R E S E A R C H

R E P O R T

MAG-welding of Zn-coated steel, a continued process study

Linus Gemvik

IM-2001- 046 Open

Swedish Institute for Metals Research ! Drottning Kristinas vg 48, S-114 28 Stockholm Tel. +46 (0)8-440 48 00 ! Fax +46 (0)8-440 45 35 ! E-mail info@simr.se ! www.simr.se MAG-welding of Zn-coated steel, a continued process study Author: Linus Gemvik Report No: IM-2001- 046 ISRN: SIMR/R -- 01/079 -- SE ISSN: 1403-848/X Print: Novum Grafiska, Stockholm 2001

Abstract
Arc welding of hot dip zinc-coated steel sheets faces a number of challenges, such as minimising the generation of spatter and porosity. These problems are caused by zinc being vaporised during the welding process. In an earlier SIMR-JTC (Swedish Institute for Metals Research - Joining Technology Centre) project, these problems were focused on to seek ways to improve the weldability. This report is a master thesis covering a continuing project on improved weldability for Zn-coated steels. The report also includes a literature study of MIG-brazing, as an alternative to MAG-welding. In addition, an attempt was made to identify key parameters for indicating suitable filler materials for welding of Zn-coated steels. Welding trials were performed on lap joints with zero gap between the plates as this is considered to be the most difficult task to manage (vaporised Zn is trapped which causes heavy arc disturbances). The welding in this project was performed in an improved fixture to maintain the zero-gap during welding. It resulted in slightly narrowed tolerances for the process, compared to the results from the earlier project. Two Zn-coating thicknesses were used, 7 m and 20 m (double-sided, Z100 and Z275). The quality of the weldments was compared to the demands in Volvo Corporate Standard 5605,515. In this work, a further evaluation of welding with solid filler materials has been performed. The results show that if the chemical composition of a solid wire is more adapted to the task of welding coated steels, it can improve the process stability and the surface conditions of a weldment. The internal porosity level remains high, however, and the process tolerances are still rather limited. The best results in these tests were achieved with thin wires and a low heat input. In the project, a number of cored wires were also investigated. Some of these were specially developed for welding of coated steels. With cored wire welding, it was possible to fulfil the demands in the Volvo Standard. Furthermore, the process ranges were much wider compared to solid wire welding. With the above mentioned methodology, an acceptably low level of internal porosity has only been achieved with cored wires. In this project, the metal cored wires gave good results on 7 m Zn-coatings. Here, the internal porosity was low and the welding was performed with very low spatter levels. With specially designated flux cored wires, both 7 m and 20 m Zn-coatings could be welded with good results. A remaining problem for the flux-cored wires is some (small) spatter and surface slags. The amount varies from case to case.

Table of Contents
1. 2. 3. Introduction ................................................................................................... 7 Objectives ...................................................................................................... 7 Literature study ............................................................................................. 7

3.1 MAG- welding of Zn-coated steel ................................................................................................... 7 3.1.1 Background................................................................................................................................ 7 3.1.2 Spatter........................................................................................................................................ 8 3.1.3 Pores .......................................................................................................................................... 8 3.1.4 Conclusions - literature study on MAG-welding....................................................................... 9 3.2 MIG/GMA-brazing of galvanised sheet in lap joints. .................................................................... 9 3.2.1 Brazing in general...................................................................................................................... 9 3.2.2 The two types of semiautomatic brazing methods of interest:................................................. 11 3.2.3 Conclusions - literature study on MIG/MAG brazing ............................................................. 12

4.
4.1

The MAG welding equipment ..................................................................... 12

Fixture .............................................................................................................................................. 13

5.
5.1

Materials....................................................................................................... 14
Base materials.................................................................................................................................. 14

5.2 Filler materials ................................................................................................................................ 15 5.2.1 Type 1 - Solid wires (sw): ....................................................................................................... 15 5.2.2 Type 2 - Metal cored wires (mcw): ......................................................................................... 15 5.2.3 Type 3 - Flux cored wires (fcw): ............................................................................................. 15

6.
6.1

Experimental................................................................................................ 16
Pre-study: bead-on plate tests ........................................................................................................ 16

6.2 Welding trials Zn-coated steel in lap joints................................................................................... 16 6.2.1 Welding on 7 m coating ........................................................................................................ 17 6.2.2 Welding 20 m coating ........................................................................................................... 17

7.
7.1

Results ......................................................................................................... 17
Pre-study: bead-on plate tests ........................................................................................................ 17

7.2 Welding Zn-coated steel in lap joints ............................................................................................ 17 7.2.1 Overview of welding trial results............................................................................................. 18 7.2.2 X-ray examinations.................................................................................................................. 18 7.2.3 Welding 7 m Zn-coated lap joints ......................................................................................... 19 7.2.4 Welding 20m Zn-coated lap joints ........................................................................................ 21

8.

Discussion ................................................................................................... 22
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9.

Conclusions................................................................................................. 24

10. Future research ........................................................................................... 24 11. Acknowledgements .................................................................................... 25 12. References................................................................................................... 25 13. Enclosures................................................................................................... 27

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1.

Introduction

Requirements for an improved corrosion resistance have led to an increasing fabrication with zinc-coated steels. The zinc-coated steel has shown excellent corrosion properties, but MAG-welding (Metal Active Gas) of these galvanised steels faces a number of problems. In this report, large parts of the second project are covered where these welding problems were studied. The two main topics consists of an attempt to identify possible key factors for an acceptable weld, and to further test possible MAG-electrodes for welding on steel with 7 m and 20 m hot-dip galvanised Zn-coatings. During MAG welding of zinc-coated steel, the zinc vaporises and forms bubbles in the weld pool. This readily leads to various types of voids. The zinc vapour also causes arc instability and increases the spatter and fume levels. The root cause of the whole problem is that zinc has a boiling point far below the weld pool temperature and the Zn-vapour expands to a much greater volume forming bubbles in the weld pool or disturbing the arc depending on the location of the zinc. This problem is much greater for 20m than for 7m-coatings. A possible way to solve these problems when joining Zn-coated steels could be to use brazing, as this generates less heat and also affects the Zn-coating less. A literature study of brazing is therefore included in this project as a comparison to welding.

2.

Objectives
To further examine and to verify data from an earlier project regarding welding of Zncoated steel sheets (lap joints with zero-gap between the plates). To develop an improved fixture for the welding trials. To search for new alternative welding process solutions for joining Zn-coated steels. To give recommendations, on basis of the results, for how MAG-welding is to be carried out in the best way.

3.

Literature study

A literature study was based on the work already made in the earlier MAG-welding of Zncoated steel- project, but more recent material and a deeper study of MIG/GMA-brazing, as an alternative to welding was included.

3.1

MAG- welding of Zn-coated steel

3.1.1 Background During MAG welding of galvanised steel, the zinc vaporises and forms bubbles in the weld pool. These bubbles lead to voids in the weld, that generally are grouped in blowholes and
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pits. The pits are surface breaking defects in the form of craters (if they are large) or ordinary surface breaking pores. Blowholes are non-visible defects in the material, i.e. internal pores and wormholes (a long dragged out cavity) created by the expanding zinc vapour. Pits can be a starting area for corrosion attacks and fatigue cracking, while too many or too large blowholes can lower the strength of the joint. The zinc vapour also disturbs the welding arc, causing arc instability and increases the spatter and fume levels. The spatter may damage the zinc coating and create an area where corrosion can start. Spatter may also stick to the nozzle of the welding gun, which can lead to blowholes formed by air entrapment due to a bad gas shielding, as well as disturbed wire feeding. [1, 2, 3, 5]. 3.1.2 Spatter Spatter during MAG welding of zinc coated steel is a common problem. It is caused by the differences in temperature between the welding arc (2000C) and the vaporisation temperature of the zinc (906C). When welding, the zinc under and near the arc is vaporised and it increases enormously in volume. This results in an agitated beam and an unstable arc, which causes spattering. There are, however, some possible ways to reduce the amount of spatter. [3, 5, 6]. The spatter generation trends described in [5] indicate that it is advantageous to promote vaporisation of zinc in front of the weld pool as a means to reduce spatter. The spatter generated in proportion to the consumed wire is the spatter generation rate. The spatter generation rate is claimed to decrease with decreasing welding speed. Since the thermal conductivity is constant this is considered to be due to the fact that with a decreasing welding speed, the high temperature zone (above the boiling point of the zinc) in front of the weld pool spreads. This causes more zinc to be vaporised. The spatter generation rate also decreases under higher welding current conditions due to arc spreading, which heats up more zinc located further forward. In addition, the weld pool is pressed further down due to the increased arc force, increasing the distance between the zinc layer in front of the weld pool that is to be vaporised and the weld pool itself, thus vaporising more of the zinc before reaching it. To reduce spatter, one could seek a higher- speed and higher-current welding condition [4]. An alternative is to reduce the welding speed. The amount of spatter may also decrease with a thinner wire [5, 20] or thinner Zn-coating [20]. 3.1.3 Pores The amount of gas pocket generation (pores and wormholes) depends on: The heat input: higher heat input melts and evaporates a larger part of the Zn-coating. (A high heat input will also, however, decrease the solidification rate of the weldment). The welding speed: a higher weld speed reduces the time for the zinc to evaporate in front of the weld pool (but at the same time, less zinc can be affected) The solidification rate of the weldment affects the amount of zinc gas bubbles that are enabled to rise through the weld pool. The joint geometry (gap or evacuation zones for the evaporated zinc) The thickness of the zinc coating, a thicker coating can result in more problems. [1, 5, 7]

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3.1.4

Conclusions - literature study on MAG-welding

Main problems: The vaporised zinc from the coating causes problems of two kinds: 1. The immediately vaporised zinc disturbs the arc when it passes (this is especially the case for lap joints), which causes spatter, or, in some cases, an incomplete weld. 2. The molten zinc in the weld pool can also be vaporised. As the vaporisation temperature of zinc is lower than the melting point of steel, this causes bubbles of zinc vapour to form and rise through the weld pool. This can result in pores (both internal and surface breaking), and, in the worst case, wormholes and craters in the weldment. Possible solutions: Problem 1: Do not use zero gap width between the plates (this is, however, not always a possible option), since the zinc vapour is allowed to escape [3]. Use forehand welding gun angles (the electrode pointing in the travel direction), to burn away zinc in front of the molten pool [1]. Optimise the process parameters in order to get a more stable metal transfer in the arc (inductance, stickout, welding speed, voltage, wire feed, gun angles, gas type and gas flow) [7]. Problem 2: Select a specialised electrode with stable arc characteristics and a possibility to take care of the zinc (i.e. zinc vapour is propagated through the weld pool, or with some chemical solution to the problem) [1]. Make a hot weld with high heat input and slow welding speed. This will burn away a lot of zinc in front of the weld pool. It will unfortunately also effectively destroy the zinc coating close to the weldment and underneath (the opposite side) [8]. Make a cold weld with low heat input in order to disturb as little of the zinc coating as possible (a narrow HAZ). This results in a lower amount of zinc that needs to propagate through the weld pool and also leaves more of the zinc coating intact. The problem here is to secure the weld penetration and the sidewall fusion, as well as a stable enough metal transfer. Also, the internal porosity level needs examination [7].

3.2

MIG/GMA-brazing of galvanised sheet in lap joints.

Figure 1.Brazed single lap joint.

3.2.1

Brazing in general

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Brazing in comparison to welding: According to [9, 10, 11, 12] the following comparisons can be made: Brazing can be a faster process than welding. Less post-treatment is required after brazing. There is a possibility to maintain the Zn-coating almost undamaged (if the brazing is done properly). Different materials can be joined with brazing, including some that are not weldable. Less heat is applied in brazing (more sensitive materials can be brazed). Wetting without melting of the base metal when brazing. The seam and nearby material are protected from corrosion by the cathode-effect from the adjacent Zn-coating (working range: up to approx. 2 mm away). It is possible to get a stronger or at least as strong a seam from brazing [13]. Joining of very thin sheets is possible with brazing. High demands on tolerances for the gap (brazing) can result in higher costs. Brazing filler materials are in general more expensive than welding filler materials (Cu-based wire or Ag-based wire). It is possible to join materials with large gaps (gap bridging), although with a risk for a significantly reduced strength in the joint [10], [8]. Reported brazing problems: Soldering cracks can appear in reformed regions [10]. Vaporised zinc can disturb the arc. Incomplete wetting can result in a faulty joint [14]. Criteria for successful brazing of lap-joints: The length of the overlap (measuring the penetration of the filler between the plates) should be greater than a critical value Lcrit in order to get a joint that is stronger than the base material (it breaks in the sheet during tensile testing, not in the brazed joint). A consideration should be taken, however, to the fact that the brazing and the joint itself could lower the strength of the joint. Stress concentrations and changes in the base metal due to the temperature during brazing (this depends on the heat-sensitivity of the material in the sheets) causes this [8, 10, 14]. In order to avoid peeling of the joint, the design should minimise stress-concentrations near the brazed joint as much as possible. One method is to make the ends of the sheets thinner (at the edge near the brazing) if the brazing seam itself is not enough to make a smooth transition in the joint. But the overlap should then be slightly longer to compensate for the reduced tensile strength in the joined sheets [8, 10, 12]. Tests done on SAE 1010 mild steel with the filler BAG-1 using a gas torch, shows that Lcrit is near 2 * tmin (the thinnest sheet) for failure in the base metal. In order to be sure, however, one should use a minimum length greater than this. Set L to 3 * tmin - this also seems to give a slight increase of the tensile strength [10]. Tensile test failures should occur in the base metal instead of in the GMA-brazed joint [9]. The gap in the joint is important and its width depends on which filler is used. The filler needs to be drawn into the gap by capillary forces during brazing. Each material has a different viscosity and has to have a different gap-width to penetrate successfully. The important measurement is the gap width at the brazing temperature. To calculate the gap before brazing, the heat expansion of the sheets is needed [8, 15].

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If the gap is too wide, the joint becomes weaker as the capillary forces get weaker and sufficient filler material cannot be drawn into the gap, resulting in an inferior joint. The joint is also subjected to both shear- and bending-stresses (in a properly designed thin joint, the filler is only subjected to shear). If, on the other hand, the gap is too narrow the penetration will not be complete because the filler cannot flow into it, resulting in a weaker joint [16]. Strong fillers could protect the joint against this, but only to a limited extent (as the filler material is weaker than the base material). It is therefore important that the gap is of the right size span in combination with a filler that easily penetrates the joint [8, 15].

Filler material selection: In order to maintain the zinc coating undamaged, it is important to use as low heat input as possible. The zinc vaporises at 907C and the coating is destroyed fast when the temperature exceeds this level. This amounts to the choice of an easily melted filler which still has some material strength, possibly with the ability to form brass together with zinc. The possible fillers are Cu-based and Ag-based alloys. Although silver is more expensive than copper, its melting point is lower than 907C which is beneficial for Zn-coatings. Even so, the Cu-based fillers are usually recommended in literature for the brazing of Zncoatings due to the higher material strength [9].
Table 1. Material data: based on [15]

Type of filler material: Cu-based Ag-based

melting point of filler material (C) 800 - 1100 600 - 950

Typical gaps when brazing lap joints Torch brazing: about 0,0 - 0,2 mm 0,05-0,15 mm MIG/GMA brazing: about 0 - 2mm -unknown-

The MIG/GMA-Brazing process does not need strict gap tolerances for a successful filling of the joint. Gaps of 0 2 mm can be handled with retained strength according to ESAB [17], and some oil on the plates is also acceptable. (This could be due to the effect of the arc force in combination with the wire feeding in this type of brazing.) 3.2.2 The two types of semiautomatic brazing methods of interest: 1. MIG-brazing (Metal Inert Gas) which means a semiautomatic process that uses a wire feeding in the same way as in MIG-welding (the same type of equipment is used). The temperature is lower and only the filler material is melted. For protection against oxidation of the molten pool, pure argon is used as shielding gas. 2. GMA-brazing differs from MIG-brazing in regard to the shielding gas used, which in this case can be different gas mixtures (not only inert gas). The shielding gas can for example be a mix of argon + 1% oxygen to increase the fluid flow capacity. For GMA-brazing, ESAB recommends [9] that the wire OK Autrod 19.30 (DIN- 1733: SG-CuSi3) is to be used together with Ar + 1% O2. Other copper-based wires can, however, also be used. The addition of Si is to hinder the forming of the brittle oxide Cu2O when using a partly active shielding gas. A pulsed arc is advantageous (it keeps the amount of heat input to a minimum so more of the zinc coating will remain). A forehand brazing gun angle is also beneficial; the melted filler is then pushed forward and into the gap. The galvanised sheet can be brazed without cleaning fluxes.

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Demands on the equipment when using Pulsed-Arc: The process must be stable when using a low background current. It must be able to work with an extremely short arc without short-circuiting (zincvapour will otherwise disturb the arc). The slope on the pulse-current needs to be steep. High precision in the process control is needed to avoid spatter (to avoid peaks). Tensile strength: The studied material [3, 9, 10, 13], show that the tensile strength of the GMA-brazed joint when joining galvanised thin sheet steel can be stronger than the base metal (when the gap is thin enough to only be affected by shear stresses). Comparative tests [9, 13] have shown that a brazed joint can also be stronger than a welded joint. Here, it was shown that OK Autrod 19.30 with Rp0.2 ~160 N/mm had joint strengths higher than 350 N/mm (the specimens fractured in the unaffected base material). As it is useful to be able to join sheets with large gaps (> 2 mm), this is also possible with brazing but in this case with a greatly reduced strength as the joint is subjected to both shear and bending stresses. Further, the capillary forces cannot completely draw the filler material into the gap, which is the most important factor to achieve a strong joint. 3.2.3 Conclusions - literature study on MIG/MAG brazing It is possible to make a brazed joint that is stronger than the base metal [13, 17]. The methodology and the process demands are slightly different when compared to welding [9]. The size of the gap is very important for the tensile strength of the joint as it regulates how much filler that can enter into the joint, and the type of stresses created by external loading [8, 10]. The MIG/GMA-processes can use gaps (about 0 2 mm) without a reduction of the strength of the joint [17]. The sheets should have an overlap of at least 3 times the thickness of the thinnest sheet [10]. In some cases, brazing can compete with welding as the joining speed is faster and less post-treatment is needed. Good results are also achieved regarding the corrosion resistance (more of the Zn-coating remains) [9].

4.

The MAG welding equipment

All the welding tests were performed in the SIMR Joining Lab with the ESAB CAB 460 multi-process welding equipment for mechanised welding, see Figure 2.

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Figure 2. ESAB CAB 460 multi-process welding equipment for mechanised welding.

This machine was equipped with an ESAB LUD 450W Aristo power source and a MEK 4C wire-feeding unit. The welding gun used was an ESAB PSF 502W.

4.1

Fixture

In Figure 3, the plate fixture from the previous project is shown (left). It had no air gap under the weld zone. This created a high cooling possibility for the weld pool, which was undesirable. Also, the size of the gap along the joint could not be guaranteed to be zero at all times. The new fixture (right) was an improvement on both accounts.

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Figure 3. The old fixture with too high cooling and traditional clamping of the plates.

Figure 4.The new fixture with improved fixturing of the plates and air gap under the weld region.

5.
5.1

Materials
Base materials

Both sheet steels from the previous project, and new material, were used. All material batches were delivered from SSAB Tunnplt AB. For the chemical analysis, see Enclosure 5.

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Table 2. Mechanical properties, new batch.

Material DOGAL B5001 DOGAL B500 Material DOGAL 800 DP DOGAL B500

Thickness 2 mm 2 mm Thickness 2 mm 2 mm

Zinc coating 20 m 7 m Zinc coating 7 m 20 m

RP02 301 MPa 301 MPa Rp0.2 N/mm2 552* 301*

Rm 374 MPa 374 MPa Rm N/mm2 866* 363* A50 % 17* 35*

A50 47 % 47 % A80 % 16* 31*

Table 3. Mechanical properties, old batch.

*Measured values (this batch).

5.2

Filler materials

5.2.1 Type 1 - Solid wires (sw): A solid wire is the most common type of wire. Here, it is a homogenous C-Mn steel wire with some extra alloy elements added. 1. OK AUTROD 12.51 (ESAB) 1,0 mm.- our reference material, an ordinary wire for low and unalloyed C-Mn steels, the main alloy elements are Si and Mn. Yield strength 490 MPa. Also, 0,8 mm was evaluated to compare the influence of the wire diameter. 2. P5800 Zircobond (Svenska Elektrod) 0,8 mm.- A wire made for repair welding, Zn-coated and primer coated surfaces (according to the manufacturer). This wire is mainly alloyed with Si, Mn, Cu, and Ti. Yield strength 450 MPa. 3. INE Galvawire (Migatronic) 0,8 mm.- A wire made for welding Zn- and Al-coated or primed surfaces (according to the manufacturer). Alloyed with relatively small quantities Si so that later galvanisation is possible, the wire is also alloyed with Mn, Ti, Al, Zr. Yield strength 480 MPa. 4. Nertalic-Zn (SAF/Air Liquide) 1,0 mm. This wire is made for welding of Electrogalvanised (Zn) and hot dipped galvanised steels with good results (according to the manufacturer). Alloyed with Mn, Si, Ti and Al. Yield strength 470 MPa. 5.2.2 Type 2 - Metal cored wires (mcw): A cored wire consists of a steel tube with a powder filling. In this case, the filling is mainly metal powder and some arc stabilising elements. 1. PZ 61.05R (ESAB) 1,4 mm. Yield strength 420 MPa. 2. PZ 61.02 (ESAB) 1,2 mm. Yield strength 460 MPa. 5.2.3 Type 3 - Flux cored wires (fcw): A cored wire with special additives such as fluxes, metal powder, and arc stabilising elements. In the case of self-shielded wires, there are also additives to create a gas shield. 1. SAFDUAL-Zn (SAF/Air Liquide) 1,0 mm. A wire made for welding galvanised, Zn-coated and primer coated or painted thin steel sheets (0,8 4 mm). Mainly alloyed
1

DOGAL is a registered trademark of SSAB Tunnplt AB. - 15 -

with aluminium and must therefore be readily mixed with the base material in the weld pool (analysis of the welding fumes show some Ba and Mg). Since the Al-content is high, the wire is recommended for single pass welding only. This wire is to be welded with shielding gas (M21) and reversed polarity. Yield strength 470 MPa. 2. ETC-Zn (Allkommers) 1,0 mm This wire turned out to be identical to SAFDUAL-Zn (apparently they are manufactured in the same factory, it behaves identically during welding and the catalogue data are identical. The yield strength is 470 MPa. 3. Lincoln Innershield NR-152 (Lincoln Sverige) 1,6 mm This is a self-shielding wire (needs no shielding gas), suitable for welding of galvanised or Zn-coated steel sheet. The yield strength is 500 MPa. 4. OK TUBROD 14.16 (ESAB) 0,8 mm- This is a self-shielding wire (no shielding gas), suitable for welding of unalloyed, galvanised or Zn-coated steel sheets. It was only possible to weld with spray arc. The tensile strength is 500 MPa.

6.
6.1

Experimental
Pre-study: bead-on plate tests

The experimental part of this project began with an attempt to rank the different filler materials by welding on uncoated steel (4 mm thick) bead on plate. The idea was based on an article on surface tension and porosity [18]. Here, a G-parameter was used to classify the filler materials characteristics. The G-parameter is modified, compared to the Gammaparameter in the article. For further details, see Enclosure 1.

6.2

Welding trials Zn-coated steel in lap joints

In the welding trials the weld quality was compared to the VOLVO Standard 5605,515
Table 4. Overview of welding trials.

Type of welding: 7 m coating Solid wires using low heat input and high X weld speed. Solid wires using high heat input. ----Metal cored wires using low heat input. Metal cored wires using high heat input. Flux cored wires using recommended settings. X X X

20 m coating Aim/Comments: Optimise the welding parameters. X X X Optimise the welding parameters. X Optimise the welding parameters. X Done in the previous project and only used as reference, no new tests. See [1]. Optimise the welding parameters.

The same methodology was used as in the previous project [1], but with an improved fixture (less cooling and a better controlled clamping), see Figures 3 and 4. Single lap
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joints (2 + 2 mm) were welded with zero-gap between the plates (single run). After cooling, the specimens were turned and a second weld was made. Since the gap was completely closed for the second weld, it was considered to be the most difficult to accomplish. In the examinations, a focus was therefore made on the second weldment (side) in each joint. (See Figure 6). 6.2.1 Welding on 7 m coating After the bead on plate-tests, the wires were welded on 7m Zn-coated steels in the lap joint. The welding parameters were optimised (voltage, inductance, stickout, wire feed, welding speed, gas type and flow, gun angles) in order to get as few pores and little spatter as possible. On the 7 m coating, solid wires were mainly tested. Some tests were, however, made with metal cored and flux cored wires. Keeping the heat input as low as possible, while still retaining a stable arc was the main approach. As shielding gas, MISON 2 8 was mostly used, as this was believed to give less spatter and a lower heat input than MISON 16. The normal mixed gas 80Ar/20CO2 and MISON 16 were, however, also used. After controlling the weld surface properties, the best weldments were X-rayed and cut up in order to be analysed in microscope. In most cases, the weldments were reproduced and the specimens analysed to verify the earlier results. 6.2.2 Welding 20 m coating Welding on 20 m Zn-coated steels was initially tested with solid wires and metal cored wires. Mainly, however, the welding tests on 20 m was made with flux cored wires (SAFDUAL-Zn, ETC-Zn, Tubrod 14.16 and Lincoln NR-152). The welding was performed in the same way as for the 7 m coating, but was more centred on minimising the spatter.

7.
7.1

Results
Pre-study: bead-on plate tests

The modified G-parameter in the test did not prove to be feasible as a ranking factor for the filler materials. However, the collected heat-input values are of interest and can be of use when discussing the weldability on Zn-coated steel. For further results, see Enclosure 1.

7.2

Welding Zn-coated steel in lap joints

In this chapter, a summary of the best results is shown. Further details are found in Enclosure 4.

MISON is a registered trademark of AGA AB. These shielding gases are specially composed for reducing the ozone level in the weld zone. The components are mainly argon with some CO2 (the number after MISON indicates the CO2 level) and 0,03% NO. - 17 -

7.2.1 Overview of welding trial results In Table 5 below, an overview of the welding trials is presented.
Table 5. Overview of welding trial results.

Type of welding: Solid wires, using low heat input and high weld speed. Solid wires, using high heat input.

7 m coating X

-----

Metal cored wires, using low heat input. Metal cored wires using high heat input. Flux cored wires using recommended settings.

X X X

20 m coating Comments: Decent results on 7 m, though X fairly large internal pore sizes. Reduced Zn-coating damage. 20 m was impossible to weld. Done in the previous project on 20 X m only. Used as a reference, see [1]. The weld speed has to be strongly reduced. High spatter level and distortion of the plates. Both 7 m and 20 m were X impossible to weld due to an unstable arc. Good arc stability on 7 m coating, X occasional large pores. 20 m was impossible to weld. Good results achieved for both 7 X m and 20 m. Weldments free (or with low level) of porosity. Some minor (fine-grained) spatter and slag remain on the plates.

7.2.2 X-ray examinations The same method was used for examining the X-ray pictures as in the previous project. In this report, the whole X-ray picture is usually shown with both weld beads visible (both sides of the lap joint).

Figure 5. In this X-ray picture, the different parts of the upper part of the lap joint is illustrated. (Scale 1:1)

Figure 6. Here, a complete lap joint is shown. Also, a typical difference between the first weld (top) and the second weld (bottom) is visible. The latter was focus for examinations in this project. (Scale 1:1) - 18 -

The X-ray results showed that even though most wires had been accepted when the surface was inspected visually, there were often large quantities of internally hidden pores in the weld bead (exception: some flux and metal cored wires). For further analysis, see Enclosure 6. 7.2.3 Welding 7 m Zn-coated lap joints The best results among the solid wires were achieved with INE-Galvawire (Figure 7). Further results are found in Enclosure 4. Weld data are found in Enclosure 3.
In the X-ray picture, the weld beads are shown. The first weld is the upper and the second (the most interesting) at the bottom. There are some pores >0,8 mm.

Figure 7. Galvawire weldment on 7 m Zn-coating, from upper left to right: Top view of welded lap joint, Xray of the overlap section (scale 1:0,8); below: Cross section of the weld (scale 5:1).

Process behaviour on 7 m Zn-coating

Process range

The Process windows for the solid wires used on 7 Zn-coating were limited. Galvawire and Nertalic-Zn gave the best results (in that order) and were easiest to use. P5800 was most difficult to get a stable process with, and this wire gave also less successful results. The metal cored wire PZ61.05R had also a narrow process window. The inductance had to be adjusted down to get sufficient start performance. The flux cored wires SAFDUAL-Zn, ETC-Zn and Lincoln NR-152 on the other hand, had relatively wide process windows and gave good results on 7m coating. There was some spatter on the plates (especially before optimisation of the process, after which they were relatively spatter free), and there was also a risk of burn through if the process was running too hot. There were some minor surface slags present (the solid and metal cored wires had very little).
- 19 -

Arc stability during welding

When welding with the solid wires, a typical short arc was aimed for. This was achieved in most cases, but the arc could be fairly sensitive as the voltage was lowered (the most sensitive was P5800). When welding with SAFDUAL-Zn or ETC-Zn the arc was very stable (not a pure short arc but similar). The self shielded Lincoln NR-152 wire was also stable and had the same kind of arc as SAFDUAL-Zn. PZ 61.05R had a very stable arc that tended to run hot and risked to burn through, especially at the end of the plates (a matter of further optimisation).
Positioning sensitivity

All wires were sensitive to the positioning of the electrode on the base plate (pbp in the charts). However, the solid wires were the most sensitive (SAFDUAL-Zn, ETC-Zn, and Lincoln NR-152 can be about a millimetre off without much problems). Visual examination of the weld beads:
Spatter:

P5800 Zircobond some spatter. Nertalic-Zn some spatter but less than P5800. Galvawire less spatter (some are almost spatter free). SAFDUAL-Zn and ETC-Zn some fine grained spatter or spatter free. PZ (both types) spatter free on 7 m. OK Tubrod 14.16 a great deal of dust and slag. Lincoln NR-152 some slag, but otherwise similar to SAFDUAL-Zn.
Surface breaking pores:

After optimisation of the process for the different wires, they all met the surface demands for porosity (P5800 was the hardest to get through). The reference wire OK Autrod 12.51 did also qualify.

Figure 8. PZ61.05R-welded specimen with 7 m Zn-coating, spatter free (scale 1:1).

- 20 -

7.2.4 Welding 20m Zn-coated lap joints Good results were achieved with SAFDUAL-Zn, ETC-Zn and Lincoln NR-152. Further results are found in Enclosure 4. Weld data are found in Enclosure 3.
In the X-ray picture, there are no visible pores larger than 0,8 mm (no porosity is shown in this close-up).

Figure 9. Lap joint with 20 m Zn-coating welded with ETC-Zn, from upper left to right: Top view of welded lap joint, X- ray of the overlap section (scale 1:1); below: Cross section of the weld (scale 5:1).

As in Figures 7 and 9, the Xray picture shows the weld beads. Here, the weld beads are free from porosity.

Figure 10. Lap joint with 20 m Zn-coating welded with the self-shielded wire Lincoln NR-152, from upper left to right: Top view of welded lap joint, X- ray of the overlap section (scale 1:1); below: Cross section of the weld (scale 5:1).

- 21 -

Process behaviour on 20 m Zn-coating SAFDUAL-Zn, ETC-Zn and Lincoln NR-152 used on the 20 m Zn-coating behaved similar to the 7 m welding, but actually had less spatter (especially after optimisation of the process). There was also a risk of burn through as on the 7 m coating when the process was running hot. The arc stability was good for most of the flux-cored wires, while the solid- and metal cored wires were unsuccessful in forming an acceptable weld on this thicker coating. For the flux-cored wires, the positioning sensitivity was about the same as when welding the 7m-coating. Visual examination of the weld beads The weld beads had the same appearance as the 7m welded specimens, except for the solid and metal cored wires. The latter had incomplete welds (very large blowholes, pits and missing parts).

8.

Discussion

As guidance to judging the quality of the different welds, the VOLVO standard [19] was used. The following criteria specifies an acceptable weld for the actual lap joint: The measuring distance is 10 cm For internal examinations of the weldment, a number of arbitrarily selected cuts are evaluated. No pores >0,8 mm. No more than two pores/cm if they are surface breaking. Maximum undercut 0,6 mm. Internal cracks maximum length 0,4 mm (must not reach HAZ or surface). Longest lack of fusion 0,4 mm (not surface breaking). With knowledge of these criteria, the quality examinations in the project were based on both visual inspection and X-ray examinations of the complete welded joints. The results showed that a high accuracy in the welding speed and electrode positioning was necessary in order to obtain a satisfactory weld bead surface for solid wires (type 1). These demands were not as strict for the cored wires SAFDUAL-Zn, ETC-Zn and Lincoln NR-152 (type 3). Among the solid wires, INE Galvawire and Nertalic-Zn had the widest process windows and were easiest to meet the surface demands with. Concerning the internal porosity level, it was often much easier to make the first side of the overlap than the second when welding with solid wires. This was not, however, the case for the flux cored wires SAFDUAL-Zn, ETC-Zn, Lincoln NR-152, where both sides of the joint performed similar in welding. This could be due to the fact that the process windows for the cored wires are wider. The extra closing of the gap (that the first weld creates) affects the solid wires more. It should be noted, however, that the intention with the gap-closing procedure was to provoke the welding process, i.e. to create a maximum porosity situation. Normally, single sided welding with a small gap is used. Figure 11 from [6] illustrates the influence of the size of the gap and the welding type on the porosity formation.

- 22 -

Some tests were made with intermittent welds (solid wires, type 1) on both sides of the lap joint. These showed lower internal porosity levels and less damage to the zinc coating.

Figure 11. The influence of the plate gap size on the porosity formation for two different types of welding on zinc-coated lap joints [6, 21].

The metal cored wires (type 2) showed good performance on the 7 m coating. A few fairly large internal pores could occur though in the weldment. On the 20 m surface, these wires were unable to run with a stable arc. An interesting point regarding spatter is that the old material batch (from the earlier project) gave less sticking spatter after welding. It seems that that the newer batch had a cleaner surface (less oil from the rolling). Also, the Zn-coating was slightly thicker on the new batch. This caused more spatter, that also stuck to the plates because they were cleaner. The spatter, when it occurred, was evenly distributed on the plates. Tests where a small amount of oil was applied to the surface showed that it was indeed the clean surface that caused the spatter to stick to the plates. There is, however, a danger here for the quality of the actual weld, as too much oil could cause wormholes, easier burning-through (perhaps due to the oil being burnt and adding to the heat input) and also a risk for an incomplete fusion in the joint. Tests with different shielding gases showed that a lower CO2 content was beneficial in reducing the spatter. The best results were achieved with MISON 8 and a high gas flow (20 22 l/min).

- 23 -

9.

Conclusions

The task was to improve the weldability (i.e. minimising the amount and size of pores and spatter) for Zn-coated steel in a lap joint with zero-gap between the plates. The following is concluded: The results show that a short electrode stickout reduces the spatter, as well as a low voltage setting. The stick-out should be selected as short as possible. Changing the inductance to a low setting can sometimes also lower the amount of spatter. Different shielding gases were evaluated. The best results were achieved with MISON 8 and a high gas flow (20 22 l/min). Combined with a short stickout, the spatter levels could be greatly reduced. More solid wires have been tested on 7 m Zn-coating (compared to the earlier project [1]). Strong improvements in regard to surface breaking pores have been achieved. Internally, though, there are still many and often fairly large pores (about 1 mm size). The best solid wire results were achieved with INE/MIGA Galvawire (no surface breaking porosity, 10 20 % internally in the weldment). See Enclosures 4 and 6. Metal cored wires PZ 61.05R and PZ 61.02 performed well on the 7 m Zn-coating when relatively high heat input was used. Occasional pores of approximately 1 mm size can occur internally in the weldment. The possibility to use a metal cored wire is interesting since there is a possibility to meet both surface and internal demands and at the same time have a slag free weld. See Enclosure 4. Most of the flux-cored wires performed well on the 7 m Zn-coating. Spatter-free (or close) welding was achieved. A small amount of slag in the weld transition region remains after welding. See Enclosure 4. Welding on 20 m Zn-coating was performed mostly with the flux-cored wires SAFDUAL-Zn, ETC-Zn and Lincoln NR-152 (the solid and metal cored wires proved unusable here). The new results were much better in regard to porosity and spatter when compared to results from the previous project. Now, only a small amount of finegrained spatter and minor slags are remaining on the plates. See Enclosure 4. Complementary and new examinations of cut specimens were made. The previous conclusions from the earlier project regarding different wires and welding conditions effect on the Zn-coating still stand. See Enclosure 2. An attempt to evaluate different electrode materials was made (G-parameter, see Enclosure 1). The suggested equations did not prove useful. The only certain result here is that the heat input is an important factor. The literature study showed that GMA- brazing is an alternative to MAG-welding. A gap width of 0 2 mm can be used without significant loss in strength [17]. High joining speeds can be used and lower heat input is possible (less damage to the coating). A possible drawback is the more expensive filler materials (compared to ordinary solid wires). This could, however, be compensated by a higher productivity.

10. Future research

The following is recommended as future research: A project concerning MIG/GMA-brazing of these joints is suggested to complete the picture of suitable joining methods for Zn-coated steels.
- 24 -

Fatigue testing of lap joints with different internal porosity levels is recommended. The question to be answered is how high level of internal porosity can be accepted for a fatigue loaded joint?

11. Acknowledgements
Companies within the SIMR Joining Technology Centre (Fogningscentrum) financed this work: AGA AvestaPolarit ESAB SAPA SCANIA SSAB Tunnplt Volvo Car Corporation I wish to express my gratitude to these companies and their representatives in the project steering-group (see report cover). A special mark of gratitude to those who made valuable technical contributions to this project: Kjell-Arne Persson, AGA AB Sven Jansson, SSAB Tunnplt AB Tapio Huhtala, ESAB Netherlands Klas Weman, ESAB Welding Equipment AB Jonas Klein, Volvo Car Corporation I also want to thank: R. Pascold, ESAB Solingen, Germany, and Margareta Nyln, SIMR (IM), Stockholm for interesting brazing discussions. And the following companies for supplying filler materials: Lincoln Sverige AB Air Liquide Welding / Oerlikon Sverige AB ESAB Sverige AB Allkommers AB Svenska Elektrod AB Migatronic Sverige AB Finally gratitude is expressed to Prof. Arne Melander, SIMR, Prof. Rolf Sandstrm, KTH, and Joakim Hedegrd, SIMR-JTC, for reviewing this work.

12. References
1. Hedegrd, Caddo, MAG-Welding of Zn-coated steels, a process study, SIMR Research Report No IM-2001-506, 2001.
- 25 -

2. Oates and Saitta, Welding handbook-materials and applications, 8th ed, Vol. 4 Part 2, pp. 111-112, 118-121, 127-129, 146-152, 155, 1998 3. G. Beranger, G. Henry, G. Sanz, The book of steel, 1994, pp 836-837. 4. Marberg, Jrgen, Some observations on welds in galvanised steel weldments, Schweissen und Schneiden, vol.36, no.7, pp. E110-E111, 1984. 5. H.Matsui and M.Yamada, Fundamental study of an arc welding procedure for hot-dip zinc-coated steel sheet, Welding International 12(7), pp. 529-538,1998. 6. H. Matsui, S. Harada, M. Ushio, Current Topics on Sheet Metal Welding in the Japanese Automobile Industry Pulsed GMA Welding of Hot-dip Galvanized Steel and AC Pulsed GMA Welding of Al Alloys, IIW Doc. XII-1674-01, pp. 123-142. 7. Howse, DS, MAG-weld procedure development for galvanneal coated high strength steel sheet, TWI, technology briefing 697/2000, (1 page), 2000 8. Frostne, H, Svetsning, 1956 pp. 38-96. 9. Rhode, H; Katic, J; Paschold, R, ESAB pulsed gas-shielded metal arc brazing of surface-coated sheets, Svetsaren vol.55, no3. 2000, pp. 20-23. 10. Brazing handbook, edition 4 1991, American Welding Society, p xvii, pp 35-38. 11. Frings, Stckel, Fully mechanised inert-gas metal-arc brazing of hot dipped galvanised thin steel sheet, Swchweissen und Schneiden, vol.38, no.12, pp. 624-629, 1986 12. Hackl, H, MIG-brazing of galvanised light-gauge sheets, Welding Review International, vol.15, no.4, pp. 122-123, 1996 13. A. Joseph, C. Webb, M. Haramia and D. Yapp, Variable Polarity Improves Weld Brazing of Galvanized Sheet, Welding journal OCT. 2001, pp. 36-39. 14. Humpston, G; Jacobson, D, Principles of soldering and brazing, 1993, pp. 132-139. 15. Brazing and soldering, CEN/TC 121/SC 8, 25 AUG 2000 16. Dilthey, Bachem, GMA-Brazing of Galvanised and Alloyed Steels-An Alternative joining Technology in Vehicle Construction, IIW-Doc., XII-1630-00 17. Pascold, R, ESAB-Solingen, Germany, telephone interview, Sept. 2001. 18. Shinoda, Takeushi and Shimizu, Effect of surface active element on porosity formation by GMA welding of Zn plated steel for automotive industry, international conference in exploiting advances in arc welding technology, Cambridge, UK, 30-31 March 1998, pp. 63-74. 19. VOLVO Standard STD 5605,515, corporate standard from 2000-12 Issue 3.

- 26 -

20. Gustafsson, Bengt-Olof, Gasmetallbgssvetsning av belagd plt, Svetsen, vol.46, no.2, pp. 10-16, 1987 21. Nishikawa, Suga and Nakano, Gas pocket generation in MAG welding of galvanised steel sheet, ISIJ International, vol.35, no.10, pp.1213-1221, 1995 22. NN, Metal Cored Wire SAFDUAL Zn Technical report, Rev:0, 02/09/93 23. Suga, Nagaoka, Nakano and Suenaga, An investigation into resistance to porosity generation in high-speed horizontal CO2 fillet welding, DOC.XII-1456-96, pp. 275293.

13. Enclosures
Enclosure 1 - Bead on plate tests. Enclosure 2 - Examination of the Zn-coating Enclosure 3 - Welding data protocol. Enclosure 4 - Details about the welding trials (short description with pictures, incl. X-ray). Enclosure 5 Base material analyses. Enclosure 6 - Internal porosity in weldments.

- 27 -

Enclosure 1-1 / 7

Bead on plate test (welding tests made on uncoated steel sheets):

The purpose with this test was to search for data in order to be able to make assessments of different filler materials suitability for welding on Zn-coated steel (7 m and 20 m), considering porosity and spatter. There are several different parameters that could be compared, but two main theories: 1. One possibility is to affect as little of the Zn-coating as possible, in order to get a more stable welding arc as the zinc is vaporised (this could give less spatter). This is obtained by keeping the heat input low, combined with a high penetration to width ratio of the weld bead (less zinc is melted, less disturbance of the arc can be obtained). 2. Another possibility could be to get a Marangoni-flow in the weld pool, where the gas bubbles are transported to the surface before the solidification by a positive material flow (in order to get fewer pores). Here, it could also be beneficial to have a large penetration to width ratio, as the arc penetrates deep and results in a positive temperature gradient that transports the gas bubbles to the side and then up to the surface of the weld pool. In order to get comparable welding results for the different filler materials, and to enable fast evaluation, single bead on plate MAG-welding was used on uncoated steel (4 mm material thickness). The samples were then cut, grinded, polished and etched in order to see the weld geometry and to measure the penetration. The results were put into charts, see Enclosure 1-2 to 1-5. Enclosure 1-6 shows the weld bead geometry. G-parameter: In an article on surface-active elements [30] the parameter Gamma (a kind of surface tension factor) was used to compare different filler materials ability to form a weld without pores. The Zn vapour in the weld pool was supposed to be pushed to the sides and up through it instead of forming pores when welding Zn-coated steel. This is called a Marangoni-flow and gamma is supposed to be as low as possible to give the best flow in the weld pool. In the SIMR-JTC project, it was decided to try a similar method for comparison, although the G-parameter here differs from the one used in the article (due to practical reasons). In the article, TIG-welding was used on a wedge consisting entirely of filler material (all-weldment, MAG-welded specimens). In this project, bead on plate MAG-welding on 4 mm uncoated steel was performed. Here, the penetration depth into the plate was measured instead of the melt-through thickness (article), as it was more time and cost efficient. Also, only MAG-welding equipment was used (which has other arc characteristics). The idea was that indications could be found that could be supportive in the choice of filler materials (which wires would possibly enable a Marangoniflow or show a connection to the rate of pores in the weld bead). Modified formula for the G-parameter:

G= 4,3*I*E/(L*(Vsv)^0,5)

Where L is the penetration of the weld (mm), 4,3 is a constant, I is the current (A), E voltage (V), Vsv is the welding speed (cm/min). This formula is the same as for the gamma parameter in [30] except for the penetration.

Enclosure 1-2 / 7

Heat input (q): The heat input is also of interest as this shows how much energy that has been transferred into the weld. A high heat input will affect a larger amount of zinc, so a low heat input appears to be desirable. Penetration/width: The third parameter of interest is the penetration / width ratio of the weld bead. In this case, as high value as possible is wanted as this gives the lowest amount of zinc in the weld pool and thus should give less porosity.

Base material used: The bead-on plate tests were performed on SS 2134, with 4 mm material thickness. Solid wires used: (No: Y1-Y13 +Y26) Autrod 12.51 (diameters 0,8 and 1,0 mm) P5800 Zircobond ( 0,8 mm) Nertalic-Zn ( 1,0 mm) MIGA / INE Galvawire ( 0,8 mm). Flux cored wires used: (No: Y14-Y25) Tubrod14.16 (self-shielded, 0,8 mm) SAFDUAL-Zn ( 1,0 mm) ETC-Zn ( 1,0 mm).

Bead on plate tests

Enclosure 1-3 / 7

welding type
MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 16 MISON 16 MISON 16 MISON 16 MISON 16 MISON 16 MISON 16 MISON 8

Gas

comments

compare these with 60cm/ min

gunangle35 gunangle35 lowest voltage good weld with gas

spec. wire material Nr Y1 Autrod12.51 Y2 PS5800Zircobond Y3 PS5800Zircobond Y4 AUTROD12.51 Y4N Nertalic-Zn Y4N#1 Nertalic-Zn Y4N#2 Nertalic-Zn Y5 Nertalic-Zn Y6 Nertalic-Zn Y7 Nertalic-Zn Y8 Nertalic-Zn Y9 AUTROD12.51 Y10 AUTROD12.51 Y11 AUTROD12.51 Y12 AUTROD12.51 Y13 Nertalic-Zn Y14 TUBROD14.16 Y15 TUBROD14.16 Y16 TUBROD14.16 Y17 SAFDUAL-Zn Y18 SAFDUAL-Zn Y19 SAFDUAL-Zn Y20 ETC-Zn Y21 ETC-Zn Y22 ETC-Zn Y23 ETC-Zn Y24 ETC-Zn Y25 ETC-Zn Y26 INE-galvawire

kortbge kortbge kortbge kortbge kortbge kortbge kortbge kortbge kortbge kortbge spraybge kortbge kortbge spraybge Rapid Arc Rapid Arc spraybge spraybge spraybge kortbge kortbge kortbge kortbge kortbge kortbge kortbge kortbge kortbge kortbge

diam (mm) 0,8 0,8 0,8 1 1 1 1 1 1 1 1 1 1 1 1 1 0,8 0,8 0,8 1 1 1 1,2 1,2 1,2 1,2 1,2 1,2 0,8

stickout * (mm) 12 12 12 12 12 12 12 12 12 12 15 12 12 15 27 28 15 15 15 12 12 12 12 12 12 12 12 12 12 * of which 2 mm within the gas cup

wirefeed (m/min) 10 10 10 10 10 10 10 10 6,7 5 13 6,7 5 13 16 16 10 10 10 3,5 3,5 3,5 4,1 4,1 2,5 2,5 2,5 2,5 10

welding speed (cm/min) 60 60 60 60 60 100 100 60 60 60 120 60 60 120 180 150 60 60 60 60 60 60 100 100 60 60 60 60 60

gasflow (l/min) 18,5 18,5 18,5 18,5 18,5 18,5 18,5 18,5 18,5 18,5 20 18,5 18,5 20 28 28 19 20 20 20 20 20 20 20 20 20 18,5

voltage (V) 19,4 19,4 19 19,3 19 19,3 21,3 18,8 16,5 15,8 32,5 17 15,5 31,3 26,7 26,3 19,8 21,3 21,5 13,3 14,5 13,3 14,2 14,8 12,3 11,3 12,3 13,3 19,3

current (A) 150 150 150 216 230 224 227 230 181 145 295 174 136 295 230 240 154 156 144 138 136 143 216 211 161 160 157 159 148

penetration (mm) 1,3 1,6 1,6 2,1 2,3 1,6 1,8 2,1 1,8 1,4 2,3 1,7 1,3 2,5 1,1 1,1 1,6 1,4 0,9 0,7 0,8 1,0 1,8 2,0 1,5 1,2 1,2 1,5 1,4

width (mm) 5,1 5,4 4,7 7,1 6,8 4,8 4,9 6,3 4,8 4,1 8,5 5,4 4,7 7,2 6,1 6,1 6,3 6,4 5,0 4,3 4,2 5,0 4,5 4,4 5,1 4,4 5,1 5,1 5,1

height G-param. q penetr./ width (mm) kJ/mm 2,4 1228 0,29 0,26 2,3 994 0,29 0,30 2,3 989 0,29 0,34 2,8 1129 0,42 0,29 2,9 1043 0,44 0,34 2,5 1162 0,26 0,34 2,2 1188 0,29 0,36 3,0 1143 0,43 0,34 2,5 947 0,30 0,37 2,4 935 0,23 0,34 1,9 1673 0,48 0,26 2,4 966 0,30 0,32 2,1 936 0,21 0,27 2,2 1479 0,46 0,34 1,9 1874 0,20 0,17 1,9 2111 0,25 0,17 1,7 1065 0,30 0,25 1,4 1318 0,33 0,22 0,9 1910 0,31 0,18 1,4 1405 0,18 0,17 1,4 1460 0,20 0,18 1,5 1056 0,19 0,20 1,6 754 0,18 0,39 1,5 689 0,19 0,45 1,5 733 0,20 0,30 1,2 836 0,18 0,27 1,4 912 0,19 0,23 1,3 783 0,21 0,29 2,4 1148 0,29 0,27

Hot start

Enclosure 1-3 / 7

Bead on plate - Results sorted by G-parameter

Enclosure 1-4 / 7

spec.
MISON 16 MISON 16 MISON 16 MISON 16 MISON 16 MISON 16 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 16 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8

wire material

stickout *

gas

comments

Hot start

lowest voltage

compare these with 60cm/ min good weld

Y21 ETC-Zn Y22 ETC-Zn Y20 ETC-Zn Y25 ETC-Zn Y23 ETC-Zn Y24 ETC-Zn Y7 Nertalic-Zn Y10 AUTROD12.51 Y6 Nertalic-Zn Y9 AUTROD12.51 PS5800Zircobond Y3 PS5800Zircobond Y2 Y4N Nertalic-Zn Y19 SAFDUAL-Zn Y14 TUBROD14.16 Y4 AUTROD12.51 Y5 Nertalic-Zn Y26 INE-galvawire Y4N#1 Nertalic-Zn Y4N#2 Nertalic-Zn Y1 Autrod12.51 Y15 TUBROD14.16 Y17 SAFDUAL-Zn Y18 SAFDUAL-Zn Y11 AUTROD12.51 Y8 Nertalic-Zn Y12 AUTROD12.51 Y16 TUBROD14.16 Y13 Nertalic-Zn

welding type diam (mm) kortbge 1,2 kortbge 1,2 kortbge 1,2 kortbge 1,2 kortbge 1,2 kortbge 1,2 kortbge 1 kortbge 1 kortbge 1 kortbge 1 kortbge 0,8 kortbge 0,8 kortbge 1 kortbge 1 spraybge 0,8 kortbge 1 kortbge 1 kortbge 0,8 kortbge 1 kortbge 1 kortbge 0,8 spraybge 0,8 kortbge 1 kortbge 1 spraybge 1 spraybge 1 Rapid Arc 1 spraybge 0,8 Rapid Arc 1

12 12 12 12 12 12 12 12 12 12 12 12 12 12 15 12 12 12 12 12 12 15 12 12 15 15 27 15 28 * of which 2 mm within the gas cup

wirefeed welding speed (m/min) (cm/min) 4,1 100 2,5 60 4,1 100 2,5 60 2,5 60 2,5 60 5 60 5 60 6,7 60 6,7 60 10 60 10 60 10 60 3,5 60 10 60 10 60 10 60 10 60 10 100 10 100 10 60 10 60 3,5 60 3,5 60 13 120 13 120 16 180 10 60 16 150

gasflow voltage current penetration width height G-param. q penetr./ width (l/min) (V) (A) (mm) (mm) (mm) kJ/mm 20 14,8 211 2,0 4,4 1,5 689 0,19 0,45 20 12,3 161 1,5 5,1 1,5 733 0,20 0,30 20 14,2 216 1,8 4,5 1,6 754 0,18 0,39 20 13,3 159 1,5 5,1 1,3 783 0,21 0,29 20 11,3 160 1,2 4,4 1,2 836 0,18 0,27 20 12,3 157 1,2 5,1 1,4 912 0,19 0,23 18,5 15,8 145 1,4 4,1 2,4 935 0,23 0,34 18,5 15,5 136 1,3 4,7 2,1 936 0,21 0,27 18,5 16,5 181 1,8 4,8 2,5 947 0,30 0,37 18,5 17 174 1,7 5,4 2,4 966 0,30 0,32 18,5 19 150 1,6 4,7 2,3 989 0,29 0,34 18,5 19,4 150 1,6 5,4 2,3 994 0,29 0,30 18,5 19 230 2,3 6,8 2,9 1043 0,44 0,34 20 13,3 143 1,0 5,0 1,5 1056 0,19 0,20 19,8 154 1,6 6,3 1,7 1065 0,30 0,25 18,5 19,3 216 2,1 7,1 2,8 1129 0,42 0,29 18,5 18,8 230 2,1 6,3 3,0 1143 0,43 0,34 18,5 19,3 148 1,4 5,1 2,4 1148 0,29 0,27 18,5 19,3 224 1,6 4,8 2,5 1162 0,26 0,34 18,5 21,3 227 1,8 4,9 2,2 1188 0,29 0,36 18,5 19,4 150 1,3 5,1 2,4 1228 0,29 0,26 21,3 156 1,4 6,4 1,4 1318 0,33 0,22 20 13,3 138 0,7 4,3 1,4 1405 0,18 0,17 20 14,5 136 0,8 4,2 1,4 1460 0,20 0,18 20 31,3 295 2,5 7,2 2,2 1479 0,46 0,34 20 32,5 295 2,3 8,5 1,9 1673 0,48 0,26 28 26,7 230 1,1 6,1 1,9 1874 0,20 0,17 19 21,5 144 0,9 5,0 0,9 1910 0,31 0,18 28 26,3 240 1,1 6,1 1,9 2111 0,25 0,17

gunangle35 with gas gunangle35

Enclosure 1-4 / 7

Bead on plate - Sorted by heat input

Enclosure 1-5 / 7

spec.
MISON 8 MISON 16 MISON 16 MISON 16 MISON 16 MISON 16 MISON 8 MISON 8 MISON 16 MISON 8 MISON 16 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8

welding type diam stickout * wirefeed welding speed (mm) (mm) (m/min) (cm/min) Y17 SAFDUAL-Zn kortbge 1 12 3,5 60 Y20 ETC-Zn kortbge 1,2 12 4,1 100 Y23 ETC-Zn kortbge 1,2 12 2,5 60 Y19 SAFDUAL-Zn kortbge 1 12 3,5 60 Y21 ETC-Zn kortbge 1,2 12 4,1 100 Y24 ETC-Zn kortbge 1,2 12 2,5 60 Y12 AUTROD12.51 Rapid Arc 1 27 16 180 Y18 SAFDUAL-Zn kortbge 1 12 3,5 60 Y22 ETC-Zn kortbge 1,2 12 2,5 60 Y10 AUTROD12.51 kortbge 1 12 5 60 Y25 ETC-Zn kortbge 1,2 12 2,5 60 Y7 Nertalic-Zn kortbge 1 12 5 60 Y13 Nertalic-Zn Rapid Arc 1 28 16 150 Y4N#1 Nertalic-Zn kortbge 1 12 10 100 Y1 Autrod12.51 kortbge 0,8 12 10 60 PS5800Zircobond Y2 kortbge 0,8 12 10 60 PS5800Zircobond Y3 kortbge 0,8 12 10 60 Y4N#2 Nertalic-Zn kortbge 1 12 10 100 Y26 INE-galvawire kortbge 0,8 12 10 60 Y6 Nertalic-Zn kortbge 1 12 6,7 60 Y9 AUTROD12.51 kortbge 1 12 6,7 60 Y14 TUBROD14.16 spraybge 0,8 15 10 60 Y16 TUBROD14.16 spraybge 0,8 15 10 60 0,8 15 10 60 Y15 TUBROD14.16 spraybge Y4 AUTROD12.51 kortbge 1 12 10 60 Y5 Nertalic-Zn kortbge 1 12 10 60 Y4N Nertalic-Zn kortbge 1 12 10 60 Y11 AUTROD12.51 spraybge 1 15 13 120 Y8 Nertalic-Zn spraybge 1 15 13 120 * of which 2 mm within the gas cup

wire material

gas

gas flow voltage current penetration width height G-param. q penetr./width comments (l/min) (V) (A) (mm) (mm) (mm) kJ/mm 20 13,3 138 0,7 4,3 1,4 1405 0,18 0,17 20 14,2 216 1,8 4,5 1,6 754 0,18 0,39 Hot start 20 11,3 160 1,2 4,4 1,2 836 0,18 0,27 20 13,3 143 1,0 5,0 1,5 1056 0,19 0,20 20 14,8 211 2,0 4,4 1,5 689 0,19 0,45 20 12,3 157 1,2 5,1 1,4 912 0,19 0,23 28 26,7 230 1,1 6,1 1,9 1874 0,20 0,17 gunangle35 20 14,5 136 0,8 4,2 1,4 1460 0,20 0,18 20 12,3 161 1,5 5,1 1,5 733 0,20 0,30 18,5 15,5 136 1,3 4,7 2,1 936 0,21 0,27 20 13,3 159 1,5 5,1 1,3 783 0,21 0,29 18,5 15,8 145 1,4 4,1 2,4 935 0,23 0,34 28 26,3 240 1,1 6,1 1,9 2111 0,25 0,17 gunangle35 18,5 19,3 224 1,6 4,8 2,5 1162 0,26 0,34 18,5 19,4 150 1,3 5,1 2,4 1228 0,29 0,26 18,5 19,4 150 1,6 5,4 2,3 994 0,29 0,30 18,5 19 150 1,6 4,7 2,3 989 0,29 0,34 18,5 21,3 227 1,8 4,9 2,2 1188 0,29 0,36 18,5 19,3 148 1,4 5,1 2,4 1148 0,29 0,27 18,5 16,5 181 1,8 4,8 2,5 947 0,30 0,37 18,5 17 174 1,7 5,4 2,4 966 0,30 0,32 19,8 154 1,6 6,3 1,7 1065 0,30 0,25 lowest voltage 19 21,5 144 0,9 5,0 0,9 1910 0,31 0,18 with gas 21,3 156 1,4 6,4 1,4 1318 0,33 0,22 good weld 18,5 19,3 216 2,1 7,1 2,8 1129 0,42 0,29 18,5 18,8 230 2,1 6,3 3,0 1143 0,43 0,34 18,5 19 230 2,3 6,8 2,9 1043 0,44 0,34 20 31,3 295 2,5 7,2 2,2 1479 0,46 0,34 20 32,5 295 2,3 8,5 1,9 1673 0,48 0,26

Enclosure 1-5 / 7

Bead on plate - Sorted by penetration/width

Enclosure 1-6 / 7

gas
MISON 16 MISON 16 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8 MISON 16 MISON 8 MISON 16 MISON 8 MISON 16 MISON 8 MISON 8 MISON 8 MISON 16 MISON 16 MISON 8 MISON 8 MISON 8 MISON 8 MISON 8

comments

Hot start

lowest voltage good weld with gas gunangle 35 gunangle 35

spec. wire material welding type diam stickout * wirefeed welding speed (mm) (mm) (m/min) (cm/min) Y21 ETC-Zn kortbge 1,2 12 4,1 100 Y20 ETC-Zn kortbge 1,2 12 4,1 100 Y6 Nertalic-Zn kortbge 1 12 6,7 60 Y4N#2 Nertalic-Zn kortbge 1 12 10 100 PS5800Zircobond kortbge Y3 0,8 12 10 60 Y4N Nertalic-Zn kortbge 1 12 10 60 Y4N#1 Nertalic-Zn kortbge 1 12 10 100 Y5 Nertalic-Zn kortbge 1 12 10 60 Y7 Nertalic-Zn kortbge 1 12 5 60 Y11 AUTROD12.51 spraybge 1 15 13 120 Y9 AUTROD12.51 kortbge 1 12 6,7 60 PS5800Zircobond kortbge Y2 0,8 12 10 60 Y22 ETC-Zn kortbge 1,2 12 2,5 60 Y4 AUTROD12.51 kortbge 1 12 10 60 Y25 ETC-Zn kortbge 1,2 12 2,5 60 Y10 AUTROD12.51 kortbge 1 12 5 60 Y23 ETC-Zn kortbge 1,2 12 2,5 60 Y26 INE-galvawire kortbge 0,8 12 10 60 Y1 Autrod12.51 kortbge 0,8 12 10 60 Y8 Nertalic-Zn spraybge 1 15 13 120 Y14 TUBROD14.16 spraybge 0,8 15 10 60 Y24 ETC-Zn kortbge 1,2 12 2,5 60 Y15 TUBROD14.16 spraybge 0,8 15 10 60 1 12 3,5 60 Y19 SAFDUAL-Zn kortbge Y16 TUBROD14.16 spraybge 0,8 15 10 60 Y18 SAFDUAL-Zn kortbge 1 12 3,5 60 Y12 AUTROD12.51 Rapid Arc 1 27 16 180 Y13 Nertalic-Zn Rapid Arc 1 28 16 150 Y17 SAFDUAL-Zn kortbge 1 12 3,5 60 * of which 2 mm within the gas cup

gasflow voltage current penetration width height G-param. q penetr./ width (l/min) (V) (A) (mm) (mm) (mm) kJ/mm 20 14,8 211 2,0 4,4 1,5 689 0,19 0,45 20 14,2 216 1,8 4,5 1,6 754 0,18 0,39 18,5 16,5 181 1,8 4,8 2,5 947 0,30 0,37 18,5 21,3 227 1,8 4,9 2,2 1188 0,29 0,36 18,5 19 150 1,6 4,7 2,3 989 0,29 0,34 18,5 19 230 2,3 6,8 2,9 1043 0,44 0,34 18,5 19,3 224 1,6 4,8 2,5 1162 0,26 0,34 18,5 18,8 230 2,1 6,3 3,0 1143 0,43 0,34 18,5 15,8 145 1,4 4,1 2,4 935 0,23 0,34 20 31,3 295 2,5 7,2 2,2 1479 0,46 0,34 18,5 17 174 1,7 5,4 2,4 966 0,30 0,32 18,5 19,4 150 1,6 5,4 2,3 994 0,29 0,30 20 12,3 161 1,5 5,1 1,5 733 0,20 0,30 18,5 19,3 216 2,1 7,1 2,8 1129 0,42 0,29 20 13,3 159 1,5 5,1 1,3 783 0,21 0,29 18,5 15,5 136 1,3 4,7 2,1 936 0,21 0,27 20 11,3 160 1,2 4,4 1,2 836 0,18 0,27 18,5 19,3 148 1,4 5,1 2,4 1148 0,29 0,27 18,5 19,4 150 1,3 5,1 2,4 1228 0,29 0,26 20 32,5 295 2,3 8,5 1,9 1673 0,48 0,26 19,8 154 1,6 6,3 1,7 1065 0,30 0,25 20 12,3 157 1,2 5,1 1,4 912 0,19 0,23 21,3 156 1,4 6,4 1,4 1318 0,33 0,22 20 13,3 143 1,0 5,0 1,5 1056 0,19 0,20 19 21,5 144 0,9 5,0 0,9 1910 0,31 0,18 20 14,5 136 0,8 4,2 1,4 1460 0,20 0,18 28 26,7 230 1,1 6,1 1,9 1874 0,20 0,17 28 26,3 240 1,1 6,1 1,9 2111 0,25 0,17 20 13,3 138 0,7 4,3 1,4 1405 0,18 0,17

Enclosure 1-6 / 7

Bead on plate - Weld bead cross sections

Y1 Y2 Y3 Y4

Enclosure 1-7 / 7
Y4N

Y4#1

Y4#2

Y5

Y6

Y7

Y8

Y9

Y10

Y11

Y12

Y13

Y14

Y15

Y16

Y17

Y18

Y19

Y20

Y21

Y22

Y23

Y24

Y25

Y26

Enclosure 2

Zn-coating damage evaluation.

LAZ-Class: I II III IV V Width of zone 0-2 mm 2-5 mm 5-10 mm 10-15 mm 15-20 mm

Nr: G1-2 N1-2 N3-2 P2 Z7-6A Z7-16A A2 A2X Z20-7L Z20-12L RZ20-2 RZ20-4 RZ20-6 RZ20-10 SJ5-2X SJ5-2 L1 R1-2 R1-4 R2

Wire: Welding type: Solid wires - low heat input INE-Galvawire fast short-arc (Mison 8) Nertalic-Zn Nertalic-Zn P5800 Zircobond fast short-arc (Mison 8) fast short-arc (Mison 8) fast short-arc (Mison 8)

Welding speed: (cm/min) 100 100 100 100 100 180 100 100 50 50 64 64 64 63 90 105 80 150 150 150

Heat input(Q): (kJ/mm) 0,17 0,18 0,17 0,14 0,17 0,17 0,18 0,17 0,34 0,43 0,18 0,18 0,17 0,2 0,24 0,22 0,22 0,31 0,23 0,27

LAZ on weld side: LAZ on under side: III III III III III IV III III V V III III III IV III II III IV IV III I I I I II I II I V V III III III IV II III III II III II

AUTROD 12.51 fast short-arc (Mison 8) AUTROD 12.51 Rapid Arc (Mison 8) AUTROD 12.51 fast short-arc (Mison 8) AUTROD 12.51 fast short-arc (Mison 8) Solid wires - high heat input AUTROD 12.51 Slow short arc (Mison25) AUTROD 12.51 Slow short arc (CO2) Flux cored wires - low heat input SAFDUAL-Zn medium speed short-arc (Mison 16) SAFDUAL-Zn medium speed short-arc (Mison 16) SAFDUAL-Zn medium speed short-arc (Mison 16) SAFDUAL-Zn medium speed short-arc (Mison 16) SAFDUAL-Zn fast short-arc (Mison 8) ETC-Zn fast short-arc (Mison 8)

Lincoln NR-152 fast short-arc (no gas, self shielding) Metal cored wires - high heat input PZ 61.05R hot Rapid Arc (80%Ar,20%CO2) PZ 61.05R hot Rapid Arc (80%Ar,20%CO2) PZ 61.02 hot Rapid Arc (80%Ar,20%CO2)

Conclusions: The solid wires with low heat input gave the best results regarding undamaged zinc, especially on the underside (sometimes as low as < 2 mm damage zone). Solid wire with high heat input gave heavy damage on the zinc coating, >15 mm zone on each side. Flux cored wire welding gave medium damage results on the zinc coating (5 - 12 mm zone). The hot welded metal cored wires had significant (> 10 mm) zinc damage on the weld side but medium damage on the underside.

Enclosure 3

Enclosure 3 Welding protocol

Enclosure 3 will be released June 30th, 2003. For further information, please contact the SIMR Joining Technology Centre.

Enclosure 4

Enclosure 4 Details about the welding trials

Enclosure 4 will be released June 30th, 2003. For further information, please contact the SIMR Joining Technology Centre.

Base material analysis and filler materials

Enclosure 5

N .005 .002 .02 . 02 .04 .03 .04 .01 .01 .00 .044 .05 .004 .001 .01 .00

Cr

Ni

Cu

Mo

Al

Nb

Ti .005 -

B .0004 -

New material delivered for use in this project (603001-3). Material Charge Thickness Coating C Si Mn P S No: mm Thickness m DOGAL B500 M21445 2 20 .05 .01 .22 .007 .018 DOGAL B500 M44640 2 7 .041 .00 .18 .012 .012 DOGAL B500 M46042 2 7 * * Material from the production line, no analysis available (same type as M4460). Cu Mo Al Nb V Ti

Old Material from the previous MAG-Zn project (also used in this project for verifying welding tests). Material Charge Thickness Coating C Si Mn P S N Cr Ni No: mm Thickness m 7 20 0.041 0.153 0.19 1.81 0.011 0.003 0.003 0.44 0.05 0.01 0.01

DOGAL 800 DP Unknown 2

0.042 0.014 0.01 -

0.003 0.004 0.001

DOGAL B500

Unknown 2

0.18 0.006 0.007 0.005 0.02 0.04 0.02 0.001 0.059

All the coated materials had hot dip galvanised coatings.

Solid wires: OK Autrod 12.51 (ESAB) 1,0 mm. Lot no. 032302 OK Autrod 12.51 (ESAB) 0,8 mm. Lot no. 012404 P5800 Zircobond (Svenska Elektrod) 0,8 mm. Charge no. 228384 INE Galvawire (Migatronic) 0,8 mm. Charge no.1/209 Nertalic-Zn (SAF/Air Liquide) 1,0 mm. Lot no. C8343G-031 Metal cored wires: PZ 61.05R (ESAB/FILARC) 1,4 mm. Lot no. 9446029 PZ 61.02 (ESAB/FILARC) 1,2 mm. Lot no ----Flux cored wires: SAFDUAL-Zn (SAF/Air Liquide) 1,0 mm. Lot no. 2401-0133 ETC-Zn (Allkommers) 1,0 mm. Lot no. 22430 OK Tubrod 14.16 (ESAB) 0,8 mm. Lot no. 63963 Lincoln NR-152 1,6 mm. Lot no. 6A12FW

Porosity evaluation - lap joints

Enclosure 6-1 / 2

Number and size of pores in a 10 cm section of a weld bead ( 3 X-ray pictures for each filler were examined).
INE-Galvawire 7 m 6 10 7 2 6 10 002 000 3 welds 1 0 0 0 Only 1 weld 10 11 17 10 5 5 1 10 3 000 3 welds 540 110 000 000 3 welds 0 0 0 0 Only 1 weld 010 000 000 000 3 welds 000 010 100 310 3 welds Nertalic-Zn 7 m SAFDUAL-Zn 7 m SAFDUAL-Zn ETC-Zn 20 m 7 m Amount of pores and their size: 01 2 00 0 00 0 00 0 2 welds Only 1 weld ETC-Zn 20 m Lincoln NR-152 7 m Lincoln NR-152 20 m PZ 61.05R 7 m PZ 61.02 7 m 1 0 0 0 Only 1 weld (done by FILARC)

Counted values of porosity

Filler: Autrod 12.51 1,0 Autrod 12.51 0,8 P5800 Zircobond Zn-coating: 7 m 7 m 7 m Pore size: 0-0,8 mm 11 20 20 6 0,9-1,5 mm 12 55 12 1,6-2,0 mm 20 11 1 >2,0 mm 7 00 0 Comments: Only 1 weld 2 welds (thinnest diam 0,8mm)

Note: all weldments examined were "No.2-welds" as described in Chapter 6.2

Mean values of porosity, sorted by zinc-coating thickness

P5800 0,8 mm 7 m

Filler: Autrod 12.51 1,0 Autrod 12.51 0,8 Zn-coating: 7 m 7 m Pore size: 0-0,8 mm 11 6 0,9-1,5 mm 12 12 1,6-2,0 mm 20 1 >2,0 mm 7 0 Comments: Only 1 weld (thinnest diam 0,8mm)

20 5 1 0 2 welds

Galvawire 0,8 mm Nertalic-Zn 1,0 SAFDUAL-Zn 1,0 ETC-Zn 1,0 mm NR-152 1,6 mm PZ61.05R 1,4 mm PZ61.02 1,2 mm NR-152 1,6 mm SAFDUAL-Zn 1,0 ETC-Zn 1,0 mm 7 m 7 m 7 m 7 m 7 m 7 m 7 m 20 m 20 m 20 m Amount of pores and their size: 7,7 12,7 3 2 0,3 0 1 1 0,5 0 9,3 6,7 0,7 0 0 0,3 0 0 0 0 0,7 4,7 0 0 0 0,3 0 0 0 0 0 0 0 0 0 1,3 0 0 0 0 Only 1 weld 3 welds 3 welds 3 welds 3 welds 3 welds Only 1 weld 2 welds Only 1 weld Only 1 weld (done by FILARC)

Note: all weldments examined were "No.2-welds" as described in Chapter 6.2 Note: the filler materials are sorted differently in this table - graph ordered

Enclosure 6-1 / 2

Enclosure 6-2 / 2

Internal porosity mean values

25

20

15

Number of pores

10

Pore size
20 5 1 0 0 0 0,7 4,7 9,3 6,7 0,7 0 0 7,7 12,7 3

7 m 7 m Autrod Autrod 12.51 1,0 12.51 0,8

7 m P5800 0,8 mm

7 m 7 m 7 m 7 m Galvawire Nertalic- SAFDUAL- ETC-Zn 0,8 mm Zn 1,0 Zn 1,0 1,0 mm 2 0 0 0

7 m 7 m 7 m NR-152 PZ61.05R PZ61.02 1,6 mm 1,4 mm 1,2 mm 0,3 0 0 0 0 0,3 0,3 1,3 1 0 0 0

20 m 20 m 20 m NR-152 SAFDUAL- ETC-Zn 1,6 mm Zn 1,0 1,0 mm 1 0 0 0 0,5 0 0 0 0 0 0 0

0-0,8 mm

11

0,9-1,5 mm

12

12

1,6-2,0 mm

20

>2,0 mm

Enclosure 6-2 / 2

Date: Pages: Language:

2001-12-20 27 + Enclosures English

Report Institutet fr Metallforskning

ISSN: ISRN: Report: 1403-848X SIMR/R--01/079--SE IM-2001-046

Title:

MAG-welding of Zn-coated steel, a continued process study

Author:

Linus Gemvik

SIMR-Project number: Research department: Approved by Head of Department: Financing:

603001-3 6, Joining Technology Centre Arne Melander Collective

Keywords:

MAG, welding, zinc-coated steels, Graduate work

Research Committee:
Kjell-Arne Persson Klas Weman Jonas Klein Roger Persson Jerker Bengtsson Sven Jansson Lars Johansson

Participating companies:
AGA AB / LindeGas Group ESAB Welding Equipment AB Volvo Car Corporation Volvo Car Corporation Volvo Car Corporation SSAB Tunnplt AB Svetskommissionen

Distribution:

Research committee, SIMR Joining Technology Centre

Drottning Kristinas vg 48, S-114 28 Stockholm, Sweden Tel +46 (8)-440 48 00, Fax +46 (8)-440 45 35 E-mail info@simr.se, www.simr.se

The Swedish Institute for Metals Research (SIMR) develops and improves metallic materials and processes for the production of materials and studies the behaviour of new materials in production engineering and in mechanical structures.

The institute is one of the leading industrial research institutes in the Nordic region, with around 100 employees. Research and development work takes place in close cooperation with Swedish and international companies in the steel, metal, production engineering and power industries.

Drottning Kristinas vg 48, S-114 28 Stockholm, Sweden Tel +46 (8)-440 48 00, Fax +46 (8)-440 45 35 E-mail info@simr.se, www.simr.se