77
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 A/SP Consultant Arnon Wexler Chairman SWSG Ford Motor Company I. Accorsi 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 Edison Welding Institute Hongyan Zhang University of Toledo
* SWSG project sub team
Page 6 of 75
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 7 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 8 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 9 of 75
200
60
37.8
mm
45.6
mm
50 mm
125 mm
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.
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.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.
mm
mm
mm
mm
Page 10 of 75
Table 3: Quality Requirements for SWSG AHSS Welding
Criterion Source Document Derivative SWSG Requirement
GM
Porosity - Internal
GM 4490M, 1991
Cross-section- 25% limit of total area
GM Porosity - Surface
GM 4490M, 1991 < 25%
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
GM Burn-through (Hole)
GM 4490M, 1991 Not allowed
Chrysler PS-9059
Under Cut (Maximum)
2002, NOV 6, CHG B
5% of thinnest metal
Convexity Not addressed
HAZ (Heat Affected Zone) Not addressed
Chrysler PS-9059
Penetration
2002, NOV 6, CHG B
>= 20% into second metal
Gap (under pressure) Not addressed
Page 11 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 12 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 MIG AC
MIG DC Number
Top Sheet Bottom Sheet
Evaluation
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
70 and 90 ksi (See each
sheet)
9 1.17mm DP780GA 1.87mm DP 780
GA AC, DC, LS,
LM, PL
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 13 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
Materials
C Mn P S Si Cr Mo Al N Ti Other
V=0.005 1.15mm DP 600 HDG
0.092 1.79 0.017 0.0059 0.005 0.188 0.177 0.054 0.020 <.002 Cu=0.041
V=0.003 1.52mm DP 600 GN
0.084 1.50 0.009 0.0073 0.010 0.032 0.315 0.054 0.017 <.002 Cu=0.037
V=0.004 3.4mm DP600 BARE
0.080 1.17 0.016 0.0055 0.057 0.624 0.004 0.042 0.013 0.003 Cu=0.016
V=0.049 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
Cu=0.021
V=0.007 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 Cu=0.023
V=0.005 1.87mm DP 780 GN
0.085 2.33 0.012 0.0059 0.006 0.238 0.291 0.055 0.013 <.002 Cu=0.025
V=0.007 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 Cu=0.028
V=0.007 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 Cu=0.031
V=0.006 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
Cu=0.160
Page 14 of 75
Material Physical Properties Table 7: Material Physical Properties.
Thickness Upper Yield Point
Lower Yield Point
Peak Load
Energy @ 0% Droop
Material Used
in Stack
(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
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 15 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 16 of 75
VICKERS HARDNESS CHART
286
261
242
268
291
334
303321
310
210211
310309
287
308
298302
291
208202
212212 212
209213 210
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
286
261
242
268
291
334
303321
310
210211
310309
287
308
298302
291
208202
212212 212
209213 210
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
287
260
215
263
307290 294
207 214210 215
213
199195
300
295
274
209212
212
217
214 211 216
211
204
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
) HAZHAZWELDBMBM
VICKERS HARDNESS CHART
287
260
215
263
307290 294
207 214210 215
213
199195
300
295
274
209212
212
217
214 211 216
211
204
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
) HAZHAZWELDBMBM
Group-1: Laser Welding (Material Combination 1) 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
Focus Position -2.0 mm Average 13.75 18.13
Gas (Laser) Ar
Max 14.83 19.84
Gap (engineered) 0 mm
Shielding Gas Flow Ar, 18 CFH
Impact Strength
Load (kN) Energy (J)
Min 41.0 76.9
Average 47.4 116.2
Max 51.6 148.3
Figure G1-1: Top sheet: 3.4mm DP600 Bare , Bottom sheet: 3.4mm DP600 Bare.
Figure G1-2: Hardness measurement path
Figure G1-4: Bottom Sheet Microhardness Traverse.
Page 17 of 75
VICKERS HARDNESS CHART
287
260
215
263
307290 294
207 214210 215
213
199195
300
295
274
209212
212
217
214 211 216
211
204
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) HAZHAZWELDBMBM
VICKERS HARDNESS CHART
287
260
215
263
307290 294
207 214210 215
213
199195
300
295
274
209212
212
217
214 211 216
211
204
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) HAZHAZWELDBMBM
V IC K E R S H A R D N E S S C H A R T
3 8 6
2 5 4
2 0 72 2 5
3 6 3
1 9 51 9 21 9 2
3 6 73 6 0
3 5 5
1 9 41 8 8
2 0 51 9 1
1 8 8
1 8 9
1 9 3 1 9 3
1 6 0
2 0 0
2 4 0
2 8 0
3 2 0
3 6 0
4 0 0
4 4 0
0 1 2 3 4 5 6
D IS P L A C E M E N T (m m )
VIC
KER
S H
AR
DN
ES
S (
HV
)
H A ZH A ZW E LDB MB M
V IC K E R S H A R D N E S S C H A R T
3 8 6
2 5 4
2 0 72 2 5
3 6 3
1 9 51 9 21 9 2
3 6 73 6 0
3 5 5
1 9 41 8 8
2 0 51 9 1
1 8 8
1 8 9
1 9 3 1 9 3
1 6 0
2 0 0
2 4 0
2 8 0
3 2 0
3 6 0
4 0 0
4 4 0
0 1 2 3 4 5 6
D IS P L A C E M E N T (m m )
VIC
KER
S H
AR
DN
ES
S (
HV
)
H A ZH A ZW E LDB MB M
Group-1: Laser Welding (Material Combination 2) Table-G1-3: Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 4.0 kW Load (kN) Energy (J)
Weld speed 2.40 m/ min Min 15.64 22.54
Focus Position +1.8 mm Average 16.44 24.55
Gas (Laser) Ar
Max 17.59 26.46
Gap (engineered) 0 mm
Shielding Gas Flow Ar, 18 CFH
Impact Strength
Load (kN) Energy (J)
Min 18.6 88.9
Average 50.4 239.3
Max 120.2 323.3
Figure G1-5: Top sheet: 1.15mm DP600 HDG, Bottom sheet: 3.2mm HSLA 350 Bare.
Figure G1-6: Hardness measurement path
Figure G1-7: Top Sheet Microhardness Traverse. Figure G1-8: Bottom Sheet Microhardness Traverse.
Page 18 of 75
VICKERS HARDNESS CHART
197
238
276267
322
297
278
311
288
264
192
212
295
169165
180166168
173
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZ
HAZWELDBMBM
VICKERS HARDNESS CHART
197
238
276267
322
297
278
311
288
264
192
212
295
169165
180166168
173
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZ
HAZWELDBMBM
VICKERS HARDNESS CHART
214
255
323
243
321
300
199 195 194194 199
304
326
189195
211191
191
204
160
200
240
280
320
360
400
440
0 1 2 3 4 5
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
214
255
323
243
321
300
199 195 194194 199
304
326
189195
211191
191
204
160
200
240
280
320
360
400
440
0 1 2 3 4 5
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
Group-1: Laser Welding (Material Combination 3) 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
Focus Position +1.5 mm Average 15.73 23.63
Gas (Laser) Ar
Max 17.59 27.08
Gap (engineered) 0.1 mm
Shielding Gas Flow Ar, 18 CFH
Impact Strength
Load (kN) Energy (J)
Min 28.5 95.8
Average 59.7 176.6
Max 117.6 303.6
Figure G1-10: Hardness measurement path Figure G1-9: Top sheet: 1.38mm HSLA 350 HDG, Bottom sheet: 3.2mm HSLA 350 Bare.
Figure G1-11: Top Sheet Microhardness Traverse. Figure G1-12: Bottom Sheet Microhardness Traverse.
Page 19 of 75
VICKERS HARDNESS CHART
256258
308
395386 390 388
409
283289
402
385 383
397
388 386392
294
273
283
281
287297
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
256258
308
395386 390 388
409
283289
402
385 383
397
388 386392
294
273
283
281
287297
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
261
399
402 395
258
287285271
390
378
387 390
383
293
290
288
267
265
263282
290
292
288
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZ
HAZ
WELD
BM
BM
VICKERS HARDNESS CHART
261
399
402 395
258
287285271
390
378
387 390
383
293
290
288
267
265
263282
290
292
288
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZ
HAZ
WELD
BM
BM
Group-1: Laser Welding (Material Combination 4)
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
Focus Position +1.8 mm Average 15.87 30.49
Gas (Laser) Ar
Max 18.72 37.19
Gap (engineered) 0.1 mm
Shielding Gas Flow Ar, 18 CFH
Impact Strength
Load (kN) Energy (J)
Min 50.5 58.9
Average 95.1 165.4
Max 154.1 308.3
Figure G1-13: Top sheet: 1.18mm DP980 GA, Bottom sheet: 1.18mm DP980 GA.
Figure G1-14: Hardness measurement path
Figure G1-15: Top Sheet Microhardness Traverse. Figure G1-16: Bottom Sheet Microhardness Traverse.
Page 20 of 75
VICKERS HARDNESS CHART
244
313
418
420404
417
398409 416
263277
248
405405404404
255
256
263
275
255
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
244
313
418
420404
417
398409 416
263277
248
405405404404
255
256
263
275
255
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
248
391
422
384
415
248261
238 240
254
423
402 402
247
239
257
250
255 257
256
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZ
HAZ
WELD
BM
BM
VICKERS HARDNESS CHART
248
391
422
384
415
248261
238 240
254
423
402 402
247
239
257
250
255 257
256
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZ
HAZ
WELD
BM
BM
Group-1: Laser Welding (Material Combination 5)
Table-G1-6: Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 4.0 kW Load (kN) Energy (J)
Weld speed 3.25 m/ min Min 15.32 25.07
Focus Position +1.8 mm Average 16.78 29.08
Gas (Laser) Ar
Max 18.31 34.04
Gap (engineered) 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
Figure G1-17: Top sheet: 1.0mm DP800 GA, Bottom sheet: 1.0mm DP800 GA.
Figure G1-18: Hardness measurement path
Figure G1-19: Top Sheet Microhardness Traverse. Figure G1-20: Bottom Sheet Microhardness Traverse.
Page 21 of 75
VICKERS HARDNESS CHART
191
234
264
326
264
364348 346
357
196196230
193
352
355 356343 346
334
195
201
193
196
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
191
234
264
326
264
364348 346
357
196196230
193
352
355 356343 346
334
195
201
193
196
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
237
267
357
361350
257256248
237
262
358
341
360
351
257
243
246 254
248252251
253
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
) HAZHAZWELDBMBM
VICKERS HARDNESS CHART
237
267
357
361350
257256248
237
262
358
341
360
351
257
243
246 254
248252251
253
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
) HAZHAZWELDBMBM
Group-1: Laser Welding (Material Combination 8)
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
Focus Position +1.5 mm Average 19.21 32.02
Gas (Laser) Ar
Max 21.58 37.91
Gap (engineered) 0.1 mm
Shielding Gas Flow Ar, 18 CFH
Impact Strength
Load (kN) Energy (J)
Min 8.6 63.2
Average 33.7 159.9
Max 54.4 348.2
Figure G1-21: Top sheet: 1.52mm DP 600Bottom sheet: 1.87mm DP 780 GN.
Figure G1-22: Hardness measurement path
Figure G1-23: Top Sheet Microhardness Traverse. Figure G1-24: Bottom Sheet Microhardness Traverse.
Page 22 of 75
VICKERS HARDNESS CHART
405395 396 399
388 394
245246
244
402
262
390
395390380
403398
228
232
230215
246
251 246
160
210
260
310
360
410
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
405395 396 399
388 394
245246
244
402
262
390
395390380
403398
228
232
230215
246
251 246
160
210
260
310
360
410
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
400
368
274
357
262
256
388394
397 397
270
259
274
262
257
233
278
248264
271 272
160
210
260
310
360
410
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NE
SS
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
400
368
274
357
262
256
388394
397 397
270
259
274
262
257
233
278
248264
271 272
160
210
260
310
360
410
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NE
SS
S (
HV
)
HAZHAZWELDBMBM
Group-1: Laser Welding (Material Combination 9)
Table-G1-8: Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 2.0 kW Load (kN) Energy (J)
Weld speed 2.60 m/ min Min 17.73 28.83
Focus Position +1.5 mm Average 18.67 31.61
Gas (Laser) Ar
Max 19.72 34.03
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
Figure G1-25: Top sheet: 1.17mm DP780 GA Bottom sheet: 1.87mm DP 780 GN.
Figure G1-26: Hardness measurement path
Figure G1-27: Top Sheet Microhardness Traverse. Figure G1-28: Bottom Sheet Microhardness Traverse.
Page 23 of 75
LASER AVERAGE IMPACT PEAK LOAD (kN)
50.39
95.11
56.47
33.72
54.65
47.36
59.73
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
180.00
200.00
IM-0
1
IM-0
2
IM-0
3
IM-0
4
IM-0
5
IM-0
8
IM-0
9
LASER AVERAGE IMPACT ENERGY (J)
116.21
239.25
165.41
253.89
159.86 162.41
176.60
0.00
100.00
200.00
300.00
400.00
500.00
600.00
IM-0
1
IM-0
2
IM-0
3
IM-0
4
IM-0
5
IM-0
8
IM-0
9
Group-1: Laser Welding (Impact Strength at 15 MPH)
Figure G1-29: Impact Strength Peak Load.
Figure G1-30: Impact Strength Energy.
Page 24 of 75
LASER AVERAGE PEAK LOAD (kN)
16.44 15.73 15.8716.78
19.21 18.67
13.75
0.00
15.00
30.00
45.00
60.00
00
-TS
-01
00
-TS
-02
00
-TS
-03
00
-TS
-04
00
-TS
-05
00
-TS
-08
00
-TS
-09
LASER AVERAGE ENERGY (J)
24.55 23.6329.08 32.02 31.61
18.1330.49
0.00
25.00
50.00
75.00
100.00
125.00
150.00
175.00
200.00
225.00
250.00
00
-TS
-01
00
-TS
-02
00
-TS
-03
00
-TS
-04
00
-TS
-05
00
-TS
-08
00
-TS
-09
Group-1: Laser Welding (Tensile Shear Data)
Figure G1-31: Tensile Shear Load.
Figure G1-32: Tensile Shear Energy.
Page 25 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 26 of 75
VICKERS HARDNESS CHART
267256
198
203
192
211
214233
243
254
236
256
239
250265
235
240235
263
246
221199196
190193
200
160
200
240
280
320
360
400
440
0 2 4 6 8 10 12
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NE
SS
(H
V) BM
WELDBM
VICKERS HARDNESS CHART
267256
198
203
192
211
214233
243
254
236
256
239
250265
235
240235
263
246
221199196
190193
200
160
200
240
280
320
360
400
440
0 2 4 6 8 10 12
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NE
SS
(H
V) BM
WELDBM
Group-2: Laser–GMAW (Material Combination 1)
Table-G2-2: Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 2.5 kW Load (kN) Energy (J)
Weld speed 10.6 m/ min Min 23.24 64.52
Focus Position +1.0 mm Average 54.14 224.10
Wire Spec. 1.14mm Dia. ER70S6
Max 67.45 295.89
MIG Current 219A
Wire Feed Rate 10.6m/ min
Weld Volts 19.2V Impact Strength
Gap (engineered) 0mm Load (kN) Energy (J)
Shielding Gas Flow Ar, 18 CFH Min 174.1 198.0
Shielding Gas 92% Ar/8% CO2 Average 174.1 198.7
Max 174.0 198.7
Figure G2-1: Top sheet: 3.4mm DP600 Bare , Bottom sheet: 3.4mm DP600 Bare.
Figure G2-2: Hardness measurement path
Figure G2-3: Microhardness Traverse.
Page 27 of 75
VICKERS HARDNESS CHART
190205
272
301
267
225
194
190
247254
338
317 327317
318
311
324 319
311
321320
258238
217209
205
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
BMWELDBM
VICKERS HARDNESS CHART
190205
272
301
267
225
194
190
247254
338
317 327317
318
311
324 319
311
321320
258238
217209
205
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
BMWELDBM
Group-2: Laser–GMAW (Material Combination 2) Table-G2-3: Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 2.0 kW Load (kN) Energy (J)
Weld speed 2.65 m/ min Min 23.24 64.52
Focus Position +1.0 mm Average 54.14 224.10
Wire Spec. 0.9mm Dia. ER70S6
Max 67.45 295.89
MIG Current 132A
Wire Feed Rate 8.7m/ min
Weld Volts 14.6V Impact Strength
Gap (engineered) 0mm Load (kN) Energy (J)
Shielding Gas Flow Ar, 18 CFH Min 23.8 197.0
Shielding Gas 92% Ar/8% CO2 Average 53.1 301.3
Max 82.6 380.7
Figure G2-4: Top sheet: 1.15mm DP600 HDG, Bottom sheet: 3.2mm HSLA 350 Bare
Figure G2-5: Hardness measurement path
Figure G2-6: Microhardness Traverse.
Page 28 of 75
VICKERS HARDNESS CHART
221
295
318
289 283293
223
198173166
163159
293
272
260
295
281
265 267
288
190
188
190
204209
235
150
190
230
270
310
350
390
430
0 2 4 6 8 10
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BMWELDBM
VICKERS HARDNESS CHART
221
295
318
289 283293
223
198173166
163159
293
272
260
295
281
265 267
288
190
188
190
204209
235
150
190
230
270
310
350
390
430
0 2 4 6 8 10
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BMWELDBM
Group-2: Laser–GMAW (Material Combination 3) 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
Focus Position +1.0 mm Average 23.34 61.60
Wire Spec. 1.0mm Dia. ER70S6
Max 24.54 65.40
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
Shielding Gas 92% Ar/8% CO2 Average 60.6 291.9
Max 102.2 347.4
Figure G2-8: Hardness measurement path Figure G2-7: Top sheet: 1.38mm HSLA 350 HDG, Bottom sheet: 3.2mm HSLA 350 Bare
Figure G2-9: Microhardness Traverse.
Page 29 of 75
VICKERS HARDNESS CHART
405
384
365
254
310
368
390373
341330 326
275
250
286
346
336
377
358 348
314321
365
329
318
399395391
294289
281
270
287
288
282262
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8 9 10 11
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
405
384
365
254
310
368
390373
341330 326
275
250
286
346
336
377
358 348
314321
365
329
318
399395391
294289
281
270
287
288
282262
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8 9 10 11
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZHAZWELDBMBM
Group-2: Laser–GMAW (Material Combination 4) 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
Focus Position +1.0 mm Average 22.48 59.04
Wire Spec. 0.9mm Dia. ER70S6
Max 25.04 69.19
MIG Current 110A
Wire Feed Rate 8.7m/ min
Weld Volts 13.3V Impact Strength
Gap (engineered) 0.1 mm Load (kN) Energy (J)
Shielding Gas Flow Ar, 18 CFH Min 22.4 186.1
Shielding Gas 92% Ar/8% CO2 Average 39.1 284.9
Max 46.8 356.7
Figure G2-10: Top sheet: 1.18mm DP980 GA, Bottom sheet: 1.18mm DP980 GA.
Figure G2-11: Hardness measurement path
Figure G2-12: Microhardness Traverse.
Page 30 of 75
VICKERS HARDNESS CHART
234
286
377
339
238
344354
391380
234
347
386
345
264
313308
346
339
344
332326
347
356
388 394
350
240
223
229
228226
246
237
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8 9
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
) HAZHAZWELDBMBM
VICKERS HARDNESS CHART
234
286
377
339
238
344354
391380
234
347
386
345
264
313308
346
339
344
332326
347
356
388 394
350
240
223
229
228226
246
237
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8 9
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
) HAZHAZWELDBMBM
Group-2: Laser–GMAW (Material Combination 5) 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
Focus Position +1.0 mm Average 20.06 44.93
Wire Spec. 0.9mm Dia. ER70S6
Max 21.58 50.00
MIG Current 124A
Wire Feed Rate 8.2m/ min
Weld Volts 15.3V Impact Strength
Gap (engineered) 0.1 mm Load (kN) Energy (J)
Shielding Gas Flow Ar, 18 CFH Min 58.1 163.5
Shielding Gas 92% Ar/8% CO2 Average 91.0 267.2
Max 129.2 326.4
Figure G2-13: Top sheet: 1.0mm DP800 GA, Bottom sheet: 1.0mm DP800 GA.
Figure G2-14: Hardness measurement path
Figure G2-15: Microhardness Traverse.
Page 31 of 75
VICKERS HARDNESS CHART
342
245
267
341348
359
325
358
222
280
312
356
254
243224
294
312
309
337
323304
317
324339
240
249
233
243245
206
196
208
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8 9 10
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
342
245
267
341348
359
325
358
222
280
312
356
254
243224
294
312
309
337
323304
317
324339
240
249
233
243245
206
196
208
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8 9 10
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZHAZWELDBMBM
Group-2: Laser–GMAW (Material Combination 8) 70 KSI Filler
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
Focus Position +1.0 mm Average 27.20 76.72
Wire Spec. 0.9mm Dia. ER70S6
Max 29.42 85.82
MIG Current 136A
Wire Feed Rate 8.9m/ min
Weld Volts 15.2V Impact Strength
Gap (engineered) 0.1 mm Load (kN) Energy (J)
Shielding Gas Flow Ar, 18 CFH Min 37.5 190.1
Shielding Gas 92% Ar/8% CO2 Average 52.9 398.2
Max 87.4 480.4
Figure G2-16: Top sheet: 1.52mm DP 600Bottom sheet: 2.0mm DP 780
Figure G2-17: Hardness measurement path
Figure G2-18: Microhardness Traverse.
Page 32 of 75
VICKERS HARDNESS CHART
382
350
242
283
319
349
380
359 355367
256
227
309
359363
371
363
264
255263255
250284
199
186190
193
199
199
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) HAZHAZWELDBMBM
VICKERS HARDNESS CHART
382
350
242
283
319
349
380
359 355367
256
227
309
359363
371
363
264
255263255
250284
199
186190
193
199
199
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) HAZHAZWELDBMBM
Group-2: Laser–GMAW (Material Combination 8) 90 kSI Filler Table-G2-8: Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 2.0 kW Load (kN) Energy (J)
Weld speed 2.60 m/ min Min 25.50 75.56
Focus Position +1.0 mm Average 28.69 87.00
Wire Spec. 0.9mm Dia. ER90SD2
Max 31.72 105.10
MIG Current 136A
Wire Feed Rate 8.9m/ min
Weld Volts 15.2V Impact Strength
Gap (engineered) 0.1 mm Load (kN) Energy (J)
Shielding Gas Flow Ar, 18 CFH Min 60.1 268.9
Shielding Gas 92% Ar/8% CO2 Average 63.8 415.7
Max 68.7 462.6
Figure G2-19: Top sheet: 1.52mm DP 600 GA Bottom sheet: 2.0mm DP 780.
Figure G2-20: Hardness measurement path
Figure G2-21: Microhardness Traverse.
Page 33 of 75
VICKERS HARDNESS CHART
223
266
346357
393375
367353 349
334 337
363
261
237
248
293
329
349
327317319
340341
360
346
377
262260
262238
235227
160
200
240
280
320
360
400
440
0 2 4 6 8 10
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
223
266
346357
393375
367353 349
334 337
363
261
237
248
293
329
349
327317319
340341
360
346
377
262260
262238
235227
160
200
240
280
320
360
400
440
0 2 4 6 8 10
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
Group-2: Laser–GMAW(Material Combination 9) 70 kSI Filler 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
Focus Position +1.0 mm Average 25.59 62.29
Wire Spec. 0.9mm Dia. ER70S6
Max 26.46 69.42
MIG Current 110A
Wire Feed Rate 8.6m/ min
Weld Volts 16.8V Impact Strength
Gap (engineered) 0.1 mm Load (kN) Energy (J)
Shielding Gas Flow Ar, 18 CFH Min 41.8 337.9
Shielding Gas 92% Ar/8% CO2 Average 62.3 381.5
Max 94.0 451.3
Figure G2-22: Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780.
Figure G2-23: Hardness measurement path
Figure G2-24: Microhardness Traverse.
Page 34 of 75
VICKERS HARDNESS CHART
379
353
300
214
236
292
316
358
378365
232
252
306
348
384
364369
392385386 388
369
244
234230
237242228 229
221
160
200
240
280
320
360
400
440
0 2 4 6 8 10
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
VICKERS HARDNESS CHART
379
353
300
214
236
292
316
358
378365
232
252
306
348
384
364369
392385386 388
369
244
234230
237242228 229
221
160
200
240
280
320
360
400
440
0 2 4 6 8 10
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ES
S (
HV
)
HAZHAZWELDBMBM
Group-2: Laser–GMAW (Material Combination 9) 90 kSI Filler
Table-G2-10: Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 2.0 kW Load (kN) Energy (J)
Weld speed 2.65 m/ min Min 22.79 54.16
Focus Position +1.0 mm Average 24.68 61.21
Wire Spec. 0.9mm Dia. ER90SD2
Max 25.46 64.90
MIG Current 118A
Wire Feed Rate 8.6m/ min
Weld Volts 16.8V Impact Strength
Gap (engineered) 0.1 mm Load (kN) Energy (J)
Shielding Gas Flow Ar, 18 CFH Min 27.4 355.7
Shielding Gas 92% Ar/8% CO2 Average 47.8 380.7
Max 100.9 406.9
Figure G2-25: Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780.
Figure G2-26: Hardness measurement path
Figure G2-27: Microhardness Traverse.
Page 35 of 75
LASER-GMAW AVERAGE IMPACT PEAK LOAD (kN)
39.07
90.96
52.88
63.78 62.31
47.7653.06
174.14
60.61
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
180.00
200.00
IM-0
1-7
0
IM-0
2-7
0
IM-0
3-7
0
IM-0
4-7
0
IM-0
5-7
0
IM-0
8-7
0
IM-0
8-9
0
IM-0
9-7
0
IM-0
9-9
0
LASER-GMAW AVERAGE IMPACT ENERGY (J)
198.73
301.30
267.22
398.20415.75
380.73381.47
284.90291.93
0.00
100.00
200.00
300.00
400.00
500.00
600.00
IM-0
1-7
0
IM-0
2-7
0
IM-0
3-7
0
IM-0
4-7
0
IM-0
5-7
0
IM-0
8-7
0
IM-0
8-9
0
IM-0
9-7
0
IM-0
9-9
0
Group-2: Laser–GMAW (Impact Strength at 15 MPH)
Figure G2-28: Impact Strength Peak Load.
Figure G2-29: Impact Strength Peak Energy.
Page 36 of 75
LASER-GMAW AVERAGE PEAK LOAD (kN)
54.14
24.7823.34 22.48
20.06
27.2028.69
25.5924.68
0.00
15.00
30.00
45.00
60.000
6-T
S-0
1-7
0
06
-TS
-02
-70
06
-TS
-03
-70
06
-TS
-04
-70
06
-TS
-05
-70
06
-TS
-08
-70
06
-TS
-08
-90
06
-TS
-09
-70
06
-TS
-09
-90
LASER-GMAW AVERAGE ENERGY (J)
224.10
61.48 61.60 59.04
76.72
87.00
62.29 61.21
44.93
0.00
25.00
50.00
75.00
100.00
125.00
150.00
175.00
200.00
225.00
250.00
06
-TS
-01
-70
06
-TS
-02
-70
06
-TS
-03
-70
06
-TS
-04
-70
06
-TS
-05
-70
06
-TS
-08
-70
06
-TS
-08
-90
06
-TS
-09
-70
06
-TS
-09
-90
Group-2: Laser–GMAW (Tensile Shear Data)
Figure G2-30: Tensile Shear Load.
Figure G2-31: Tensile Shear Energy.
Page 37 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 38 of 75
VICKERS HARDNESS CHART
207
264
291
327
349
320
283
266
220204
197195
198
191193190
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BM
WELD
BM
VICKERS HARDNESS CHART
207
264
291
327
349
320
283
266
220204
197195
198
191193190
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BM
WELD
BM
VICKERS HARDNESS CHART
197
214227
283
359359
311
236
343
185
185
191
199
191
204
339
343
193
197
186189200205
210218
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BMWELD
BM
VICKERS HARDNESS CHART
197
214227
283
359359
311
236
343
185
185
191
199
191
204
339
343
193
197
186189200205
210218
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BMWELD
BM
Group-3: Laser–Plasma Welding (Material Combination 1)
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
Position of Plasma Tip Above Surface
5.0 mm Average 36.8 55.0
Distance Between Laser and Plasma Spot
3.0 mm
Max 49.7 71.7
Figure G3-1: Top sheet: 3.4mm DP600 Bare, Bottom sheet: 3.4mm DP600 Bare
Figure G3-2: Hardness measurement path
Figure G3-3: Top Sheet Microhardness Traverse. Figure G3-4: Bottom Sheet Microhardness Traverse.
Page 39 of 75
VICKERS HARDNESS CHART
207
264
291
327
349
320
283
266
220204
197195
198
191193190
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) BM
WELDBM
VICKERS HARDNESS CHART
207
264
291
327
349
320
283
266
220204
197195
198
191193190
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) BM
WELDBM
VICKERS HARDNESS CHART
197
214227
283
359359
311
236
343
185
185
191
199
191
204
339
343
193
197
186189200205
210218
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BMWELD
BM
VICKERS HARDNESS CHART
197
214227
283
359359
311
236
343
185
185
191
199
191
204
339
343
193
197
186189200205
210218
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BMWELD
BM
Group-3: Laser–Plasma Welding (Material Combination 2)
Table-G3-3 Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 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
Position of Plasma Tip Above Surface
5.0 mm Average 59.3 59.3
Distance Between Laser and Plasma Spot
3.0 mm
Max 89.7 89.7
Figure G3-5: Top sheet: 1.15mm DP600 HDG, Bottom sheet: 3.2mm HSLA 350 Bare
Figure G3-6: Hardness measurement path
Figure G3-7: Top Sheet Microhardness Traverse. Figure G3-8: Bottom Sheet Microhardness Traverse.
Page 40 of 75
VICKERS HARDNESS CHART
196186
205
234
286
168163175
191
183 183
209
225
328315321
299286
236
192181
206
171
163
150
190
230
270
310
350
390
430
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) BM
WELD
BM
VICKERS HARDNESS CHART
196186
205
234
286
168163175
191
183 183
209
225
328315321
299286
236
192181
206
171
163
150
190
230
270
310
350
390
430
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) BM
WELD
BM
VICKERS HARDNESS CHART
184
203 205193
183
185 186 191
193
196207
215
238
312
306
308
307297
239
213
194 192191
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BM
WELDBM
VICKERS HARDNESS CHART
184
203 205193
183
185 186 191
193
196207
215
238
312
306
308
307297
239
213
194 192191
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BM
WELDBM
Group-3: Laser–Plasma Welding (Material Combination 3)
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
Position of Plasma Tip Above Surface
5.0 mm Average 78.5 189.6
Distance Between Laser and Plasma Spot
3.0 mm
Max 96.1 308.7
Figure G3-10: Hardness measurement path Figure G3-9: Top sheet: 1.38mm HSLA 350HDG, Bottom sheet: 3.2mm HSLA 350 Bare
Figure G3-11: Top Sheet Microhardness Traverse. Figure G3-12: Bottom Sheet Microhardness Traverse.
Page 41 of 75
VICKERS HARDNESS CHART
400
325
253
380
400
253252
390
398389
384
417401
393
373
392
399
282
280
274
312
310
303
290
281
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZHAZ
WELD
BM
BM
VICKERS HARDNESS CHART
400
325
253
380
400
253252
390
398389
384
417401
393
373
392
399
282
280
274
312
310
303
290
281
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZHAZ
WELD
BM
BM
VICKERS HARDNESS CHART
288 284 286300304
275 277287
286 280 279 279
285276
263
245
258278 274
286
278
245
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) BMWELD
BM
VICKERS HARDNESS CHART
288 284 286300304
275 277287
286 280 279 279
285276
263
245
258278 274
286
278
245
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) BMWELD
BM
Group-3: Laser–Plasma Welding (Material Combination 4)
Table-G3-5 Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 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
Position of Plasma Tip Above Surface
5.0 mm Average 26.8 127.8
Distance Between Laser and Plasma Spot
2.5 mm
Max 35.2 190.4
Figure G3-13: Top sheet: 1.18mm DP980 GA, Bottom sheet: 1.18mm DP980 GA.
Figure G3-14: Hardness measurement path
Figure G3-15: Top Sheet Microhardness Traverse. Figure G3-16: Bottom Sheet Microhardness Traverse.
Page 42 of 75
VICKERS HARDNESS CHART
399
232
294
399386
400407
395
240247 268
231
416
416
390 389399
406
232
244
246
251 242
248
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) HAZ
HAZWELD
BM
BM
VICKERS HARDNESS CHART
399
232
294
399386
400407
395
240247 268
231
416
416
390 389399
406
232
244
246
251 242
248
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) HAZ
HAZWELD
BM
BM
VICKERS HARDNESS CHART
240 236 235 233
272281
230242
251240
243
247
244238 239 234
223224
245
227243 244
249
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BM
WELDBM
VICKERS HARDNESS CHART
240 236 235 233
272281
230242
251240
243
247
244238 239 234
223224
245
227243 244
249
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
BM
WELDBM
Group-3: Laser–Plasma Welding (Material Combination 5)
Table-G3-6 Parameters and Data
Parameter Value 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
Position of Plasma Tip Above Surface
5.0 mm Average 22.7 28.4
Distance Between Laser and Plasma Spot
2.5 mm
Max 47.7 56.5
Figure G3-17: Top sheet: 1.0mm DP800 GA, Bottom sheet: 1.0mm DP800 GA.
Figure G3-18: Hardness measurement path
Figure G3-19: Top Sheet Microhardness Traverse. Figure G3-20: Bottom Sheet Microhardness Traverse.
Page 43 of 75
VICKERS HARDNESS CHART
354
266
236
191
222
239
293
351 348
195
319
192
207
322322
325
360
347
350348
191
190191
200
189160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZ
HAZ
WELD
BM
BM
VICKERS HARDNESS CHART
354
266
236
191
222
239
293
351 348
195
319
192
207
322322
325
360
347
350348
191
190191
200
189160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7 8
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
)
HAZ
HAZ
WELD
BM
BM
VICKERS HARDNESS CHART
255261
253 258 254
246
323
375
330
258247
250 251 256 252 253
363
248
260256
261256
250
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) BM
WELD
BM
VICKERS HARDNESS CHART
255261
253 258 254
246
323
375
330
258247
250 251 256 252 253
363
248
260256
261256
250
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) BM
WELD
BM
Group-3: Laser–Plasma Welding (Material Combination 8)
Table-G3-7 Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 4.0 kW Load (kN) Energy (J)
Weld speed 41.60 mm/ sec Min 13.90 20.79
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 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
Position of Plasma Tip Above Surface
5.0 mm Average 41.0 268.3
Distance Between Laser and Plasma Spot
3.0 mm
Max 49.7 330.3
Figure G3-21: Top sheet: 1.52mm DP 600Bottom sheet: 1.87mm DP 780
Figure G3-22: Hardness measurement path
Figure G3-23: Top Sheet Microhardness Traverse. Figure G3-24: Bottom Sheet Microhardness Traverse.
Page 44 of 75
VICKERS HARDNESS CHART
380
349
265280
343
371
404 397
224
392 391
382385388
398
375
389
395
235
234219
229227
233
222
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) HAZHAZ
WELD
BM
BM
VICKERS HARDNESS CHART
380
349
265280
343
371
404 397
224
392 391
382385388
398
375
389
395
235
234219
229227
233
222
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6 7
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) HAZHAZ
WELD
BM
BM
VICKERS HARDNESS CHART
253263
248
328
361
385393
254250
252254256255
258
361
370
370
253
254255
249247253
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) BMWELD
BM
VICKERS HARDNESS CHART
253263
248
328
361
385393
254250
252254256255
258
361
370
370
253
254255
249247253
160
200
240
280
320
360
400
440
0 1 2 3 4 5 6
DISPLACEMENT (mm)
VIC
KE
RS
HA
RD
NES
S (
HV
) BMWELD
BM
Group-3: Laser–Plasma Welding (Material Combination 9)
Table-G3-8 Parameters and Data
Parameter Value Tensile Shear Strength
Laser power 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
Position of Plasma Tip Above Surface
5.0 mm Average 26.1 37.9
Distance Between Laser and Plasma Spot
3.0 mm
Max 39.5 46.4
Figure G3-25: Top sheet: 1.17mm DP780 GA Bottom sheet: 1.87mm DP 780.
Figure G3-26: Hardness measurement path
Figure G3-27: Top Sheet Microhardness Traverse. Figure G3-28: Bottom Sheet Microhardness Traverse.
Page 45 of 75
LASER-PLASMA AVERAGE IMPACT PEAK LOAD (kN)
59.25
26.8422.67
40.99
26.06
36.83
78.46
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
180.00
200.00
IM-0
1
IM-0
2
IM-0
3
IM-0
4
IM-0
5
IM-0
8
IM-0
9
LASER-PLASMA AVERAGE IMPACT ENERGY (J)
55.02
203.94
127.83
28.40
268.28
37.90
189.64
0.00
100.00
200.00
300.00
400.00
500.00
600.00
IM-0
1
IM-0
2
IM-0
3
IM-0
4
IM-0
5
IM-0
8
IM-0
9
Group-3: Laser–Plasma Welding (Impact Strength at 15 MPH)
Figure G3-29: Impact Strength Peak Load.
Figure G3-30: Impact Strength Energy.
Page 46 of 75
LASER-PLASMA AVERAGE PEAK LOAD (kN)
14.29
18.09 17.61
12.3410.61
15.1216.49
0.00
15.00
30.00
45.00
60.00
00
-TS
-01
00
-TS
-02
00
-TS
-03
00
-TS
-04
00
-TS
-05
00
-TS
-08
00
-TS
-09
LASER-PLASMA AVERAGE ENERGY (J)
29.68 29.1124.89
12.72
23.3527.57
17.27
0.00
25.00
50.00
75.00
100.00
125.00
150.00
175.00
200.00
225.00
250.00
00
-TS
-01
00
-TS
-02
00
-TS
-03
00
-TS
-04
00
-TS
-05
00
-TS
-08
00
-TS
-09
Group-3: Laser–Plasma Welding (Tensile Shear Data)
Figure G3-31: Tensile Shear Load.
Figure G3-32: Tensile Shear Energy.
Page 47 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 48 of 75
VICKERS HARDNESS CHART
222229
240
264266263272 272
267
258
245
237
204221
265
269
257 260 266264
204
212
207
217 220204
197
185
160
200
240
280
320
360
0 2 4 6 8 10 12 14
DISPLACEMENT (mm)
VIC
KERS H
AR
DN
E
HAZHAZWELDBMBM
Group-4: GMAW AC (Material Combination 1) Table-G4-2: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 41.23 106.49
Wire Diameter 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 195A
Wire Feed Rate 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
Shielding Gas Flow 35 CFH Average 174.7 171.7
Shielding Gas 90% Ar / 10% CO2
Max 473.0 235.5
Top sheet: 3.4mm DP600 Bare Bottom sheet: 3.4mm DP600 Bare.
Figure G4-1: Cross-Section.
Figure G4-2: Microhardness Traverse.
Page 49 of 75
VICKERS HARDNESS CHART
280
232
191
207217
245246240 240
252 250243 240
217
212
217
199
190
202
230222
241
238236
236
233241
244
234238
202
193
214
203
160
200
240
280
320
0 2 4 6 8 10 12 14 16
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ESS (
HAZHAZWELDBMBM
Group-4: GMAW AC (Material Combination 2) Table-G4-3: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 23.24 58.57
Wire Diameter 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)
Tip Recess/Extension .0625 in. (1.5 mm)
Travel Angle 40 deg. Push
Work Angle 30 deg.
MIG Current 110A
Wire Feed Rate 245 in./min
(6.22 m/min) Impact Strength
Weld Volts 19.5V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 25.9 59.0
Shielding Gas Flow 35 CFH Average 96.9 296.6
Shielding Gas 90% Ar / 10% CO2
Max 186.8 368.2
Top sheet: 1.15mm DP600 HDG Bottom sheet: 3.2mm HSLA 350 Bare
Figure G4-3: Cross-Section.
Figure G4-4: Microhardness Traverse.
Page 50 of 75
VICKERS HARDNESS CHART
235
183189
198
220229
271280
285278
201
209
239
216
268
285
245
232
273
272274272271
279
267271
196
195196
197
193
191
150
190
230
270
310
0 2 4 6 8 10 12 14 16
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ESS (
HAZHAZWELDBMBM
Group-4: GMAW AC (Material Combination 3) Table-G4-4: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 23.59 54.31
Wire Diameter 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 115A
Wire Feed Rate 280 in./min
(7.11 m/min) Impact Strength
Weld Volts 19.5V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 63.8 76.8
Shielding Gas Flow 35 CFH Average 110.1 279.8
Shielding Gas 90% Ar / 10% CO2
Max 142.6 411.8
Figure G4-5: Cross-Section.
Top sheet: 1.38mm HSLA 350 HDG Bottom sheet: 3.2mm HSLA350 Bare
Figure G4-6: Microhardness Traverse.
Page 51 of 75
VICKERS HARDNESS CHART
404
357
243
265
317
345
379
289282
316
380
284
251
290
376
388
368
368
290277
271270
288
291
271268260
259
274
160
200
240
280
320
360
400
440
0 2 4 6 8 10 12
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ESS (
HAZHAZWELDBMBM
Group-4: GMAW AC (Material Combination 4) Table-G4-5 Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 19.67 43.79
Wire Diameter 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)
Tip Recess/Extension .0625 in. (1.5 mm)
Travel Angle 40 deg. Push
Work Angle 30 deg.
MIG Current 95A
Wire Feed Rate 202 in./min
(7.11 m/min) Impact Strength
Weld Volts 18.5V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 33.8 194.8
Shielding Gas Flow 35 CFH Average 59.7 299.1
Shielding Gas 90% Ar / 10% CO2
Max 94.3 343.7
Top sheet: 1.18mm DP980 GA Bottom sheet: 1.18mm DP980 GA.
Figure G4-7: Cross-Section.
Figure G4-8: Microhardness Traverse.
Page 52 of 75
VICKERS HARDNESS CHART
360
320
289
236
315
231248244
307
376
387
307
342
404
272
381
297
286
303
312
296
277
283
224220
234
229212
160
200
240
280
320
360
400
440
0 2 4 6 8 10 12
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ESS (
HAZHAZWELDBMBM
Group-4: GMAW AC (Material Combination 5) Table-G4-6: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 22.22 47.59
Wire Diameter 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 85A
Wire Feed Rate 198 in./min
(6.22 m/min) Impact Strength
Weld Volts 18V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 22.3 310.7
Shielding Gas Flow 35 CFH Average 22.3 327.8
Shielding Gas 90% Ar / 10% CO2
Max 22.3 349.6
Top sheet: 1.0mm DP800 GA Bottom sheet: 1.0mm DP800 GA.
Figure G4-9: Cross-Section.
Figure G4-10: Microhardness Traverse.
Page 53 of 75
VICKERS HARDNESS CHART
358
336
302293
247
205219
254 254239
250
182
325
211224
264
274266
232234
251
240243
245
235218
216187
195
180
150
190
230
270
310
350
390
0 2 4 6 8 10 12 14
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ESS (
HAZHAZWELDBMBM
Group-4: GMAW AC (Material Combination 8) 70 KSI Filler Table-G4-7: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 30.56 84.26
Wire Diameter 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)
Tip Recess/Extension .0625 in. (1.5 mm)
Travel Angle 40 deg. Push
Work Angle 30 deg.
MIG Current 120A
Wire Feed Rate 290 in./min
(7.37 m/min) Impact Strength
Weld Volts 21V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 38.6 425.0
Shielding Gas Flow 35 CFH Average 59.2 467.7
Shielding Gas 90% Ar / 10% CO2
Max 70.1 541.8
Top sheet: 1.52mm DP 600 Bottom sheet: 2.0mm DP 780 GN
Figure G4-11: Cross-Section.
Figure G4-12: Microhardness Traverse.
Page 54 of 75
VICKERS HARDNESS CHART
296280
187200
217227
288
255
330
291
336
301288
298
325
244
187
237
345
288 281288
323
353
230
240
233
183
180
184
150
190
230
270
310
350
390
430
0 2 4 6 8 10 12 14
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ESS (
HAZHAZWELDBMBM
Group-4: GMAW AC (Material Combination 8) 90 kSI Filler Table-G4-8: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER90S-D2 Min 33.10 100.02
Wire Diameter 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 120A
Wire Feed Rate 290 in./min
(7.37 m/min) Impact Strength
Weld Volts 21V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 53.1 467.9
Shielding Gas Flow 35 CFH Average 66.4 495.1
Shielding Gas 90% Ar / 10% CO2
Max 104.1 508.7
Top sheet: 1.52mm DP 600 GA Bottom sheet: 2.0mm DP 780 GN
Figure G4-13: Cross-Section.
Figure G4-14: Microhardness Traverse.
Page 55 of 75
VICKERS HARDNESS CHART
330320
295
210
250
312
343
376
293
268
299
330
264
210
350356
391
281276
292298292
303
310
247
268
245
233221
223226
218
160
200
240
280
320
360
400
440
0 2 4 6 8 10 12 14
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ESS (
HAZHAZWELDBMBM
Group-4: GMAW AC (Material Combination 9) 70 kSI Filler Table-G4-9: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 22.56 45.29
Wire Diameter 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 110A
Wire Feed Rate 260 in./min
(6.60 m/min) Impact Strength
Weld Volts 22V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 19.2 359.3
Shielding Gas Flow 35 CFH Average 54.7 380.5
Shielding Gas 90% Ar / 10% CO2
Max 93.7 424.3
Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780 GN
Figure G4-15: Cross-Section.
Figure G4-16: Microhardness Traverse.
Page 56 of 75
VICKERS HARDNESS CHART
310
277
298
325
373
211226 239
250
303
392
331
344
383
373357
357
312
318
339
314
332
208
219
266270
245
243
160
200
240
280
320
360
400
440
0 2 4 6 8 10 12 14
DISPLACEMENT (mm)
VIC
KER
S H
AR
DN
ESS (
HAZHAZWELDBMBM
Group-4: GMAW AC (Material Combination 9) 90 kSI Filler Table-G4-10: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER90S-D2 Min 25.26 66.95
Wire Diameter 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 110A
Wire Feed Rate 260 in./min
(6.60 m/min) Impact Strength
Weld Volts 22V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 50.0 89.5
Shielding Gas Flow 35 CFH Average 64.9 325.2
Shielding Gas 90% Ar / 10% CO2
Max 77.6 423.2
Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780 GN
Figure G4-17: Cross-Section.
Figure G4-18: Microhardness Traverse.
Page 57 of 75
GMAW-AC AVERAGE IMPACT PEAK LOAD (kN)
59.72
22.32
59.17
66.36 64.9354.70
96.90
174.70
110.10
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
180.00
200.00
IM-0
1-7
0
IM-0
2-7
0
IM-0
3-7
0
IM-0
4-7
0
IM-0
5-7
0
IM-0
8-7
0
IM-0
8-9
0
IM-0
9-7
0
IM-0
9-9
0
GMAW-AC AVERAGE IMPACT ENERGY (J)
171.70
296.58 299.06
327.80
467.69
495.07
325.22
380.48
279.80
0.00
100.00
200.00
300.00
400.00
500.00
600.00
IM-0
1-7
0
IM-0
2-7
0
IM-0
3-7
0
IM-0
4-7
0
IM-0
5-7
0
IM-0
8-7
0
IM-0
8-9
0
IM-0
9-7
0
IM-0
9-9
0
Group-4: GMAW AC (Impact Strength at 15 MPH)
Figure G4-19: Impact Strength Peak Load.
Figure G4-20: Impact Strength Energy.
Page 58 of 75
GMAW-AC AVERAGE PEAK LOAD (kN)
44.73
26.19 25.79
21.8422.93
32.3933.37
30.6128.62
0.00
15.00
30.00
45.00
60.00
00
-TS
-01
-70
00
-TS
-02
-70
00
-TS
-03
-70
00
-TS
-04
-70
00
-TS
-05
-70
00
-TS
-08
-70
00
-TS
-08
-90
00
-TS
-09
-70
00
-TS
-09
-90
GMAW-AC AVERAGE ENERGY (J)
132.69
77.07
61.7352.53
105.59
78.50
89.53
94.29
68.80
0.00
25.00
50.00
75.00
100.00
125.00
150.00
175.00
200.00
225.00
250.00
00
-TS
-01
-70
00
-TS
-02
-70
00
-TS
-03
-70
00
-TS
-04
-70
00
-TS
-05
-70
00
-TS
-08
-70
00
-TS
-08
-90
00
-TS
-09
-70
00
-TS
-09
-90
Group-4: GMAW AC (Tensile Shear Data)
Figure G4-21: Tensile Shear Load.
Figure G4-22: Tensile Shear Energy.
Page 59 of 75
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
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.
Travel
Page 60 of 75
VICKERS HARDNESS CHART
219
237
194
194
198
194
231
206
207 206
222 220
210
240
225
227
243
223224
232
231
238244242
242
248
237
234
236
245
234232
231
226
203213
217
199
213
197
203203
0
50
100
150
200
250
300
0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00
DISPLACEMENT (mm)
VIC
KERS H
ARDNESS (
BM (Base Metal)
HZ (HAZ)
HV (Weld)
HZ (HAZ)
BM (Base Metal)
Group-5: GMAW DC (Material Combination 1) Table-G5-2: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 53.08 167.08
Wire Diameter 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 240A
Wire Feed Rate 530 in./min 13.5 m/min)
Impact Strength
Weld Volts 28V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 150.6 186.8
Shielding Gas Flow 35 CFH Average 167.9 220.8
Shielding Gas 90% Ar / 10% CO2
Max 209.5 247.7
Top sheet: 3.4mm DP600 Bare Bottom sheet: 3.4mm DP600 Bare.
Figure G5-1: Cross-Section
Figure G5-2: Microhardness Traverse.
Page 61 of 75
VICKERS HARDNESS CHART
183 185
222
291291
176
186
190
190
255
209
243
254
254252248
242
266259
250262
263
266 259
259
208
213226
208201
193196
204
0
50
100
150
200
250
300
350
0.00 2.00 4.00 6.00 8.00 10.00 12.00
DISPLACEMENT (mm)
VIC
KERS H
ARDNESS (
BM (Base Metal)
HZ (HAZ)
HV (Weld)
HZ (HAZ)
BM (Base Metal)
Group-5: GMAW DC (Material Combination 2) Table-G5-3: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 25.90 67.07
Wire Diameter 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 120A
Wire Feed Rate 290 in./min
(7.37 m/min) Impact Strength
Weld Volts 22V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 64.3 350.8
Shielding Gas Flow 35 CFH Average 85.3 376.0
Shielding Gas 90% Ar / 10% CO2
Max 94.7 395.2
Top sheet: 1.15mm DP600 HDG Bottom sheet: 3.2mm HSLA 350 Bare
Figure G5-3: Cross-Section.
Figure G5-4: Microhardness Traverse.
Page 62 of 75
VICKERS HARDNESS CHART
169175
196200200
169
167
171
161
184
227
234235
240
230 225
237239
236
232
207
221 225
206
209
201 201207
207
0
50
100
150
200
250
300
0.00 2.00 4.00 6.00 8.00 10.00 12.00
DISPLACEMENT (mm)
VIC
KERS H
ARDNESS (
BM (Base Metal)
HZ (HAZ)
HV (Weld)
HZ (HAZ)
BM (Base Metal)
Group-5: GMAW DC (Material Combination 3) Table-G5-4: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 20.27 86.56
Wire Diameter 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 140A
Wire Feed Rate 330 in./min
(8.38 m/min) Impact Strength
Weld Volts 21V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 68.4 192.8
Shielding Gas Flow 35 CFH Average 105.5 239.2
Shielding Gas 90% Ar / 10% CO2
Max 163.3 367.5
Figure G5-5: Cross-Section.
Top sheet: 1.38mm HSLA 350 HDG Bottom sheet: 3.2mm HSLA350 Bare
Figure G5-6: Microhardness Traverse.
Page 63 of 75
VICKERS HARDNESS CHART
241
283
345359
378386
370370
245
259
271
333
276
280
289
321
278268269
278
268
285
379
378
259
305
333
245
344
245
263
0
50
100
150
200
250
300
350
400
450
0.00 2.00 4.00 6.00 8.00 10.00 12.00
DISPLACEMENT (mm)
VIC
KERS H
ARDNESS (
BM (Base Metal)
HZ (HAZ)
HV (Weld)
HZ (HAZ)
BM (Base Metal)
Group-5: GMAW DC (Material Combination 4) Table-G5-5: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 22.36 70.52
Wire Diameter 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)
Tip Recess/Extension .0625 in. (1.5 mm)
Travel Angle 40 deg. Push
Work Angle 30 deg.
MIG Current 115A
Wire Feed Rate 210 in./min
(5.33 m/min) Impact Strength
Weld Volts 21V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 2.8 120.6
Shielding Gas Flow 35 CFH Average 17.0 134.9
Shielding Gas 90% Ar / 10% CO2
Max 29.8 163.5
Top sheet: 1.18mm DP980 GA Bottom sheet: 1.18mm DP980 GA.
Figure G5-7: Cross-Section.
Figure G5-8: Microhardness Traverse.
Page 64 of 75
VICKERS HARDNESS CHART
246
331
349
387376
330
366366
229
223
311
344
309
338331
327
322
319317
389
237
297
332
372
330
376
372
223226
0
50
100
150
200
250
300
350
400
450
0.00 2.00 4.00 6.00 8.00 10.00 12.00
DISPLACEMENT (mm)
VIC
KERS H
ARDNESS (
BM (Base Metal)
HZ (HAZ)
HV (Weld)
HZ (HAZ)
BM (Base Metal)
Group-5: GMAW DC (Material Combination 5) Table-G5-6: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 16.85 30.15
Wire Diameter 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 85A
Wire Feed Rate 188 in./min
(4.78 m/min) Impact Strength
Weld Volts 19V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 18.5 3.1
Shielding Gas Flow 35 CFH Average 27.0 63.1
Shielding Gas 90% Ar / 10% CO2
Max 85.4 522.5
Top sheet: 1.0mm DP800 GA Bottom sheet: 1.0mm DP800 GA.
Figure G5-9: Cross-Section.
Figure G5-10: Microhardness Traverse.
Page 65 of 75
VICKERS HARDNESS CHART
226
241
276
307
360
319319
271
215
240
253
258274
292
269
266
273 268
251
256258
269
250257
221
256
203205
298
193
191 192
191
0
50
100
150
200
250
300
350
400
0.00 2.00 4.00 6.00 8.00 10.00 12.00
DISPLACEMENT (mm)
VIC
KERS H
ARDNESS (
BM (Base Metal)
HZ (HAZ)
HV (Weld)
HZ (HAZ)
BM (Base Metal)
Group-5: GMAW DC (Material Combination 8) 70 KSI Filler Table-G5-7: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 32.96 106.03
Wire Diameter 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 150A
Wire Feed Rate 300 in./min
(7.62 m/min) Impact Strength
Weld Volts 22V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 49.4 478.6
Shielding Gas Flow 35 CFH Average 79.5 539.0
Shielding Gas 90% Ar / 10% CO2
Max 92.0 582.0
Top sheet: 1.52mm DP 600 Bottom sheet: 2.0mm DP 780 GN
Figure G5-11: Cross-Section.
Figure G5-12: Microhardness Traverse.
Page 66 of 75
VICKERS HARDNESS CHART
1.14
1.52
2.29
2.67
3.05
3.433.43
3.81 4.57
7.24
7.62
8.76
9.91
10.29
0.76
0.38
0.00
1.91
6.866.10
5.72
5.33
4.19
4.95
6.48
9.53
11.05
8.76
9.14
11.0511.8111.43
0
50
100
150
200
250
300
350
400
0.00 2.00 4.00 6.00 8.00 10.00 12.00
DISPLACEMENT (mm)
VIC
KERS H
ARDNESS (
BM (Base Metal)
HZ (HAZ)
HV (Weld)
HZ (HAZ)
BM (Base Metal)
Group-5: GMAW DC (Material Combination 8) 90 kSI Filler Table-G5-8: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER90S-D2 Min 29.34 82.14
Wire Diameter 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 150A
Wire Feed Rate 300 in./min
(7.62 m/min) Impact Strength
Weld Volts 22V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 55.4 497.5
Shielding Gas Flow 35 CFH Average 80.0 523.4
Shielding Gas 90% Ar / 10% CO2
Max 122.2 548.8
Top sheet: 1.52mm DP 600 GA Bottom sheet: 2.0mm DP 780 GN
Figure G5-13: Cross-Section.
Figure G5-14: Microhardness Traverse.
Page 67 of 75
VICKERS HARDNESS CHART
1.14
1.91
2.29
2.67
3.43
3.814.194.19
4.57
5.33
8.008.38
9.53
9.91
10.29
11.050.00
0.38
0.76
1.52
3.05
7.24
5.72
4.95
6.106.48
6.86 7.62
9.148.76
11.43
0
50
100
150
200
250
300
350
400
450
0.00 2.00 4.00 6.00 8.00 10.00 12.00
DISPLACEMENT (mm)
VIC
KERS H
ARDNESS (
BM (Base Metal)
HZ (HAZ)
HV (Weld)
HZ (HAZ)
BM (Base Metal)
Group-5: GMAW DC (Material Combination 9) 70 kSI Filler Table-G5-9: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER70S3 Min 22.74 51.81
Wire Diameter 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 125A
Wire Feed Rate 265 in./min
(6.73 m/min) Impact Strength
Weld Volts 21V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 94.6 176.8
Shielding Gas Flow 35 CFH Average 109.8 350.0
Shielding Gas 90% Ar / 10% CO2
Max 138.9 415.1
Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780 GN
Figure G5-15: Cross-Section.
Figure G5-16: Microhardness Traverse.
Page 68 of 75
VICKERS HARDNESS CHART
1.14
1.91
2.292.67
3.05
3.433.43
3.81
4.19
4.57
4.95
6.48 7.247.62
9.14
9.53
9.91
1.52
0.760.38
0.00
8.006.866.10
5.72
5.33
8.38
8.76
10.29 11.05
11.8111.43
10.67
0
50
100
150
200
250
300
350
400
450
0.00 2.00 4.00 6.00 8.00 10.00 12.00
DISPLACEMENT (mm)
VIC
KERS H
ARDNESS (
BM (Base Metal)
HZ (HAZ)
HV (Weld)
HZ (HAZ)
BM (Base Metal)
Group-5: GMAW DC (Material Combination 9) 90 kSI Filler Table-G5-10: Parameters and Data
Parameter Value Tensile Shear Strength
Travel Speed 30 in/min (762
mm/min) Load (kN) Energy (J)
Wire Spec. ER90S-D2 Min 23.40 59.41
Wire Diameter 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 125A
Wire Feed Rate 265 in./min
(6.37 m/min) Impact Strength
Weld Volts 21V Load (kN) Energy (J)
Gap (engineered) 0.5 mm Min 33.1 194.8
Shielding Gas Flow 35 CFH Average 75.8 322.1
Shielding Gas 90% Ar / 10% CO2
Max 103.1 361.6
Top sheet: 1.17mm DP780 GA Bottom sheet: 2.0mm DP 780 GN
Figure G5-17: Cross-Section.
Figure G5-18: Microhardness Traverse.
Page 69 of 75
GMAW-DC AVERAGE IMPACT PEAK LOAD (kN)
167.92
85.31
26.96
79.50 79.98
109.81
75.78
17.01
105.47
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
180.00
200.00
IM-0
1-7
0
IM-0
2-7
0
IM-0
3-7
0
IM-0
4-7
0
IM-0
5-7
0
IM-0
8-7
0
IM-0
8-9
0
IM-0
9-7
0
IM-0
9-9
0
GMAW-DC AVERAGE IMPACT ENERGY (J)
220.78
375.95
134.89
63.14
538.99523.38
349.97
322.10
239.17
0.00
100.00
200.00
300.00
400.00
500.00
600.00
IM-0
1-7
0
IM-0
2-7
0
IM-0
3-7
0
IM-0
4-7
0
IM-0
5-7
0
IM-0
8-7
0
IM-0
8-9
0
IM-0
9-7
0
IM-0
9-9
0
Group-5: GMAW DC (Impact Strength at 15 MPH)
Figure G5-19: Impact Strength Peak Load.
Figure G5-20: Impact Strength Energy.
Page 70 of 75
GMAW-DC AVERAGE PEAK LOAD (kN)
27.01
21.75
26.11
18.22
34.21 33.91
24.11
28.84
59.43
0.00
15.00
30.00
45.00
60.00
00
-TS
-01
-70
00
-TS
-02
-70
00
-TS
-03
-70
00
-TS
-04
-70
00
-TS
-05
-70
00
-TS
-08
-70
00
-TS
-08
-90
00
-TS
-09
-70
00
-TS
-09
-90
GMAW-DC AVERAGE ENERGY (J)
208.69
71.9379.29
37.10
113.36109.69
59.84
78.11
92.91
0.00
25.00
50.00
75.00
100.00
125.00
150.00
175.00
200.00
225.00
250.00
00
-TS
-01
-70
00
-TS
-02
-70
00
-TS
-03
-70
00
-TS
-04
-70
00
-TS
-05
-70
00
-TS
-08
-70
00
-TS
-08
-90
00
-TS
-09
-70
00
-TS
-09
-90
Group-5: GMAW DC (Tensile Shear Data)
Figure G5-21: Tensile Shear Load.
Figure G5-22: Tensile Shear Energy.
Page 71 of 75
Appendix A: Welding Equipment Photographs
Figure A1: Laser system arrangement.
Figure A2: Laser system arrangement.
Laser Head
Page 72 of 75
Figure A4: Laser-MIG system arrangement.
Figure A3: Laser-GMAW system arrangement.
GMAW Torch
Page 73 of 75
Figure A5: Laser-Plasma-Hybrid system arrangement.
Figure A6: Laser-Plasma-Hybrid robot system.
Plasma Torch
Page 74 of 75
Figure A7: GMAW torch. Travel right to left.
Figure A8: Robot used for GMAW (AC and DC) welding.
Filler Material
Page 75 of 75
Figure A9: AC and DC GMAW Power Supplies.
2000 Town Center, Suite 320Southfield, Michigan 48075Tel: 248.945.4777www.a-sp.org
