Johnny K Larsson et al. Page 1 Issue date: 2008-10-28, Security Class: Open LättUHS Slutseminarium Swerea IVF, sal “Vinga”, Mölndal 2008-10-28 Weldability Testing of new Grades of Ultra High Strength Steels [Svetsbarhetsbedömning av nya UHSS-kvaliteter] Johnny K Larsson Joel Lundgren Martin Olsson Gert Larsson Glenn Hopkins Volvo Car Corporation, Gothenburg
Johnny K Larsson et al. Page 1 Issue date: 2008-10-28, Security Class: Open LättUHS Slutseminarium Swerea IVF, sal “Vinga”, Mölndal 2008-10-28 Weldability.
Apr 01, 2015
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Johnny K Larsson et al.
Page 1Issue date: 2008-10-28, Security Class: Open
LättUHS SlutseminariumSwerea IVF, sal “Vinga”, Mölndal2008-10-28
Weldability Testing of new Grades of Ultra High Strength Steels[Svetsbarhetsbedömning av nya UHSS-kvaliteter]
Johnny K LarssonJoel LundgrenMartin OlssonGert LarssonGlenn Hopkins
Volvo Car Corporation, Gothenburg
Johnny K Larsson et al.
Page 2Issue date: 2008-10-28, Security Class: Open
Table of Content
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Introduction of VCC’s Routines for Joinability
Scope of Welding Trials
Criteria for an Approved RSW 1-D Lobe
Aspects on RSW of UHSS
GMAW 2-D Lobe and Process Tolerances
Summary and Future Outlook
Johnny K Larsson et al.
Page 3Issue date: 2008-10-28, Security Class: Open
Routines for Evaluation of “Joinability”
Resistance Spot Welding Gas Metal Arc Welding Laser Beam Welding Brazing Technologies Adhesive Bonding Mechanical Joining Fasteners (weld bolts & nuts)
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Johnny K Larsson et al.
Page 4Issue date: 2008-10-28, Security Class: Open
Five Material Combinations for RSW:
21-522 1.4 mm USIBOR 1500 P / 0.9 mm Rephos260 70G70G HD / 1.5 mm DP1000 70G70G HD
21-523 1.5 mm DP1000 70G70G HD / 1.4 mm USIBOR 1500 P / 2.5 mm Rephos260 70G70G HD
21-524 1.4 mm USIBOR 1500 P / 1.5 mm DP1000 70G70G HD / 2.0 mm Boron 1500 P
21-525 Same as above but with adhesive Betamate XW-1496V between USIBOR and DP1000
21-526 1.5 mm DP1000 70G70G HD / 1.5 mm DP1000 70G70G HD
Two Material Combinations for GMAW:
135-91 1.5 mm DP1000 70G70G HD / 2.0 mm Boron 1500 P
135-92 1.5 mm DP1000 70G70G HD / 1.5 mm DP1000 70G70G HD
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Scope of Welding TrialsRSW and GMAW of Material Stack-ups including DP1000
Reference Object: Volvo XC90
Johnny K Larsson et al.
Page 5Issue date: 2008-10-28, Security Class: Open
Robust 1-D Welding Lobe for a Three Sheet Metal Stack-UpDP600 (1.65mm), Boron steel (1.4mm), mild steel (0.77mm)
Current range
> 1.0kA Good weldability
05 - 1.0kA Limited weldability
< 0.5kA Unacceptable weldability
Minimum nugget diameter: 4.5 mm
N.B. For classification in accordance to the above criteria, a nugget diameter d = dmin + 1 mm shall be obtained before the spatter limit is reached
8.2-9.6 kA
6.4-4.5 mm
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Johnny K Larsson et al.
Page 6Issue date: 2008-10-28, Security Class: Open
Welding Lobe for Materials Combination #1 [JPS-nr. 21-522]
Sill Inner / Rfr. Sill Inner / Sill Outer
Materials Thickness
WSS-M1A322-A3 / AlSi Boron 1500 1.60
WSS-M1A341-A2 / 70G70G-HD RP 260 0.90
WSS-M1A348-A9 / 70G70G-HD DP 1000 1.50
OK
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Electrode Force = 4.9 kN; Welding Time = 530 ms; Cooling Time = 150 ms
Johnny K Larsson et al.
Page 7Issue date: 2008-10-28, Security Class: Open
Welding Lobe for Materials Combination #2 [JPS-nr. 21-523]
Sill Outer / Sill Inner / Cover Plate [without adhesive between sills]
Materials Thickness
WSS-M1A348-A9 / 70G70G-HD DP 1000 1.50
WSS-M1A322-A3 / AlSi Boron 1500 1.60
WSS-M1A341-A2 / 70G70G-HD RP 260 2.50
OK
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Electrode Force = 5.1 kN; Welding Time = 720 ms; Cooling Time = 150 ms
Johnny K Larsson et al.
Page 8Issue date: 2008-10-28, Security Class: Open
Welding Lobe for Materials Combination #3 [JPS-nr. 21-524]
B-pillar Rfr. / Sill Outer / Sill Inner [without adhesive between sills]
Materials Thickness
WSS-M1322-A3 / un-coated Boron 1500 2.00
WSS-M1A348-A9 / 70G70G-HD DP 1000 1.50
WSS-M1A322-A3 / AlSi Boron 1500 1.60
OK
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Electrode Force = 5.2 kN; Welding Time = 680 ms; Cooling Time = 150 ms
Johnny K Larsson et al.
Page 9Issue date: 2008-10-28, Security Class: Open
Welding Lobe for Materials Combination #4 [JPS-nr. 21-525]
B-pillar Rfr. / Sill Outer / Sill Inner [with Betamate XW-1496V adhesive between sills]
Materials Thickness
WSS-M1322-A3 / un-coated Boron 1500 2.00
WSS-M1A348-A9 / 70G70G-HD DP 1000 1.50
WSS-M1A322-A3 / AlSi Boron 1500 1.60
Weld lobe size identical to 21-524 !!
7.9 – 9.4 kA
OK
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Electrode Force = 5.2 kN; Welding Time = 680 ms; Cooling Time = 150 ms
Johnny K Larsson et al.
Page 10Issue date: 2008-10-28, Security Class: Open
Welding Lobe for Materials Combination #5 [JPS-nr. 21-526]
Basic Testing
Materials Thickness
WSS-M1A348-A9 / 70G70G-HD DP 1000 1.50
WSS-M1A348-A9 / 70G70G-HD DP 1000 1.50
OK
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Electrode Force = 4.9 kN; Welding Time = 400 ms; Cooling Time = 150 ms
Johnny K Larsson et al.
Page 11Issue date: 2008-10-28, Security Class: Open
Aspects on Spot Welding ofHigh, Extra High and Ultra High Strength Steels
9,3 mm
8,0 mm
Weld Nugget
Increased electrode force
Increased weld time
Decreased weld current
Optimized hold time to avoid brittleness
Pulsed welding is favourable
Larger electrode caps are recommended
9,3 mm
8,0 mmRisk of pore formation
Occurrence of partial plug failure
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Johnny K Larsson et al.
Page 12Issue date: 2008-10-28, Security Class: Open
Welding Lobe for Materials Combination #6 [JPS-nr. 135-91]
Sill Outer / B-pillar Rfr.
OK OK
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Power Source: Fronius TPS4000
Wire Feeder: Robacta Drive VR 1500
Shielding Gas: Ar 80% / CO2 20% [ATAL]
Filler Wire: EN-440 G3Si1 1.0 mm
Materials Thickness
WSS-M1A348-A9 / 70G70G-HD DP 1000 1.50
WSS-M1322-A3 / un-coated Boron 1500 2.00
Johnny K Larsson et al.
Page 13Issue date: 2008-10-28, Security Class: Open
Welding Lobe for Materials Combination #7 [JPS-nr. 135-92]
Basic Testing
Weldlobe 2D
0
3
6
9
12
15
18
21
0 1 2 3 4 5 6 7 8 9 10
Wire speed (m/min)
Tra
vel s
pee
d (
mm
/s)
OK OK
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Materials Thickness
WSS-M1A348-A9 / 70G70G-HD DP 1000 1.50
WSS-M1A348-A9 / 70G70G-HD DP 1000 1.50
Power Source: Fronius TPS4000
Wire Feeder: Robacta Drive VR 1500
Shielding Gas: Ar 80% / CO2 20% [ATAL]
Filler Wire: EN-440 G3Si1 1.0 mm
Johnny K Larsson et al.
Page 14Issue date: 2008-10-28, Security Class: Open
Robot
Correct welding position
Perpendicular angel towards the sheets
Product
Geometry and gaps
Spatter protection (covers)
Welding gun
Good electrode matching
No electrode slipping
The electrical circuit and copper parts checked
Cooling water circuit OK
Critical Parameters for an Optimal Spot Welding Result
Welding parameters
Welding current
Welding time
Gun force
Pulse & slopes
Polarity at MFDC (Peltier effect))
Tipdresser
Good cutter-knifes
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Johnny K Larsson et al.
Page 15Issue date: 2008-10-28, Security Class: Open
LättUHS Slutseminarium, Swerea IVF Mölndal, 2008-10-28
Johnny K Larsson, [email protected]
Thank you for your attention!
Related Documents
