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12th 2018, 12thCIRP CIRPConference Conferenceon onIntelligent IntelligentComputation ComputationininManufacturing ManufacturingEngineering, Engineering,18-20 CIRPJuly ICME '18 12th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME '18 Gulf of Naples, Italy 28thhybrid CIRP Design Conference, May 2018, Nantes, France Fiber laser-MAG welding of DP/AISI 316 and TWIP/AISI 316
Fiber laser-MAG hybrid welding of DP/AISI dissimilar weld 316 and TWIP/AISI 316 A new methodology to analyze the functional dissimilar weld and physical architecture of a, a a a Giuseppe *, Andrea , Patrizia Perulli , Paolo Posa ,Pasquale Russo Spenab existingCasalino products for anAngelastro assembly oriented product family identification a, a a a b Giuseppe Casalino *, Andrea Angelastro , Patrizia Perulli , Paolo Posa ,Pasquale Russo Spena DMMM, Politecnico di Bari, viale Japigia 182, Bari 70124, Italy Paul Stief *,diJean-Yves Alain Etienne, AliItalySiadat DMMM, Politecnico di Dantan, Bari, piazza viale Japigia 182,5, Bari 70124, Italy Facoltà Scienze e Tecnologie, Università Bolzano39100, a
b
a
Facoltà di Scienze e Tecnologie, piazza Università 5, Bolzano39100, Italy Écoleauthor. Nationale d’Arts etfax: Métiers, Arts et MétiersE-mail ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France * Corresponding Tel.:Supérieure +39-080-5962753; +39-080-5962788. address:
[email protected] * Corresponding author. Tel.: +39-080-5962753; fax: +39-080-5962788. E-mail address:
[email protected] * Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address:
[email protected] b
Abstract Abstract In this paper, TWinning-Induced Plasticity (TWIP), Dual Phase (DP) and austenitic stainless (AISI 316) steels were joined together by hybrid Abstract laser/arc welding with an austenitic steel filler. Microstructural and mechanical characterization welded joints carried out by In this paper, TWinning-Induced Plasticity (TWIP), Dual Phase (DP) and austenitic stainless (AISIof316) steels werewas joined together by optical hybrid microscopy, microhardness, tensile and bend tests. The heat affected zone (HAZ)characterization at the TWIP side fullyjoints austenitic and exhibited grain laser/arc welding with an austenitic steel filler. Microstructural and mechanical of was welded was carried out by aoptical Incoarsening; today’s business environment, theand trend towards product variety and(HAZ) customization istransformations unbroken. toaustenitic this development, the the need of atmicrohardness, the DP side, new martensite formed close to the fusion zone and other phase moving toward base microscopy, tensile bend tests. more The heat affected zone at the TWIP side was Due fullyoccurred and exhibited a grain agile and production systems emerged to cope with various products and product families. design optimize production metal; at reconfigurable theatAISI 316side, side, stringers of untreated ferrite δ the inside the zone austenitic matrix was observed. All To theoccurred tensile and welded specimens coarsening; the DP new martensite formed close to fusion and other phase transformations moving toward thebroke base systems asthe well asstainless to theTWIP/AISI optimal product matches, analysis methods arewas needed. Indeed, ofThe thewelded known specimens methods aim to within austenitic steel. 316 welds exhibited a greater tensile strength than DP/AISI 316most ones. bending tests confirmed metal; at AISI 316choose side, stringers of untreated ferrite δproduct inside the austenitic matrix observed. All the tensile broke analyze a product or one family on the316 physical Different product families, however, may differ in terms of the and the ductility of both sortsproduct of joints. within austenitic stainless steel. TWIP/AISI welds level. exhibited a greater tensile strength than DP/AISI 316 largely ones. The bending testsnumber confirmed nature ofThe components. This impedes anB.V. efficient comparison and choice of appropriate product family combinations for the production © 2018 Authors. Published by Elsevier the ductility of both sorts of fact joints. system. AThe new methodology is proposed to analyze existing products in CIRP view of their functional and physical architecture. The aim is to cluster Peer-review under responsibility of Elsevier the scientific committee of the 12th Conference on Intelligent Computation in Manufacturing © 2018 Authors. Published by B.V. © 2019 The Authors. Published by Elsevier B.V. these productsunder in new assembly oriented productcommittee families for optimization ofConference existingonassembly lines and the creation future reconfigurable Engineering. Peer-review under responsibility thescientific scientific committee of 12th CIRP on Intelligent Computation inof Manufacturing Peer-review responsibility ofofthe ofthe thethe 12th CIRP Conference Intelligent Computation in Manufacturing Engineering. assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and Engineering. steel; DP steel; AISI 316 steel; Hybrid laser arc welding; Dissimilar weld;architecture Austenitic filler; Mechanical and microstructural aKeywords: functionalTwip analysis is performed. Moreover, a hybrid functional and physical graph (HyFPAG) is the output characterization which depicts the similarity product families providing design support Dissimilar to both, production system andand product designers. An illustrative Keywords:between Twip steel; DP steel; AISI 316bysteel; Hybrid laser arc welding; weld; Austenitic filler;planners Mechanical microstructural characterization example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of have an strength and ductility due to the formation of 1. Introduction thyssenkrupp Presta France is then carried out to give a first industrial evaluation of excellent the proposed approach. mechanical twins strength during plastic deformation. Twins cause ofa have an excellent and ductility due to the formation Introduction ©1.2017 The Authors. Published by Elsevier B.V. high strain hardening, thus preventing necking and, in turn,a mechanical twins during plastic deformation. Twins cause Nowadays, the automotive industry committee is continuously Peer-review under responsibility of the scientific of the 28th CIRP Design Conference 2018.
reducing vehiclethe weight to reduce industry fuel consumption and gas Nowadays, automotive is continuously this gas reason, structural and body panels are subjected emissions, as wellcomponents as to improve crashworthiness. For this to demands for lightweight andand “tailor-made” reason, structural components body panelsmulti-materials are subjected solutions, the usage assemblingmulti-materials of advanced to demandsincluding for lightweight and and “tailor-made” 1.solutions, Introduction high strength steels (AHSSs). including the usage and assembling of advanced AHSSs exhibit an excellent combination of mechanical high strength steels (AHSSs). Due to such the asfast development instrength, the of domain of properties, aanremarkable tensile high energy AHSSs exhibit excellent combination mechanical communication and an ongoing trend of digitization and absorption, ductility, formability and good fatigue resistance properties, such as a remarkable tensile strength, high energy digitalization, manufacturing enterprises are fatigue facing important [1, 2]. However, the material selection strategy in the absorption, ductility, formability and good resistance challenges inindustry today’s market environments: a continuing automotive does not only aim to a weight reduction [1, 2]. However, the material selection strategy in the tendency reduction ofeverything product anda or make towards carsindustry safer, but alsonot istoneeded to times produce automotive does only aimdevelopment a weight reduction successful vehicle. In joining different materialsa shortened product lifecycles. In addition, is antoincreasing or make cars safer, butthis alsocontext, everything isthere needed produce is of paramount importance. successful vehicle. In this being context, joining demand of customization, at the samedifferent time in materials a global High-manganese steels, all namely is of paramount competition withimportance. competitors over theTWinning world. ThisInduced trend, Plasticity steels (TWIP), have been recently proposed for car High-manganese namely TWinning which is inducing thesteels, development from macro toInduced micro structural applications. These normally contain a high Plasticityresults steels (TWIP), have steels been recently for car markets, in diminished lot sizes dueproposed to augmenting amountvarieties ofapplications. manganese (15-30 %low-volume Mn), whichproduction) retains aa fully structural These to steels normally contain high product (high-volume [1]. austenitic at room temperature. TWIP amount of microstructure manganese (15-30 % Mn), a steels fully To cope with this augmenting variety as which well asretains to be able to austenitic microstructure at room temperature. TWIP steels identify possible optimization potentials in the existing 2212-8271 ©system, 2018 The it Authors. Publishedtobyhave Elsevier B.V. knowledge production is important a precise Keywords: Assembly; Design method; Familyfuel identification emissions, as well as to crashworthiness. reducing vehicle weight toimprove reduce consumption For and
postponing fracturethus [5-8]. high strain final hardening, preventing necking and, in turn, Other AHSSs like Dual postponing final fracture [5-8].Phase (DP) steels are used to fabricate car-bodylike components (e.g., bumpers, side used impact Other AHSSs Dual Phase (DP) steels are to beams, [9]. DP steels combine high tensile fabricateetc.) car-body components (e.g., abumpers, side strength impact (usually from[9]. 500DP to 1200 with aa high goodtensile formability [1, beams, etc.) steelsMPa) combine strength of the product range characteristics and/or 10] because a mixed microstructure martensite dispersed (usually fromof500 to and 1200 MPa) with of a manufactured good formability [1, assembled in of thisa system. In this context, main in in soft ferritic matrix.microstructure Mechanical strength andchallenge ductility of 10]a because mixed ofthe martensite dispersed modelling and isMechanical now only to cope with single DPa steels can analysis bematrix. designed by not properly varying volume in soft ferritic strength and the ductility of products, a can limited product range or existing product fraction ratio ofbe these two phases. DP steels designed by properly varying thefamilies, volume but also to be able to analyze and to compare products define When corrosion resistance, durability and tooutward fraction ratio of these two phases. appearance are the main austenitic new productcorrosion families. Itresistance, can requirements, be observed that classical existing When durability and stainless outward steels are often chosen of other steel grades and appearance are are the maininstead requirements, stainless product families regrouped in function ofaustenitic clients or features. protective coatings. steels areassembly often chosen instead other are steelhardly grades and However, oriented productoffamilies to find. Austenitic stainless steelsproducts normally excellent protective coatings. On the product family level, differhave mainly in two mechanical properties, in terms strength and ductility, Austenitic stainless normally have excellent main characteristics: (i) both thesteels number ofofcomponents and (ii) the which make them a promising solution for impact-resistance mechanical properties, both in terms of strength and ductility, type of components (e.g. mechanical, electrical, electronical). carClassical body parts. Therefore, an increasing use this steel grade which make them a promising solutionmainly for of impact-resistance methodologies considering single products is foreseen in the fabrication of structural components for the car body parts. Therefore, an increasing use of this steel or solitary, already existing product families analyzegrade the automotive industry. is foreseen in the fabrication of structural components for the product structure on a physical level (components level) which automotive industry. causes difficulties regarding an efficient definition and comparison of different product families. Addressing this
Peer-review the scientific committee 2212-8271 ©under 2018responsibility The Authors. of Published by Elsevier B.V.of the 12th CIRP Conference on Intelligent Computation in Manufacturing Engineering. Peer-review under responsibility of the scientific committee of the 12th CIRP Conference on Intelligent Computation in Manufacturing Engineering. 2212-8271©©2017 2019The The Authors. Published by Elsevier 2212-8271 Authors. Published by Elsevier B.V. B.V. Peer-reviewunder underresponsibility responsibility scientific committee of the CIRP Conference on 2018. Intelligent Computation in Manufacturing Engineering. Peer-review of of thethe scientific committee of the 28th12th CIRP Design Conference 10.1016/j.procir.2019.02.035
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A sheet-metal car body can have about 250 distinct parts, which are fabricated with different metal alloys. Therefore, joining of different metals is one of major tasks in vehicle production. Ytterbium fiber laser has demonstrated its capability of welding a variety of metal alloys in similar and dissimilar joints [11-14]. In many cases, it can be successfully coupled to an arc torch to offer some advantages like low heat input, high welding speed, arc stability, good process stability and weld penetration [15, 16]. This paper aims to assess the weldability of sheets of an AISI 316 stainless steel with a TWIP and DP steel. A fiber laser-MAG hybrid welding system was used. A filler material 316-Si/SKR-Si was employed to join the steels to avoid the formation of harmful Mn segregations and brittle martensite in the fusion zone of joints, as demonstrated by previous studies [1, 17]. The dissimilar welds were characterized in terms of microstructure, tensile properties, and bending behavior. 2. Experimental procedure The sheets were 1.5 mm thick and they were welded in butt configuration. Table 1 and 2 show the chemical composition of TWIP, DP, and AISI 316 steels. The heat source for the joining process was an Ytterbium Laser (IPG YLS-4000) combined with a MAG generator, with the laser beam being the leading welding source (see Fig. 1) [18]. The laser beam was delivered through a 200 μm diameter fiber with the maximum power of 4 kW and a continuous wavelength of 1070.6 nm. The laser beam was focused on the sheet surface (Fig. 1) by a lens with a 250 mm focal distance. The MAG torch was tilted at an angle of 40 °. The two heat sources were distant 2 mm each other. The shielding gas was a mixture of 87 % Ar and 13 % CO2 to promote process stability and satisfactory joints. Table 1. Chemical composition of TWIP and DP steels (% wt.). Metal
C
Si
Mn
Cr
Mo
Al
TWIP
Ti
B
0.66
0.20
23.4
0.13
0.12
DP
0.09
0.21
1.65
0.43
-
0.038
-
0.002
0.03
0.003
-
Table 2. Chemical composition of AISI 316 (weight %). C
Cr
Mn
Mo
Ni
P
S
Si
Fe
0.08
18
2
3
14
0.045
0.03
1
balance
316LSi/SKR-Si
C 0.016
Si 0.82
Mn 1.65
Cr 18.1
Mo 2.57
Ni 12.33
Cu 0.03
Table 4. Process parameters of experimental test. Laser power (W) 1500
Laser speed (m/min) 2.4
Wire feed speed (m/min) 8.6
Current (A)
Voltage (V)
94
20.2
An austenitic filler wire (316L-Si/SKR-Si) with a dimeter of 0.8 mm was used during the joining tests. Table 3 reports its chemical composition. The process parameters used in the experimental tests are displayed in Table 4. Optical microscopy (Nikon Epiphot 200, Nikon microscope) was performed on the cross section of the dissimilar welds to evaluate joint quality. Metallographic specimens were prepared with standard grinding and polishing techniques. The following etchants were used to reveal joints microstructures: • Glyceregia solution, 15 ml HCl, 15 ml glycerol, 5 ml HNO3 for AISI 316 and TWIP steels. • Le Pera solution, 1 % vol. metabisulfite in distilled water and 4 % vol. picric acid in ethanol for DP steel. The same metallographic samples were also used to carry out Vickers microhardness measurements (Affri, Induno Olona, VA, Italy) by using a load of 0.3 kg. Vickers microhardness indentations were carried out along the middle of the weld cross section thickness. Tensile and bending tests were carried out to evaluate weld strength and formability. 3. Weld appearance and microstructure
Table 3 Chemical composition of austenitic filler. Filler
Fig. 1. Schematic configuration of laser-MAG hybrid welding.
P 0.023
The fusion zone (FZ) of the two dissimilar joints DP/AISI 316, Fig. 2, and TWIP/AISI 316, Fig. 3, does not show the presence of evident porosity or cracks. FZ of TWIP/AISI 316 joint is made up of a dendritic structure, Fig. 4. As expected, dendrites proceed toward the weld centerline along the direction of heat transfer [19, 20]. Some small shrinkage cavities could be present in the interdendritic regions because the solidification process. In the TWIP steels, shrinkage defects are highly expected owing to its high volumetric contraction during solidification [21-23]. DP/AISI 316 joints show a significant microstructural change in the DP HAZ due to the thermal cycle occurring during the joining
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Fig. 2. Optical macrograph of the DP/AISI 316 joint cross section. Fig. 6. Fine austenitic microstructure of the base material (BM) and grain coarsening at the HAZ TWIP side.
Fig. 3. Optical macrograph of the TWIP/AISI 316 joint cross section.
Fig. 7. Delta ferrite stringers at the HAZ AISI 316 side.
Fig. 4. Dendritic structure of the FZ and shrinkage cavities of TWIP/AISI 316 joints. Fig. 8. Austenitic microstructure of AISI 316 steel with δ ferrite stringers.
Fig. 5. FZ and different heat-affected zones in dissimilar joint DP/AISI 316. BM: base material.
As shown in Fig. 5, DP HAZ can be divided into three regions, as follows: HAZ 1, in which the martensite is the main constituent due to the high temperature close to the FZ and final rapid cooling; HAZ 2, which belongs to the intercritical temperature range where steel partially austenitized and then quenched to martensite, whereas the original ferrite mainly softened; HAZ 3, which is the original martensite tempered and ferrite softened area, with the amount of martensite that decreases moving away from the fusion zone [24, 25]. TWIP steel exhibits a fine austenitic microstructure, while grain coarsening is clearly visible in its HAZ, Fig. 6.
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The HAZ AISI 316 close to the fusion zone shows the presence of δ ferrite stringers (Fig. 7). It is known from the literature that the formation of δ ferrite stringers along HAZ grain boundaries hinders grain growth [28]. The formation of δ ferrite stringers could be caused by the migration of ferrite stabilizers, such as Cr and Mn, from the filler metal [28]. Fig. 8 shows the microstructure of AISI 316 stainless steel with the presence of δ ferrite stringers elongated along the rolling direction. 4. Weld microhardness Weld microhardness varies notably throughout the DP/AISI 316 joint. The hardness of DP base metal was 215 ± 5 HV0.3. At the DP side, the hardness of the HAZ close to the FZ is significantly high, above 300 HV0.3, because of the presence of a fully martensitic microstructure. Hardness reduces close to the base metal coherently with the microstructural transformations discussed previously, Fig. 9. The tempering of martensite in the HAZ 3 region has led to a hardness lower than that of the parent material. In the FZ, hardness is a quite low due to its austenitic microstructure. The hardness of TWIP base metal was 245 ± 5 HV0.3. The HAZ TWIP shows a lower microhardness than that of the base material due to the coarsening and softening of austenitic grains (Fig. 10). The FZ of dissimilar joint TWIP/AISI 316 shows a low microhardness due to the austenitic microstructure, also promoted by the nature of the filler. The dissimilar joints exhibit the same hardness profile at the austenitic stainless steel.
At the AISI 316 HAZ side, grain growth was limited, and hardness values became higher if compared with those of the base material (Figs. 9, 10). In this regard, it has been demonstrated that the formation of δ ferrite stringers along HAZ grain boundaries could contribute to restrict grain growth [28]. 5. Tensile test Tensile specimens were taken perpendicular to the weld seam. The sample width was 10 mm. The main mechanical properties resulting from the tensile tests performed on the dissimilar joints are displayed in Fig. 11 and listed in Table 5. TWIP/AISI 316 weld exhibited a greater tensile strength and elongation at fracture than DP/AISI 316 one. The differences of UTS and elongation are not significant as the rupture regarded the same material, i.e. AISI 316. The experimental error is the responsible for that difference All the tensile specimens broke within austenitic stainless steel, with the FZ and the HAZ exhibiting an adequate mechanical resistance. As shown in Fig. 12, welded samples fractured by a ductile rupture. Strength and ductility (i.e. large elongation at fracture) of joints is ensured by the austenitic microstructure of the FZ and by twinning effects occurring during plastic deformation, which is basically promoted by the important levels of manganese and nickel in welds [30, 31]. These properties are of great interest in the automotive industry to improve vehicle performance in terms of safety and fuel consumption. .
Fig. 9. Vickers Microhardness of the TWIP/AISI 316 joint. Fig. 11. Tensile curves of dissimilar specimens.
Fig. 10. TWIP-AISI 316 Vickers Microhardness [HV 0,3/15].
Fig. 12. TWIP/AISI cracked specimen.
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Table 5. Tensile properties for dissimilar joints DP/AISI 316-TWIP/AISI 316. UTS: ultimate tensile strength, max: elongation at fracture; y: yield strength. UTS [Mpa]
max [%]
y [Mpa]
DP/AISI 316
614
61
325
TWIP/AISI 316
672
51
350
DP
880
15
490
TWIP
1050
40
420
AISI 316
640
50
320
6. Bending test The dissimilar welded joints were subjected to three points bending test to evaluate the weld quality. The good bend behavior of welds has been confirmed by observations with naked eye, Fig. 13, and optical microscopy, Fig. 14 and 15. Both the joint types did not show defects on the weld surface after bending, even if they were subject to very high local deformations.
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7. Conclusions This work concerns weldability of TWIP and DP advanced high strength steels with an AISI316 austenitic stainless steel by means of hybrid MAG-laser welding in butt configuration. The microstructures, mechanical properties and bending of DP/AISI 316 and TWIP/AISI 316 dissimilar joints have been assessed and discussed. The main results are summarized as follows: 1) The HAZ at the TWIP side was fully austenitic and exhibited a grain coarsening. At the DP side new martensite formed close to the FZ, whose amount reduces moving away from the weldment. DP steel is more susceptible to the thermal cycle induced by the welding process than TWIP steel. 2) The HAZ at the DP side close to the FZ shows the maximum hardness, coherently with the presence of a fully martensitic microstructure. The HAZ of the TWIP steel exhibits a microhardness slightly lower than that of the corresponding base material, due to the softening and coarsening of austenitic grains during the welding process. 3) The FZ of TWIP/AISI 316 joint exhibit some small shrinkage porosities due to the solidification process. 4) TWIP/AISI 316 joints show a significant combination of strength and ductility, favored by twinning effect occurring during plastic deformation. DP/AISI joints also show a good mechanical strength and ductility, even though more limited than TWIP /AISI welds. All the tensile specimens broke within austenitic stainless steel. 5) The bending tests confirmed the attitude of the weld towards ductility. Both samples show defect-free surfaces and cross sections. Therefore, MAG-laser welding can be considered a valid welding technology to realize “tailormade” solutions for welded sheets components in the automotive industry. References
Fig. 13 (a) Joint appearance after the bend test . (b) Frontal views shows the absence of cracks on weld surface.
Fig. 14. Joint DP/AISI 316 cross section after bending.
Fig. 15. Joint TWIP/ AISI 316 cross section after bending.
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