fiber laser welding Archives

Microstructural Effects of Adding Colloidal Graphite to Al-Si-Coated PHS

Optimizing weld morphology and mechanical properties of

laser welded Al-Si coated 22MnB5 by surface application of

colloidal graphite

Researchers at University of Waterloo discovered the microstructural effects of adding colloidal graphite to Al-Si coated 22MnB5 Press Hardened Steel.^K-51 Laser welds were made on 1.5 mm thick Al-Si coated 22MnB5 PHS perpendicular to the rolling direction. Pure colloidal graphite suspended in isopropanol base was applied to the area being welded and the resulting graphite coating after evaporation ranged from 5 µm to 130 μm for testing. Parameters used for the weld are: 4kW power, 6m/min welding speed, beam diameter of 0.3 mm, and laser defocus of 6mm. Samples were then hot stamped by heating for 6 min to 930 ᵒC in a furnace and then water quenched at a cooling rate greater than 30 ᵒC/s.

Al-Si coating is excellent at preventing oxidation and decarburization of high strength steel at elevated temperatures. However, during welding there is diffusion of Al into the fusion zone which stabilizes ferrite at elevated temperature reducing the strength of the welded joint. Colloidal graphite coating decreases the Al content and increases C content of the fusion zone. As shown in Figure 1, The mechanism for reduction in Al content is due the graphite coating acting as an insulator to the Al-Si coating which then causes an ejection of the molten Al-Si coating from the surface. Figure 2 displays a proportional reduction of Al in the fusion zone with increasing graphite coating thickness up to 40 μm where after the reduction in Al is minimal. This is attributed to the initial reduction of Al being caused by the ejection of the molten Al-Si from underneath the graphite coating. Graphite coating greater than 40 µm does not aid in additional ejection of Al-Si and the Al-Si coating already diluted in the weld pool will not be removed.

Figure 1: Al-Si ejection mechanism.^K-51

Figure 2: Al and C content in weld with increasing graphite thickness.^K-51

Summary

Ferrite concentration in the fusion zone was reduced from approx. 40% with no graphite coating to approx. 2% with 130 μm graphite coating thickness (Figure 3). The increase in C content and reduction in Al content resulted in an increase in austenite being stabilized at elevated temperature rather than ferrite and therefore a larger percentage of martensite results after hot stamping. The average fusion zone hardness increased from 320 HV with no coating to 540 HV with 130 μm coating thickness (Figure 4). The weld strength of the sample with no graphite coating was 1249±15MPa whereas the weld strength with a coating of 130 µm was 1561±7MPa which matches the base metal (Figure 5). With an increase in graphite coating thickness there is an increase in weld strength that can eventually match the base metal strength.

Figure 3: Ferrite concentration in weld.^K-51

Figure 4: Fusion Zone Hardness vs. Graphite Thickness.^K-51

Figure 5: Weld strength vs. Graphite Thickness.^K-51

Effect of GA Coating Weight on PHS

Joining, Laser Welding, Press Hardened Steels

This study^R-25, conducted by the Centre for Advanced Materials Joining, Department of Mechanical & Mechatronics Engineering, University of Waterloo, and ArcelorMittal Global Research, utilized 2mm thick 22MnB5 steel with three different coating thicknesses, given in Table 1. The fiber laser welder used 0.3mm core diameter, 0.6mm spot size, and 200mm beam focal length. The trials were done with a 25° head angle with no shielding gas but high pressure air was applied to protect optics. Welding passes were performed using 3-6kW power increasing by 1 kW and 8-22m/min welding speed increasing by 4m/min. Compared to the base metal composition of mostly ferrite with colonies of pearlite, laser welding created complete martensitic composition in the FZ and fully austenized HAZ while the ICHAZ contained martensite in the intergranular regions where austenization occurred.

Table 1: Galvanneal Coatings.^R-25

Figure 1: Base metal microstructure(P=pearlite, F=ferrite, Γ=Fe3Zn10, Γ1=Fe5Zn21 and δ=FeZn10)

Figure 1: Base metal microstructure(P=pearlite, F=ferrite, Γ=Fe₃Zn₁₀, Γ1=Fe₅Zn₂₁ and δ=FeZn₁₀).^R-25

Figure 2: Welded microstructure — (a) overall view, (b) HAZ, (c) ICHAZ at low and (d) high magnifications, (e) UCHAZ (f) FZ, and (g) coarse-lath martensitic structure (where M; martensite, P: pearlite, F: ferrite).^R-25

Given the lower boiling temperature of Zn at 900 °C as compared to Fe, the interaction of the laser with the Zn plasma that forms upon welding affects energy deliverance and depth of penetration. Lower coating weight of (100 g/m²) resulted in a larger process window as compared to (140 g/m²). Increased coating weight will reduce process window and need higher power and lower speeds in order to achieved proper penetration as shown in Figure 3 and Figure 4. Depth of penetration due to varying welding parameters was developed:

d=(H-8.6+0.08C)/(0.09C-4.8)

[d= depth of penetration(mm), H= heat input per unit thickness(J/mm²), C= coating weight(g/m²)]

Given the reduction in power deliverance, with an increase in coating weight there will be an expected drop in FZ and HAZ width. Regardless of the coating thickness, the HAZ maintained its hardness between BM and FZ. No direct correlation between coating thickness and YS, UTS, and elongation to fracture levels were observed. This is mainly due to the failure location being in the BM.

Figure 3: Process map of the welding window at coating weight of (a) 100 g/m2, (b) 120 g/m2, and (c) 140 g/m2.

Figure 3: Process map of the welding window at coating weight of (a) 100 g/m², (b) 120 g/m², and (c) 140 g/m².^R-25

Figure 4: Heat input per unit thickness vs depth of penetration.^R-25