Resistance spot welding of Docol and Dogal

Dr. Anders Ivarson, anders.ivarson@ssab.com

ESAB Spot weldning machine
 Spot welding
 Seam welding
 Projektion welding

http://www.youtube.com/watch?v=b2n_kpLXwY8
Resistance spot welding (RSW)

Q = I2 x R x t

Q = energy (J)

I = welding current (A)

R = Electrical resistance (ohm)

t = welding time (s)

 Electrical resistance
The resistance of the welding circuit consists of material and contact
(surface) resistances:
- note that the highest values are
at the sheet interfaces
(contact resistance)

(Source: KIMAB)
Welding parameters in spot welding

 Electrode face diam.

 Electrode force (F)
 Squeeze time (TA)
 Welding time (TS)
 Current (IS)
 Hold time (TH)
 Resistance spot welding (RSW)

 Most common welding method in automotive (approx 5000 welds/car)

 Benefits
– Well-known method for designers in automotive
– Low distortions of sheets due to low heat input
– Very low cost (approx 0.003 €/spot weld)
– Clamping and welding in same operation
– Small gaps between sheets not a problem
 Drawbacks
– Access from both sides needed
– Indentation in the sheet
– Low fatigue strength
Spot welding of
advanced high strength steels

Advanced high strength steels

can be spot welded to:

 Other mild steels

 Other high strength steels

 Itself (the same steel grade)

Testing of resistance spot welds

 Peel test

 (weld diameter, type of fracture)

 Metallographic examination of cross section

 (photo, hardness)

 Shear test

 (strength, type of fracture)

 Cross tension test

 (weld diameter, strength, type of fracture)

 Spot weld surface cracks

Testing of spot welds – Peel test

Loading direction

Peel test

Loading direction
Cross section and hardness test
Testing of spot welds - Shear test
Testing of spot welds – Cross tension test

Loading direction

Spot weld

Loading direction
Fracture load of spot welds
for Docol steels
Different tests for evaluation of
spot weldability

 Available welding current range

(weldability lobe)

 Type of fracture in peel, cross

tension and shear test

 Electrode life
Different type of fracture for spot welds

Plug fracture

Partial interfacial fracture

Interfacial fracture
Influence of steel composition
on spot weldability

 Steel composition is especially important for

welding methods with high cooling rates e.g.
– Spot welding
– Laser welding

 An increased amount of alloying elements will

impair the spot weldability.
Spot welding. Carbon equivalent formulas.
Most common formula today:

CE = C + Mn/20 + Si/30 + 2P + 4S (≤ 0.24%)

”Tanakas” formula (used by SSAB for many years):

CE = 1.5C + P + 3S (≤ 0.23%)
Steel composition of some Docol/Dogal AHSS
Steel grade C Si Mn CE
% % % %

Dogal 600 DP 0,11 0,2 1,6 0,23

Dogal 800 DP 0,15 0,2 1,8 0,28

Docol 1200 M 0,11 0,2 1,6 0,24

Docol 1000 LCE 0,13 0,2 1,0 0,22

1) CE = C + Mn/20 + Si/30 + 2P + 4S
 Recommendations for spot welding of
Docol mild steels

 Welding data
 Electrode tip diameter:
 Electrode force:
 Welding time:
 Hold time:
 Current level:
approx. 5 t mm
approx. 2200 x t (N)
approx 10 x t per - AC (200 x t ms - MFDC)
approx. 10 per (200 ms)
decided after welding tests

( t = thickness in mm for the thinnest sheet)

 Welding data for spot welding of Docol
and Dogal AHSS

 Higher electrical resistivety and lower thermal conductivity compared to

mild steels demands other welding parameters

 The importance of changed welding parameters increases with

increasing strength and increased amount of alloying elements

Spot welding recommendations for AHSS

- AC or MFDC machines
- Same electrodes as for mild steels (CuCrZr)
- Conventional single pulse welding

Best results are obtained with:

• Increased electrode force
• Longer welding time
Influence of electrode force on welding current
range – Docol 1000 DP 1.2 mm

Electrode force

5000 N
Welding data
 El. tip diam: 6 mm
4000 N  Weld time: 14 cyc
 Hold time: 10 cyc
 Min plug diam: 4 mm
3000 N

Welding current (kA)

4 5 6 7 8 9 10
Influence of welding time on available current
range – Docol 800 DP 1.5 mm

Welding time (cycles)

18
Welding data
 El. tip diam: 6 mm
 El. Force: 5100N
15
 Hold time: 10 cyc
 Min plug diam: 4 mm

12

Welding current (kA)

5 6 7 8 9 10
 Weldability lobes

 Which type of test? Peel or cross tension?

 Which minimum weld size is accepted? (a common

value is 4x(t)0.5 mm, t = thickness of the thinnest sheet)

 What is the requirement regarding current range?

 Two sheet joints most common but sometimes also

three sheet joints are tested.
 Dogal 1000 DPX (1,1 mm) welded to Dogal 1000 DPX (1,1 mm)
8,0
7,5 Welding data (AC, 50 Hz)
7,0 Electrode cap: B (ISO 5821)
Electrode: 16/6
6,5
Electrode force: 3 kN
Plug diameter (mm)

6,0 Welding tim e: 18 cyc

5,5 Hold tim e: 10 cyc No splash

5,0 Splash
4,5
4,0 0,5
Min plug=4 (t)
3,5
3,0
2,5 Cross tension tests
Type of failure: Full plug
2,0
1,5
1,0
4,0 4,5 5,0 5,5 6,0 6,5 7,0 7,5 8,0
Current (kA)
Weld growth curve (plug diam vs welding current)

RESISTANCE SPOT WELDING OF DOCOL 1000 LCE

8,0
7,5
Steel 1: Docol 1000 LCE, t=1.5 mm
7,0
Steel 2: Docol 1000 LCE, t=1.5 mm
Plug diameter (mm)

6,5
6,0
Cross tension test
5,5 Splash
Full plug fracture Welding data (MFDC)
5,0 Electr. cap: Type B
4,5 Cap size: 16/6
Min. plug Electr. force: 4.0 kN
4,0 diam. 4.9 mm Weld time: 300 ms
(4 t^0.5) Hold time: 200 ms
3,5
3,0
4,0 4,5 5,0 5,5 6,0 6,5 7,0 7,5 8,0 8,5 9,0

Current (kA)
Weld growth curve for Docol 1400 M ZE, 1.5 mm

Min. plug
diam. 4.9 mm
(4 t^0.5)
 Resistance spot weldability of Docol / Dogal
1)
Steel grade C CE Weldability Remarks
(%) (%)
Docol 500 LA 0.06 0.18 Very good weldability
Docol 500 DP 0.08 0.19 Very good weldability
Docol 500 DL 0.05 0.17 Very good weldability
Docol 600 DP 0.11 0.21 Very good weldability
Docol 600 DL 0.10 0.22 Very good weldability
Docol 800 DP 0.13 0.25 Good weldability Not always plug fracture
Docol 800 DL 0.14 0.26 Good weldability Not always plug fracture
Docol 1000 DP 0.15 0.28 Good weldability Not always plug fracture
Docol 1000DPZE 0.15 0.28 Good weldability Not always plug fracture
Docol 1000 LCE 0.13 0.22 Very good weldability
Docol 900 M 0.05 0.19 Very good weldability
Docol 900 M ZE 0.05 0.19 Very good weldability
Docol 1200 M 0.11 0.24 Good weldability Not always plug fracture
Docol 1200MZE 0.11 0.24 Good weldability Not always plug fracture
Docol 1400 M 0.17 0.30 Good weldability Not always plug fracture
Docol 1400MZE 0.17 0.28 Good weldability Not always plug fracture
Docol 1500 M 0.20 0.30 Good weldability Not always plug fracture
Docol Roll 800 0.14 0.26 Good weldability Not always plug fracture
Docol Roll 1000 0.14 0.26 Good weldability Not always plug fracture
Dogal 500 LAD 0.13 0.26 Good weldability Not always plug fracture
Dogal 600 DP 0.11 0.23 Good weldability Risk for surface cracks
Dogal 800 DPX 0.15 0.28 Reduced weldability High risk for surface cracks
Dogal 1000DPX 0.185 0.32 Reduced weldability High risk for surface cracks

1) CE = C + Mn/20 + Si/30 + 2P + 4S
 Surface cracks in RSW of zinc coated steels

 The reason to the cracks is overheating in combination with

liquid metal embrittlement of Zn and Cu

 Depth of crack normally <0.10 mm but in some cases

deeper (0.3-0.7 mm).

 Small cracks in centre of spot weld have no detrimental

effects on properties

 Small cracks are normally accepted by automotive industry

 Electro galvanized steel more resistant than hot dip

galvanized
Global welding standard from GM (GWS-5A)
 Surface cracks in RSW of zinc coated steels

 Cracking is influenced by many factors

 Welding equipment / parameters. High risk for cracks:

– Misalignment of electrodes

– Too low cooling of electrodes

– Thin sheets

– High weld heat on surface - high weld current

– Small contact diameter of electrode

 An increased carbon content of steel increases risk of cracking

Weldability lobe
For constant electrode force and constant electrode tip diameter

Weldability
lobe