Effects of Steel Coatings On Electrode Life in Resistance Spot Welding of Galvannealed Steel Sheets
Effects of Steel Coatings On Electrode Life in Resistance Spot Welding of Galvannealed Steel Sheets
Effects of Steel Coatings On Electrode Life in Resistance Spot Welding of Galvannealed Steel Sheets
2236 to 2242
#2010 The Japan Institute of Metals
The effects of different galvannealed (GA) coatings, containing Fe varying from 7.0 to 11.4 mass%, on steel sheets on the electrode life in
resistance spot welding (RSW) have been investigated with metallurgical analysis of the coating microstructures and properties, and the surfaces
and cross-sections of failed electrodes. The results showed that the electrode life in RSW of GA steel with 11.4 mass% Fe in coating was 110%
higher than that with coatings containing 7.0 or 9.6 mass% Fe. The improvement was believed to be caused by the build-up of a Fe-rich alloy
layer on the electrode surface, which could serve as a barrier to prevent copper loss from the electrode surfaces to the steel sheets, thus reducing
the growth rate of the electrode tip face diameters. In addition, higher Fe content in the coating resulted in increased contact resistance and hence
a lower welding current needed in RSW. [doi:10.2320/matertrans.M2010239]
(Received July 21, 2010; Accepted August 26, 2010; Published October 27, 2010)
Keywords: resistance spot welding, galvannealed steel, electrode life, coating composition and microstructures
1. Introduction
resistance welding of nickel-plated steel, and indicated that current test (to determine the welding current that will be
the electrode coating could serve as a barrier layer to reduce used in the endurance test), all on the same set of two
the Cu loss from the electrode, increasing electrode life. electrodes.20)
Pickett et al.,19) in an investigation of electrode life in In the stabilization tests, the initial current was selected to
RSW of GA steels with coatings containing different Fe be 7000 A, based on the AWS standard on 0.7-mm-thick
contents, have shown that the electrode life was increased by zinc-alloy coated steel sheets. Stabilization weld-button size
two-fold when Fe content increased from 8 to 10 mass% and (SWS) is defined as 90 percent of the dressed tip face
further increased when Fe increased to 13 mass%. But, diameter without expulsion or severe sticking,20) which was
unfortunately, the electrode life tests were arbitrarily stopped 4.4 mm in this work based on 0:9 4:9 mm rounded to the
at 10,000 welds for 13 mass% Fe so that the exact improve- closest 0.1 mm (4.9 mm is the average of measured initial tip
ment was not quantified. Also the reason for the increase in face sizes Using the carbon imprint technique,21) which were
electrode life was not discussed. The present work has aimed 4.90, 4.91 and 4.88 mm for the electrodes for steels #1, #2
at clarifying the effects of steel coatings on electrode life in and #3 respectively). Weld (button) size was determined by
RSW of GA steels and the mechanism of improving electrode the button left on one steel sheet after peel testing.20) Once
life by increasing Fe content in the coating. the total welds reached 250, the stabilization test ended and
the same set of electrodes moved on to the current test.20)
2. Experimental At the start of the current test, the initial current I0 should
be sufficiently low to produce a weld that is at least 0.5 mm pffi
The steel substrate used in this work was 0.7 mm in smaller than the minimum weld size (MWS), defined as 4 t
thickness with chemical composition, in mass%, as C ¼ (tpisffiffiffiffiffiffithe
ffi thickness of the coated steel sheet), i.e., MWS ¼
0:003, Si ¼ 0:01, Mn ¼ 0:09, P ¼ 0:009, S ¼ 0:005, Al ¼ 4 0:7 ¼ 3:35 mm in this work. This initial current was
0:051, Cr ¼ 0:012, Mo ¼ 0:003, Cu ¼ 0:018, Ni ¼ 0:008, selected to be 8300 A, 7300 A and 7200 A for steels #1, #2
Sn ¼ 0:003, V ¼ 0:002, Nb ¼ 0:014, Ti ¼ 0:026. The coat- and #3, respectively, based on the weld size and welding
ing thickness on both steel sides and the nominal Fe content current data from the stabilization test. The final currents,
in the coatings are 9.2, 8.9 and 8.5 mm, 7.0, 9.6 and based on when expulsion or severe electrode sticking
11.4 mass%, respectively for steels #1, #2 and #3, which occurs,20) was determined to be 9200, 8700, 8500 A for
were the averages of 10 measurements each by a JEOL JSM- steels #1, #2 and #3, respectively. The total welds made in
6460 scanning electron microscope (SEM) equipped with the stabilization and current tests were 274, 288 and 288,
energy-dispersive spectrometer (EDS) on the cross-sections respectively for steels #1, #2 and #3.
of steel sheets. X-ray diffraction (XRD) analysis was The welding current for the endurance test is set as the final
conducted using a Rigaku AFC8 power X-ray diffractometer current less 200 A, i.e., 9000 A, 8500 A and 8300 A for steels
using Cu K radiation. Micro-hardness of steel coatings was #1, #2 and #3, respectively. According to the AWS stand-
measured using a HMV 2000 Vickers hardness tester at 5 g ard,20) when the weld button size drops to a value lower than
load on prepared metallographic cross-section samples. MWS, i.e., 3.35 mm, the number of welds made is deemed
All spot welds were produced by an air operated stationary endurance life. In this work, electrode life is taken as the
single phase alternating current (AC) RSW machine of sum of total welds made in the stabilization, current and
250 kVA rating at 60 Hz. The electrodes used in this work endurance tests.
were RWMA Group A, Class II, Cu-Cr-Zr domed-flat nose, Figure 2 shows the carbon imprints of electrode tip faces at
female caps with nominal tip face diameter of 4:8 mm the start of the stabilization test, and the start and end of the
0:5 mm. Electrode force (2000 N), weld time (11 cycles), endurance test with electrode tip face diameter as 4.91, 4.88
cooling water flow (4 L/min), welding rate (25 welds/min), and 4.90 mm respectively for steels #1, #2, and #3 after
and short (5 cycles) and long hold time (90 cycles), specified the stabilization and current tests. This indicates that no
by recommended practices of the AWS standard, AWS/ significant change took place in the electrode tip morphology
ANSI/SAE D8.9-97,20) were used in this work. Based on the and size before and after the stabilization and current tests.
standard, electrode life can be determined in an endurance Only one pair of electrodes for each type of steel coating
test following a weld size stabilization test (to compensate for was tested because of the limited supply of steel sheets. But
the dynamic behavior of welding current versus weld size fortunately the electrode life tests using the AWS standard
that occurs when making welds with new electrodes) and a showed very good consistency in RSW of these GA steels.19)
2238 X. Hu et al.
Fig. 3 SEM backscatter images at lower and higher magnification of highlighted areas for steels #1 (a) and (b), #2 (c) and (d), and #3 (e)
and (f), respectively.
Effects of Steel Coatings on Electrode Life in Resistance Spot Welding of Galvannealed Steel Sheets 2239
(a)
Fig. 5 Button diameter versus the number of welds during endurance test.
(a)
Fig. 8 Electrode tip face diameter versus the number of welds during
endurance test.
(b)
(c)
Fig. 9 Copper content on the button (weld) surfaces.