NIST AHSS Workshop Joining Feng v3 Final PDF

Challenges and Opportunities
in Joining Advanced High

Strength Steels
Zhili Feng
Oak Ridge National Laboratory
Managed by UT-Battelle
for the Department of Energy
Challenges in Welding of AHSS

Higher carbon and alloying element contents make AHSS
more sensitive to the welding thermal cycle, resulting
greater variations of microstructures and properties of
weld
Microstructure and properties can highly depend on
welding conditions and steel chemistry
Welding practices developed for one types of AHSS may
not apply to other types
Weld quality
Weld structural performance (static, fatigue, impact/crash)
There are wide range of grades and types of AHSS and

they continue to evolve
2 Managed by UT-Battelle
Microstructural Gradient in a Boron Steel

Weld
Weld
Base Metal
Martensite in BM
CGHAZ
Martensite
Tempered Martensite
Below Ta1
Below Intercritical region
Intercritical region
Above Ta3
Tempered M
High % Ferrite +
Low % Martensite
GB Ferrite +
high % Martensite
Microhardness Mapping: Local strength

variation and HAZ Softening
Boron Steel, Hardened
HAZ Softening
Microhardness Map
Intercritical T
HAZ Softening is More Pronounced in

Higher Grade Steels
HSLA590
DP980
Hardened Boron Steel
Normalized Hv with respect to base metal Hv
Mechanism of HAZ Softening of AHSS

HAZ softening is primarily related to the
intercritical region
Supercritical region (above TA3)
Single austenite phase region
On-cooling, austenite decomposition to
low temperature phases depends on
hardenability (composition) of steel and
cooling rate
Intercritical region (between TA1 and TA3)

Co-existence of ferrite and austenite
Austenite decomposes
Ferrite will remain on cooling
Below TA1
Tempering of martiniste/bainite
Extent of HAZ soften depending on the

initial base metal microstructure &
hardness, steel chemistry and welding
thermal cycle
Static Tensile Failure Location Correlates

to HAZ Softening Region
DP980-5B, after tensile test
(DP980)
Static Joint Strength of GEN 1 AHSS

AHSS has higher weld strength (static and impact) than mild
steel, though with a deduction compared to base steel
Normalized Joint Strength (vs DR210)
4.8
4.5
Weld Tensile Strength
Actual BM Tensile Strength
Normalized Joint Strength
Normalized BM Strength
4.5
2500
4.0
3.5
2000
2.4
1500
1.8
1000
1.0
500
5.0
1.0
1.8
636 641
1.8
1.8
641 647
352 352
1.9
2.0
2.0
2.5
2.8
2.6
734 848
2.5
2.0
2.1
2.0
972
861 896
543
2.0
1593
1.5
693 690
3.0
2.4
1.6
577 654
2.8
721
986
714
1689
924
1.5
1.0
0.5
0.0
DR210
DP600
HDGI, A
DP600
HDGI, B
DP600
HSLA590
DP780
Steels
Boron, UHT
M130
DP980
M220
Boron, HT
Normalized Strength
Tensile Strength (MPa)
3000
Joint Efficiency: A Practical Design Index

Joint efficiency is proposed to quantify the reduced weld strength for
design
Cross weld tensile strength generally increases, as base metal strength
increases
Joint Efficiency
2500
120%
99%
100%
99%
2000
88%
96%
100%
87%
73%
80%
Weld Tensile Strength
1500
56%
Actual BM Tensile Strength
55%
Joint Efficiency
1000
60%
45%
1593
500
636 641
641 647
577 654
693 690
DP600
HDGI, A
DP600
HDGI, B
DP600
HSLA590
352 352
734
848
986
972
861 896
543
721
714
1689
924
40%
20%
0%
DR210
DP780
Boron, UHT
M130
DP980
M220
Steels
Joint efficiency = weld strength/BM strength

Boron, HT
Joint Efficiency
Tensile Strength (MPa)
100%
HAZ Softening Influences Impact

Behavior of AHSS Weld (5 to 25 mph)
DR210
DP780
Boron Steel
HAZ Softening in Resistance Spot Weld of

AHSS
Y, mm
2.0
500
1.5
1.0
335
0.5
0.0
0
170
X, mm
Boron
TRIP780
1mm
450
400
Weld nugget hardening
350
500
Microhardness (HV 500g)
Microhardness (HV500g)
600
300
HAZ softening
250
200
DP980
150
400
HAZ softening
300
200
Traverse
Basemetal
DP980 Base Metal
DP980
100
Boron steel
100
0
5
Distance (mm)
10
0
0
Distance (mm)
10
12
14
Effect of Weld Nugget Size on Joint

Strength
17000#
DP980#
Peak%Load%(N)%
15000#
Boron#
TRIP780#
13000#
11000#
9000#
7000#
5000#
3#
4#
4#
5#
5#
6#
Weld%Nugget%Size%(mm)%
Lap shear, 1-mm nominal thickness

6#
Failure Mode as Function of Fusion

Zone Size - DP800 Cross Tension
ln(Fusion Zone, mm)
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
2.0
99
1.0
80
0.0
60
40
-1.0
Interfacial Fracture - Small Weld
20
Interfacial Fracture - Nominal Weld
10
-2.0
Nugget Pull-Out - Nominal Weld
Nugget Pull-Out - Large Weld
2
4.0
5.0
6.0
7.0
8.0
9.0
10.0
Fusion Zone (mm)
15.0
.0
-3.0
-4.0
LnLn(1/(1 -F))
Failure Probability, F
95
90
Resistance Spot Welds

Failure mode changes from interfacial to button
pull-out as the weld nugget reaches a critical
size
Static strength and energy absorption of a spot
weld strongly depends on the nugget size
Fatigue of AHSS Welds

Recent studies by A/SP, DOE Lightweight Materials Program and
others have shown that, unlike the base metal case, welds of AHSS
do not exhibit appreciable increase in fatigue strength (i.e. weld
fatigue strength is insensitive to the steel type and grades of current
AHSS).
Down-gaging of AHSS for light-weighing would result in increase in
applied stresses in the weld region, and potentially shorten the
fatigue life and durability of body structures.
Fatigue performance of welded joints is a critical element in
durability because the likeliest fatigue failure location are often at
welds
Therefore, the use of AHSS for light-weighing must be accomplished
by approaches to improve the fatigue performance of the weld joint
(John Bonnen and R.M. Iyengar, 2006, Int. Auto. Body Congress).
Fatigue strength of AHSS weld is

insensitive to steel types and grades
GMAW fillet welds are shown; spot welds are similar
Boron
Annealed
DP600
DR210
Boron
Hardened
HSLA590
DP780
M130
103
Yan et al (SAE 2005)

104
105
M220
DP980
106
Feng et al (SAE 2009)
107
Fatigue Failure at Weld Root or Toe, Away

from HAZ Softening Region
2.0 mm DR210 uncoated-fatigue tested,

1,164,447 cycles at 1200/120 lbs
2.0 mm HSLA590 uncoated-fatigue tested,

749,637 cycles at 1200/120 lbs
2.0 mm DP600 uncoated-fatigue tested,

177,810 cycles at 1200/120 lbs

819,203 cycles at 1200/120 lbs

543,481 cycles at 1200/120 lbs
2.0 mm Boron heat treated uncoated-fatigue

tested, 106,413 cycles at 1200/120 lbs
Factors Governing Weld Fatigue Strength

Stress concentration due to weld geometry and
weld surface quality/discontinuity
SCF = 6-9 from FEM analysis for lap joint under
tensile loading
High tensile residual stresses at the weld toe

and other critical locations
Weld microstructure change (limited knowledge)
HAZ softening has minimal influence
Improve Weld Profile to Reduce Stress

Concentration
2.0 mm DP780 Bare, Baseline
2.0 mm DP980 Bare, Baseline
2.0 mm DP780 Bare, Improved
2.0 mm DP980 Bare, Improved
Fatigue Life Comparison
2.0mm HSLA 080 Bare Improv ed Welding Parameters

2.0mm DP780 Bare Improv ed Welding Parameters
2.0mm DP980 Bare Improv ed Welding Parameters
2.0mm Boron HT Bare Improv ed Welding Parameters
Nominal Stress Range (MPa)
300
200
100
Baseline Range
1000
103
10000
4
10
100000
5
10
Cycles to Failure
1000000
6
10
10000000
7
10
Improve Weld Fatigue Life through Surface

Residual Stress Control
Post-weld surface residual stress modification
Principle: by means of surface plastic deformation

Laser shot peening, Sand blasting/peening, Low plasticity
burnishing
In-process residual stress control
Principle: control and alter the normal thermal

expansion/contraction sequence of welding
In-process proactive thermomechanical management
Special weld filler metal by means of low-temperature phase
transformation
Others
Post-weld heat treatment

Mechanical stretching
Fatigue Life Improvement by Surface

Residual Stress Modification
Example: Laser shock peening of friction stir weld of Al7075
for aerospace applications (NASA, Hatamleh, et al 2006)
Benefit of Compressive Surface Residual

Stress
Low Plasticity Burnishing (Hornbach et al)
Work in Japan Demonstrating the

Effectiveness of LTPT on fatigue life)
(Ohta et al, Welding in the World, 2000)
Integrated Model to Predict Welding Effects on

AHSS Microstructure & Performance
Weld Performance
Properties
Welding Process
& Parameters
Thermal
History
Process Model
Structural
Model
Microstructural
Model
Experiments
Weldment
Microstructure
Structure-Property
Relation
Choose appropriate individual models for each physical process, and integrate them
Generally adopted for many welding processes
Many individual models are already available
Integrated thermal-metallurgicalmechanical modeling of AHSS welds

Capable of predicting HAZ softening and other microstructural changes
Boron HT
Resistance Spot Welding: Process to

Crash Performance
Global:
Crash performance of
Multi-welds component
Local:
weld process and
property modeling
I, F
Robust
Spot Weld Element
(SWE)
400
3
Y, mm
350
2
300
250
200
0
0
10
X, mm
Microstructure & property

details of a single weld
Resistance Spot Welding: Process to

Crash Performance
Incrementally coupled electric-thermal

mechanical-metallurgical model to predict
weld microstructure and properties as function
of steel chemistry and welding conditions.
Special spot weld element formulation

incorporating effect of weld properties and
weld geometry allowing for robust crash
simulations of welded structures
I, F
Nugget core
(RIGID)
HAZ
1
Base
metal
Interfacial failure
Button pullout failure
Integrated Model for FSW of Al Alloys

Integrated multi-physics simulations provide realistic prediction of failure and
insights to the performance of Al 6061 friction stir welds
Arbitrary LagrangianEulerian (ALE) finite

element mode predicts
weld defect formation
under conditions.
Hardness
Temperature
Predicted void location!
Failure Under Loading!
Void in actual weld!
55!
Residual
Stress
Weld !
Centerline!
As load increases
Strain field before

tensile test
Strain Localization
Failure line in HAZ!
55!
Actual weld!
Necking
& Failure
Weld modeling
Considerable progress in developing integrated
weld process and performance modeling in the past
decades or so
Some remaining issues
More fundamental understanding and accurate prediction

of non-equilibrium phase transformation processes during
welding
More accurate failure/fracture prediction under complex
microstructure gradient in the weld region
In-Situ Neutron Experiment Study of NonEquilibrium Steel Phase Transformation Relevant

to Welding
Programmable thermo-mechanical device

Incident Beam
Collimators
Fast resistive heating of high strength steel in a controlled atmosphere box at SNS VULCAN
Heated Sample
DP980 Complete heating and cooling cycle

Significant Achievement: Direct measurement with 1 sec time resolution (@ 3C/s). A
first for such type of in-situ neutron experiment.
Cooling
Sample was heated up to 1050C at 3C/s, and then cooled down in argon gas
atmosphere to room temperature.
1050C
Heating
fcc
bcc
No retained austenite (fcc) after heating.

Effect of Heating Rate on Phase

Transformation in DP980
T=126.5C
T=147.7C
3C/s
Ferrite
Austenite
30C/s
Ferrite
Austenite
Boltzmann Fit of Sheet1 VfBoltzmann Fit of Sheet1 VfBoltzmann Fit of Book2_P
Boltzmann Fit of Book2_Q1
% (9,@LG)
% (10,@LG)
1.0
0.9
0.8
Vol. Fraction
0.7
(bcc)
0.6
30C/s
3C/s
0.5
0.4
(fcc)
0.3
0.2
0.1
0.0
720
740
760
780
800
820
840
860
880
900
Temp
Two-step phase transformation at 3C/s.
Q&P Steel (3C/s heating, complete thermal

cycle)
Observation of Retained Austenite after heating cycle
1050C
bcc
fcc
Joining AHSS with Other Materials

Material Combination
Steel to Al
Steel to Mg
Steel Grade
Material Stacks
Surface Requirement
Bonding Mechanism
Lap shear strength (N)
Steel to Al
Steel to Mg
Z load (N)
Process Time (sec)
Weld bonding
Comsumable Bit
Cost
Nonconsumerable Tool
FBJ
SPR
FSSW
Ultrasonic
yes
yes
All AHSS
2T, 3T
no restriction
yes
difficult
up to DP780
2T, 3T
no restriction
coated steel
TBD
All AHSS
2T
Zn coating
Metallurgical +
Mechnical
Mechanical
coated steel
TBD
All AHSS
2T
Zn coating
Brazing or
Metallurgical +
Mechanical
6300 - 8100
~5400
~ 9000
1.5 - 2
Feasible
Yes
SPR comparable
5000 - 5500
cracking
20,000 or higher
<1
yes
Yes
low
Cost
Machine cost
2500 - 3500
TBD
TBD
<4
Difficult
~3000
TBD
Low
~2
Difficult
Yes
Yes
High (specialty
alloy)
Potentially high
(high power)
Low (tool steel)

comparable
comparable
Brazing, or
metallurgical
comparable
Summary: Joining of AHSS

Challenges and Opportunities
Fundamental understanding and predictive capability
to quantify the effects of welding and service loading
on the structural performance of welded AHSS autobody parts;
Design guidelines and weld performance data to
assist rapid structure design and prototyping, CAE
model for weld structure performance design;
Welding techniques and practices to improve
structural performance of AHSS welded auto body
components

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Challenges and Opportunities

in Joining Advanced High

Challenges in Welding of AHSS

There are wide range of grades and types of AHSS and

Microstructural Gradient in a Boron Steel

Microhardness Mapping: Local strength

Boron Steel, Hardened

HAZ Softening is More Pronounced in

Hardened Boron Steel

Normalized Hv with respect to base metal Hv

Mechanism of HAZ Softening of AHSS

Intercritical region (between TA1 and TA3)

Extent of HAZ soften depending on the

Static Tensile Failure Location Correlates

Static Joint Strength of GEN 1 AHSS

Weld Tensile Strength

Actual BM Tensile Strength

Normalized Joint Strength

Tensile Strength (MPa)

Joint Efficiency: A Practical Design Index

Weld Tensile Strength

Actual BM Tensile Strength

Joint efficiency = weld strength/BM strength

Tensile Strength (MPa)

HAZ Softening Influences Impact

HAZ Softening in Resistance Spot Weld of

Weld nugget hardening

Microhardness (HV 500g)

DP980 Base Metal

Effect of Weld Nugget Size on Joint

Lap shear, 1-mm nominal thickness

Failure Mode as Function of Fusion

Interfacial Fracture - Nominal Weld

Nugget Pull-Out - Nominal Weld

Nugget Pull-Out - Large Weld

Fusion Zone (mm)

Resistance Spot Welds

Fatigue of AHSS Welds

Fatigue strength of AHSS weld is

Yan et al (SAE 2005)

Feng et al (SAE 2009)

Fatigue Failure at Weld Root or Toe, Away

2.0 mm DR210 uncoated-fatigue tested,

2.0 mm HSLA590 uncoated-fatigue tested,

2.0 mm DP600 uncoated-fatigue tested,

2.0 mm DP780 uncoated-fatigue tested,

2.0 mm DP980 uncoated-fatigue tested,

2.0 mm Boron heat treated uncoated-fatigue

Factors Governing Weld Fatigue Strength

High tensile residual stresses at the weld toe

Improve Weld Profile to Reduce Stress

2.0 mm DP780 Bare, Baseline

2.0 mm DP980 Bare, Baseline

2.0 mm DP780 Bare, Improved

2.0 mm DP980 Bare, Improved

Fatigue Life Comparison

2.0mm HSLA 080 Bare Improv ed Welding Parameters

Nominal Stress Range (MPa)

Improve Weld Fatigue Life through Surface

Principle: by means of surface plastic deformation

In-process residual stress control

Principle: control and alter the normal thermal