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Double-Sided Arc Welding of AA5182-O Aluminum Sheet for Tailor Welded Blank Applications

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Double-Sided Arc Welding of AA5182-O Aluminum Sheet for Tailor Welded Blank Applications Moulton/Weckman Supp. Jan 09:Layout 1 12/14/09 3:12 PM Page 11 Double-Sided Arc Welding of AA5182-O Aluminum Sheet for Tailor Welded Blank Applications The conduction-mode double-sided arc welding process may be a viable alternative to traditional welding processes for aluminum tailor welded blanks BY J. A. MOULTON AND D. C. WECKMAN Introduction for any welding process, as not only must ABSTRACT the weld have strengths comparable to the Automotive manufacturers are coming base metal, but it must also have sufficient The viability of using the double- under increasing regulatory pressure to ductility that it does not fail during draw- sided arc welding (DSAW) process, continually improve the overall fleet ing or stretching in the forming operation comprised of a plasma arc welding mileage of their automobiles and to move (Refs. 1, 2). torch above and gas tungsten arc weld- toward use of more environmentally Further savings in automotive body ing torch below the joint, to produce friendly fuels and energy sources such as weight can be realized by making TWBs autogenous square welds between 1.0- hybrid and all-electric drive systems. Con- from lighter aluminum alloys such as and 1.5-mm-thick AA5182-O alu- sequently, there is much interest in devel- AA5754 and AA5182 for semistructural minum sheets for applications such as opment and assessment of new materials and internal closure applications and tailor welded blanks (TWB) has been and manufacturing technologies that will AA6111 for inner and external closure studied. Visually acceptable com- allow fabrication of lighter automotive panels (Refs. 2, 3). These alloys have been plete-joint-penetration, conduction- bodies and structural components that used in the automotive industry for their mode DSA welds were produced with continue to meet or exceed current safety good strength-to-weight ratio and forming good cathodic cleaning of the oxide and crash worthiness standards. For ex- characteristics; however, the high thermal from both sides of the sheets over a ample, CO2 laser welding of tailor welded conductivity and thermal expansion coef- wide range of welding speeds and blanks (TWB) of automotive steel sheets ficient, low absorptivity, a tenacious alu- powers from 10 mm/s when using 1.8 is a relatively new technology that has minum oxide, and a sensitivity to hydrogen kW to 70 mm/s when using 4.6 kW. been shown to provide many advantages porosity make the welding of wrought alu- Transverse tensile tests showed that over the use of monolithic blanks includ- minum alloys more challenging than the the weld strength was similar to the ing up to 30% weight savings for structural welding of traditional sheet steel alloys. To thinner base metal sheet; however, the components (Refs. 1, 2). Tailor welded facilitate manufacturing of aluminum displacement to failure was always less blanks are composite blanks made from alloy TWBs in a high-speed production than the base metal. Hydrogen poros- combinations of different sheet steel and environment, new welding techniques ity was observed in the welds; how- galvanized coating thicknesses that are must be identified and assessed. Recent WELDING RESEARCH ever, this was significantly reduced by joined together along butt joints using studies suggest that electron beam weld- stainless steel wire brushing all af- long, complete penetration square welds. ing (EBW), laser beam welding (LBW), fected surfaces prior to welding. SEM- Once welded, the TWB is stamped and and variable-polarity plasma arc welding EDS analysis and microhardness tests formed into a structural component such (VPPAW) are the welding processes most showed that there was no significant as an inner door panel. Manufacturing of likely to be successful for welding of alu- variation in composition and hardness TWBs for the automotive industry re- minum alloy TWBs (Refs. 4, 5). between the base metal and weld quires welding processes capable of mak- While CO2 laser welding is commonly metal. The DSAW process was found ing high quality, complete joint penetra- used to fabricate steel TWBs, aluminum to be capable of producing welds with tion welds between two sheets of different has a low absorptivity at the CO2 wave- excellent visual quality at welding thicknesses at high welding speeds (Ref. length, which prevents absorption of the speeds that exceed those of traditional 1). This is a very demanding application laser beam energy (Refs. 6, 7). Nd:YAG arc welding processes, thus demon- laser welding is preferred for welding alu- strating the potential for attaining the minum alloys due to the higher absorptiv- high productivity rates required for KEYWORDS ity of aluminum at the Nd:YAG wave- aluminum TWB applications. length (Ref. 8). Deutsch et al. (Refs. 9, 10) Aluminum Alloys reported that single-beam Nd:YAG laser Double-Sided Arc Welding welds on 1-mm-thick AA 5182-O alu- Hydrogen Porosity minum alloy sheet exhibited spiky under- Tailor Welded Blanks bead surfaces that they attributed to pref- J. A. MOULTON ([email protected] erential vaporization of the Mg in the alloy terloo.ca) and D. C. WECKMAN (dweck- and resultant keyhole instabilities. No [email protected]) are with Department of Me- combination of welding parameters could chanical & Mechatronics Engineering, University be found to eliminate this surface defect. of Waterloo, Waterloo, Ont., Canada. WELDING JOURNAL 11-s Moulton/Weckman Supp. Jan 09:Layout 1 12/11/09 2:57 PM Page 12 A B Fig. 1 — Schematic diagram of the DSAW process with a PAW torch above Fig. 2 — Weld cross-sectional geometry illustrating the difference in weld and a GTAW torch below the shimmed and clamped AA 5182-O aluminum metal drop-through for welds produced between 1- and 1.5-mm-thick sheet specimens. AA5182-O aluminum alloy sheets with the following: A — Bottom sheet surfaces aligned prior to welding; B — top sheet surfaces aligned prior to welding. (etch: Keller’s (Ref. 29)). WELDING RESEARCH Fig. 3 — Schematic showing PAW torch standoff and electrode setback re- Fig. 4 — A 4.8-mm-diameter W-0.8% Zr electrode originally ground to a quired to prevent electrode-to-orifice cup short circuiting for the following: A sharp 20-deg cone angle after VPPAW for only 1 min showing significant — An electrode ground to a 20-deg cone angle; B — a blunt electrode. erosion and formation of a molten balled tip. However, Deutsch et al. (Refs. 9, 10) and stabilities induced by the high vapor pres- nonsymmetric weld profiles and pro- Punkari et al. (Refs. 11, 12) later showed sure of magnesium in the aluminum alloy nounced angular distortion of the sheets. that visually acceptable dual-beam (Refs. 10, 12, 14, 15). Double-sided arc welding (DSAW), Nd:YAG laser welds could be produced in The feasibility of applying VPPAW to shown schematically in Fig. 1, is a relatively 1-mm-thick 5182 and 5754 aluminum alloy the manufacture of TWBs has been inves- new arc welding process that was patented sheet using total welding powers of 4.5 to tigated by Deutsch (Ref. 9) and Punkari by Zhang and Zhang (Ref. 16) in 1999. The 5.0 kW and travel speeds of 6 to 7.5 m/min. (Ref. 11) using 1.6-mm-thick AA5182 and DSAW process uses one welding power The high energy density typical of laser AA5754 aluminum sheet. A maximum supply and two torches, frequently a plasma beams has been reported to cause loss of welding speed near 3 m/min was reported, arc welding (PAW) and gas tungsten arc alloying elements such as magnesium by which was limited by the arc’s ability to ca- welding (GTAW) torch each connected di- vaporization during CO2 laser welding thodically clean the surface oxide at higher rectly to one of the power supply terminals. (Refs. 13, 14). Moon and Metzbower (Ref. speeds (Ref. 9). A stainless steel backing The torches are positioned on opposite 13) reported that the loss of magnesium in bar was required to control the under-bead sides of the work-piece such that the weld- the weld metal contributed to a loss in geometry. This acted as an additional heat ing current flows from one torch through strength in AA5456 aluminum alloy welds sink and restricted cathodic cleaning of the the workpiece to the opposite torch. The since this alloy derives its strength through oxide to the top weld bead surface. Thus, plates to be welded are grounded and not solid solution strengthening from the oxide inclusions and incomplete fusion de- part of the electric welding circuit. Zhang et magnesium. Porosity is another problem fects were sometimes evident on the un- al. (Refs. 17–22) have examined the feasi- that has been reported in laser welding of derside of the weld. In addition, Punkari bility of using the DSAW process to make aluminum alloys. Pores have been attrib- (Ref. 11) found that substantial welding uphill, keyhole-mode welds in 6- to 12-mm uted to either hydrogen gas porosity or oc- power was required to prevent oxide inclu- thick plain carbon steel, stainless steel, or cluded vapor pores caused by keyhole in- sions, which resulted in wide welds with aluminum alloy plates. 12-s JANUARY 2010, VOL 89 Moulton/Weckman Supp. Jan 09:Layout 1 12/11/09 3:01 PM Page 13 Fig. 5 — Images of 4.8-mm-diameter W-0.8% Zr electrodes after DSAW. Fig. 6 — The normal start-up voltage transient in conduction-mode DSAW The electrode on the right was ground to a 20-deg cone and truncated to 3.2 of aluminum sheet with a blunt electrode and 6.25-mm setback exceeded the mm diameter and exhibits a larger molten spot after welding than the blunt maximum ±44 V of the power supply and caused shutdown.
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