This paper presents an experimental investigation of laser welding low carbon galvanized steel in butt-joint configurations. The experimental work is focused on the effects of various laser welding parameters on the welds quality. The investigations are based on a structured experimental design using the Taguchi method. Welding experiments are conducted using a 3 kW Nd:YAG laser source. The selected laser welding parameters (laser power, welding speed, laser fiber diameter, gap between sheets and sheet thickness) are combined and used to evaluate the variation of four weld quality attributes (bead width, penetration depth, underfill and hardness) and to identify the possible relationship between welding parameters and weld physical and geometrical attributes. The effects of these parameters are studied using ANOVA to find their contributions to the variation of different weld characteristics. Plots of the main effects and the interaction effects are also used to understand the influence of the welding parameters. The results reveal that all welding parameters are relevant to bead width (BDW) and depth of penetration (DOP) with a relative predominance of laser power and welding speed. The effect of laser fiber diameter on penetration depth is insignificant. Typical gap-dependent weld shapes show that a small gap results in a narrower and deeper weld. Due to the standard sheared edge, an underfill between 5% and 10% occurs for no-gap experiments. The resulting hardness values are relatively similar for all the experimental tests.
Laser welding is used in the automotive industry for welding bodies with up to 30 m of welds length per vehicle. In order to design lighter cars for reduced fuel consumption, the most recent developments use tailor-welded blank, requiring various metals types and thicknesses to be welded together before the forming process. Such blank can have the right properties located precisely where they are needed, minimizing the use of materials and reducing the weight and cost [
The welding of thin steel sheets is mainly done with overlap welding or butt- joint welding. Galvanized sheets are used for corrosion prevention, but the zinc vaporizes at a lower temperature (1180 K) than that at which the steel fuses (1730 K). Due to this discrepancy, problems occur during overlap laser welding of galvanized sheets: vaporization of the zinc might displace liquid steel, and vapour can get trapped in the weld and create porosities [
Butt-joint welding is commonly used to avoid these kinds of problems, but this configuration requires very precise positioning. A vertical gap of only 15% of the thickness and a horizontal gap of 10% of the thickness can be tolerated to ensure quality and filling of the weld. For sheets thinner than 3 mm, this means less than a 0.5 mm gap on along more than 10 cm of weld. Since laser welding is an autogenous process, the residual stress developed during cooling is used to fill the gap up to at least 80% of the thickness, which is generally required in the automotive industry. Another requirement is that the laser diameter (about 0.4 mm) be two times larger than the gap to avoid defects. To reach positioning requirements, laser cutting, precision die blanking, or edge preparation are commonly used for linear welding [
Neural networks have been used to determine the maximum gap that can be welded depending on the welding speed, the laser power and the sheet thickness [
Based on all these works and observations, it is clear that positioning and welding parameters need to be controlled precisely to produce the desired welding quality especially in the case of butt-joint welding of automotive bodies and tailor blank. A structured experimental investigation is required to understand the effects and the interaction of various parameters in orders to build an efficient weld quality predictive modeling.
The paper presents an experimental investigation of laser welding low carbon galvanized steel in butt-joint configurations. The effects of welding parameters and conditions (laser power, welding speed, laser fiber diameter, gap between sheets and sheet thickness) on the variation of weld quality attributes (bead width, penetration depth, underfill and hardness) are studied. Analysis of variance is executed to quantify the impact of each parameter on the welds quality and assess the parameters interactions. The combination of welding parameters and conditions that can give the best welds quality for various thickness with or without gap are identified.
The experimental investigations were conducted using galvanized steel ASTM A635CS with galvanneal A40 coating. The sheet thickness was chosen to fit within the thickness range usually used for automotive bodies (0.8 - 3.6 mm). Three different thicknesses are taken: gauges 11, 14 and 20, respectively 3.132 mm, 1.994 mm and 1.006 mm. The chemical compositions of all sheets are shown in
The welding equipment was a six-axis-robotic system FANUC M-710ic equipped with a fiber Laser source IPG YLS-3000-ST2 and a laser head HIGHYAG BIMO. The Nd:YAG laser source emits light with a wavelength of 1070 nm and a maximum power of 3 kW. The power is transferred through an optical fiber, with a diameter of 200 µm, to the laser head, with a focal length of 300 mm. A collimator allows the user to adjust the beam diameter between 340 µm and 520 µm.
Component | C | Mn | P | S | Si | Cu | Ni | Cr | Al | N |
---|---|---|---|---|---|---|---|---|---|---|
Gauge 11 (3 mm) | 0.04 | 0.19 | 0.005 | 0.002 | 0.01 | 0.01 | 0.02 | 0.009 | 0.038 | 0.0039 |
Gauge 14 (2 mm) | 0.09 | 0.35 | 0.005 | 0.01 | 0.02 | 0.05 | 0.04 | 0.06 | 0.03 | 0.0029 |
Gauge 20 (1 mm) | 0.05 | 0.24 | 0.009 | 0.013 | 0.007 | 0.029 | 0.012 | 0.037 | 0.04 | 0.004 |
system. The air gap was created using a 0.1 mm thick steel strip positioned between the samples.
After welding, the welded assemblies were cut perpendicular to the weld surface to obtain the desired cross-sections. The cut specimens were then prepared for microscopic observation using standard procedures including grinding, polishing, and etching.
An optical microscope, Clemex MMT Type A, with a CMT program was used for the evaluation of the weld dimensions. For each experiment, three dimensions were measured (penetration, width, and lack); each measurement was taken 3 times and then averaged to obtain the data used in the analysis.
Vickers micro-hardness testing was conducted with the same equipment using a load of 500 g and a dwell time of 15 s. The base material measurements were taken far from the fusion zone. All indentations were adequately spaced so that the strain fields from adjacent indents would not interfere with each other.
Laser power, welding speed, sheet thickness, beam diameter, and gap are the parameters used in this study. The thickness and laser beam diameter are chosen to fit with the available ranges: 1 mm, 2 mm and 3 mm for the thickness and 340 µm to 520 µm for the diameter. The results of preliminary studies on the para- meters limitations and the results of others similar studies [
For the gap, three relevant information emerged from the literature review. The gap has to be less than 10% of the workpiece thickness and less than the diameter of the laser beam. A gap ranging from 0.1 mm to 0.2 mm is generally used and gives good results. Considering these constraints, a gap of 0.1 mm is needed, leaving only the welding speed and laser power to be determined. These two parameters are known to be very influential. Using the results of the preliminary tests, the upper and lower limits are taken to respect the weld penetration constraint. This means that the lowest speed with the highest power can result in full weld penetration for a 3 mm thickness specimen, and the highest speed with lowest power can result in partial weld for a 1 mm thickness specimen. Three levels are chosen to assess the nonlinear components of the parameter effects: speed between 3 and 9 m/min, and power between 2 and 3 kW. The factors and levels chosen can be seen in
These factors and levels are used to generate an experiment design that will yield the maximum data with the minimum experimentation efforts. The Taguchi method is used to achieve an efficient statistical analysis. An explanation of this method can be found in [
During the repeatability tests, the depth of penetration, bead width, and underfill are precisely measured. In order to evaluate the total measurement error resulting from non-studied parameters such as workpiece positioning, parameter stability and change in environment during the experiments, average of quality attributes, standard deviations, and the relative errors are estimated.
The results in
Factors | Levels | ||
---|---|---|---|
1 | 2 | 3 | |
Gap (mm) | 0 | 0.1 | - |
Thickness (mm) | 1 | 2 | 3 |
Power (kW) | 2 | 2.5 | 3 |
Speed (m/min) | 3 | 6 | 9 |
Diameter (µm) | 340 | 450 | 520 |
(a) no gap | DOP (µm) | BDW (µm) | Undercut (µm) | (b) with gap | DOP (µm) | BDW (µm) | Undercut (µm) |
---|---|---|---|---|---|---|---|
Min | 1493 | 971 | 154 | Min | 1167 | 713 | 360 |
Max | 1612 | 1080 | 254 | Max | 1353 | 922 | 507 |
Mean | 1542 | 1023 | 212 | Mean | 1253 | 822 | 422 |
Standard deviation | 38 | 32 | 30 | Standard deviation | 43 | 42 | 39 |
Relative error | 2% | 3% | 12% | Relative error | 3% | 3% | 7% |
standard deviation is slightly higher for the gap test. That means there is lower repeatability in the gap positioning.
An underfill of 10% of the thickness is present in the case of experimentation without gap. This must be caused by the edge morphology of the sheared edge. Flat or concave welds are produced using laser cutting or precision die blanking. A small gap exists when two sheared specimens are connected, as only the 2 burnished zone are in contact, the rest of the edge are spaced. The underfilling becomes about 20% of the thickness with the gap experiment.
To obtain the effects of each factor on the weld dimensions, ANOVA were carried out based on the measured results as illustrated in
Any factor whose p-value is under 10% will be considered meaningful. According to the results for the BDW, every factor is found to be meaningful. The gap is the least meaningful factor, with a p-value of 7%. For the DOP, the range of variation in diameter is found to not be an impacting factor, while all the
Source | Sum of squares | dof | Mean square | F value | p value Prob > F | Percent contribution | |
---|---|---|---|---|---|---|---|
Gap | 57,537 | 1 | 57,537 | 8.07 | 7% | 2% | |
Thickness | 53,538 | 2 | 26,769 | 3.76 | 3% | 2% | |
Power | 65,022 | 2 | 32,511 | 4.56 | 2% | 2% | |
Diameter | 237,072 | 2 | 118,536 | 16.63 | 0% | 13% | |
Speed | 1,336,393 | 2 | 668,197 | 93.74 | 0% | 63% | |
Error | 313,653 | 44 | 7128 | - | - | 18% | |
Total | 2,313,027 | 53 | - | - | - | 100% | |
Source | Sum of squares | dof | Mean square | F value | p value Prob > F | Percent contribution | |
---|---|---|---|---|---|---|---|
Gap | 227,587 | 1 | 227,587 | 3.32 | 8% | 2% | |
Thickness | 4,009,900 | 2 | 2,004,950 | 29.26 | 0% | 39% | |
Power | 922,458 | 2 | 461,229 | 6.73 | 0% | 8% | |
Diameter | 239,568 | 2 | 119,784 | 1.75 | 19% | 1% | |
Speed | 2,522,684 | 2 | 1,261,342 | 18.41 | 0% | 24% | |
Error | 2,014,932 | 44 | 45,794 | - | - | 24% | |
Total | 9,937,129 | 53 | - | - | - | 100% |
other factors are meaningful. The percentage contribution for the BDW attributes 18% of variation to non-studied factors, with the two main factors being speed (63%) and diameter (13%). The major factors for the DOP are speed (24%) and thickness (39%), while non-studied factors represent 24% of variation.
To visualize whether the effect of one factor depends on the level of another factor, we used an interaction plot. Parallel lines in an interaction plot indicate no interaction; otherwise, the greater the difference in slope between the lines, the higher the degree of interaction. Only one significant difference in slope is found for the BDW. As can be seen in
Interaction seems to be found between the thickness and the other factors for the DOP.
The shape of the weld is mainly determined by the welding mode conduction or keyhole. As we can see in Assuncao study [
The weld shape is supposed to be from small and round to thin and deep, which is what we observe. Four weld shapes are considered: 1) round welds are
the welds almost in conduction mode (U weld), 2) wide V welds are the welds in transition mode (HV weld), 3) sharp V welds are those between transition mode and keyhole mode 4) weld), and 5) parallel edge welds are those with full penetration done in keyhole mode (H weld).
The use of a gap tends to make only sharp V shaped welds in the case of partial penetration welds. The assumption can be made that the gap allows an easier penetration for the weld because the melted metal can flow into the gap. The deepest penetrations achieved with gap are deeper than penetrations without gap because of this easier penetration. The higher penetrations achieved with gap are shallower than those without gap, because there is more underfilling caused by the gap. We can also remark that all sharp V welds without gap have more than 50% penetration, which is where the burnished zone and the fracture zone begin forming an unintended gap between the pieces.
The experimental results reveal that tests with gap have more underfill than those with no gap.
in the graph. The underfill also increases slightly with the thickness because of the sheared edge that creates more gap with increased thickness. In order to achieve good weld on thicker plate, wider weld have to be done if there’s no additional edge preparation.
This paper presents an experimental investigation of laser welding low carbon galvanized steel in butt-joint configurations. The experimental work is focused on bead width, penetration depth, underfill and hardness using various laser welding parameters such as laser power, welding speed, laser fiber diameter, gap between sheets and sheet thickness. There are 54 experimental tests taken all factors known to have an influence on welds quality to conduct a systematic study using Taguchi methods. ANOVA analysis and effect plot diagrams are also used to evaluate the effects and the percentage contribution of the laser welding parameters on the characteristics of the weld. The micro hardness measurements show coherent results with an increase in the weld hardness from 150 Hv to 330 Hv. The ANOVA analysis reveals that the welding parameters that have significant effects on the weld quality are laser power, welding speed, laser fiber diameter and sheet thickness. The gap between sheets has a positive effect on the weld dimensions by making the weld thinner and deeper permitting the higher speeds for the same penetration. The use of a gap decreases the thickness effect on the bead width and facilitates the formation of V shaped welds. An underfill between 5% and 10% is observed for no-gap experiments and increases by about 10% when using gap. The sheared edges explain several observations on the underfill and the shape of the weld. Finally, the welding parameters that can give the best welds quality for various thickness with or without gap are identified.
Jacques, L. and El Ouafi, A. (2017) Experimental Investigation of Laser Welding Process in Butt-Joint Configurations. World Journal of Engineering and Technology, 5, 77-89. https://doi.org/10.4236/wjet.2017.51007