ARW Presentation
-
Upload
rajendra-pethe -
Category
Documents
-
view
224 -
download
0
Transcript of ARW Presentation
-
8/7/2019 ARW Presentation
1/41
w w w . a s p . o r g
www.a-sp.org
Development of Starting WeldSchedules for AHSS
SORPAS Modeling of Starting Point Weld Schedules with
Experimental Evaluation and Validation
Michael L. Kuntz University of WaterlooDonald F. Maatz Jr. RoMan Engineering Services
Eric Pakalnins - Chrysler
John C. Bohr General MotorsTed Coon & Armando Joaquin - FordAuto/SteelPartnership
-
8/7/2019 ARW Presentation
2/41
w w w . a s p . o r g
Background
Starting Point Weld Schedules Used by automotive manufacturers for first welds as
a basis for weld schedule development Schedules depend on the governing metal thickness
(GMT) and material coating
Schedules currently in use for mild steel and HSLA(IISI Groups 1 and 2) need to be adjusted for AHSS(Groups 3 and 4) to produce acceptable weld quality
Developing starting point weld schedules is potentiallytedious and material intensive due to the wide range of material combinations.
-
8/7/2019 ARW Presentation
3/41
w w w . a s p . o r g
Objectives
Phase I Verify starting point weld schedules for IISI Groups 3
and 4 AHSS using the SORPAS finite elementsoftware, and
Suggest schedule improvement if necessary because of undersized welds or other observed defects.
Phase II Verify RSW Weld Schedule Effectiveness by:
Peel Inspection Mechanical Evaluation Metallographic Analysis
-
8/7/2019 ARW Presentation
4/41w w w . a s p . o r g
Scope of Work
Weld schedules developed with A/S-P member input AC & MFDC OEM production Cu-Zr electrode tips
AC: AWS D8.6 ball nose , 4.8 mm contact face diameter MFDC: ISO 5821 B nose, 6/8 mm contact face diameter
Thickness combinations: Test A: 2T stack-up, similar thickness Test B: 2T stack-up, thickness ratio 1:2.5
Test C: 3T stack-up, mild and BH steels to group 3 and 4
AC electrode MFDC electrode
-
8/7/2019 ARW Presentation
5/41w w w . a s p . o r g
3T Stack-Up Thickness Combinations
3T Simulations with thin Mild Steel (140YS/270TS)
Uncoated Gages(mm) Coated Gages(mm)
#1 #2 #3 #4 #5 #6
Thin (mild) 1.08 0.92 0.76 0.64 0.76 0.64
Thick 2.70 2.30 1.90 1.60 1.90 1.60
Thick 2.70 2.30 1.90 1.60 1.90 1.60
Stack-upDescription
1.601.901.601.902.302.70Thick
1.601.901.601.902.302.70Thick
0.640.760.640.760.921.08Thin (mild)#6#5#4#3#2#1
Coated Gages(mm)
Uncoated Gages(mm)Stack-upDescription
3T Simulations with thin BH Steel
-
8/7/2019 ARW Presentation
6/41w w w . a s p . o r g
Phase I - Simulation
Steels that were selected for simulation: Bare and Zn-coated IISI Groups 3 and 4
TRIP 800 MPa DP 600 MPa DP 980 MPa
Uncoated Hot Stamped Boron Bare and Zn-coated IISI Groups 1 and 2
Mild 140 YS/270TS BH 210 MPa
-
8/7/2019 ARW Presentation
7/41w w w . a s p . o r g
Simulation Parameters
SORPAS v.7 FEA software Squeeze time - 5 cycles
Current specified by RMS with a constant currentcontrol power supply 60 Hz AC with a conduction angle of 60%
Axissymetric 2.5d model with 500 elements SORPAS interface condition parameter - 1.0
10C water cooling HDGI coating weight of 75 g/m 2 per side for coated
materials
-
8/7/2019 ARW Presentation
8/41w w w . a s p . o r g
AC Welding Simulation Results Summaries
-
8/7/2019 ARW Presentation
9/41w w w . a s p . o r g
AC - Uncoated Steel Schedules
AC Weld Schedules (For Squeeze Time Use 5 cycles)
Uncoated IISI Group 3 (High Strength >500-800 MPa) and Group 4 (Ultra High Strength >800 MPa)
Test GMTRange (mm)
WeldForce(lbs)
WeldTime
(cycles)
CoolTime
(cycles)
Numberof
Pulses
WeldSequence(Cycles)
HoldTime
(Cycles)
WeldCurrent
(kA)
ElectrodeShank Diameter
(mm)
A, B 0.70 - 0.79 480 9 0 1 9 2 8.0 15.9
A, B 0.80 - 0.99 670 9 0 1 9 2 8.0 15.9
A, B 1.00 - 1.29 670 10 0 1 10 2 9.0 15.9A 1.30 - 1.59 950 12 0 1 12 2 10.0 15.9
A,C 1.60 - 1.89 1200 7 1 2 7-1-7 5 10.5 19.0
A,C 1.90 - 2.29 1660 7 1 3 7-1-7-1-7 5 11.5 19.0
A,C 2.30 - 2.69 1660 8 2 3 8-2-8-2-8 10 12.0 19.0
A,C 2.70 - 3.00 1900 8 2 3 8-2-8-2-8 10 12.5 19.0
-
8/7/2019 ARW Presentation
10/41w w w . a s p . o r g
AC - Coated Steel Schedules
AC Weld Schedules (For Squeeze Time Use 5 cycles)
Coated IISI Group 3 (High Strength >500-800 MPa) and Group 4 (Ultra High Strength >800 MPa)
Test GMTRange(mm)
WeldForce(lbs)
WeldTime
(cycles)
CoolTime
(cycles)
Numberof
Pulses
WeldSequence(Cycles)
HoldTime
(Cycles)
WeldCurrent
(kA)
ElectrodeShank Diameter
(mm)
A, B 0.70 - 0.79 480 14 0 1 14 2 9.0 15.9
A, B 0.80 - 0.99 670 14 0 1 14 2 9.5 15.9A 1.00 - 1.29 670 16 0 1 16 2 10.0 15.9
A 1.30 - 1.59 950 7 1 3 7-1-7-1-7 5 11.0 15.9
A,C 1.60 - 1.89 1200 8 2 3 8-2-8-2-8 5 11.5 19.0
A,C 1.90 - 2.29 1660 8 2 4 8-2-8-2-8-2-8 5 12.5 19.0
-
8/7/2019 ARW Presentation
11/41w w w . a s p . o r g
Test A DP980 Results
-
8/7/2019 ARW Presentation
12/41w w w . a s p . o r g
Test B TRIP800 Results
-
8/7/2019 ARW Presentation
13/41
-
8/7/2019 ARW Presentation
14/41
w w w . a s p . o r g
Test C DP980-Mild Steel Results
-
8/7/2019 ARW Presentation
15/41
w w w . a s p . o r g
Test C DP980-BH Results
-
8/7/2019 ARW Presentation
16/41
w w w . a s p . o r g
DC Welding Simulation Results Summaries
DC U d S l S h d l
-
8/7/2019 ARW Presentation
17/41
w w w . a s p . o r g
DC - Uncoated Steel Schedules
Uncoated IISI Group 3 (High Strength >500-800 MPa) and Group 4 (Ultra High Strength >800 MPa)
Test GMT Range(mm)Weld Force
(N)Weld Time
(ms)Weld Current
(kA)Hold Time
(ms)
Electrode
FaceDiameter
(d 2)
ElectrodeWidth
(d 1)
A, B 0.70 - 0.79 2800 210 6.5 105 6 16
A, B 0.80 - 0.99 3400 210 7.6 105 6 16
A, B 1.00 - 1.294400 270 9.3 135 6 16
A 1.30 - 1.59 5300 350 10.6 175 8 20
A,C 1.60 - 1.89 6400 440 11.2 220 8 20
A,C 1.90 - 2.29 7700 560 12.0 280 8 20
A,C 2.30 - 2.69 8500 670 12.5 335 8 20
A,C 2.70 - 3.00 10200 880 13.6 440 8 20
DC C t d St l S h d l
-
8/7/2019 ARW Presentation
18/41
w w w . a s p . o r g
DC - Coated Steel Schedules
Coated IISI Group 3 (High Strength >500-800 MPa) and Group 4 (Ultra High Strength >800 MPa)
Test GMT Range(mm)Weld Force
(N)Weld Time
(ms)Weld Current
(kA) Hold Time
ElectrodeFace
Diameter(d 2)
ElectrodeWidth
(d 1)
A, B 0.70 - 0.79 2800 230 7.8 115 6 16
A, B 0.80 - 0.99 3400 250 8.5 125 6 16A 1.00 - 1.29 4400 310 10.1 155 6 16
A 1.30 - 1.59 5300 400 11.5 200 8 20
A,C 1.60 - 1.89 6400 480 12.4 240 8 20
A,C 1.90 - 2.29 7700 600 13.2 300 8 20
Test A DP600 Res lts
-
8/7/2019 ARW Presentation
19/41
w w w . a s p . o r g
Test A DP600 Results
Test A TRIP800 Results
-
8/7/2019 ARW Presentation
20/41
w w w . a s p . o r g
Test A TRIP800 Results
Test B DP600 Results
-
8/7/2019 ARW Presentation
21/41
w w w . a s p . o r g
Test B DP600 Results
Test C DP600 Mild Steel Results
-
8/7/2019 ARW Presentation
22/41
w w w . a s p . o r g
Test C DP600-Mild Steel Results
Test C DP980-Mild Steel Results
-
8/7/2019 ARW Presentation
23/41
w w w . a s p . o r g
Test C DP980-Mild Steel Results
Test C DP980-BH Results
-
8/7/2019 ARW Presentation
24/41
w w w . a s p . o r g
Test C DP980 BH Results
Phase I - Conclusions
-
8/7/2019 ARW Presentation
25/41
w w w . a s p . o r g
Phase I Conclusions
Starting point RSW schedules were checked using thecommercially available SORPAS v.7 software
Weld schedules for both AC and DC RSW of both coated and
bare AHSS were evaluated and found to give acceptable results The given starting point weld schedules can be used to ensureacceptable weld size during the development of production RSWschedules
The schedules are intentionally hot as they are designed toproduce large welds over a wide range of conditions
Expulsion can be expected with these schedules and the
necessary safety precautions should be exercised These RSW schedules are not optimized for production
conditions
Phase II - Validation
-
8/7/2019 ARW Presentation
26/41
w w w . a s p . o r g
Phase II Validation
Evaluate the starting point weld schedules for variouscombinations of steel grades and gauges
590R 1.20, 1.40, 1.54 DP600 1.20, 1.60, 1.97, 2.20 DP750 1.50 (planned for DP780, substituted) DP780 1.15, 1.60
TRIP800 1.00, 1.50 DP980 1.40, 1.60, 1.92
Weld sample coupons based on AWS D8.9M:2002
Size and weld placement determined by material gauge All 3T assemblies produced with 2 x 6 coupons
Assembly and Inspection Procedure
-
8/7/2019 ARW Presentation
27/41
w w w . a s p . o r g
y p
Peel samples (weld 5 samples, evaluate 3) Visual inspection per AWS D8.1M:2007, Section 5.1 Peel inspection per AWS D8.1M:2007, Section 5.3
Tensile-shear and cross-tension samples (weld 5 samples,evaluate 3)
Weld property determination per AWS D8.9M:2002, Section 11.6 Static peak load
Evaluate results per AWS D8.1M:2007, Section 5.4
Metallographic (weld 2 samples, evaluate 1) Sample preparation per AWS D8.9M:2002, Section 11.5
Micro-hardness and un-etched photo not required Evaluate results per AWS D8.1M:2007, Section 5.2
Peel Test Requirements
-
8/7/2019 ARW Presentation
28/41
w w w . a s p . o r g
ee est equ e e ts
Test inspection requirements - Peel Samples Visual inspection per AWS D8.1M:2007, Section 5.1
Surface imperfection inspection without magnification Indentation measurement with depth gauge
Peel inspection per AWS D8.1M:2007, Section 5.3 Weld size requirements based on GMT and requirements of
Table-2 Fracture mode
Tensile Test Requirements
-
8/7/2019 ARW Presentation
29/41
w w w . a s p . o r g
q
Test inspection requirements mechanicals (TS & CT) Weld property determination per AWS D8.9M:2002, Section 11.6
Static pull @ 10 mm/min Evaluate results per AWS D8.1M:2007, Section 5.4
Weld size Fracture mode
Peak load weld strength (per Equations Below)
Metallographic Test Requirements
-
8/7/2019 ARW Presentation
30/41
w w w . a s p . o r g
g p q
Test inspection requirements - metallographic Sample preparation per AWS D8.9M:2002, Section 11.5
Micro-hardness and un-etched photo not required Etched photomicrograph at 10X
Evaluate results per AWS D8.1M:2007, Section 5.2 Fused nugget diameter
Depth of penetration Welding discontinuities
Porosity Voids Cracks
Internal Surface
Results Indentation AC
-
8/7/2019 ARW Presentation
31/41
w w w . a s p . o r g
1.201.401.541.201.601.971.15
1.501.601.001.501.401.601.92
1.2/2.2
1.15/1.6
1.0/1.5
1.4/1.92
1.0/2.2
1.0/1.92
0.45 0.42 0.360.49 0.47 0.44
1.11
0.41
0.59
0.590.50
0.52 0.52
0.66 0.660.55 0.55
0.480.59
1.05
0.64 0.61 0.450.29 0.42
0.39 0.38
0.48 0.49 0.500.77 0.83 0.68
0.52
0.360.420.460.36
Weld IndentationMaterial A
(Top)Material B
(Middle)Material C(Bottom)
Test2 - Top 2 - Bottom 4 - Bottom
30%Limit
Peel Sample Weld Indentation (mm)
DP750DP780 (B) 0.41 0.420.470.53TRIP800TRIP800
DP980
0.45
0.470.630.37
590R590R (B)
590RDP600DP600DP600DP780
DP600DP980 (B)
DP600DP980 (B)
DP600DP780 (B)TRIP800
DP980 (B)
DP980 (B)DP980 (B)
0.480.41 0.37
0.32 0.370.66
0.41 0.40
----
590R590R (B)
590R
---
DP600DP600DP780
DP750
--
-
0.53 0.50
0.48 0.42
0.32
0.36 / 0.660.35 / 0.480.30 / 0.45
0.450.420.480.58
0.420.52
0.410.49
0.570.60 0.49 0.37
0.420.64 0.64 0.63
0.470.60
0.67 0.731.06 0.79 0.781.26
-
----
---
DP780TRIP800
DP980
MildMild
DP600
DP780 (B)TRIP800TRIP800
DP980DP980 (B)DP980 (B)
4165r20a
4165r16a
4165r17a
4165r18a
4165r19a
4165r12a
4165r13a
4165r14a
4165r15a
4165r8a
4165r9a
4165r10a
4165r11a
4165r1a
4165r2a
GMT
0.45
4165r3a
4165r4a
4165r5a
4165r6a
4165r7a
DP600
4 - Top0.410.500.530.370.440.69
0.35
0.450.480.30
0.42 / 0.58
0.30 / 0.660.30 / 0.58
Results Indentation DC
-
8/7/2019 ARW Presentation
32/41
w w w . a s p . o r g
4 - Top
GMT
Weld IndentationMaterial A
(Top)Material B
(Middle)Material C(Bottom)
Test2 - Top 2 - Bottom 4 - Bottom
30%Limit
Peel Sample Weld Indentation (mm)
1.201.401.541.201.601.971.151.501.601.001.501.401.601.92
1.2/2.2
1.15/1.6
1.0/1.5
1.4/1.92
1.0/2.2
1.0/1.92
0.450.42
0.590.350.450.480.30
0.20
0.20
0.27
0.25 0.250.17 0.17 0.19
DP600DP980 (B)
----
--
----
--
-
590R-
DP600
0.19
0.31
DP780
DP600
-
0.480.36
0.360.420.46
0.25
0.200.160.20
0.55 0.58 0.85
0.33 0.36 0.310.28 0.260.27
0.30 0.29 0.320.17 0.20 0.21
0.260.25
0.68 0.66 0.44
0.31 0.31 0.470.18
0.54
0.31 0.27 0.32
0.51 0.44 0.42
0.310.480.210.13
0.18
0.20 0.220.15 0.18 0.16
0.19
0.25 0.28 0.26
0.450.43
0.21
0.620.43 0.40
0.60 0.42 0.740.65 0.37 0.490.75
DP980 (B)
DP600
---
TRIP800TRIP800
DP980
DP980 (B)
DP980 (B)DP980 (B)
DP600DP780 (B)TRIP800
DP600DP780DP750
DP780 (B)
590R (B)590R
DP600DP600
DP780 (B)
DP980
Mild
TRIP800
DP980 (B)DP980 (B)
DP600DP780
Mild
TRIP800TRIP800
DP980
DP750
590R
590R
DP600
590R (B)
4165r13d
4165r18d
4165r19d4165r20d
4165r14d
4165r15d
4165r16d4165r17d
4165r9d
4165r10d
4165r11d
4165r12d
4165r5d
4165r6d
4165r7d
4165r8d
4165r1d
4165r3d
4165r4d
4165r2d
0.45
0.68
0.28
0.450.460.440.20
0.92 0.30 / 0.660.30 / 0.58
0.480.58
0.36 / 0.660.35 / 0.480.30 / 0.450.42 / 0.58
Results Mechanical Testing AC
-
8/7/2019 ARW Presentation
33/41
w w w . a s p . o r g
1.201.401.541.201.601.971.15
1.501.601.001.501.401.601.92
1.201.151.001.40
685.7790.3281.0685.7589.1
790.31248.9382.2
419.7589.1726.5419.7
4165r19a4165r20a
DP600
1687.7
1588.0
1101.01461.7
1069.2
1196.81871.01250.01836.8
5553.3
5838.3
4004.3
1283.81617.81866.4
2370.0
1304.82008.92744.6
3419.23349.2
5408.8
5624.7
4785.03616.0
6042.0
4897.8
4048.0
3550.2
Mechanical Verification - AWS D8.1M:2007Material A
(Top)Material B
(Middle)Material C(Bottom)
TestCT AveragePeak Load
GMT
TS AveragePeak Load
D8.1TS
D8.1CT
1659.7
DP600DP600DP780
1818.5
1557.2
1912.71886.31531.8
2242.2
590R590R (B)
590R
TRIP800
DP600
DP750DP780 (B) 2555.51290.1
5053.76204.0
TRIP800DP980
DP600DP980 (B)
DP980 (B)
-
1452.72087.53076.2
DP980 (B)DP980 (B)
2493.3
TRIP800
DP600DP780 (B)
4327.0
1304.81557.21290.12493.3
-
-------
590R590R (B)
590RDP600DP600DP600DP780
DP750
3046.26527.0
3985.03921.3
790.31180.2
419.7382.2281.0589.1
1184.0
--
-
----
--
DP980 (B)
DP780TRIP800
DP980
MildMild
DP600
DP780 (B)TRIP800TRIP800
DP980DP980 (B)DP980 (B)
4165r15a4165r16a4165r17a4165r18a
4165r11a4165r12a4165r13a4165r14a
4165r7a
4165r8a4165r9a4165r10a
4165r3a4165r4a4165r5a4165r6a
4165r1a4165r2a
Results Mechanical Testing DC
-
8/7/2019 ARW Presentation
34/41
w w w . a s p . o r g
Mechanical Verification - AWS D8.1M:2007Material A
(Top)Material B
(Middle)Material C(Bottom)
TestCT AveragePeak Load
GMT
TS AveragePeak Load
D8.1TS
D8.1CT
1.201.401.541.201.601.971.151.501.601.001.501.401.601.92
1.201.151.001.40
685.7
419.7
382.2
790.3
1283.81617.81866.41304.8
589.1726.5419.7790.3
1248.9
685.7589.1790.3
1180.2
281.0
1611.31280.22348.2
1884.32668.0
589.1
419.7382.2281.0
3022.33422.2
1802.2
1763.32676.32843.21598.7
1085.84165r1d 3232.8
6906.36668.24004.76821.76326.07995.7
-
--
-
--
TRIP800
DP780DP750
DP780 (B)
DP600
590R590R (B)
590R
DP980 (B)
-
DP600
--
DP980
---
3060.36226.7
4647.55755.7
1290.12493.3
4179.0
7802.5
8193.7
3606.3
2555.51290.1
1557.2
1304.83813.74889.3
7711.8
2370.02493.33046.24004.3
1557.2
2744.6
2760.82976.2
2008.9
2242.2
959.8
2780.32010.0
-
DP980 (B)
DP600
---
-
DP980
DP750
DP600
DP980 (B)
DP980 (B)DP980 (B)
DP600DP780 (B)TRIP800
DP600DP780
DP600DP600
DP780 (B)
DP600DP600DP780
-
TRIP800
Mild
TRIP800TRIP800
DP980
Mild
TRIP800
DP980 (B)DP980 (B)
590R
590R590R (B)
4165r19d4165r20d
4165r14d
4165r15d4165r16d4165r17d
4165r11d4165r12d4165r13d
4165r18d
4165r7d4165r8d4165r9d
4165r10d
4165r4d
4165r2d
4165r5d4165r6d
4165r3d
Metallographic Inspection
-
8/7/2019 ARW Presentation
35/41
w w w . a s p . o r g
1.15 mm DP780 Galvanized / 1.15 mm DP780 GalvanizedAC 7 DC 7
Metallographic Inspection
-
8/7/2019 ARW Presentation
36/41
w w w . a s p . o r g
1.20 mm DP600 Galvanized / 2.20 mm DP600 GalvanizedAC 15 DC 15
Metallographic Inspection
-
8/7/2019 ARW Presentation
37/41
w w w . a s p . o r g
1.40 mm DP980 Galvanized / 1.92 mm DP980 BareAC 18 DC 18
Phase II - Summary (1 of 2)
-
8/7/2019 ARW Presentation
38/41
w w w . a s p . o r g
Weld Schedules AC and DC schedules specify different electrodes
Direct comparison of results difficult
DC schedules had lower gauge transition to large electrodes AC @ 1.60 mm vs. DC @ 1.30 mm Affected amount of visible surfacing cracking and measurable
indentation in materials between the transition gauges Material between 1.30 and 1.60 mm (Trials #3 & #8) Longer hold times for DC
Minor reduction in void formation (Trial #19) Nearly all schedules evaluated produced expulsion Indentation may predetermine peel weld size (Trials #11 & #19)
Phase II - Summary (2 of 2)
-
8/7/2019 ARW Presentation
39/41
w w w . a s p . o r g
Visual surface inspection No evidence of surface cracking
Did not use magnification device
Most indentation measurements in excess of 30% limit DC slightly better due to electrode geometry
Mechanical evaluation All peak loads exceeded requirements of AWS D8.1
Many results 2x or 3x greater than requirements
Metallographic evaluation Over 50% of welds with surface cracks
More evidence of AC surface cracks than DC
Acknowledgements
-
8/7/2019 ARW Presentation
40/41
w w w . a s p . o r g
Kevin Chan, Huys Industries simulation work on DCweld schedules
Wenqi Zhang, SWANTEC Software and Engineering
ApS technical support with SORPAS software
FOR MORE INFORMATION
-
8/7/2019 ARW Presentation
41/41
w w w . a s p . o r g
Contact:Mike Bzdok, Project Manager(248) 945-4778
[email protected] Pakalnins(248) 576-7454