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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.

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Presentation on theme: "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."— Presentation transcript:

1 Johnny K Larsson et al. Page 1 Issue date: , Security Class: Open LättUHS Slutseminarium Swerea IVF, sal “Vinga”, Mölndal 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

2 Johnny K Larsson et al. Page 2 Issue date: , Security Class: Open Table of Content LättUHS Slutseminarium, Swerea IVF Mölndal,  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

3 Johnny K Larsson et al. Page 3 Issue date: , 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,

4 Johnny K Larsson et al. Page 4 Issue date: , Security Class: Open Five Material Combinations for RSW : mm USIBOR 1500 P / 0.9 mm Rephos260 70G70G HD / 1.5 mm DP G70G HD mm DP G70G HD / 1.4 mm USIBOR 1500 P / 2.5 mm Rephos260 70G70G HD mm USIBOR 1500 P / 1.5 mm DP G70G HD / 2.0 mm Boron 1500 P Same as above but with adhesive Betamate XW-1496V between USIBOR and DP mm DP G70G HD / 1.5 mm DP G70G HD Two Material Combinations for GMAW: mm DP G70G HD / 2.0 mm Boron 1500 P mm DP G70G HD / 1.5 mm DP G70G HD LättUHS Slutseminarium, Swerea IVF Mölndal, Scope of Welding Trials RSW and GMAW of Material Stack-ups including DP1000 Reference Object: Volvo XC90

5 Johnny K Larsson et al. Page 5 Issue date: , Security Class: Open Robust 1-D Welding Lobe for a Three Sheet Metal Stack-Up DP600 (1.65mm), Boron steel (1.4mm), mild steel (0.77mm) Current range > 1.0kAGood weldability kALimited weldability < 0.5kAUnacceptable weldability Minimum nugget diameter: 4.5 mm N.B. For classification in accordance to the above criteria, a nugget diameter d = d min + 1 mm shall be obtained before the spatter limit is reached kA mm LättUHS Slutseminarium, Swerea IVF Mölndal,

6 Johnny K Larsson et al. Page 6 Issue date: , Security Class: Open Welding Lobe for Materials Combination #1 [JPS-nr ] Sill Inner / Rfr. Sill Inner / Sill Outer MaterialsThickness WSS-M1A322-A3 / AlSiBoron WSS-M1A341-A2 / 70G70G-HDRP WSS-M1A348-A9 / 70G70G-HDDP OK LättUHS Slutseminarium, Swerea IVF Mölndal, Electrode Force = 4.9 kN; Welding Time = 530 ms; Cooling Time = 150 ms

7 Johnny K Larsson et al. Page 7 Issue date: , Security Class: Open Welding Lobe for Materials Combination #2 [JPS-nr ] Sill Outer / Sill Inner / Cover Plate [without adhesive between sills] MaterialsThickness WSS-M1A348-A9 / 70G70G-HDDP WSS-M1A322-A3 / AlSiBoron WSS-M1A341-A2 / 70G70G-HDRP OK LättUHS Slutseminarium, Swerea IVF Mölndal, Electrode Force = 5.1 kN; Welding Time = 720 ms; Cooling Time = 150 ms

8 Johnny K Larsson et al. Page 8 Issue date: , Security Class: Open Welding Lobe for Materials Combination #3 [JPS-nr ] B-pillar Rfr. / Sill Outer / Sill Inner [without adhesive between sills] MaterialsThickness WSS-M1322-A3 / un-coatedBoron WSS-M1A348-A9 / 70G70G-HDDP WSS-M1A322-A3 / AlSiBoron OK LättUHS Slutseminarium, Swerea IVF Mölndal, Electrode Force = 5.2 kN; Welding Time = 680 ms; Cooling Time = 150 ms

9 Johnny K Larsson et al. Page 9 Issue date: , Security Class: Open Welding Lobe for Materials Combination #4 [JPS-nr ] B-pillar Rfr. / Sill Outer / Sill Inner [with Betamate XW-1496V adhesive between sills] MaterialsThickness WSS-M1322-A3 / un-coatedBoron WSS-M1A348-A9 / 70G70G-HDDP WSS-M1A322-A3 / AlSiBoron Weld lobe size identical to !! 7.9 – 9.4 kA OK LättUHS Slutseminarium, Swerea IVF Mölndal, Electrode Force = 5.2 kN; Welding Time = 680 ms; Cooling Time = 150 ms

10 Johnny K Larsson et al. Page 10 Issue date: , Security Class: Open Welding Lobe for Materials Combination #5 [JPS-nr ] Basic Testing MaterialsThickness WSS-M1A348-A9 / 70G70G-HDDP OK LättUHS Slutseminarium, Swerea IVF Mölndal, Electrode Force = 4.9 kN; Welding Time = 400 ms; Cooling Time = 150 ms

11 Johnny K Larsson et al. Page 11 Issue date: , Security Class: Open Aspects on Spot Welding of High, Extra High and Ultra High Strength Steels  Increased electrode force  Increased weld time  Decreased weld current  Optimized hold time to avoid brittleness  Pulsed welding is favourable  Larger electrode caps are recommended Risk of pore formation Occurrence of partial plug failure LättUHS Slutseminarium, Swerea IVF Mölndal,

12 Johnny K Larsson et al. Page 12 Issue date: , Security Class: Open Welding Lobe for Materials Combination #6 [JPS-nr ] Sill Outer / B-pillar Rfr. OK LättUHS Slutseminarium, Swerea IVF Mölndal, 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 MaterialsThickness WSS-M1A348-A9 / 70G70G-HDDP WSS-M1322-A3 / un-coatedBoron

13 Johnny K Larsson et al. Page 13 Issue date: , Security Class: Open Welding Lobe for Materials Combination #7 [JPS-nr ] Basic Testing OK LättUHS Slutseminarium, Swerea IVF Mölndal, MaterialsThickness WSS-M1A348-A9 / 70G70G-HDDP 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

14 Johnny K Larsson et al. Page 14 Issue date: , 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,

15 Johnny K Larsson et al. Page 15 Issue date: , Security Class: Open LättUHS Slutseminarium, Swerea IVF Mölndal, Johnny K Larsson, Thank you for your attention!


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