Abstract
The extensive use of galvanized interstitial-free (IF) steels in the automotive industry makes their resistance spot welding (RSW) metallurgy important. In this study, the relationships between microstructure, macrostructure, mechanical performance, and failure mode of resistance spot welds of galvanized IF steels were investigated. In order to characterize the macro- or microstructure, geometry, mechanical performance, and failure mode of the welds, stereographic microscopy, optical microscopy, scanning electron microscopy (SEM), and microhardness techniques were used. The results showed that the heat-affected zone (HAZ) includes ferrite grains that were elongated in the direction of heat transfer from the weld pool boundary to the base metal (BM). In addition, it was found that the nugget microstructure contains lath martensite, bainite, and different ferrite morphologies. Increasing the amount of heat input led to a decrease in martensite phase content in the weld nugget (WN) microstructure. Microhardness test results showed that the hardness of the WN is higher than the HAZ and BM. In the tensile shear tests, interfacial fracture and pullout fracture followed by BM sheet tearing were observed. It was seen that a WN with size \( 4 \times \sqrt t \) (t = sheet thickness) does not lead to pullout fracture. Finally, it was found that due to lower electrical resistivity of the steel in contrast to advanced high-strength steels, higher welding currents and longer welding times should be used in order to ensure the formation of large enough WNs and, thus, the satisfactory mechanical performance of the resistance spot welds.
Similar content being viewed by others
References
1. G.P. Sing, A.P. Moon, S. Sengupta, G. Deo, S. Sangal, and K. Mondal: J. Mater. Eng. Perform., 2015, vol. 24, pp. 1961–74.
2. L.Q. Guo, D. Liang, Y. Bai, X.L. Miao, L.J. Qiao, and A.A.Volinsky: Corrosion, 2014, vol. 70, pp. 1024–30.
3. P. Murkute, J. Ramkumar, and K. Mondal: J. Mater. Eng. Perform., 2016, vol. 25, pp. 2878–88.
4. W.R. Osorio, L.C. Peixoto, and A. Garcia: J. Mater. Corros., 2010, vol. 61, pp. 407–11.
5. R. Rana, S.B. Singh, and O.N. Mohanty: Corros. Eng. Sci. Technol., 2011, vol. 46, pp. 517–20.
6. G. Chakraborty, T.K. Pal, and M.Shome: J. Mater. Sci. Technol., 2011, vol. 27, pp. 382–86.
7. A. Bak and S. Gündüz: J. Automob. Eng., 2010, vol. 224, pp. 29–40.
8. M. Takahashi: ISIJ Int., 2015, vol. 55, pp. 79–88.
9. S. Hoile: Mater. Sci. Technol.., 2000, vol. 16, pp. 1079–93.
10. M.R.A. Shawon, F. Gulshan, and A.S.W. Kurny: J. Inst. Eng. India Ser. D, 2015, vol. 96, pp. 29–36.
A.C. Baldim, S.C. da Costa, and T.C.S. Aguiar: Weld. Int., 2017, vol. 31, pp. 259–67.
12. M. Goodarzi, S.P.H. Marashi, and M. Pouranvari: J. Mater. Process. Technol., 2009, vol. 209, pp. 4379–84.
H.K.D.H. Bhadeshia: Phase Transformations during Spot Welding of Interstitial-Free Steel. Proc. Int. Conf. on Interstitial-Free Steels, Jamshedpur, 2010, pp. 1–11.
14. M. Pouranvari and S.P.H. Marashi: Sci. Technol. Weld. Join., 2013, vol. 18, pp. 361–403.
15. R. Ashiri, M.A. Haque, C.-W. Ji, H.R. Salimijazi, and Y.-D. Park: Scripta Mater., 2015, vol. 109, pp. 6–10.
16. R. Ashiri, M. Shamanian, H.R. Salimijazi, M.A. Haque, J.-H. Bae, C.-W. Ji, K.-G. Chin, and Y.-D. Park: Scripta Mater., 2016, vol. 114, pp. 41–47.
17. S. Rajakumar and V. Balasubramanian: J. Adv. Microsc. Res., 2015, vol. 10, pp. 146–54.
P. Howe and S.C. Kelley: Report No. 880280, SAE International, 1988.
M.I. Khan: Master’s Thesis, University of Waterloo, Waterloo, 2007.
20. S.S. Rao, R. Chhibber, K.S. Arora, and M. Shome: J. Mater. Process. Technol., 2017, vol. 246, pp. 252–61.
21. M. Pouranvari, H.R. Asgari, S.M. Mosavizadeh, P.H. Marashi, and M. Goodarzi: Sci. Technol. Weld. Join., 2007, vol. 12, pp. 217–25.
F. Mirzaei, H. Ghorbani, and F. Kolahan: Int. J. Adv. Manuf. Technol., 2017, vol. 92, pp. 1–13.
23. D. Kianersi, A. Mostafaei, and J. Mohammadi: Metall. Mater. Trans. A, 2014, vol. 45A, pp. 4423–42.
24. D.S. Safanama, S.P.H. Marashi, and M. Pouranvari: Sci. Technol. Weld. Join., 2012, vol. 17, pp. 288–94.
25. D.J. Radakovic and M. Tumuluru: Weld. J., 2012, vol. 91, pp. 8–15.
26. M. Tumuluru: Weld. J., 2007, vol. 86, pp. 161–69.
27. R. Ashiri, S.P.H. Marashi, and Y.-D. Park: Weld. J., 2018, vol. 97, pp. 157–69.
28. M. Pouranvari and S.P.H. Marashi: Mater. Sci. Eng. A, 2011, vol. 528, pp. 8337–43.
29. D.J. Radakovic and M. Tumuluru: Weld. J., 2008, vol. 87, pp. 96–105.
Standard Test Method for Analysis of Carbon and Low-Alloy Steel by Spark Atomic Emission Spectrometry. ASTM E415-14, ASTM International, West Conshohocken, 2014.
Test Methods for Evaluating the Resistance Spot Welding Behavior of Automotive Sheet Steel Materials. ANSI/AWS/SAE/D8.9M-2012, American Welding Society, Miami, 2012.
Standard Test Methods for Determining Average Grain Size,” ASTM E112-13, ASTM International, West Conshohocken, 2013.
G. Krauss: Am. Soc. Met., 1980, p. 291.
ASM Handbook Committee: Metals Handbook: Heat Treating, ASM International, Metals Park, 1991
35. J.Z. Chen and D.F. Farson: J. Mater. Process. Technol., 2006, vol. 178, pp. 251–58.
36. E. Bayraktar, D. Kaplan, L. Devillers, and J.P. Chevalier: J. Mater. Process. Technol., 2007, vol. 189, pp. 114–25.
37. M. Pouranvari, A. Abedi, P. Marashi, and M. Goodarzi: Sci. Technol. Weld. Join., 2008, vol. 13, pp. 39–43.
38. P. Marashi, M. Pouranvari, S. Amirabdollahian, A. Abedi, and M. Goodarzi: Mater. Sci. Eng. A, 2008, vol. 480, pp. 175–80.
39. M. Pouranvari and S.P.H. Marashi: Mater. Des., 2010, vol. 31, pp. 3647–52.
40. M. Pouranvari and P. Marashi: Metalurgija, 2009, vol. 15, pp. 149–57.
41. H.K.D.H. Bhadeshia and J.W. Cheristian: Metall. Mater. Trans. A, 1990, vol. 21A, pp. 767–97.
Y. Ohmori, H. Ohtsubo, Y.C. Jung, S. Okaguchi, and H. Ohtani: Metall. Mater. Trans. A, 1994, vol. 25A, pp. 1981–89.
43. D. Phelan and R. Dippenaar: Metall. Mater. Trans. A, 2004, vol. 35A, pp. 3701–06.
44. H.I. Aaronson, G. Spanos, R.A. Masamura, R.G. Vardiman, D.W. Moon, E.S.K. Menon, and M.G. Hall: Mater. Sci. Eng. B, 1995, vol. 32, pp. 107–23
45. H.K.D.H. Bhadeshia and R.W.K. Honeycombe: Steels: Microstructures and Properties, 3rd ed., Butterworth-Heinemann, Elsevier, Oxford, United Kingdom, 2006.
46. S. Kou: Welding Metallurgy, 2nd ed., Wiley-Interscience, Hoboken, NJ, 2003.
47. M. Tamizi, M. Pouranvari, and M. Movahedi: Sci. Technol. Weld. Join., 2017, vol. 22, pp. 327–35.
48. I. Hajiannia, M. Shamanian, M. Atapour, E. Ghassemali, and R. Ashiri: Cog. Eng., 2018, vol. 5, pp. 1–13.
49. G. Mukhopadhyay, S. Bhattacharya, and K.K. Ray: J. Mater. Process. Technol., 2009, vol. 209, pp. 1995–2007.
50. R. Ashiri, H. Mostaan, and Y.-D. Park: Metall. Mater. Trans. A, 2018, vol. 49A, 6161-72.
Author information
Authors and Affiliations
Corresponding authors
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Manuscript submitted December 6, 2017.
Rights and permissions
About this article
Cite this article
Salimi Beni, S., Atapour, M., Salmani, M.R. et al. Resistance Spot Welding Metallurgy of Thin Sheets of Zinc-Coated Interstitial-Free Steel. Metall Mater Trans A 50, 2218–2234 (2019). https://doi.org/10.1007/s11661-019-05146-8
Received:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11661-019-05146-8