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Welding Ultra High Strength
Steels
HistoryA Manufacturers point of view
Carl Occhialini 2-18-2004
[email protected]
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A TEAM OF THREE
1. STEEL PRODUCERS
2. MANUFACTURERS OF WELDINGCONSUMABLE & EQUIPMENT
3. FABRICATORS
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How to Weld Them
Wrought (Iron) Low-Med-High
Carbon Steels
High Strength LowAlloy Steels
Ultra High Strength
Steels
1850 1935 1925 1980
1965 Current
1985 Future
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WROUGHT
Best Processing Rolled Slag Into The Steels Used Consumables
With Cleaning
Capabilities
Welding De-gassed-slagged
Impurities Were Part Of The Process
Used High Heat Inputs
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CARBON STEELSLOW-MED-HIGH
Better Quality Steels More Refined
More Homogeneous Welding De-gassed Re-refined
SMAW-FCAW-GMAW-SAW
From Ductile To Hard To Weld
Welding With High Heat Input
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High Strength Low AlloyHSLA
Better Quality More Refined
GMAW-FCAW-SAW-SMAW Better Properties By Processing Steel
Limit Heat Input To Retain Properties
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Advanced High Strength SteelAHSS
High Quality High To Ultra High Properties
Heat Treated In The Process GMAW-FCAW
Relies On Controlling Heat Input To Retain
Properties
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Automated Design of Experiment (DOE)
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Properties of Base Metals
WROUGHTTENSILE
30-46,000
CARBON
30-60,000
HSLA
45-75,000
AHSS
60-140,000
YIELD
26,000 30,000 45,000 60-140,000
ELONGATION
35% 25% 22% 16-27%
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Wrought to AHSS
0
50
100
150
200
250
300
Wrought
Carbon
HSLA
AHSS
WS/BM
W-DH-I
WS/BM Weld strengthhigher than base metal
W-D Weld
discontinuitiesacceptable.
H-I The more heat
input, the better.
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Mechanical and metallurgical evaluation ofDP590 arc welds
DP590T lap joint hardness tranverse - C2 (DP590T, 1.5mm)
100
120
140
160
180
200
220
240
260
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Samples (0.38 mm spacing )
VHN@500gload
Base Metal
HAZ
Weld Metal
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CURRENT CONSIDERATIONS
210 MPa 30,000 si SMAW GMAW-MC FCAW
310 MPa 45 000 si ALL ALL ALL
430 MPa 60,000 si ALL ALL ALL
480 MPa 70 000 si ONLY7070187028--
ALLE70S364--
ALLE70T71T
550 MPa 80 000 si ONLY80E8018C1B2C3
ONLY80ER80SNi 1D2
ONLY 80E80&81T--
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FUTURE CONDITIONS
SMAW GMAW FCAW
620 MPa 90 k psi E9018B3 E09SD2 E91T1K2
690 MPa 100 k psi E11018-M ER100-110-S E110C-G
760 MPa 110 k psi E11018-M ER110S-1 E110T-1-5
830 MPa 120 k psi E12018-M-M1 ER120S-1 E120T-1-5
900 MPa 130 k psi
TBD ? TBD965 MPa 140 k psi TBD ? TBD
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AUTOMOTIVE APPLICATIONSAHSS
Frames Engine Cradles
Cross Members
Bumpers
Suspension Members
Unibody Structures
INCREASE STRENGTH
DECREASE WEIGHT
CORROSION
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WELDING COATED STEELS
GMAW Easy to use
Clean
Spatter
Porosity
Lack of fusion
FCAW Easy to alloy
Wider properties
Feedability
Smoke
Slag
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Conclusion WeldingAHSS UP TO 600 MPa Manufacturers
Conventional Consumables 70,000 PSI
Higher Quality Welds
Porosity
More Attention to Details
Heat Input
Heat Affected Zone
Choose Your Process
GMAW Pulse
Readjust For Coatings
Zinc
Better High Strength Products
More Sophisticated Equipment
Upgrade Weld Engineering
GMAW- MC- FCAW
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QUESTIONS :
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