Materials and Design 63 (2014) 151–158

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Materials and Design

journal homepage: www.elsevier.com/locate/matdes

Resistance spot welding macro characteristics of the dissimilar thickness

dual phase steels
Hongqiang Zhang a, Xiaoming Qiu a,⇑, Yang Bai a, Fei Xing a, Haiyan Yu b, Yanan Shi c
a
Key Laboratory of Automobile Materials of Ministry of Education, School of Materials Science and Engineering, Jilin University, No. 5988 Renmin Street, Changchun 130025, China
b
Sanyou Automobile Parts Manufacturing Co., Ltd, Changchun 130022, China
c
BAIC MOTOR Sales Co., Ltd, Beijing 100028, China

a r t i c l e i n f o a b s t r a c t

Article history: In the present work, macro characteristics of the dissimilar thickness dual phase steel resistance spot
Received 28 October 2013 welding joints were described in terms of melting rate, indentation rate, nugget diameter and indentation
Accepted 28 May 2014 diameter. The results revealed that the melting rate of the DP600 side was higher than that of the DP780
Available online 6 June 2014
side and the indentation rate of the DP600 side was lower than that of the DP780 side of the welded
joints. The base metal lap order had the important effect on nugget diameter, and the DP780/DP600 spot
Keywords: welded joints tended to get the larger nugget diameter than DP600/DP780 spot welded joints with the
Macro characteristics
same process parameters. The indentation diameters of DP600 and DP780 sides depended on the
Dual phase steels
Resistance spot welding
electrode geometry and force.
Ó 2014 Elsevier Ltd. All rights reserved.

1. Introduction load low cycle. Khan et al. [11] studied the hardness profile of
dissimilar HSLA350/DP600 resistance spot welds and found that
Advanced high-strength steels (AHSS) combine strength and the hardness in the fusion zone (FZ) was higher than that in the
ductility by phase transformation and solution strengthening and base metal (BM) due to the formation of lath martensite.
achieve a strength-to-weight ratio for lightweight applications in Hernandez et al. [12] studied the mechanical properties of dissim-
the automobile industry [1,2]. Dual phase (DP) steel is one of the ilar DP600/DP780 spot-weld joints and found that HAZ softening
most common AHSS due to the good formability and ductility with promoted a pullout failure mode and fracture occurred first in
relatively high strength, continuous yielding followed by rapid the DP780.
work hardening, a low yield to tensile strain ratio and non-aging The macro characteristics of spot welded joint also have
behavior at ambient temperature [3–5]. In order to maximize effi- important influence on quality and performance. Increasing
ciency and performance, the dissimilar material combinations are independent depth led to stress concentration and provided the
very widely used in automotive industry [6]. The adoption of dis- potential location for shear–tensile failure [13]. Nugget diameter
similar metal combinations provides possibilities for the flexible affects the tensile–shear strength of the spot welded joints.
design of the products using each material efficiently. However, there are few literatures about macro characteristics of
Resistance spot welding is an important method in automobile spot-welded joints.
manufacturing till today and a typical vehicle could need 3000– Considering the facts above, the aim of this research is to study
7000 spot welds [7,8]. Quality and performance of the resistance the macro characteristics of dissimilar thickness dual phase steel
spot welds are very important to the durability and safety design RSW joints including melting rate, indentation rate, nugget diame-
of vehicles [9]. The quality of the spot-weld was examined by ter and indentation diameter. The effects of process parameters
destructive tests to determine whether a satisfactory weld had and BM lap orders on the spot welded joint macro characteristics
been produced, such as quasi-static tensile test and dynamic cycle are discussed.
test. Pal and Bhowmick [10] studied the high cycle fatigue behavior
of DP780 steel sheet and found that DP780 spot-weld joints had
almost similar fatigue behavior at low load high cycle and high 2. Experimental details

1.2 mm thick dual phase steel DP780 and 1.5 mm thick dual
⇑ Corresponding author. Tel.: +86 1594 8092 895; fax: +86 04301 8570 1297. phase steel DP600 were used as the base metals. The mechanical
E-mail address: [email protected] (X. Qiu). properties of the base metals are presented in Table 1. The

http://dx.doi.org/10.1016/j.matdes.2014.05.060
0261-3069/Ó 2014 Elsevier Ltd. All rights reserved.
152 H. Zhang et al. / Materials and Design 63 (2014) 151–158

Table 1
Mechanical properties of DP780 and DP600.

Tensile strength Yield strength Yield tensile Elongation

(MPa) (MPa) rate (%) (%)
DP780 842 530 0.63 18.5
DP600 610 395 0.65 26

Fig. 1. Electrode shape (a) and geometry dimensions (b).

Fig. 2. Schematic of the weld joint cross-section.

Fig. 4. The effect of welding time on the melting rate of the welded joints
(I = 8.0 kA, F = 4.0 kN), (a) DP600/DP780 and (b) DP780/DP600.

dimensions of the base metals were 110 mm  30 mm. RSW was

carried out on a 200 kVA pneumatically operated single phase
RSW machine. Truncated cone caps of 16 mm diameter and
6 mm tip diameter made from RMAW Class II copper–chromium
material were considered for bottom and top electrodes, as shown
in Fig. 1a and b.
After welding, spot welded joints were cut using an electrical
discharge cutting machine. The samples were grounded and pol-
ished, and then were etched by a 4% nital solution for 7–10 s at
room temperature. The macrostructure of the spot welded joint
was characterized by optical microscopy and the dimensions were
measured by auto-CAD software. Two lapping modes were used
during RSW. One is DP780/DP600, which means DP780 is on the
top; the other is DP600/DP780, which means DP600 is on the
top. The macro characteristics of the welded joints were described
in terms of melting rate, indentation rate, nugget diameter and
indentation diameter. These characteristics were evaluated using
a standard tensile test according to JIS [14]. Fig. 2 shows the
schematic of a welded joint cross-section. Indentation rate can be
calculated by the following equation:
d ¼ c=T  100% ð1Þ
where d is indentation rate, c is indentation depth, T is the thickness
of BM. The melting rate is evaluated as follows:
c ¼ t=T  100% ð2Þ

Fig. 3. The effect of welding current on the melting rate of the welded joints where c is melting rate, t is the maximum melting depth, T is the
(T = 18 cycles, F = 4.0 kN), (a) DP780/DP600 and (b) DP600/DP780. thickness of BM.
 H. Zhang et al. / Materials and Design 63 (2014) 151–158 153

Fig. 5. The effect of electrode force on the melting rate of the welded joints
(I = 8.0 kA, T = 18 cycles), (a) DP600/DP780 and (b) DP780/DP600. Fig. 6. The effect of welding current on the indentation rate of the welded joints
(T = 18 cycles, F = 4.0 kN), (a) DP600/DP780 and (b) DP780/DP600.
3. Results and discussion
melting rates of both sides were similar with the extension of
With the different thickness, chemical composites and manu- welding time (Fig. 4b).
facturing process of base metals, the macro characteristics of dis- Fig. 5a shows the influence of electrode force on the melting
similar thickness RSW joints are also different. rate of the DP600/DP780 welded joints. The melting rate of the
DP600 side was higher than that of the DP780 side. With the
3.1. Melting rate increasing of electrode force, the melting rate of the DP780 side
decreased from 71.85% to 62.31% while the melting rate of the
Fig. 3a shows the influence of welding current on the melting DP600 side kept increasing. For the DP780/DP600 welded joints,
rate of the DP600/DP780 welded joints. When the welding current with the increasing of electrode force, the melting rate of the
was lower than 10.0 kA, the melting rate of the DP600 side was DP600 side increased first and then decreased slowly while the
higher than that of the DP780 side. While the welding current melting rate of the DP780 side decreased first and then increased
was between 10.0 and 12.0 kA, the melting rates of both sides slowly. When the electrode force was 4.0 kN, the melting rates of
tended to be equal. For the DP780/DP600 welded joints, the melt- DP600 and DP780 sides reached the maximum values (76.83%
ing rate of the DP600 side was higher than that of the DP780 side and 68.57%), as shown in Fig. 5b.
with the increasing of the welding current, as shown in Fig. 3b.
Pouranvari and Marashi [15] researched the spot-welded joint 3.2. Indentation rate
dilution of low carbon and austenitic stainless steels with the
increasing of welding current, and found that the dilution Electrode indentation depth should be kept at a minimum
increased by increasing welding current up to 8.5 kA and then kept value. Decreasing indentation depth can enhance the spot weld
remain beyond 8.5 kA. load carrying capacity and energy absorption capability [16]. In
The effect of welding time on the melting rate of the welded order to attain a good weld surface, indentation should be below
joints was illustrated in Fig. 4, and the melting rate of DP600 side the limits of 20% of steel thickness.
was higher than that of the DP780 side. For the DP600/DP780 Fig. 6 shows the influence of welding current on the indentation
welded joints, when the welding time was between 18 and rate of the DP600/DP780 and DP780/DP600 welded joints. With
22 cycles, the melting rates of both sides were equal. With the the increasing of welding current, the indentation rate of the
extension of welding time, the melting rate of the DP780 side DP780 side was always higher than that of the DP600 side. When
decreased at 26 cycles while the melting rate of the DP600 side the welding current was 10.0 kA, the indentation rate had more
increased (Fig. 4a). For the DP780/DP600 welded joints, the than the limits of 20%. The reason should be the spot welded joints
154 H. Zhang et al. / Materials and Design 63 (2014) 151–158

Fig. 7. The effect of welding time on the indentation rate of the welded joints
Fig. 8. The effect of electrode force on the indentation rate of the welded joints
(I = 8.0 kA, F = 4.0 kN), (a) DP600/DP780 and (b) DP780/DP600.
(I = 8.0 kA, T = 18 cycles), (a) DP600/DP780 and (b) DP780/DP600.

had been experienced expulsion. Expulsion leads to the formation

DP780 and DP600 sheets’ RSW was obtained in welding current
of excessive indentation, and indentation causes significant mate-
8.0 kA and at electrode force 4.0 kN for welding time 18 cycles
rial flow and gross deformation within the sheet metal [17,18].
without expulsion, and the indentation rates of DP600/DP780
The effect of welding time on the indentation rate of the welded
and DP780/DP600 were 16.73% and 17.27%, respectively.
joints was illustrated in Fig. 7. For the DP600/DP780 welded joints,
the indentation rate of DP780 side increased gradually and reached
the maximum value (25.04%) at the welding time 26 cycles. The 3.3. Nugget diameter
growth rate of the indentation rate of the DP600 side decreased
when the welding time was beyond 10 cycles (Fig. 7a). For the Fig. 9a shows the effect of welding current on the nugget diam-
DP780/DP600 welded joints, both indentation rates increased first eter. With the increasing of welding current, the nugget diameters
and then decreased before 22 cycles. When the welding time was of two BM lap orders gradually increased and then decreased. The
beyond 22 cycles, the indentation rate of the DP600 side kept nugget diameters of DP780/DP600 welded joints were larger than
increasing and the indentation rate of the DP780 side reached those of DP600/DP780 welded joints. Marya and Gayden [19]
the maximum value (21.45%) at 26 cycles (Fig. 7b). researched the RSW of two galvanized DP600 steels with 1.8 and
Fig. 8 shows the effect of the electrode force on the indentation 2.0 mm sheet thickness, and found that the nugget diameters in
rate of the welded joints. With the increasing of the electrode force, both steels stabilized slightly above 6.0 mm with the increasing
the indentation rates of DP600 and DP780 sides increased first and of welding current. In this research, the nugget diameters in both
then decreased, and the indentation rate of DP780 side was always BM lap orders stabilized above 7.0 mm, and the similar phenome-
higher than that of the DP600 side. For the DP600/DP780 welded non was reported in the literature [12].
joints, the maximum indentation rates of the DP600 and DP780 As welding times were increased, the nugget diameters of
sides were reached at electrode force 5.5 kN, 15.91% and 22.83%, DP780/DP600 welded joints were larger than those of the DP600/
respectively (Fig. 8a). For the DP780/DP600 welded joints, the DP780 welded joints, as shown in Fig. 9b. Fig. 9c shows the effect
maximum indentation rates of the DP600 and DP780 sides at elec- of electrode force on the nugget diameter. As can be seen, the nug-
trode force 5.0 kN were 14.12% and 16.73%, respectively (Fig. 8b). get diameters gradually increased with the increasing of electrode
The maximum tensile strength value of galvanized chromate steel force, and BM lap order has no effect on the nugget diameter. Ma
sheets’ RSW was obtained in welding current 11.0 kA and at elec- et al. [20] researched the nugget diameters for high and low elec-
trode force 6.0 kN for welding time 10 cycles, and the indentation trode force (3.34 kN and 2.00 kN) welds for different welding times
rate was 8% [8]. However, the maximum tensile strength value of and found that lower electrode force favoured a larger nugget
 H. Zhang et al. / Materials and Design 63 (2014) 151–158 155

Fig. 10. The effect of welding current on the indentation diameter, (a) DP780/
DP600 and (b) DP600/DP780.

3.4. Indentation diameter

Fig. 10 shows the effect of welding current on the indentation

diameters of welded joints. As can be seen, with the increasing
welding current, both side indentation diameters increased gradu-
ally. However, the indentation diameters of the DP600/DP780
welded joints got the minimum value (4.99 mm) with the welding
current 8.0 kA. With the increasing of welding time, the indenta-
tion diameters of the DP780/DP600 welded joints increased grad-
ually, and both side indentation diameters were approximately
equal (Fig. 11a). The indentation diameters of the DP600/DP780
welded joints increased first and then decreased gradually. The
indentation diameter of DP780 side was always larger than that
of the DP600 side (Fig. 11b).
As electrode forces were increased, the indentation diameters
Fig. 9. The effect of process parameters on the nugget diameter, (a) welding current of the DP600/DP780 and DP780/DP600 welded joints remained
(I = 8.0 kA, F = 4.0 kN), (b) welding time (T = 18 cycles, F = 4.0 kN) and (c) electrode constant, as shown in Fig. 12. The BM lap orders have little
force (I = 8.0 kA, T = 18 cycles).
effect on the indentation diameters for the different welding cur-
rents and electrode forces. The indentation diameter depended
to a great extent on the electrode geometry and electrode pres-
diameter. In this study, the nugget diameter at electrode force sure [13].
4.0 kN was bigger than electrode force 6.5 kN, and the similar phe-
nomenon was reported in the literature [21]. 3.5. The macro characteristics of the welded joints
Based on the above results, the lap order of DP780/DP600
tended to get a larger nugget diameter than that of DP600/DP780 The dissimilar thickness dual phase steel RSW joints have three
for the different welding currents and times. main macro characteristics as follows:
156 H. Zhang et al. / Materials and Design 63 (2014) 151–158

Fig. 11. The effect of welding time on the indentation diameter, (a) DP780/DP600 Fig. 12. The effect of electrode force on the indentation diameter, (a) DP780/DP600
and (b) DP600/DP780. and (b) DP600/DP780.

(1) The melting rate of DP600 side was always higher than that
of the DP780 side. Based on the above results, process
parameters had a little effect on both side melting rates.
The reason should be related to the BM thickness. For the
dissimilar thickness RSW joints, final solidification line was
located in the geometrical center of the total thickness of
the combination, rather than at the sheet/sheet interface
[22]. The weld nugget (white dotted line) moved towards
the DP600 side, as shown in Fig. 13. As a result, DP600 side
had the higher melting rate than DP780 side.
(2) The indentation rate of DP600 side was always lower than
that of DP780 side. Based on the above results, the reason
was the different physical properties of base metals rather
than process parameters and BM lap order. Fig. 14 shows
the resistivity of the base metals at 20 °C. The resistivity of
DP780 was greater than DP600. Temperature has an impor-
Fig. 13. The offset of the weld nugget of the dissimilar thickness welded joint.
tant effect on the resistivity and they have the following
relationship [23]:
qT ¼ q20 ½1 þ aðT  20Þ ð3Þ Heat input (Q) is proportional to the resistivity (R) with the same
where qT is the resistivity at T °C; q20 is the resistivity at 20 °C; a is welding current (I) and welding time (t). The greater the resistivity
the temperature coefficient of resistance. The temperature coeffi- of base metal, the more the heat input. DP780 has greater resistivity
cient of resistance of the iron is 0.005 °C1 at 20 °C. According to and more heat input than DP600. Thus, the indentation of DP780
the principle of Joule [24]: side is deeper than DP600 side.
(3) Resistance is changing in the resistance spot welding. In
Q ¼ I2 Rt ð4Þ order to discuss, we extracted the quasi-steady-state
 H. Zhang et al. / Materials and Design 63 (2014) 151–158 157

4. Conclusions

Macro characteristics of the dissimilar thickness dual phase

RSW joints were described in terms of melting rate, indentation
rate, nugget diameter and indentation diameter. Some results can
be concluded as follows:

(1) The melting rate of the DP600 side is always higher than that
of the DP780 side of the welded joints, and the reason is that
weld nugget moves towards the DP600 side.
(2) The indentation rate of the D600 side is always lower than
that of the DP780 side of the welded joints. This can be
attributed to the greater resistivity and more heat input of
DP780 side.
(3) The DP780/DP600 welded joints tend to get a larger nugget
diameter than DP600/DP780 welded joints with the same
process parameters. The indentation diameters of both sides
depend on the electrode geometry and force.
Fig. 14. The comparison of resistivity between DP780 and DP600.

Acknowledgement

This work was supported by the Jilin Provincial Technology

Research and Development Program, China (20115003).

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