A/SP Joining Technologies Committee Report
ADVANCED HIGH STRENGTH
STEEL (AHSS) WELD
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
Arnon Wexler
Chairman SWSG
I. Accorsi
A/SP Consultant
Ford Motor Company
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
RoMan Engineering Services
Warren Peterson
Hongyan Zhang
* SWSG project sub team
Edison Welding Institute
University of Toledo
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/m2
for galvanneal, 60g/m2 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 – Pulsed DC
GMAW (MIG)
GMAW – Pulsed AC
GMAW – Laser Assisted
Hybrid YAG Laser/GMAW-Pulsed DC
Laser
YAG Laser
Laser - Plasma Assisted
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
m
m
m
m
m
m
m
m
37.8 mm
60
45
.6
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.
50 mm
125 mm
200
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
GM
Porosity - Internal
Cross-section- 25% limit of total area
GM 4490M, 1991
GM
Porosity - Surface
< 25%
GM 4490M, 1991
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
Chrysler PS-9059
Under Cut (Maximum)
5% of thinnest metal
2002, NOV 6, CHG B
Convexity
Not addressed
HAZ (Heat Affected Zone)
Not addressed
Chrysler PS-9059
Penetration
>= 20% into second metal
2002, NOV 6, CHG B
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
Top Sheet
Bottom Sheet
Number
Evaluation
MIG AC
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
1.87mm DP 780
GA
AC, DC, LS,
LM, PL
9
1.17mm DP780GA
1.87mm DP 780
GA
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
C
Mn
P
S
Si
Cr
Mo
Al
N
Ti
1.15mm
DP 600
HDG
0.092
1.79
0.017
0.0059
0.005
0.188
0.177
0.054
0.020
<.002
1.52mm
DP 600 GN
0.084
1.50
0.009
0.0073
0.010
0.032
0.315
0.054
0.017
<.002
3.4mm
DP600
BARE
0.080
1.17
0.016
0.0055
0.057
0.624
0.004
0.042
0.013
0.003
3.2mm
HSLA 350
BARE
0.074
1.28
0.013
0.0077
0.026
0.023
0.003
0.041
0.010
0.002
1.18mm
DP 980 GN
0.131
2.62
0.012
0.0067
0.016
0.227
0.310
0.049
0.011
0.002
1.87mm
DP 780 GN
0.085
2.33
0.012
0.0059
0.006
0.238
0.291
0.055
0.013
<.002
1.17mm
DP 780 GN
0.124
2.10
0.017
0.0039
0.030
0.234
0.169
0.058
0.014
0.002
1.0mm DP
800 GN
0.131
2.06
0.023
0.0050
0.020
0.234
0.179
0.076
0.015
0.002
1.38mm
HSLA 350
HDG
0.067
0.629
0.010
0.0066
0.252
0.054
0.014
0.05
0.052
0.012
Materials
Other
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=0.160
Page 13 of 75
Material Physical Properties
Table 7: Material Physical Properties.
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
Material
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 LIHM200
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
Parameter
Value
Tensile Shear Strength
Laser power
4.0 kW
Load (kN)
Energy (J)
Weld speed
1.00 m/ min
Min
12.66
16.11
-2.0 mm
Average
13.75
18.13
Ar
Max
14.83
19.84
Focus Position
Gas (Laser)
Gap (engineered)
0 mm
Shielding Gas Flow
Ar, 18 CFH
Impact Strength
Load (kN)
Min
41.0
76.9
Average
47.4
116.2
Max
51.6
148.3
VICKERS HARDNESS CHART
VICKERS HARDNESS CHART
HAZ
HAZ
WELD
BM
BM
400
334
320
302
280
240
303
291 291
268
212
212 211
309 308
298
321
310 310
286
287
261
242
210
212
200
209213
210
202
208
160
440
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
440
360
Energy (J)
HAZ
HAZ
WELD
BM
BM
400
360
307
320
295
290 294
287
300
280
263
240
217
210 215
200 212 214 211 216
211
204
260
274
215
207
213
195
199
214
212
209
160
0
1
2
3
4
5
DISPLACEMENT (mm)
6
7
0
1
2
3
4
5
6
7
DISPLACEMENT (mm)
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
Value
Tensile Shear Strength
Laser power
4.0 kW
Load (kN)
Energy (J)
Weld speed
2.40 m/ min
Min
15.64
22.54
+1.8 mm
Average
16.44
24.55
Ar
Max
17.59
26.46
Parameter
Focus Position
Gas (Laser)
Gap (engineered)
0 mm
Shielding Gas Flow
Ar, 18 CFH
Impact Strength
Load (kN)
Min
18.6
88.9
Average
50.4
239.3
Max
120.2
323.3
VICKERS HARDNESS CHART
V IC K ER S H A R D N ES S C H A R T
440
HAZ
HAZ
W ELD
BM
BM
440
HAZ
HAZ
WELD
BM
BM
400
360
307
320
295
290
294
287
300
280
263
240
217
210
200 212 214
215
211 216
211
204
260
274
215
207
213
195
199
214
212
209
160
0
1
2
3
4
5
6
7
DISPLACEMENT (mm)
Figure G1-7: Top Sheet Microhardness Traverse.
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
Energy (J)
400
386
360 363 367
360
355
320
280
254
240
192
2 0 0 1 9 11 8 9
160
0
188
225
207
205
193193
1
1 9 51 9 2
188
194
2
3
4
5
6
D IS P LA C E M E N T (m m )
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
Parameter
Value
Tensile Shear Strength
Laser power
4.0 kW
Load (kN)
Energy (J)
Weld speed
1.90 m/ min
Min
13.99
20.34
+1.5 mm
Average
15.73
23.63
Ar
Max
17.59
27.08
Focus Position
Gas (Laser)
Gap (engineered)
0.1 mm
Shielding Gas Flow
Ar, 18 CFH
Impact Strength
Load (kN)
Min
28.5
95.8
Average
59.7
176.6
Max
117.6
303.6
VICKERS HARDN ESS CHART
VICKERS HARDNESS CHART
HAZ
W ELD
BM
BM
360
320
311
297
278
280
276
240
200
295
288
264
267
238
212
168
166
197
192
173
180
169
160
0
1
2
3
4
165
5
HAZ
HAZ
WELD
BM
BM
440
HAZ
400
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
440
322
Energy (J)
400
360
326
321
320
300
280
255
240
200
323
304
191
194 199
204
243
214
211
199
195 194
189
195
191
160
6
D ISPLA CEM ENT (m m )
Figure G1-11: Top Sheet Microhardness Traverse.
0
1
2
3
4
5
DISPLACEMENT (mm)
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
Parameter
Value
Tensile Shear Strength
Laser power
4.0 kW
Load (kN)
Energy (J)
Weld speed
2.70 m/ min
Min
13.62
25.80
+1.8 mm
Average
15.87
30.49
Ar
Max
18.72
37.19
Focus Position
Gas (Laser)
Gap (engineered)
0.1 mm
Shielding Gas Flow
Ar, 18 CFH
Impact Strength
Load (kN)
Energy (J)
50.5
58.9
Min
Average
95.1
165.4
Max
154.1
308.3
V IC K E R S H A R D N E SS C H A R T
402
4 00
395
385
3 60
3 20 297
287
283
386
383
397
390
388
388
386
392
308
289
2 80
281
H AZ
H AZ
W ELD
BM
BM
409
283
294
256 273
258
2 40
2 00
1 60
0
1
2
3
4
5
6
D IS P L A C E M E N T (m m )
Figure G1-15: Top Sheet Microhardness Traverse.
HAZ
440
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
4 40
VICKERS HARDNESS CHART
HAZ
402
387 390 390
400
360
280
292
290
BM
BM
288 287
285
271
288
WELD
399
383
378
320
395
265
282
258
261
267
263
240
293
290
200
160
0
1
2
3
4
5
6
DISPLACEMENT (mm)
Figure G1-16: Bottom Sheet Microhardness Traverse.
Page 19 of 75
Group-1: Laser Welding (Material Combination 5)
Figure G1-18: Hardness measurement path
Figure G1-17: Top sheet: 1.0mm DP800 GA,
Bottom sheet: 1.0mm DP800 GA.
Table-G1-6: Parameters and Data
Value
Parameter
Tensile Shear Strength
Laser power
4.0 kW
Weld speed
3.25 m/ min
Min
+1.8 mm
Average
16.78
29.08
Ar
Max
18.31
34.04
Focus Position
Gas (Laser)
Gap (engineered)
Load (kN)
Energy (J)
15.32
25.07
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 CHART
420
404
400
404 404
417
398
409
405
416
HAZ
HAZ
WELD
BM
BM
418
405
360
320
313
275
280
277
255
263
240
256
244
263
255
248
200
160
0
1
2
3
4
5
6
DISPLACEMENT (mm)
Figure G1-19: Top Sheet Microhardness Traverse.
440
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
440
VICKERS HARDNESS CHART
423
400
HAZ
415
391
HAZ
422
402 402
WELD
BM
384
BM
360
320
280
255 257257
240 250
256
254
248
247 248
240
238
261
239
200
160
0
1
2
3
4
5
6
DISPLACEMENT (mm)
Figure G1-20: Bottom Sheet Microhardness Traverse.
Page 20 of 75
Group-1: Laser Welding (Material Combination 8)
Figure G1-22: Hardness measurement path
Figure G1-21: Top sheet: 1.52mm DP 600
Bottom sheet: 1.87mm DP 780 GN.
Table-G1-7: Parameters and Data
Parameter
Value
Tensile Shear Strength
Laser power
4.0 kW
Load (kN)
Energy (J)
Weld speed
2.00 m/ min
Min
16.82
26.55
+1.5 mm
Average
19.21
32.02
Ar
Max
21.58
37.91
Focus Position
Gas (Laser)
Gap (engineered)
0.1 mm
Shielding Gas Flow
Ar, 18 CFH
Impact Strength
Load (kN)
Min
8.6
63.2
Average
33.7
159.9
Max
54.4
348.2
VICKERS HARDNESS CHART
VICKERS HARDNESS CHART
HAZ
HAZ
WELD
BM
BM
400
352
364
348
355
320
280
356
346
357
334
343
326
346
264
240
264
234
230
196 196
200
193
201
196
191
195
193
160
0
1
2
3
4
5
6
DISPLACEMENT (mm)
Figure G1-23: Top Sheet Microhardness Traverse.
440
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
440
360
Energy (J)
HAZ
HAZ
WELD
BM
BM
400
358
361
360
350
360
341
320
280
253
240
256
251 252
267
248
248
357
351
262
246 254
237
237
257
257
243
200
160
0
1
2
3
4
5
6
DISPLACEMENT (mm)
Figure G1-24: Bottom Sheet Microhardness Traverse.
Page 21 of 75
Group-1: Laser Welding (Material Combination 9)
Figure G1-26: Hardness measurement path
Figure G1-25: Top sheet: 1.17mm DP780 GA
Bottom sheet: 1.87mm DP 780 GN.
Table-G1-8: Parameters and Data
Value
Tensile Shear Strength
Laser power
Parameter
2.0 kW
Load (kN)
Energy (J)
Weld speed
2.60 m/ min
Min
17.73
28.83
+1.5 mm
Average
18.67
31.61
Ar
Max
19.72
34.03
Focus Position
Gas (Laser)
Gap (engineered)
0.1 mm
Shielding Gas Flow
Ar, 20 CFH
Impact Strength
Load (kN)
Energy (J)
Min
48.8
133.2
Average
56.5
162.4
Max
65.7
192.6
VICKERSHARDNESSCHART
402 405
410
395
396
399
403
398
390
380
360
388
394
HAZ
HAZ
WELD
BM
BM
390
395
310
260
246
251
246
262
232
244
246
210
215
230
245
228
160
0
1
2
3
4
5
6
DISPLACEMENT (mm)
Figure G1-27: Top Sheet Microhardness Traverse.
VICKERS HARDNESSS (HV)
VICKERS HARDNESS (HV)
VICKERS HARDNESS CHART
410
388
360
394
HAZ
HAZ
WELD
BM
BM
397 397
400
368
357
310
274 270 278
260
259
262
271
274
257
256
264
262
248
233
210
272
160
0
1
2
3
4
5
6
DISPLACEMENT (mm)
Figure G1-28: Bottom Sheet Microhardness Traverse.
Page 22 of 75
Group-1: Laser Welding (Impact Strength at 15 MPH)
LASER AVERAGE IMPACT PEAK LOAD (kN)
200.00
180.00
160.00
140.00
120.00
95.11
100.00
80.00
59.73
60.00
47.36
56.47
54.65
50.39
33.72
40.00
20.00
IM-09
IM-08
IM-05
IM-04
IM-03
IM-02
IM-01
0.00
Figure G1-29: Impact Strength Peak Load.
LASER AVERAGE IMPACT ENERGY (J)
600.00
500.00
400.00
300.00
253.89
239.25
176.60
200.00
165.41
159.86
162.41
116.21
100.00
IM-09
IM-08
IM-05
IM-04
IM-03
IM-02
IM-01
0.00
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
16.44
15.00
13.75
15.73
15.87
18.67
16.78
00-TS-05
00-TS-08
00-TS-09
29.08
32.02
31.61
00-TS-05
00-TS-08
00-TS-04
30.49
00-TS-04
00-TS-03
00-TS-02
00-TS-01
0.00
Figure G1-31: Tensile Shear Load.
LASER AVERAGE ENERGY (J)
250.00
225.00
200.00
175.00
150.00
125.00
100.00
75.00
24.55
23.63
00-TS-02
00-TS-03
25.00
18.13
00-TS-01
50.00
00-TS-09
0.00
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 LIHM200
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
Parameter
Value
Tensile Shear Strength
Laser power
2.5 kW
Load (kN)
Weld speed
10.6 m/ min
Min
23.24
64.52
+1.0 mm
Average
54.14
224.10
1.14mm Dia. ER70S6
Max
67.45
295.89
Focus Position
Wire Spec.
MIG Current
Wire Feed Rate
219A
10.6m/ min
Weld Volts
19.2V
Impact Strength
Gap (engineered)
0mm
Load (kN)
Shielding Gas Flow
Energy (J)
Ar, 18 CFH
Min
174.1
198.0
92% Ar/8% CO2
Average
174.1
198.7
Max
174.0
198.7
VICKERS HARDNESS CHART
440
VICKERS HARDNESS (HV)
Shielding Gas
Energy (J)
BM
WELD
BM
400
360
320
280
263
233
240
214
203
250
267
254
243
256
265
256
239
236
235
235
240
221
211
200
198
246
192
196
190
199 200
193
160
0
2
4
6
8
10
12
DISPLACEMENT (mm)
Figure G2-3: Microhardness Traverse.
Page 26 of 75
Group-2: Laser–GMAW (Material Combination 2)
Figure G2-5: Hardness measurement path
Figure G2-4: Top sheet: 1.15mm DP600
HDG, Bottom sheet: 3.2mm HSLA 350 Bare
Table-G2-3: Parameters and Data
Value
Tensile Shear Strength
Laser power
Parameter
2.0 kW
Load (kN)
Energy (J)
Weld speed
2.65 m/ min
Min
23.24
64.52
+1.0 mm
Average
54.14
224.10
0.9mm Dia. ER70S6
Max
67.45
295.89
Focus Position
Wire Spec.
MIG Current
132A
Wire Feed Rate
8.7m/ min
Weld Volts
14.6V
Gap (engineered)
Load (kN)
Energy (J)
Ar, 18 CFH
0mm
Min
23.8
197.0
92% Ar/8% CO2
Average
53.1
301.3
Max
82.6
380.7
Shielding Gas Flow
VICKERS HARDNESS CHART
440
VICKERS HARDNESS (HV)
Shielding Gas
Impact Strength
BM
WELD
BM
400
360
338
327 318 324 319 321
317
320
317
311
280
301
272
258
254
247
240
200
194
190
320
311
267
238
225
205
190
217
209
205
160
0
1
2
3
4
5
6
7
8
DISPLACEMENT (mm)
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
Parameter
Value
Tensile Shear Strength
Laser power
2.0 kW
Load (kN)
Energy (J)
Weld speed
2.60 m/ min
Min
22.14
56.75
+1.0 mm
Average
23.34
61.60
1.0mm Dia. ER70S6
Max
24.54
65.40
Focus Position
Wire Spec.
MIG Current
219A
Wire Feed Rate
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
92% Ar/8% CO2
Average
60.6
291.9
Max
102.2
347.4
VICKERS HARDNESS CHART
430
VICKERS HARDNESS (HV)
Shielding Gas
BM
WELD
BM
390
350
318
295295
310
283
293
281
221
230
190
289
293
288
272
270
267
265
260
223
235
209
198
159 163
204
190
190
166 173
188
150
0
2
4
6
8
10
DISPLACEMENT (mm)
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
Parameter
Value
Tensile Shear Strength
Laser power
1.3 kW
Load (kN)
Energy (J)
Weld speed
2.65 m/ min
Min
20.43
48.39
+1.0 mm
Average
22.48
59.04
0.9mm Dia. ER70S6
Max
25.04
69.19
Focus Position
Wire Spec.
MIG Current
110A
Wire Feed Rate
8.7m/ min
Weld Volts
Gap (engineered)
Shielding Gas Flow
Impact Strength
0.1 mm
Load (kN)
Energy (J)
Ar, 18 CFH
Min
22.4
186.1
92% Ar/8% CO2
Average
39.1
284.9
Max
46.8
356.7
VICKERS HARDNESS CHART
440
VICKERS HARDNESS (HV)
Shielding Gas
13.3V
365
360
320
395
391
390
400
373
368
377
341
358
294
289
280
HAZ
HAZ
WELD
BM
BM
405
384
365
330 326329
348
310
346
336
321
281
270
399
314
318
275
286
262
254
240
288
287
282
250
200
160
0
1
2
3
4
5
6
7
8
9
10
11
DISPLACEMENT (mm)
Figure G2-12: Microhardness Traverse.
Page 29 of 75
Group-2: Laser–GMAW (Material Combination 5)
Figure G2-14: Hardness measurement path
Figure G2-13: Top sheet: 1.0mm DP800 GA,
Bottom sheet: 1.0mm DP800 GA.
Table-G2-6: Parameters and Data
Parameter
Value
Tensile Shear Strength
Laser power
1.3 kW
Load (kN)
Energy (J)
Weld speed
2.65 m/ min
Min
18.01
37.64
+1.0 mm
Average
20.06
44.93
0.9mm Dia. ER70S6
Max
21.58
50.00
Focus Position
Wire Spec.
MIG Current
124A
Wire Feed Rate
8.2m/ min
Weld Volts
Gap (engineered)
Shielding Gas Flow
Impact Strength
0.1 mm
Load (kN)
Energy (J)
Ar, 18 CFH
Min
58.1
163.5
92% Ar/8% CO2
Average
91.0
267.2
Max
129.2
326.4
VICKERS HARDNESS CHART
440
VICKERS HARDNESS (HV)
Shielding Gas
15.3V
400
386
388
347
360
356
345
320
344
350
346
354
377
344
339
347
339
332
326
313
308
286
280
264
246
240
HAZ
HAZ
WELD
BM
BM
391
380
394
240
229
234
237
223
226
200
238
228
160
0
1
2
3
4
5
6
7
8
9
DISPLACEMENT (mm)
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
Parameter
Value
Tensile Shear Strength
Laser power
2.0 kW
Load (kN)
Energy (J)
Weld speed
2.60 m/ min
Min
25.27
67.26
+1.0 mm
Average
27.20
76.72
0.9mm Dia. ER70S6
Max
29.42
85.82
Focus Position
Wire Spec.
MIG Current
136A
Wire Feed Rate
8.9m/ min
Weld Volts
Gap (engineered)
Shielding Gas Flow
Impact Strength
Load (kN)
Energy (J)
190.1
Ar, 18 CFH
Min
37.5
92% Ar/8% CO2
Average
52.9
398.2
Max
87.4
480.4
VICKERS HARDNESS CHART
440
VICKERS HARDNESS (HV)
Shielding Gas
15.2V
0.1 mm
HAZ
HAZ
WELD
BM
BM
400
360
339
341
348
324
317
254
240
206
208
224
358
337
320
280
359
323
304
325
312
309
356
342
312
294
267
280
245 243 249
245
243
233
240
222
200
196
160
0
1
2
3
4
5
6
7
8
9
10
DISPLACEMENT (mm)
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
Value
Tensile Shear Strength
Laser power
Parameter
2.0 kW
Load (kN)
Energy (J)
Weld speed
2.60 m/ min
Min
25.50
75.56
+1.0 mm
Average
28.69
87.00
0.9mm Dia. ER90SD2
Max
31.72
105.10
Focus Position
Wire Spec.
MIG Current
136A
Wire Feed Rate
8.9m/ min
Weld Volts
15.2V
Gap (engineered)
Load (kN)
Energy (J)
Ar, 18 CFH
0.1 mm
Min
60.1
268.9
92% Ar/8% CO2
Average
63.8
415.7
Max
68.7
462.6
Shielding Gas Flow
VICKERS HARDNESS CHART
440
VICKERS HARDNESS (HV)
Shielding Gas
Impact Strength
400
380
367
355
359
360
349 363
320
382
350
359
319
309
283
280
227
240
200
371
363
199
199
193
HAZ
HAZ
WELD
BM
BM
284
242
250 256
263
255
264
255
199
186
190
160
0
1
2
3
4
5
6
7
8
DISPLACEMENT (mm)
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
Parameter
Value
Tensile Shear Strength
Laser power
2.0 kW
Load (kN)
Energy (J)
Weld speed
2.65 m/ min
Min
24.82
59.9
+1.0 mm
Average
25.59
62.29
0.9mm Dia. ER70S6
Max
26.46
69.42
Focus Position
Wire Spec.
MIG Current
Wire Feed Rate
110A
8.6m/ min
Weld Volts
Gap (engineered)
Shielding Gas
Impact Strength
0.1 mm
Load (kN)
Energy (J)
Ar, 18 CFH
Min
41.8
337.9
92% Ar/8% CO2
Average
62.3
381.5
Max
94.0
451.3
VICKERS HARDNESS CHART
HAZ
HAZ
WELD
BM
BM
440
VICKERS HARDNESS (HV)
Shielding Gas Flow
16.8V
393
377 375 367
363
353 360 349
349
334 337
346
400
360
346 341 340
320
319
280
240
317
327
357
329
293
262
266
238
227
223
235
261
248
262
260
237
200
160
0
2
4
6
8
10
DISPLACEMENT (mm)
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
Value
Tensile Shear Strength
Laser power
Parameter
2.0 kW
Load (kN)
Energy (J)
Weld speed
2.65 m/ min
Min
22.79
54.16
+1.0 mm
Average
24.68
61.21
0.9mm Dia. ER90SD2
Max
25.46
64.90
Focus Position
Wire Spec.
MIG Current
Wire Feed Rate
118A
8.6m/ min
Weld Volts
Gap (engineered)
Shielding Gas
Impact Strength
Load (kN)
Energy (J)
27.4
355.7
Ar, 18 CFH
Min
92% Ar/8% CO2
Average
47.8
380.7
Max
100.9
406.9
VICKERS HARDNESS CHART
HAZ
HAZ
WELD
BM
BM
440
VICKERS HARDNESS (HV)
Shielding Gas Flow
16.8V
0.1 mm
386
400
378
360
384
379
369
353
364
348
320
316
306
292
280
240
365 369
358
388 385 392
228
229
221
200
300
230
214
244
242 237
252
236
232
234
160
0
2
4
6
8
10
DISPLACEMENT (mm)
Figure G2-27: Microhardness Traverse.
Page 34 of 75
Group-2: Laser–GMAW (Impact Strength at 15 MPH)
LASER-GMAW AVERAGE IMPACT PEAK LOAD (kN)
200.00
180.00
174.14
160.00
140.00
120.00
100.00
90.96
80.00
63.78
60.61
60.00
62.31
52.88
53.06
47.76
39.07
40.00
20.00
IM-09-90
IM-09-70
IM-08-90
IM-08-70
IM-05-70
IM-04-70
IM-03-70
IM-02-70
IM-01-70
0.00
Figure G2-28: Impact Strength Peak Load.
LASER-GMAW AVERAGE IMPACT ENERGY (J)
600.00
500.00
291.93
380.73
IM-09-90
301.30
300.00
381.47
IM-09-70
415.75
398.20
400.00
284.90
267.22
200.00
198.73
100.00
IM-08-90
IM-08-70
IM-05-70
IM-04-70
IM-03-70
IM-02-70
IM-01-70
0.00
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
27.20
24.78
23.34
28.69
25.59
24.68
22.48
20.06
15.00
06-TS-09-90
06-TS-09-70
06-TS-08-90
06-TS-08-70
06-TS-05-70
06-TS-04-70
06-TS-03-70
06-TS-02-70
06-TS-01-70
0.00
Figure G2-30: Tensile Shear Load.
LASER-GMAW AVERAGE ENERGY (J)
250.00
225.00
224.10
200.00
175.00
150.00
125.00
100.00
87.00
61.48
61.60
59.04
62.29
61.21
06-TS-09-90
75.00
06-TS-09-70
76.72
44.93
50.00
25.00
Figure G2-31: Tensile Shear Energy.
06-TS-08-90
06-TS-08-70
06-TS-05-70
06-TS-04-70
06-TS-03-70
06-TS-02-70
06-TS-01-70
0.00
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
Parameter
Value
Tensile Shear Strength
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
5.0 mm
Average
36.8
55.0
3.0 mm
Max
49.7
71.7
Position of Plasma Tip
Above Surface
Distance Between
Laser and Plasma
Spot
VICKERS HARDNESS CHART
VICKERS HARDNESS CHART
BM
WELD
400
BM
360
349
327
320
320
291
280
283
266
264
240
200
198
195
220
207
197
204
190 193
191
1
2
3
4
5
6
7
8
DISPLACEMENT (mm)
Figure G3-3: Top Sheet Microhardness Traverse.
BM
WELD
400
360
343
343
BM
359
339
320
311
283
280
240
185
200
160
160
0
440
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
440
199
191
185
0
1
204
236
227
214
210
218
197
191
197
205
193
200 189 186
2
3
4
5
6
7
DISPLACEMENT (mm)
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
Value
Tensile Shear Strength
Laser power
Parameter
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
5.0 mm
Average
59.3
59.3
3.0 mm
Max
89.7
89.7
Position of Plasma Tip
Above Surface
Distance Between
Laser and Plasma
Spot
VICKERS HARDNESS CHART
VICKERS HARDNESS CHART
BM
WELD
BM
400
360
349
327
320
320
291
280
283
266
264
240
200
220
198
207
195 197
204
190 193
191
1
2
3
4
5
6
7
8
DISPLACEMENT (mm)
Figure G3-7: Top Sheet Microhardness Traverse.
BM
WELD
400
360
343
343
BM
359
339
320
311
283
280
240
185
200
160
160
0
440
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
440
185
0
199
191
1
204
236
227
214
210
218
197
191
197
205
193
200 189 186
2
3
4
5
6
7
DISPLACEMENT (mm)
Figure G3-8: Bottom Sheet Microhardness Traverse.
Page 39 of 75
Group-3: Laser–Plasma Welding (Material Combination 3)
Figure G3-10: Hardness measurement path
Figure G3-9: Top sheet: 1.38mm HSLA 350
HDG, Bottom sheet: 3.2mm HSLA 350 Bare
Table-G3-4 Parameters and Data
Parameter
Value
Tensile Shear Strength
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
5.0 mm
Average
78.5
189.6
3.0 mm
Max
96.1
308.7
Position of Plasma Tip
Above Surface
Distance Between
Laser and Plasma
Spot
VICKERS HARDNESS CHART
VICKERS HARDNESS CHART
BM
WELD
390
BM
350
321
315
328
310
299
286 286
270
234
230
196
190
163
205
191 186
236
225
206
209
175 183
183
1
2
192
181
163
171
150
0
168
3
4
5
6
440
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
430
BM
WELD
400
BM
360
312
320
280
240
200
8
DISPLACEMENT (mm)
Figure G3-11: Top Sheet Microhardness Traverse.
307
183
184
185 186
0
1
193
191
2
203
196
207
3
297
239
238
160
7
308
306
205
213
215
194
4
5
193
191
192
6
7
DISPLACEMENT (mm)
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
Value
Tensile Shear Strength
Laser power
Parameter
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
5.0 mm
Average
26.8
127.8
2.5 mm
Max
35.2
190.4
Position of Plasma Tip
Above Surface
Distance Between
Laser and Plasma
Spot
VICKERS HARDNESS CHART
VICKERS HARDNESS CHART
417
401
393
400
380
360
320
399
389
392
373
384
398
BM
BM
325
303
281
310
WELD
390
312
280
HAZ
HAZ
400
282
274
290
280
253
252
240
200
440
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
440
BM
WELD
400
BM
360
320
288
280
286
284
280
300 304
286
279
285
279
240
276
277
275
263
258
245
278
287
286
278
274
245
200
160
160
0
1
2
3
4
5
6
7
DISPLACEMENT (mm)
Figure G3-15: Top Sheet Microhardness Traverse.
0
1
2
3
4
5
6
DISPLACEMENT (mm)
Figure G3-16: Bottom Sheet Microhardness Traverse.
Page 41 of 75
Group-3: Laser–Plasma Welding (Material Combination 5)
Figure G3-18: Hardness measurement path
Figure G3-17: Top sheet: 1.0mm DP800 GA,
Bottom sheet: 1.0mm DP800 GA.
Table-G3-6 Parameters and Data
Value
Parameter
Tensile Shear Strength
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
5.0 mm
Average
22.7
28.4
2.5 mm
Max
47.7
56.5
Position of Plasma Tip
Above Surface
Distance Between
Laser and Plasma
Spot
VICKERS HARDNESS CHART
416
399
386
416
400
400
407
390 389
360
HAZ
406
395
399
HAZ
399
WELD
BM
BM
320
294
280
247
248
268
232
240
251
242
232
231
246
240
244
200
160
0
1
2
3
4
5
6
7
DISPLACEMENT (mm)
Figure G3-19: Top Sheet Microhardness Traverse.
440
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
440
VICKERS HARDNESS CHART
BM
WELD
BM
400
360
320
272
280
240
247
243
240
244
236
235
281
233
245
238
239
234
200
223
224
242
230
251
240
249
244
243
227
160
0
1
2
3
4
5
6
DISPLACEMENT (mm)
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
Parameter
Value
Tensile Shear Strength
Laser power
4.0 kW
Weld speed
41.60 mm/ sec
Min
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
Load (kN)
Energy (J)
13.90
20.79
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
5.0 mm
Average
41.0
268.3
3.0 mm
Max
49.7
330.3
Position of Plasma Tip
Above Surface
Distance Between
Laser and Plasma
Spot
VICKERS HARDNESS CHART
VICKERS HARDNESS CHART
440
HAZ
400
HAZ
360
360
351 348 350 348
325
320
322
WELD
BM
354
BM
347
319
322
293
280
266
240
239
195 200
200
236
222
207
191
191
160
0
192
189
1
191
190
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
440
BM
WELD
400
363
360
330
323
320
280
BM
375
247
255
261
250 251 256
240
253
258
256 260 258
254
246
252 253
248
261
250
256
200
160
2
3
4
5
6
7
8
DISPLACEMENT (mm)
Figure G3-23: Top Sheet Microhardness Traverse.
0
1
2
3
4
5
6
7
DISPLACEMENT (mm)
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
Value
Tensile Shear Strength
Laser power
Parameter
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
5.0 mm
Average
26.1
37.9
3.0 mm
Max
39.5
46.4
Position of Plasma Tip
Above Surface
Distance Between
Laser and Plasma
Spot
VICKERS HARDNESS CHART
VICKERS HARDNESS CHART
440
392
400
395
371
360
404
389
388
375
398
385
HAZ
HAZ
391
397
WELD
380
382
BM
BM
349
343
320
280
240
280
265
235
233
227 222
200
224
219
229 234
160
VICKERS HARDNESS (HV)
VICKERS HARDNESS (HV)
440
385
400
361
370
328
BM
370
361
360
BM
WELD
393
320
280
258 253
263
240
255
256 254
255 254 254
250
248
253
253
252
247 249
200
160
0
1
2
3
4
5
6
7
DISPLACEMENT (mm)
Figure G3-27: Top Sheet Microhardness Traverse.
0
1
2
3
4
5
6
DISPLACEMENT (mm)
Figure G3-28: Bottom Sheet Microhardness Traverse.
Page 44 of 75
Group-3: Laser–Plasma Welding (Impact Strength at 15 MPH)
LASER-PLASMA AVERAGE IMPACT PEAK LOAD (kN)
200.00
180.00
160.00
140.00
120.00
100.00
78.46
80.00
59.25
60.00
40.00
40.99
36.83
26.84
26.06
22.67
20.00
IM-09
IM-08
IM-05
IM-04
IM-03
IM-02
IM-01
0.00
Figure G3-29: Impact Strength Peak Load.
LASER-PLASMA AVERAGE IMPACT ENERGY (J)
600.00
500.00
400.00
300.00
268.28
203.94
189.64
200.00
127.83
100.00
55.02
37.90
28.40
IM-09
IM-08
IM-05
Figure G3-30: Impact Strength Energy.
IM-04
IM-03
IM-02
IM-01
0.00
Page 45 of 75
Group-3: Laser–Plasma Welding (Tensile Shear Data)
LASER-PLASMA AVERAGE PEAK LOAD (kN)
60.00
45.00
30.00
18.09
15.00
17.61
15.12
14.29
16.49
12.34
10.61
00-TS-09
00-TS-08
00-TS-05
00-TS-04
00-TS-03
00-TS-02
00-TS-01
0.00
Figure G3-31: Tensile Shear Load.
LASER-PLASMA AVERAGE ENERGY (J)
250.00
225.00
200.00
175.00
150.00
125.00
100.00
75.00
50.00
25.00
17.27
29.68
29.11
24.89
23.35
27.57
12.72
Figure G3-32: Tensile Shear Energy.
00-TS-09
00-TS-08
00-TS-05
00-TS-04
00-TS-03
00-TS-02
00-TS-01
0.00
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/200
Robot: OTC Daihen Robot Dynamic 4000 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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
Wire Diameter
ER70S3
Min
41.23
106.49
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
Wire Feed Rate
195A
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
35 CFH
Average
174.7
171.7
90% Ar / 10% CO2
Max
473.0
235.5
Shielding Gas Flow
VICKERS HARDNESS CHART
360
VICKERS HARDNE
Shielding Gas
HAZ
HAZ
WELD
BM
BM
320
280
240
229
222
240
200
272
264 266 263
269
204
197
204
265
257 260
272
267
258
266264
245
237
221
212
217 220
207
204
185
160
0
2
4
6
8
10
12
14
DISPLACEMENT (mm)
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
Figure G4-3: Cross-Section.
Table-G4-3: Parameters and Data
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
ER70S3
Min
23.24
58.57
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)
Wire Diameter
Tip Recess/Extension
.0625 in. (1.5 mm)
Travel Angle
40 deg. Push
Work Angle
30 deg.
MIG Current
Wire Feed Rate
110A
245 in./min
(6.22 m/min)
Weld Volts
Impact Strength
Load (kN)
Energy (J)
Gap (engineered)
0.5 mm
Min
25.9
59.0
Shielding Gas Flow
35 CFH
Average
96.9
296.6
90% Ar / 10% CO2
Max
186.8
368.2
VICKERS HARDNESS CHART
320
VICKERS HARDNESS (
Shielding Gas
19.5V
280
HAZ
HAZ
WELD
BM
BM
280
241
240
217
214
230
222
252 250
243 240
240 240
236
244
238236
217
233
241
234
232
238
217
212
202
207
203
200
245246
199
202
193
191
190
160
0
2
4
6
8
10
12
14
16
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
Wire Diameter
ER70S3
Min
23.59
54.31
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
Wire Feed Rate
115A
280 in./min
(7.11 m/min)
Impact Strength
19.5V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
63.8
76.8
Shielding Gas Flow
35 CFH
Average
110.1
279.8
90% Ar / 10% CO2
Max
142.6
411.8
VICKERS HARDNESS CHART
310
VICKERS HARDNESS (
Shielding Gas
285
271
270
285
280
278
279
268
271267
273
271 272274 272
239
245
230
193
235
232
229
220
216
209
191
190
HAZ
HAZ
WELD
BM
BM
198
189
183
197
201
196
196 195
150
0
2
4
6
8
10
12
14
16
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
ER70S3
Min
19.67
43.79
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)
Wire Diameter
Tip Recess/Extension
.0625 in. (1.5 mm)
Travel Angle
40 deg. Push
Work Angle
30 deg.
MIG Current
Wire Feed Rate
95A
202 in./min
(7.11 m/min)
Impact Strength
18.5V
Load (kN)
Energy (J)
Weld Volts
Gap (engineered)
0.5 mm
Min
33.8
194.8
Shielding Gas Flow
35 CFH
Average
59.7
299.1
90% Ar / 10% CO2
Max
94.3
343.7
VICKERS HARDNESS CHART
440
VICKERS HARDNESS (
Shielding Gas
388
400
368
379
368
360
376
345
320
260
259
240
265
357
316
317
280 274
HAZ
HAZ
WELD
BM
BM
404
380
289
282
290
270
243
271
290
284
291
288
268
277
271
251
200
160
0
2
4
6
8
10
12
DISPLACEMENT (mm)
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
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Parameter
Travel Speed
Wire Spec.
Wire Diameter
ER70S3
Min
22.22
47.59
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
Wire Feed Rate
85A
198 in./min
(6.22 m/min)
Impact Strength
18V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
22.3
310.7
Shielding Gas Flow
35 CFH
Average
22.3
327.8
90% Ar / 10% CO2
Max
22.3
349.6
VICKERS HARDNESS CHART
440
VICKERS HARDNESS (
Shielding Gas
HAZ
HAZ
WELD
BM
BM
404
400
376
360
315
307
312
297
303
280
200
360
342
320
240
387
381
229
307
289
277
286
234
320
296
283
272
244
236
220
212
248
231
224
160
0
2
4
6
8
10
12
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
ER70S3
Min
30.56
84.26
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)
Wire Diameter
Tip Recess/Extension
.0625 in. (1.5 mm)
Travel Angle
40 deg. Push
Work Angle
30 deg.
MIG Current
Wire Feed Rate
120A
290 in./min
(7.37 m/min)
Impact Strength
21V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
38.6
425.0
Shielding Gas Flow
35 CFH
Average
59.2
467.7
90% Ar / 10% CO2
Max
70.1
541.8
VICKERS HARDNESS CHART
390
VICKERS HARDNESS (
Shielding Gas
336
325
310
302
293
274
266
264
254 245
270
224
211 219
230
190
HAZ
HAZ
WELD
BM
BM
358
350
195
187
251
254
232
250
239
235
218
247
243
240
234
205
216
182
180
150
0
2
4
6
8
10
12
14
DISPLACEMENT (mm)
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
Figure G4-13: Cross-Section.
Table-G4-8: Parameters and Data
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
Wire Diameter
ER90S-D2
Min
33.10
100.02
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
Wire Feed Rate
120A
290 in./min
(7.37 m/min)
Impact Strength
21V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
53.1
467.9
Shielding Gas Flow
35 CFH
Average
66.4
495.1
90% Ar / 10% CO2
Max
104.1
508.7
VICKERS HARDNESS CHART
HAZ
HAZ
WELD
BM
BM
430
VICKERS HARDNESS (
Shielding Gas
390
353
350
330
310
288
270
291
288
255
230
323
336
301
298
288
281
288
325
296
280
237
227
217
200
180
187
190
345
240
244
233
230
183 184
150
0
2
4
6
8
10
12
14
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
45.29
Wire Spec.
Wire Diameter
ER70S3
Min
22.56
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
Wire Feed Rate
110A
260 in./min
(6.60 m/min)
Impact Strength
22V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
19.2
359.3
Shielding Gas Flow
35 CFH
Average
54.7
380.5
90% Ar / 10% CO2
Max
93.7
424.3
VICKERS HARDNESS CHART
440
VICKERS HARDNESS (
Shielding Gas
356
360
376
350
343
320
312 310
280
240
200
HAZ
HAZ
WELD
BM
BM
391
400
226
223
218
250
330
292298 292
299
293
303
281
268
276
330
320
295
221
210
268
264
245
233
247
160
0
2
4
6
8
10
12
14
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
66.95
Wire Spec.
Wire Diameter
ER90S-D2
Min
25.26
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
Wire Feed Rate
110A
260 in./min
(6.60 m/min)
Impact Strength
22V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
50.0
89.5
Shielding Gas Flow
35 CFH
Average
64.9
325.2
90% Ar / 10% CO2
Max
77.6
423.2
VICKERS HARDNESS CHART
440
VICKERS HARDNESS (
Shielding Gas
400
383
360
344
320
331
298
270
280
357
339
332
325
314
357
373
373
318
310
312
303
277
266
245
240
HAZ
HAZ
WELD
BM
BM
392
243
250
219
239
226
211
200
208
160
0
2
4
6
8
10
12
14
DISPLACEMENT (mm)
Figure G4-18: Microhardness Traverse.
Page 56 of 75
Group-4: GMAW AC (Impact Strength at 15 MPH)
GMAW-AC AVERAGE IMPACT PEAK LOAD (kN)
200.00
180.00
174.70
160.00
140.00
120.00
110.10
96.90
100.00
80.00
66.36
59.72
60.00
64.93
54.70
59.17
40.00
22.32
20.00
IM-09-90
IM-09-70
IM-08-90
IM-08-70
IM-05-70
IM-04-70
IM-03-70
IM-02-70
IM-01-70
0.00
Figure G4-19: Impact Strength Peak Load.
GMAW-AC AVERAGE IMPACT ENERGY (J)
600.00
495.07
500.00
467.69
380.48
400.00
IM-04-70
200.00
IM-03-70
300.00
296.58
299.06
IM-02-70
327.80
279.80
325.22
171.70
100.00
Figure G4-20: Impact Strength Energy.
Page 57 of 75
IM-09-90
IM-09-70
IM-08-90
IM-08-70
IM-05-70
IM-01-70
0.00
Group-4: GMAW AC (Tensile Shear Data)
GMAW-AC AVERAGE PEAK LOAD (kN)
60.00
45.00
44.73
32.39
33.37
30.61
28.62
30.00
26.19
25.79
21.84
22.93
15.00
00-TS-09-90
00-TS-09-70
00-TS-08-90
00-TS-08-70
00-TS-05-70
00-TS-04-70
00-TS-03-70
00-TS-02-70
00-TS-01-70
0.00
Figure G4-21: Tensile Shear Load.
GMAW-AC AVERAGE ENERGY (J)
250.00
225.00
200.00
175.00
150.00
132.69
125.00
94.29
100.00
105.59
89.53
68.80
75.00
78.50
77.07
61.73
52.53
50.00
25.00
Figure G4-22: Tensile Shear Energy.
Page 58 of 75
00-TS-09-90
00-TS-09-70
00-TS-08-90
00-TS-08-70
00-TS-05-70
00-TS-04-70
00-TS-03-70
00-TS-02-70
00-TS-01-70
0.00
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 4000 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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
Wire Diameter
ER70S3
Min
53.08
167.08
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
Wire Feed Rate
240A
530 in./min
13.5 m/min)
Impact Strength
28V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
150.6
186.8
Shielding Gas Flow
35 CFH
Average
167.9
220.8
90% Ar / 10% CO2
Max
209.5
247.7
VICKERS HARDNESS CHART
300
BM (Base Metal)
242
250
222
VICKERS HARDNESS (
Shielding Gas
198
207 206
200
194
234
231
244
231
HZ (HAZ)
248
238
242
237
245
234
231
236
232
243
232
HV (Weld)
240
227
226 224 223
225
219
237
220 217
210
206
HZ (HAZ)
BM (Base Metal)
213
203
203
213
199
194
203
197
194
150
100
50
0
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
DISPLACEMENT (mm)
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
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Parameter
Travel Speed
Wire Spec.
Wire Diameter
ER70S3
Min
25.90
67.07
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
Wire Feed Rate
120A
290 in./min
(7.37 m/min)
Weld Volts
Impact Strength
Load (kN)
Energy (J)
Gap (engineered)
0.5 mm
Min
64.3
350.8
Shielding Gas Flow
35 CFH
Average
85.3
376.0
90% Ar / 10% CO2
Max
94.7
395.2
VICKERS HARDNESS CHART
350
BM (Base Metal)
HZ (HAZ)
300
HV (Weld)
291
263
259
255
VICKERS HARDNESS (
Shielding Gas
22V
250
252
209
200
262
266
HZ (HAZ)
266
259
254
259
250
248
254
242
222
190 186
190
BM (Base Metal)
243
226
213
208
183
185
208
201
196 193
204
176
150
100
50
0
0.00
2.00
4.00
6.00
8.00
10.00
12.00
DISPLACEMENT (mm)
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
Figure G5-5: Cross-Section.
Table-G5-4: Parameters and Data
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Parameter
Travel Speed
Wire Spec.
Wire Diameter
ER70S3
Min
20.27
86.56
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
Wire Feed Rate
140A
330 in./min
(8.38 m/min)
Weld Volts
Impact Strength
Load (kN)
Energy (J)
Gap (engineered)
0.5 mm
Min
68.4
192.8
Shielding Gas Flow
35 CFH
Average
105.5
239.2
90% Ar / 10% CO2
Max
163.3
367.5
VICKERS HARDNESS CHART
300
BM (Base Metal)
HZ (HAZ)
250
240
239
227
230
VICKERS HARDNESS (
Shielding Gas
21V
200
184
169 171
169
150
167
237
235
HV (Weld)
232
234
225
236
221
HZ (HAZ)
225
207
200
196
206
209
BM (Base Metal)
207
201 201
207
175
161
100
50
0
0.00
2.00
4.00
6.00
8.00
10.00
12.00
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
ER70S3
Min
22.36
70.52
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)
Wire Diameter
Tip Recess/Extension
.0625 in. (1.5 mm)
Travel Angle
40 deg. Push
Work Angle
30 deg.
MIG Current
Wire Feed Rate
115A
210 in./min
(5.33 m/min)
Impact Strength
21V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
2.8
120.6
Shielding Gas Flow
35 CFH
Average
17.0
134.9
90% Ar / 10% CO2
Max
29.8
163.5
VICKERS HARDNESS CHART
450
BM (Base Metal)
400
350
VICKERS HARDNESS (
Shielding Gas
333
HZ (HAZ)
378
333
HV (Weld)
379
344
HZ (HAZ)
BM (Base Metal)
321
305
300
271
250
386
378
370
359
345
283
285
269
278
268
278
289
245
259
276
268
263
280
259
241
245
245
200
150
100
50
0
0.00
2.00
4.00
6.00
8.00
10.00
12.00
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Wire Spec.
Wire Diameter
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
ER70S3
Min
16.85
30.15
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
Wire Feed Rate
85A
188 in./min
(4.78 m/min)
Weld Volts
Impact Strength
Load (kN)
Energy (J)
Gap (engineered)
0.5 mm
Min
18.5
3.1
Shielding Gas Flow
35 CFH
Average
27.0
63.1
90% Ar / 10% CO2
Max
85.4
522.5
VICKERS HARDNESS CHART
450
BM (Base Metal)
400
387
376
350
VICKERS HARDNESS (
Shielding Gas
19V
376
366
349
311
331
331
330
317
327
200
229
HZ (HAZ)
HV (Weld)
372
HZ (HAZ)
332
338
319
322
300
250
344
389
372
BM (Base Metal)
330
309
297
237
246
226 223
223
150
100
50
0
0.00
2.00
4.00
6.00
8.00
10.00
12.00
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
Wire Diameter
ER70S3
Min
32.96
106.03
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
Wire Feed Rate
150A
300 in./min
(7.62 m/min)
Impact Strength
22V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
49.4
478.6
Shielding Gas Flow
35 CFH
Average
79.5
539.0
90% Ar / 10% CO2
Max
92.0
582.0
VICKERS HARDNESS CHART
400
BM (Base Metal)
360
350
HZ (HAZ)
HV (Weld)
319
274
258
250
298
307
300
VICKERS HARDNESS (
Shielding Gas
276
273
269
271
258 250 251
257
256
240
253
268
241
HZ (HAZ)
BM (Base Metal)
292
269
266
256
221
226
215
205
191
203
193 191
200
192
150
100
50
0
0.00
2.00
4.00
6.00
8.00
10.00
12.00
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
Wire Diameter
ER90S-D2
Min
29.34
82.14
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
Wire Feed Rate
150A
300 in./min
(7.62 m/min)
Impact Strength
22V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
55.4
497.5
Shielding Gas Flow
35 CFH
Average
80.0
523.4
90% Ar / 10% CO2
Max
122.2
548.8
VICKERS HARDNESS CHART
400
9.14
3.81
350
4.57
4.95
5.33
7.62
6.10
3.05
300
VICKERS HARDNESS (
Shielding Gas
4.19
2.67
5.72
7.24
BM (Base Metal)
9.53
HZ (HAZ)
HV (Weld)
9.91
HZ (HAZ)
8.76
BM (Base Metal)
10.29
8.76
3.43
250
1.91
200
6.86
6.48
0.00
0.38
0.76
2.29
11.05
11.43
11.81
11.05
1.52
1.14
150
100
50
0
0.00
2.00
4.00
6.00
8.00
10.00
12.00
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
Wire Diameter
ER70S3
Min
22.74
51.81
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
Wire Feed Rate
125A
265 in./min
(6.73 m/min)
Impact Strength
21V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
94.6
176.8
Shielding Gas Flow
35 CFH
Average
109.8
350.0
90% Ar / 10% CO2
Max
138.9
415.1
VICKERS HARDNESS CHART
450
8.76
350
9.14
3.05
0.00
0.38
0.76
1.14
1.52
3.43
2.67
HZ (HAZ)
9.91
4.19
3.81
4.57
300
250
BM (Base Metal)
9.53
400
VICKERS HARDNESS (
Shielding Gas
HV (Weld)
HZ (HAZ)
10.29
4.95
5.33
6.86 7.62
8.38
5.72
8.00
6.10
6.48 7.24
BM (Base Metal)
11.4311.05
1.91
2.29
200
150
100
50
0
0.00
2.00
4.00
6.00
8.00
10.00
12.00
DISPLACEMENT (mm)
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
Parameter
Travel Speed
Value
Tensile Shear Strength
30 in/min (762
mm/min)
Load (kN)
Energy (J)
Wire Spec.
Wire Diameter
ER90S-D2
Min
23.40
59.41
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
Wire Feed Rate
125A
265 in./min
(6.37 m/min)
Impact Strength
21V
Load (kN)
Weld Volts
Energy (J)
Gap (engineered)
0.5 mm
Min
33.1
194.8
Shielding Gas Flow
35 CFH
Average
75.8
322.1
90% Ar / 10% CO2
Max
103.1
361.6
VICKERS HARDNESS CHART
450
400
VICKERS HARDNESS (
Shielding Gas
6.10
3.43
350
3.05
3.81
4.95
8.38
BM (Base Metal)
5.72
HV (Weld)
HZ (HAZ)
9.14
BM (Base Metal)
9.53
2.67
2.29
0.00
0.38
HZ (HAZ)
8.76
4.57
300
250
4.19
8.00
6.86
7.24
7.62
6.48
5.33
0.76
1.14
1.52
9.91
1.91
10.29
200
11.43
10.67
11.81
11.05
150
100
50
0
0.00
2.00
4.00
6.00
8.00
10.00
12.00
DISPLACEMENT (mm)
Figure G5-18: Microhardness Traverse.
Page 68 of 75
Group-5: GMAW DC (Impact Strength at 15 MPH)
GMAW-DC AVERAGE IMPACT PEAK LOAD (kN)
200.00
180.00
167.92
160.00
140.00
120.00
109.81
105.47
100.00
85.31
79.50
80.00
79.98
75.78
60.00
40.00
26.96
17.01
20.00
IM-09-90
IM-09-70
IM-08-90
IM-08-70
IM-05-70
Figure G5-19: Impact Strength Peak Load.
IM-04-70
IM-03-70
IM-02-70
IM-01-70
0.00
GMAW-DC AVERAGE IMPACT ENERGY (J)
600.00
538.99
523.38
500.00
400.00
375.95
349.97
322.10
300.00
239.17
220.78
200.00
134.89
100.00
63.14
IM-09-90
IM-09-70
IM-08-90
IM-08-70
IM-05-70
IM-04-70
IM-03-70
IM-02-70
IM-01-70
0.00
Figure G5-20: Impact Strength Energy.
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
28.84
30.00
27.01
26.11
24.11
21.75
18.22
15.00
00-TS-09-90
00-TS-09-70
00-TS-08-90
00-TS-08-70
00-TS-05-70
00-TS-04-70
00-TS-03-70
00-TS-02-70
00-TS-01-70
0.00
Figure G5-21: Tensile Shear Load.
GMAW-DC AVERAGE ENERGY (J)
250.00
225.00
208.69
200.00
175.00
150.00
125.00
113.36
109.69
92.91
100.00
79.29
78.11
71.93
75.00
59.84
50.00
37.10
25.00
Figure G5-22: Tensile Shear Energy.
Page 70 of 75
00-TS-09-90
00-TS-09-70
00-TS-08-90
00-TS-08-70
00-TS-05-70
00-TS-04-70
00-TS-03-70
00-TS-02-70
00-TS-01-70
0.00
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
2000 Town Center, Suite 320
Southfield, Michigan 48075
Tel: 248.945.4777
www.a-sp.org