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Yeong-Do Park
Yereum Kim
Md Rumman Ul Ahsan
Contents
Introduction
1
Experimental procedure
2
Conclusion
4
1
Introduction
Reason for Zinc Coating
• Protect the components from aqueous corrosion by barrier protection and galvanic
protection.
• Based on coating type, zinc-coating can provide corrosion resistance up to 10
years.
Challenges in welding of zinc coated steels
Porosities
• Presence of porosities drastically reduces the joint strength compromising vehicle safety.
Challenges in welding of zinc coated steels
Burn
Through
Porosity
Research focuses:
1. Development of wire for less porosity.
Heat input 2. Modification the welding process for less
porosity.
Research Lacking:
1. Effects of welding parameters on
porosity formation over a large range.
2. Research work associating the CMT
process.
The CMT Process
Lower limit for short arc or • CMT process can produce same
pulsed arc welding deposition at lower current and voltage
compared to short circuit or pulsed arc
process.
• CMT process has weldability at a
lower Current and Voltage (Heat input)
compared to other processes.
200
Voltage (V)
16
180
160 14
140 12
120 10
CMT Short-arc CMT Short-arc
Process Process
Objectives
Spot weld
Direction of welding
• Samples are spot welded before experiments to ensure zero gap.
(+) (-)
Increase (+) (-)
90°
Torch angle Push angle
Direction of welding
Porosities
Porosities
Total bead
Weld Length
Vapor pressure of
zinc
Buoyancy
Zinc Vapor
Heat Input
Solidification rate
bubble growth)
Porosity (Area %)
6 6
4 4
2 2
0 0
6
• Occurrence of maximum porosity is observed
within the medium range for each parameters.
4
40 60 80 100 120
Welding Speed (cpm)
3.2 Effect of welding Parameters
Effect of Heat inputon amount of porosity.
Welding Current: 200 A, Welding Speed: 40~120 cpm
10
Welding Speed: 60 cpm, Weldinc Current: 120~263 A
Porosity (Area %)
6
100
Zinc Vapor Escape frequency
50
25
0
Critical Heat input High Heat input
Heat input (J/mm)
3.3 Mechanisms of Porosity Formation
Critical heat Input vs. High Heat Input
5
High Heat input
4
Porosity (Area %)
0
Critical Heat input High Heat input
(350 J/mm) (400 J/mm)
Heat Input (J/mm) Critical Heat input
High Heat input Critical Heat input
3.3 Mechanisms of Porosity Formation
Low Heat Input vs. Critical heat Input
30 5
Zn Vapor Escape Frequency
4
20
Porosity (Area %)
(Count Per Second)
10
2
0
1
-10 0
Low Heat input Critical Heat input Low Heat input Critical Heat input
Heat Input (J/mm) Heat Input (J/mm)
3.3 Mechanisms of Porosity Formation
Low Heat Input vs. Critical heat Input
Low Heat input Critical Heat input
Low Heat= less Zn vapor= Less Porosity High Heat= More Zn vapor= More Porosity
Low Heat= Fast Cooling= Small porosity High Heat= Slow Cooling= Large porosity
3.3 Mechanisms of Porosity Formation
Reason for Porosity Distribution Pattern :
10
8
Porosity (Area %)
6 Welding Speed
Welding Current
4
Zn vapor formation & growth is less Heat Input (J/mm) Zn vapor Escape rate is High
3.4 Optimized Welding Conditions for Porosity
At Heat input Below 250 J/mm and Above 350 J/mm, Porosity is less than 2%.
For all welding speeds, maximum Higher porosity is formed within heat input range of
250~350 J/mm.
4
Conclusion
Conclusion
Questions