INVESTIGATION ON THE DIFFERENT TYPES OF MATERIALS OF JOINING

FOR AUTOMOTIVE PANEL

MOHAMAD SUHAIMI BIN SAMSUD1N

A report in partial fulfillment of the requirements for the award of the degree of Bachelor of Mechanical Enginering with Manufacturing Engineering

Faculty of Mechanical Engineering Universiti Malaysia Pahang

NOVEMBER 2007
PRPST&i(AN NtVER 4 flt. ,IALAV S1A PAHANG No. Png9n oehafl

(.,.

030497 Taikh 30 MAY 2t1U '5

ABSTRACT

The technique of joining two or more different panels is called as Tailor Welded Blank (TWB). The panels could vary in thicknesses, grades or coating and joined by the mean of welding. This technique is widely being used by automotive manufacturer in the world because of the abundant benefits. But, Malaysian automotive manufacturers are still lack of this advancement. Hence, this project endeavors to build a platform for the industries by pioneering researches in this area. So, the purpose of the project is to find the best joining materials to be integrated into TWB by comparing each specimen and then proposed the potential TWBs to be used as automotive panel specially aimed for door inner panel for the hinge section. Base metals of 0.7mm thick from SPCC and SPCEN grades and 1.2 mm thick from SPHC, SAPH 370 and SGACC grades are chosen to be the joining materials and laser welding is chosen to be the method for joining. Each specimen will be tensile tested in order to find the properties that influence the weldability, formability and drawability of the TWBS. Then the data obtained will be analyze by distinguishing them into several sets of parameter to determine the significant factor and thus, decided the best material combination as the potential Tailor Welded Blanks.

VII

ABSTRAK

Teknik menyambung dua atau lebih panel dipanggil sebagai Adunan Kepingan Dikimpal atau "Tailor Welded Blank" (TWB). Panel - panel mi boleh berbagai dari segi tebal, gred, salutan yang mana disambungkan melalui teknik kimpalan. Teknik mi digunakan oleh hampir kesemua pengusaha automotif di dunia disebabkan oleh kelebihannya. Tetapi, pengusaha automotif di malaysia masih tertinggal dari segi kemajuan mi. Oleh itu, projek liii berusaha membina asas kepada industri mi dengan memulakan penyelidikan di bidang yang dimaksudkan. Sebagai permulaan, projek mi bertujuan untuk mencani bahan peyambungan terbaik untuk diadaptasikan ke dalam TWB dengan membandingkan setiap spesimen seterusnya memilih kombinasi bahan berpotensi untuk diaplikasikan kepada panel automotif yang dikhususkan kepada panel dalaman pintu bahagian engsel. Kepingan logam dan gred SPCC dan SPCEN berketebalan 0.7mm dan gred SPHC, SAPH 370 dan SGACC berketebalan 1.2mm dipilih sebagai bahan peyambungan dan kimpalan laser dipilih sebagai cam peyambungan. Setiap spesimen akan diuji untuk mencani elemen yang mempenganuhi kebolehubahan, kebolehtanikan, dan kebolehkimpalan sesuatu TWB. Data yang didapati akan dianalisis dengan membezakan setiap spesimen kepada beberapa parameter untuk mementukan faktor-faktor yang mempengaruhi dan seterusnya memilih kombinasi balm terbaik yang berpotensi dijadikan sebagai TWB.

viii

TABLE OF CONTENTS

CHAPTER

TITLE

PAGE

TITLE PAGE T SUPERVISOR DECLARATION STUDENT DECLARATION DEDICATION ACXNOWLEGDEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS LIST OF ABBREVIATIONS. LIST OF APPENDICES

1 11 111

iv
V

vi vii
viii xi xi" xv xvi xvii

INTRODUCTION

1.1 Project background

1 2 2

1.2 Problem Statements 1.3 Aim and Objectives 1.4 Project Scopes

ix LITERATURE REVIEW

2.1

Tailor Welded Blanks 2.2.1 Hot Rolled (HR) Steel Sheet 2.2.1.1 2.2.1.2 2.2.2.1 2.2.2.2 2.2.3.1 SPHC SAPH 370 SPCC SPCEN SGACC

4 6 7 7 8 8 9 9 10 10 11 14 15 16 17 17 17 19 19 20 20 21 21 21

2.2. Automotive Panels

2.2.2 Cold Rolled (CR) Steel Sheet

2.2.3 Hot Dip Galvanized Steel Sheet 2.3 Laser Beam Welding 2.4 Flat Rolling 2.4.1 Hot Rolling 2.4.2 Cold Rolling
2.5

Cost Consideration

2.6 Thickness of Sheet Metal 2.7 Stamping 2.8 Tensile 2.8.1 Tensile Test Machine 2.8.2 Hooke's Law 2.8.3 Modulus of Elasticity 2.8.4 Yield Strength
2.8.5 Strain

2.8.6 Ultimate Tensile Strength

METHODOLOGY

3.1 Introduction 3.2 Literature Review 3.3 Identify Process and Main Consent 3.4 Formulate Aim and Objectives

22 24 24 24

x 3.5 Method of investigation and Solution 25 25

3.5.1 Shearing 3.5.2 Ler Welding

3.5.3 Tensile Testing

27 30 31 31

3.6 Data collection 3.7 Comparison and Conclusion

4 RESULTS AND DISCUSSION

4.1

Introduction 4.2.1 Results of Base Metal Testing 4.2.2 Results of TWB Combinations Testing

32 32 33 34 38 39 40 42 43 44

4.2 Tensile Testing Results

4.3 Data Interpretations 4.3.1 Yield Strength 4.3.2 Tensile Strength 4.3.3 Elongation! Percent Strain 4.3.4 Overall Findings 4.4 Discussion

CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion 5.2 Recommendation

46 46 48 50-60

REFERENCES Appendices A-E

xi

LIST OF TABLES

TABLE NO.

TITLE

PAGE

2.1

Mechanical properties and chemical composition of

RS 03131 hot rolled mild steel sheets and strips.

7 8

2.2 2.3

Comparison of JIS specification with similar standards Mechanical properties and chemical composition of MS G 3113 hot rolled steel sheet and strip for automobile structural uses

2.4

Mechanical properties of MS 03141 cold rolled mild steel sheets and strips 9

2.5

Chemical composition of MS G 3141 cold rolled mild steel sheets and strips 10

2.6

Mechanical properties MS 03302 cold rolled hot-dip Galvanized 11 11 14 25 28 31

2.7 2.8 3.1 3.2 3.3

Comparison of MS specification with similar standards Effect of beam weaving with different amplitudes List of specimen needed for the project Laser Welding Parameters Example of data collection table

xii 4.1 4.2 Data Collections for the base metal Data collections for the TWBs combination 33 38

xlii

LIST OF FIGURES

FIGURE NO.

TITLE

PAGE

2.1 2.2 2.3 2.4

Examples of typical use of tailor welded blanks Steel door with tailor welded inner panel Welding types used for Tailor Welded Blanks Effect of filler wire use and Effects of filler wire on weld hardness

5 5

13 14

2.5

Effect of planishing on weld hardness Schematic outline of steel making from raw material to by-products

2.6

15 18 23 26 26 27 28 29 29

2.7 3.1 3.2 3.3 3.4

3.5

TWBs are stamped using an ordinary press Methodology flow chart Dimension for shearing NC shearing machine model MVS 6131 Sheared base metal specimens
An ORLaser laser beam welding machine model HTS 160

3.6 3.7

Laser welding process Laser welded TWBs

xiv

3.8 3.9 4.1 4.2 4.3 4.4

4.5

TWBs tensile specimen dimension Instron Universal Testing Model 3369 Fractured tensile specimens of TWBs Comparison of TWBs yield strength to their base metals Comparison of each TWBs yield strength Comparison of TWBs tensile strength to their base metals Comparison of each TWBs tensile strength Comparison of TWBs elongation to their base metals Comparison of each TWBs elongation Overall findings

30 30 34 39 39 40 41 42 42 43

4.6. 4.7 4.8

xv

LIST OF SYMBOLS

A E e F

Area Modulus of Elasticity Strain Force Instantaneous length Initial length Pressure Change in length Strain Stress

L0 P AL a

xvi

LIST OF ABBREVIATIONS

CQ CR DDQ HR MS SAPH SGACC

- -

Commercials Quality Cold Rolled Deep Draw Quality Hot Rolled Japanese industrial Standards Hot Rolled Steel Sheet for Automobile Structural Uses Hot Dip Galvanized Cold Roll Steel Sheet with Commercial Quality

SPCC SPCEN SPHC TWB UTS YS

- - - - - -

Cold Rolled Steel Sheet with Commercial Quality Cold Rolled Steel Sheet with Deep Drawing Quality Hot Rolled Steel Sheet with Commercial Quality Tailor Welded Blanks Ultimate Tensile Strength Yield Strength

xvii

LIST OF APPENDICES

APPENDIX

TITLE

PAGE

A B C-i C-2 C-3 C-4 C-5 C-6 D-1 D-2 E

Laser Welding Process Tensile Testing Process Tensile testing results SPCC-SPHC Tensile testing results SPCC-SAPH 370 Tensile testing results SPCC-SGACC Tensile testing results SPCEN-SPHC Tensile testing results SPCEN-SAPH 370 Tensile testing results SPCEN-SGACC Laser welding machine technical data Laser welding machine system features. Tailor Welded Blanks Door Inner Panel
I

50 51
52

53
54 55

56 57 58
59

60

CHAPTER 1

INTRODUCTION

1.1

Background

During the past two decades, government fuel conservation and safety mandates along with environmental concerns have prompted the automotive industry to design lighter cars for reduced fuel consumption, while improving the overall structure of their vehicles for occupant safety. Corrosion protection was also much improved during this period. These changes added to escalating manufacturing costs at a time when the industry was struggling with a serious threat from global competition.

To reduce weight and costs, alternative materials such as aluminum and composite materials have been proposed and used for body panels, but none has shown the versatility of steel. High strength steels, coated steels, laminated steels and various thawing quality grades give steel the ability to meet most automotive requirements.

In conventional door, normal inner panel and bracket are two different parts. This method cost lots of money due to materials, dies, welding, assemblies, storage and logistic. By combining these two components into a single blank those difficulties can be reduce and allows automobiles to be manufactured more efficiently. As a result, a process called tailor welded blank has been developed and adapted by most automotive manufacturer nowadays. Not only door panel but also

2 others automotive panel employ this technique. So the aim of this study is to investigate whether the materials chosen are suitable for automotive door inner panel using the same concept of tailor welded blank.

1.2 Problem statements

i) The increasing demand for improved fuel efficiency and environmental concerns make the automotive industry to industry to design lighter cars for reduced fuel consumption.

ii) To reduce costs by using steels rather than highly cost alternative material.
J

1.3 Project Aim and Objectives

The aim of the project is to find the best joining materials for automotive door inner panel to be used in Tailor Welded Blank (TWB) technique. The objectives this study is to: i) To compare the specimens aft, fter investigation in finding the best result. ii) Propose new material combination to be applied in TWB process.

1.4

Project Scopes

This study will investigate on different type of material of joining by using automotive steel panel that are SPCC, SPCEN, SPHC, SGACC, and SAPH 370. The Panels grades are chosen from normal draw, extra draw, galvanized and structural steels that typically used in automotive fields. To imitate the actual TWB panels,

method of welding two small panels with different thicknesses and properties will be done. The testing will be done by using tensile test machine.

CHAPTER 2

LITERATURE REVIEW

2.1

Tailor Welded Blanks

Tailor welded blank, where multiple sheets of material are welded together prior to the forming process. The differences in the material within a TWB can be in the thickness, grade, or coating of the material (Kinsey and Cao, 2003).

Tailor Welded Blanks (TWB) are those in which sheets of different thickness and/or properties are joined by laser, seam or plasma welding before press forming (Anon, 2004).

Tailor-welded blanks (TWB) are comprised of two or more sheets of metal which has dissimilar strength or thickness that are welded into a single blank. Tailor Welded Blanks are stamped into automotive body panels and offer reduced part weight and improved material use (Anon, 2004).

A tailor welded blank is composed of more than two materials with similar or different strengths or thicknesses joined together to form a single part before the forming operation. The main advantage of using a TWB is that it gives thicker or stronger materials at critical parts of the sheet metal blank so as to increase the local stiffness. This can also reduce the weight of automotive panels (Anon, 2003).

5 Corer Am
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Frrri

MuIO
C,cfrponnb!rt PiI

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S^

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/
IRo1Q1rent

T/f
FIDDJ Pin <:Z2^

PANT Doc.r I,nc

,,..
From Doo r

Figure 2.1: Examples of typical use of Tailor Welded Blanks (Anon, 1995)

TW& D

tDnrfmnev - S(TWB) 2 DrOur- S&

3

4 R rner P& I
5 6 Frat Dwar I fuf i
(2) Scr (4)

Figure 2.2: Steel door with tailor welded inner panel (Anon, 1999)

Types of welds which are used or have been considered for Tailor Welded Blanks include: i) ii) iii) iv) Laser Beam Resistance Mash Seam High-Frequency Induction Electron Beam (non-vacuum)

(Anon, 1995)

ekft
L: ,d TYI P.r

r
.'.

.
C.

,'-:;

'c(

/4
tr bir,
Vep4h IWOr.om wsin;

2.
HIiiuc4iuu

buff roan y eld n

rmw CIO
,r \

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r) I

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Resiane roller moshiap seam weId1n

'Cuff

toflbEofl

Figure 2.3: Welding types used for Tailor Welded Blanks (Anon, 1995).

2.2

Automotive Panels There are many types of automotive panels depends on process, grades,

coatings and thicknesses. One of the main producers of the material is coming from Japan and Korea and also they are the main player in these industries. So, Japanese Industrial Standards (JIS) is chosen for material grading through this entire project.

7 2.2.1 Hot Rolled (BR) Steel Sheet

Steel sheets produced right after hot rolling processes are called Hot Rolled Steel Sheet. There are many types of Hot Rolled Steel Sheet for example SPHC, SPHD, SPHE, SPFH, SAPH and etc. The abbreviations stated are named according to Japanese Industrial Standard (JIS) grade. Come in various length, width and thicknesses according to manufacturers.

2.2.1.1SPHC

SPHC is defined as Hot Rolled Steel Sheet with Commercial Quality (CQ). This type of sheet is used for general purposes such as general forming and deep drawing process.

SPHC in Japanese Industrial Standard (JIS) are coded under: MS G 3131: 2005 - Hot rolled mild steel plates, sheets and strips.

Table 2.1: Mechanical properties and chemical composition of iTS 0 3131 hot rolled mild steel sheets and strips
Tensile Test Elongation, % Tensile Thickness Strength 1.2mmto N/mm2 1.6 mm excl. 0.050 max. 0.040 max. 270 min. 276 mim 270 min. 270 min. 27 min. 30,min. 31 mm. 37 min.

Designation

chemical Composition, % Mn r 0.05, 0 max. 0.040 max.

SPPC SPHD SPHE

0.15 max, U.lOmax, O.lOmax, 0.08 max.

060rax 050max,, 0.50 max. 0.6,0 max,

0.030 max. H 0.035 max. 002$max. 0.025 max.

SPHF

8 Table 2.2: Comparison of ills specification with similar standards JIS G3131 SPHC H-RoUed Mild G131 SPHD ASTM A569 A621 BS BS1449-HRI4 BS 1449-HR15 BS 1449 . HR3 (DIN) DIN 1614-StW22 ISO ISO 3573-HRi23.4 ISO 631 7-HR1,2 3.4

DIN 1614StW23 DIN 1614-StW24

Steel Sheets and Strip 03131 SPHE A822

BS 1449-HR4 BS 1449-HR1 BS 1449-HR2

2.2.1.2 SAPH 370

SAPH is defined as Hot Rolled Steel Sheet for Automobile Structural Uses. This type of steel is outstanding in strength, drawability and weldability that are used for automobile frame, wheels and other parts.

SAPH in Japanese Industrial Standard (JIS) are coded under: MS G 3113:2006 - Hot rolled steel plate, sheet and strip for automobile structural uses.

Table 2.3: Mechanical properties and chemical composition of ITS G 3113 hot rolled steel sheet and strip for automobile structural uses
Tensile Designation Chemical Composition, % Yield Point, N/mm 2 Thickness 6mmunder Test eongatlon. % Tensile Strength N/mm2 310 min. 370 min. 400 mm. 440 mm.

P SAPH310 SAPH370 SAPH400 SAPH440

0.040maxJ 0.040max. 0.040max.I 0.040max. 0.040 max. I 0.040 max. 0.040 max. 0.040 max.

I ThIckness 8mm lol4mmlnci. (185 min.) I (185mm.) I (175 min.) 225 min. I 225 min. I 215 min. I 235 mm. 255 mm. 235 mm. 305 mm. 1 295 mm. I 275 mm.
Thickness 6mm to8nirnexcl.

Thickness 1.6mm to 2.Ommexcl. 33 min. 32mm. 31 mm. 29 mm.

1
I

Thickness 2.0 mm to 2.Smmexcl. 34 min. 33 min. 32 mm. 30 mm.

2.2.2 Cold Rolled (CR) Steel Sheet

Steel sheets produced after cold rolling processes are called Cold Rolled Steel Sheet. There are many types of Cold Rolled Steel Sheet for example SPCC, SPCC-T, SPCD, SPCE, SPCEN, SPFC (ITS grade) and etc. These types of steel are applied to

various fields including automotives, electric household appliances, and furniture office equipment.

2.2.2.1 SPCC

SPCC defined as Cold Rolled Steel Sheet with Commercial Quality (CQ). These types of steel are best suited for automobiles, electrical appliances, etc due to wider workable range.

SPCC in Japanese Industrial Standard (JIS) is coded under: MS G 3141: 2005 Cold-reduced rolled carbon steel sheets and strips

2.2.2.2 SPCEN

SPCEN is defined as Cold Rolled Steel Sheet with Deep Drawing Quality (DDQ). These types of steel are best suited for automobiles, electrical appliances, etc due to wider workable range.

SPCEN in Japanese Industrial Standard (JTS) are coded same as SPCC: MS G 3141: 2005 - Cold-reduced rolled carbon steel sheets and strips

Table 2.4: Mechanical properties of JIS G 3141 cold rolled mild steel sheets and strips.
Test Type Classification Designation SPCC Commercial quality SPCCT Drawing quality SPCD SPCE Deep drawing quality SPCF Exbs-ep&awitogiatty SPCG or S,84, 2, 1 S. S S S Yes 0.25t
gt1n

Tension test reissis grisi- Elongation mm. % 0.25t 0.60t<1.0

(240) (220) (210) (190) 270 270S 270 270 270

36 38 40 42 44

Standard cold-rolled steel sheets and cots IJISG3141t _

lEll Table 2.5: Chemical composition of MS G 3141 cold rolled mild steel sheets and strips Designation SPCC SPCD SPCE
SPCF SPCG''

C 0.15 012
ZO.10 0.08 0.02

Mn 0.60 050
0.45 0.45 0.25

P 0.100 0040
0.030 0.030 0.020

S 0.050 0040
0.030 0.030 0.020

2.2.3 Blot Dip Galvanized Steel Sheet

Hot-dip galvanized steel sheets are produced by applying a coating of molten zinc to the surface of hot-rolled or cold-rolled base material by the "hot dip" galvanizing process. There are much type of grade for example SGAHC, SGACC, SGACD, and etc. Having an excellent corrosion resistance, these products are used in a wide range of fields such as automotive, electric appliance, and building material applications.

2.2.3.1 SGACC SGACC is defined as Hot Dip Galvanized Cold Roll Steel Sheet with Commercial Quality (CQ). This type of steel is use inner and outer panel of automobiles. Also use as fuel tanks.

SGACC in Japanese Industrial Standard (JTS) are coded under: MS G 3302: 2005 - Hot-dip zinc-coated steel sheets and coils

11 Table 2.6: Mechanical properties JIS G 3302 cold rolled hot-dip galvanized
Elongation

Classification

Thickness mm --.

Yield Point . mm. KglrrO -

Tensile Strength .

________
28 28 28 28

Kg/m2

mm.

...... 0.4026and
over, under 0.60

mm 11602$and over, under 1_0 1.025and Over, under 1.6

SGCC SGCD1 9GCD2 SGCD3 si:

:. 34 35 38 .38

....,

35 38 40 37 39 41 41

.: ..

. .... .,

...1.J .

40

Table 2.7: Comparison of JIS specification with similar standards

Classification /Standards Commarciat Lock forming Drawing Deepdrawing Non Aging Deep Drawing Non Aging Extra Deep Drawing STM 03302 SGCC SGCDI SGCO2 SGCO3 SOCO 3M . 89 A526 4527 4528 4542
A653-CQ EN10142

DX51D 0X52D DX53D 0X54D

4653-LEO AL 653-DQ A653-DOSK

2.3 Laser-Beam Welding (LBW)

To produce a fusion weld, Laser-beam Welding utilizes a high-power laser beam as the source of heat. It has high energy density and, therefore, deeppenetrating capability because the beam can be focused onto a very small area. The beam can be directed, shaped, and focused precisely on the workpieces.

Laser-beam Welding creates good quality welds with minimum shrinkage and distortion. This type of welds have good strength and generally ductile and free of porosity. The process can be automated and can be used on a variety of materials thickness of up to 25mm (1 in.). It is particularly effective in thin workpices.

Laser welding techniques nowadays are highly developed resulting very strong weld joints. Significant flexibility in product design, structural stiffness, crash