27 29.68 29.11 24.89 12.72 23.35 27.57 0.00 00-TS-01 00-TS-02 00-TS-03 00-TS-04 00-TS-05 00-TS-08 00-TS-09 Figure G3-32: Tensile Shear Energy. Page 46 of 75
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 2 1.15mm DP600 HDG 3.2mm HSLA 350 Bare 3 1.38mm HSLA 350 HDG 3.2mm HSLA 350 Bare 4 1.18mm DP980 GA 1.18mm DP980 GA 5 1.0mm DP800 GA 1.0mm DP800 GA 8 1.52mm DP 600 1.87mm DP 780 GN 9 1.17mm DP780GA 1.87mm DP 780 GN Machines: Power Source: OTC Daihen AC/MIG/ Robot: OTC Daihen Robot Dynamic 0 DR Page 47 of 75
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 41.23 106.49 Wire Diameter 0.035 in. (0.9 mm) Average 44.73 132.69 Gas Cup Size.625 in. (16 mm) Max 47.16 147.92 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 20.6 103.0 Shielding Gas Flow 35 CFH Average 174.7 171.7 Shielding Gas 90% Ar / 10% CO 2 Max 473.0 235.5 VICKERS HARDNE 204 197 185 269 222 229 204 221 264 266 263 272 272 267 258 265 257 260 266264 237 245 207 217 212 220 0 2 4 6 8 10 12 14 204 Figure G4-2: Microhardness Traverse. Page 48 of 75
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 23.24 58.57 Wire Diameter 0.035 in. (0.9 mm) Average 26.19 68.80 Gas Cup Size.625 in. (16 mm) Max 30.38 86.07 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 25.9 59.0 Shielding Gas Flow 35 CFH Average 96.9 296.6 Shielding Gas 90% Ar / 10% CO 2 Max 186.8 368.2 VICKERS HARDNESS ( 217 214 203 230 222 238236 233 217 207 191 252 250 245246 241 243 236 244 241 234 238 217 232 212 202 199 190 202 193 0 2 4 6 8 10 12 14 16 Figure G4-4: Microhardness Traverse. Page 49 of 75
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 23.59 54.31 Wire Diameter 0.035 in. (0.9 mm) Average 25.79 77.07 Gas Cup Size.625 in. (16 mm) Max 27.39 92.51 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 63.8 76.8 Shielding Gas Flow 35 CFH Average 110.1 279.8 Shielding Gas 90% Ar / 10% CO 2 Max 142.6 411.8 VICKERS HARDNESS ( 310 270 230 268 191 198 190 193 183 189 285 285 278 279 271 229 220 216 245 271267 272274272 271 232 273 239 209 235 201 197 196 195 196 150 0 2 4 6 8 10 12 14 16 Figure G4-6: Microhardness Traverse. Page 50 of 75
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 19.67 43.79 Wire Diameter 0.035 in. (0.9 mm) Average 21.84 61.73 Gas Cup Size.625 in. (16 mm) Max 24.66 80.55 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 33.8 194.8 Shielding Gas Flow 35 CFH Average 59.7 299.1 Shielding Gas 90% Ar / 10% CO 2 Max 94.3 343.7 VICKERS HARDNESS ( 440 388 380 404 368 379 368 376 357 345 316 317 289 282 284 291 290 288 274 290 268 260 265 270 277 271 271 259 243 251 0 2 4 6 8 10 12 Figure G4-8: Microhardness Traverse. Page 51 of 75
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 22.22 47.59 Wire Diameter 0.035 in. (0.9 mm) Average 22.93 52.53 Gas Cup Size.625 in. (16 mm) Max 23.43 56.65 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 22.3 310.7 Shielding Gas Flow 35 CFH Average 22.3 327.8 Shielding Gas 90% Ar / 10% CO 2 Max 22.3 349.6 VICKERS HARDNESS ( 440 234 229 342 312 307 315 297 296 303 283 212 236 381 286 272 404 277 376 387 307 244 289 220 248 231 224 0 2 4 6 8 10 12 Figure G4-10: Microhardness Traverse. Page 52 of 75
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 30.56 84.26 Wire Diameter 0.035 in. (0.9 mm) Average 32.39 94.29 Gas Cup Size.625 in. (16 mm) Max 33.47 101.59 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 38.6 425.0 Shielding Gas Flow 35 CFH Average 59.2 467.7 Shielding Gas 90% Ar / 10% CO 2 Max 70.1 541.8 VICKERS HARDNESS ( 390 350 310 270 230 190 195 187 224 211 219 205 182 325 274 266 264 254 245 251 254 234 232 243 358 336 302 293 247 250 239 235 218 216 180 150 0 2 4 6 8 10 12 14 Figure G4-12: Microhardness Traverse. Page 53 of 75
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 33.10 100.02 Wire Diameter 0.035 in. (0.9 mm) Average 33.37 105.59 Gas Cup Size.625 in. (16 mm) Max 33.64 112.46 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 53.1 467.9 Shielding Gas Flow 35 CFH Average 66.4 495.1 Shielding Gas 90% Ar / 10% CO 2 Max 104.1 508.7 VICKERS HARDNESS ( 430 390 350 310 270 230 190 217 227 180 187 330 336 353 301 288 291 288 298 288 281 288 255 345 323 325 296 237 244 233 230 183 184 150 0 2 4 6 8 10 12 14 Figure G4-14: Microhardness Traverse. Page 54 of 75
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 22.56 45.29 Wire Diameter 0.035 in. (0.9 mm) Average 28.62 78.50 Gas Cup Size.625 in. (16 mm) Max 33.14 103.65 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 19.2 359.3 Shielding Gas Flow 35 CFH Average 54.7 380.5 Shielding Gas 90% Ar / 10% CO 2 Max 93.7 424.3 VICKERS HARDNESS ( 440 226 223 218 210 356 391 376 350 343 330 312 310 292 298292 299 293 303 281 268 276 250 330 295 268 264 245 247 233 221 0 2 4 6 8 10 12 14 Figure G4-16: Microhardness Traverse. Page 55 of 75
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 25.26 66.95 Wire Diameter 0.035 in. (0.9 mm) Average 30.61 89.53 Gas Cup Size.625 in. (16 mm) Max 32.87 100.66 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 50.0 89.5 Shielding Gas Flow 35 CFH Average 64.9 325.2 Shielding Gas 90% Ar / 10% CO 2 Max 77.6 423.2 VICKERS HARDNESS ( 440 270 266 243 245 277 331 298 357 373 344 339 373 332 357 325 314 318 312 392 383 303 250 226 239 310 208 219 211 0 2 4 6 8 10 12 14 Figure G4-18: Microhardness Traverse. Page 56 of 75
Group-4: GMAW AC (Impact Strength at 15 MPH).00 GMAW-AC AVERAGE IMPACT PEAK LOAD (kn) 180.00 174.70.00 140.00 120.00 110.10 100.00 96.90 80.00 60.00 59.72 59.17 66.36 64.93 54.70 40.00 20.00 22.32 0.00 IM-01-70 IM-02-70 IM-03-70 IM-04-70 IM-05-70 IM-08-70 IM-08-90 IM-09-70 IM-09-90 Figure G4-19: Impact Strength Peak Load. GMAW-AC AVERAGE IMPACT ENERGY (J) 600.00 500.00 467.69 495.07.00 380.48 327.80 325.22 300.00 296.58 279.80 299.06.00 171.70 100.00 0.00 IM-01-70 IM-02-70 IM-03-70 IM-04-70 IM-05-70 IM-08-70 IM-08-90 IM-09-70 IM-09-90 Figure G4-20: Impact Strength Energy. Page 57 of 75
Group-4: GMAW AC (Tensile Shear Data) GMAW-AC AVERAGE PEAK LOAD (kn) 60.00 45.00 44.73 30.00 32.39 33.37 28.62 30.61 26.19 25.79 21.84 22.93 15.00 0.00 00-TS-01-70 00-TS-02-70 00-TS-03-70 00-TS-04-70 00-TS-05-70 00-TS-08-70 00-TS-08-90 00-TS-09-70 00-TS-09-90 Figure G4-21: Tensile Shear Load. GMAW-AC AVERAGE ENERGY (J) 250.00 225.00.00 175.00 150.00 132.69 125.00 100.00 94.29 105.59 89.53 75.00 50.00 68.80 77.07 61.73 52.53 78.50 25.00 0.00 00-TS-01-70 00-TS-02-70 00-TS-03-70 00-TS-04-70 00-TS-05-70 00-TS-08-70 00-TS-08-90 00-TS-09-70 00-TS-09-90 Figure G4-22: Tensile Shear Energy. Page 58 of 75
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 2 1.15mm DP600 HDG 3.2mm HSLA 350 Bare 3 1.38mm HSLA 350 HDG 3.2mm HSLA 350 Bare 4 1.18mm DP980 GA 1.18mm DP980 GA 5 1.0mm DP800 GA 1.0mm DP800 GA 8 1.52mm DP 600 1.87mm DP 780 GN 9 1.17mm 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
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 53.08 167.08 Wire Diameter 0.035 in. (0.9 mm) Average 59.43 208.69 Gas Cup Size.625 in. (16 mm) Max 62.81 243.14 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 150.6 186.8 Shielding Gas Flow 35 CFH Average 167.9 220.8 Shielding Gas 90% Ar / 10% CO 2 Max 209.5 247.7 300 VICKERS HARDNESS ( (Base Metal) HZ () 244 248 242 243 238 245 250 HV (Weld) 234 232 231 227 242 237 HZ () 222 234 236 237 220 217 231 231 232 226 223 219 213 (Base Metal) 207 198 206 224 225 203 203 210 213 206 194 199 203 194 197 194 150 100 50 0 0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 Figure G5-2: Microhardness Traverse. Page 60 of 75
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 25.90 67.07 Wire Diameter 0.035 in. (0.9 mm) Average 27.01 71.73 Gas Cup Size.625 in. (16 mm) Max 27.74 77.28 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 64.3 350.8 Shielding Gas Flow 35 CFH Average 85.3 376.0 Shielding Gas 90% Ar / 10% CO 2 Max 94.7 395.2 350 VICKERS HARDNESS ( 300 250 150 100 190 190 186 183 185 176 209 255 222 252 291 263 262 259 259 266 259 250 266 254 248 254 242 243 226 213 208 208 201 196 193 204 (Base Metal) HZ () HV (Weld) HZ () (Base Metal) 50 0 0.00 2.00 4.00 6.00 8.00 10.00 12.00 Figure G5-4: Microhardness Traverse. Page 61 of 75
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 20.27 86.56 Wire Diameter 0.035 in. (0.9 mm) Average 21.75 92.91 Gas Cup Size.625 in. (16 mm) Max 23.23 95.95 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 68.4 192.8 Shielding Gas Flow 35 CFH Average 105.5 239.2 Shielding Gas 90% Ar / 10% CO 2 Max 163.3 367.5 300 VICKERS HARDNESS ( 250 150 100 169 167 171 169 175 161 184 239 196 227 237 235 230 225 234 232 221 225 236 206 207 209 207 207 201 201 (Base Metal) HZ () HV (Weld) HZ () (Base Metal) 50 0 0.00 2.00 4.00 6.00 8.00 10.00 12.00 Figure G5-6: Microhardness Traverse. Page 62 of 75
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 22.36 70.52 Wire Diameter 0.035 in. (0.9 mm) Average 26.11 79.29 Gas Cup Size.625 in. (16 mm) Max 32.32 108.41 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 2.8 120.6 Shielding Gas Flow 35 CFH Average 17.0 134.9 Shielding Gas 90% Ar / 10% CO 2 Max 29.8 163.5 450 (Base Metal) 350 333 359 345 378 386 370 321 378 379 344 333 HZ () HV (Weld) HZ () (Base Metal) VICKERS HARDNESS ( 300 271 283 245 250 259 241 150 289 285 269 278 268 278 268 276 305 263 259 245 245 100 50 0 0.00 2.00 4.00 6.00 8.00 10.00 12.00 Figure G5-8: Microhardness Traverse. Page 63 of 75
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 16.85 30.15 Wire Diameter 0.035 in. (0.9 mm) Average 18.22 37.10 Gas Cup Size.625 in. (16 mm) Max 20.85 51.07 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 18.5 3.1 Shielding Gas Flow 35 CFH Average 27.0 63.1 Shielding Gas 90% Ar / 10% CO 2 Max 85.4 522.5 450 VICKERS HARDNESS ( 350 300 250 150 229 223 311 246 331 349 387 376 330 317 366 331 327 344 338 319 322 309 332 376 372 389 330 372 297 237 226 223 (Base Metal) HZ () HV (Weld) HZ () (Base Metal) 100 50 0 0.00 2.00 4.00 6.00 8.00 10.00 12.00 Figure G5-10: Microhardness Traverse. Page 64 of 75
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 32.96 106.03 Wire Diameter 0.035 in. (0.9 mm) Average 34.21 113.36 Gas Cup Size.625 in. (16 mm) Max 35.62 117.96 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 49.4 478.6 Shielding Gas Flow 35 CFH Average 79.5 539.0 Shielding Gas 90% Ar / 10% CO 2 Max 92.0 582.0 VICKERS HARDNESS ( 350 300 250 150 258 253 226 274 241 276 307 273 319 269 271 258 251 250 256 257 268 269 298 266 292 256 221 215 205 203 193 191 191 192 (Base Metal) HZ () HV (Weld) HZ () (Base Metal) 100 50 0 0.00 2.00 4.00 6.00 8.00 10.00 12.00 Figure G5-12: Microhardness Traverse. Page 65 of 75
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 29.34 82.14 Wire Diameter 0.035 in. (0.9 mm) Average 33.91 109.69 Gas Cup Size.625 in. (16 mm) Max 36.01 122.63 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 55.4 497.5 Shielding Gas Flow 35 CFH Average 80.0 523.4 Shielding Gas 90% Ar / 10% CO 2 Max 122.2 548.8 VICKERS HARDNESS ( 350 300 250 150 0.00 0.38 0.76 1.14 1.91 1.52 2.29 2.67 3.05 3.43 3.81 4.57 4.95 5.33 6.10 4.19 5.72 6.86 6.48 7.24 7.62 9.14 (Base Metal) 9.53 HZ () 9.91 HV (Weld) HZ () 8.76 10.29 (Base Metal) 8.76 11.81 11.43 11.05 11.05 100 50 0 0.00 2.00 4.00 6.00 8.00 10.00 12.00 Figure G5-14: Microhardness Traverse. Page 66 of 75
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 22.74 51.81 Wire Diameter 0.035 in. (0.9 mm) Average 24.11 59.84 Gas Cup Size.625 in. (16 mm) Max 26.13 69.07 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 94.6 176.8 Shielding Gas Flow 35 CFH Average 109.8 350.0 Shielding Gas 90% Ar / 10% CO 2 Max 138.9 415.1 450 VICKERS HARDNESS ( 350 300 250 150 0.00 0.38 0.76 1.14 1.52 1.91 2.29 3.05 2.67 3.43 4.19 3.81 4.57 4.95 5.33 6.86 5.72 7.62 6.10 6.48 7.24 8.38 8.00 8.76 9.53 9.14 9.91 10.29 11.43 11.05 (Base Metal) HZ () HV (Weld) HZ () (Base Metal) 100 50 0 0.00 2.00 4.00 6.00 8.00 10.00 12.00 Figure G5-16: Microhardness Traverse. Page 67 of 75
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 23.40 59.41 Wire Diameter 0.035 in. (0.9 mm) Average 28.84 78.11 Gas Cup Size.625 in. (16 mm) Max 31.68 89.56 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 33.1 194.8 Shielding Gas Flow 35 CFH Average 75.8 322.1 Shielding Gas 90% Ar / 10% CO 2 Max 103.1 361.6 450 VICKERS HARDNESS ( 350 300 250 150 100 0.00 0.38 0.76 1.14 1.52 1.91 2.67 2.29 3.05 3.43 3.81 4.19 4.57 5.33 4.95 6.10 5.72 6.86 6.48 7.24 7.62 8.38 8.00 8.76 9.14 9.53 9.91 11.43 10.29 11.05 10.67 11.81 (Base Metal) HZ () HV (Weld) HZ () (Base Metal) 50 0 0.00 2.00 4.00 6.00 8.00 10.00 12.00 Figure G5-18: Microhardness Traverse. Page 68 of 75
Group-5: GMAW DC (Impact Strength at 15 MPH).00 GMAW-DC AVERAGE IMPACT PEAK LOAD (kn) 180.00 167.92.00 140.00 120.00 100.00 105.47 109.81 80.00 85.31 79.50 79.98 75.78 60.00 40.00 20.00 17.01 26.96 0.00 IM-01-70 IM-02-70 IM-03-70 IM-04-70 Figure G5-19: Impact Strength Peak Load. IM-05-70 IM-08-70 IM-08-90 IM-09-70 IM-09-90 600.00 GMAW-DC AVERAGE IMPACT ENERGY (J) 538.99 523.38 500.00.00 375.95 349.97 322.10 300.00 239.17 220.78.00 134.89 100.00 63.14 0.00 IM-01-70 IM-02-70 IM-03-70 Figure G5-20: Impact Strength Energy. IM-04-70 IM-05-70 IM-08-70 IM-08-90 IM-09-70 IM-09-90 Page 69 of 75
Group-5: GMAW DC (Tensile Shear Data) GMAW-DC AVERAGE PEAK LOAD (kn) 60.00 59.43 45.00 34.21 33.91 30.00 27.01 21.75 26.11 24.11 28.84 18.22 15.00 0.00 00-TS-01-70 00-TS-02-70 00-TS-03-70 00-TS-04-70 00-TS-05-70 00-TS-08-70 00-TS-08-90 00-TS-09-70 00-TS-09-90 250.00 Figure G5-21: Tensile Shear Load. GMAW-DC AVERAGE ENERGY (J) 225.00 208.69.00 175.00 150.00 125.00 113.36 109.69 100.00 92.91 75.00 71.93 79.29 59.84 78.11 50.00 37.10 25.00 0.00 00-TS-01-70 00-TS-02-70 00-TS-03-70 00-TS-04-70 00-TS-05-70 00-TS-08-70 00-TS-08-90 00-TS-09-70 00-TS-09-90 Figure G5-22: Tensile Shear Energy. Page 70 of 75
Appendix A: Welding Equipment Photographs Laser Head Figure A1: Laser system arrangement. Figure A2: Laser system arrangement. Page 71 of 75
Figure A3: Laser-GMAW system arrangement. GMAW Torch Figure A4: Laser-MIG system arrangement. Page 72 of 75
Plasma Torch Figure A5: Laser-Plasma-Hybrid system arrangement. Figure A6: Laser-Plasma-Hybrid robot system. Page 73 of 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
Figure A9: AC and DC GMAW Power Supplies. Page 75 of 75
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