A novel electrode tip geometry to mitigate liquid metal embrittlement during resistance spot welding

Dupuy, Thomas

doi:10.1007/s40194-022-01343-z

Cited by 6 publications

(1 citation statement)

References 20 publications

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“…LME can cause brittle failure in a normally ductile solid metal or alloy when it is in contact with a liquid metal, and subjected to an externally applied tensile stress. The occurrence and severity of LME cracks in RSW of zinc-coated AHSS and UHSS are influenced by weld process factors, such as the electrode geometry, [27][28][29][30] electrode or workpiece misalignments, [31,32] heat input, [30,32,33] or hold time, [34] all of which affect the thermal-mechanical conditions that the material is subjected to during welding. Whether or not these thermal-mechanical conditions lead to LME cracking, is also dependent on material-related factors, including the substrate microstructure, [35][36][37] substrate composition, [38,39] and zinc layer properties.…”

Section: Lme During Rsw Of Zinc-coated Ahss and Uhssmentioning

confidence: 99%

Optimization of Hot Forming Temperature to Minimize Liquid Metal Embrittlement Induced Cracking in Resistance Spot Welded Zinc‐Coated Medium Manganese Steel

Rana

2023

steel research int.

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Herein, an investigation on the influence of the hot press forming (HPF) temperature cycles of a medium manganese, high ductility, zinc‐coated steel with ≈1000 MPa final tensile strength (HPF1000‐GI), with a specific emphasis on the risks of liquid metal embrittlement (LME) induced cracking during resistance spot welding (RSW) is presented. The HPF1000‐GI steel is hot press formed using several temperature cycles, and subsequently the LME sensitivity of the variously hot press formed materials are investigated using both dedicated RSW experiments as well as high‐temperature tensile testing. It is shown that the LME sensitivity of the HPF1000‐GI steel is significantly reduced after hot forming at higher intercritical temperatures, and that this favorable behavior is caused by microstructural changes at the coating‐substrate interface.

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Section: Lme During Rsw Of Zinc-coated Ahss and Uhssmentioning

confidence: 99%

Optimization of Hot Forming Temperature to Minimize Liquid Metal Embrittlement Induced Cracking in Resistance Spot Welded Zinc‐Coated Medium Manganese Steel

Rana

2023

steel research int.

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A novel electrode tip geometry to mitigate liquid metal embrittlement during resistance spot welding

Dupuy

2022

Weld World

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Effect of a variable electrode force on the LME crack formation during resistance spot welding of 3G AHSS

Ullrich,

Jüttner

2024

Weld World

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In the pursuit of lightweight vehicles, third-generation advanced high-strength steels (3G AHSS) with increased mechanical properties are desired to be used for critical components. However, the exposure of these zinc-coated AHSS to the manufacturing conditions during resistance spot welding can trigger liquid metal embrittlement (LME), possibly compromising the mechanical properties. As the reproducibility of LME cracks in resistance spot welding is a challenge, the effect on the static and dynamic mechanical properties of the welds is not yet fully clarified and therefore a distinction between critical and non-critical cracks is not implemented in current standards. To achieve this, it is necessary to provoke LME cracks of a given size, for example by increasing the welding current, reducing the electrode force and hold time, or using manufacturing discontinuities. Due to its significant effect on the heat input and the tensile stresses during the resistance spot welding process, which impacts the LME crack propagation, the focus of this paper is on the electrode force. An expulsion-free decreasing force profile, which consists of a force run-in, force decrease, and force run-out time, has been derived in a two-stage Face-Centered-Central-Composite design of experiment for an electrogalvanized third-generation advanced high-strength steel (3G AHSS) DP1200 HD. The crack location, length, depth, and nugget geometries were investigated for each weld. With the decreasing force profile, it was possible to generate type A, B, and C cracks by parameter adaption, with type B and C cracks being the most dominant. The type C crack formation was investigated by aborting the welding process in defined time steps and the LME cracking mechanism was confirmed by welding dezincified samples. Based on the investigations carried out, the force profile was found suitable for generating different LME crack sizes to further investigate the mechanical joint properties as it was able to reproducibly generate defined cracks without expulsion and excessive electrode indentation while maintaining a minimum nugget diameter.

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A novel electrode tip geometry to mitigate liquid metal embrittlement during resistance spot welding

Cited by 6 publications

References 20 publications

Optimization of Hot Forming Temperature to Minimize Liquid Metal Embrittlement Induced Cracking in Resistance Spot Welded Zinc‐Coated Medium Manganese Steel

Optimization of Hot Forming Temperature to Minimize Liquid Metal Embrittlement Induced Cracking in Resistance Spot Welded Zinc‐Coated Medium Manganese Steel

A novel electrode tip geometry to mitigate liquid metal embrittlement during resistance spot welding

Effect of a variable electrode force on the LME crack formation during resistance spot welding of 3G AHSS

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