RevivalofArcWeldingMethodsforBody in WhiteApplicationsCompatibilityMode
RevivalofArcWeldingMethodsforBody in WhiteApplicationsCompatibilityMode
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All content following this page was uploaded by Mr. Johnny K. Larsson on 14 August 2015.
Johnny K Larsson
Volvo Car Corporation
Table of Content
Introduction
Arc Welding in the Body Shop
Pros and Cons of Arc Welding
Which Way Forward ?
Cold Metal Transfer Technology
Case Study on USIBOR® Welding
Production Trials at Volvo Torslanda Plant
Summary and Future Outlook
Resistance Welding Laser Welding Shielded Arc Welding Arc Splash Welding
Spot, Seam, Projection CO2, Nd/Yr:YAG, Fiber MIG, MAG, TIG Bolt, Stud
Tº
Some prefered system solutions at VCC require GMAW Welded side door hinges
Single framing station
Main drivers and benefits
High strength
Single sided access
Enabler for scaleability
Superior gap bridgability
Windscreen Flange 60 mm
Shotgun member 610 mm
A-pillar inner 138 mm
A-pillar sleeve 60 mm
B-pillar / sill inner 174 mm
C-pillar / sill inner 120 mm
Inside D-pillar ( V - models) 150 mm
Crash box 568 mm
Johnny
Dept: Dept:81331,
K Larsson, Joel
Technical
Lundgren
Specialist BIW Joining Technologies
Issue date: 2009-04-30, Security Class: Open
Page 6
9th EAC&E: “Joining in Automotive Engineering”
Sill Outer LH/RH Reinf. B-pillar (patch) LH/RH Reinf. C-Pillar LH/RH Bumper Beam
Thickness: 1.3 mm Thickness: 1.4/ 2.0 mm (patch) Thickness: 1.0 mm Thickness: 1.6 mm
Coated: Usibor (Arcelor) Coated: Boron02 (SSAB) Coated: Usibor (Arcelor) Coated: Usibor (Arcelor)
Supplier: Gestamp HardTech Supplier: Gestamp HardTech Supplier: Gestamp HardTech Supplier: Gestamp HardTech
Soft conditions
Yield strength 360-500 MPa
Tensile strength 540-680 MPa
Elongation > 10%
Hot-dip FeAlSi-alloying- and AlSi-top coat AlSi top coat
FeAlSi-alloying
USIBOR-USIBOR NO
USIBOR as bottom sheet NO
Other combinations including USIBOR have to be tested on a
case-by-case basis for each specific application (thickness
combinations etc.)
”Problem Solvers”
Acceptance of an increased repair and scrap rate
Design for NOT using GMAW
Introduce an alternative arc welding method
Conventional GMAW
• Welding parameters or welding range could not be found
• Occurence of weld defects such as exessive penetration and burn-through
Investigated countermeasures
• Different wfs were tested in order to change the mode of transfer
(short arc to spray arc): 2 m/min to 8 m/min Not possible to find
• Change of the offset side: -0.5 mm any welding
• Change of the diameter of the G3Si1 wire from 1.0 to 0.8 mm
parameters which
resulted in O.K. welds
• Change of the welding position: Flat PB without tilt
CMT
• It is possible to find a welding range !!!
Conventional GMAW
• Very difficult to find a welding range
• Difficult to find welding parameters that are reproducible
• Occurence of weld defects such as undercut, holes and
internal porosity
Investigated countermeasures
• To allow degassing; change of wire [Nertalic Zn] or an
established gap between the sheets
• Variation of the torch angle
• Sense of welding; push-pull
• Tests with different offset side
CMT
• It is possible to find a welding range !!!
Summa 274
3603 11-62-070 135_6030 Windscreen flange 8693820 Cowl mbr upr 0.97, V1159, Z140 30640465 A-pillar inr lwr 1.60, V1479, Z140
3603 11-62-070 135_6142 A-pillar Uniside 30640465 A-plr inner lwr 1.60, V1479, Z140 30640473 Body side outer 0.77, V1159, Z100
3603 11-62-070 135_6144 A-pillar Amazon member 30640465 A-plr inner lwr 1.60, V1479, Z140 30640457 Sidembr upr otr 0.87, V1357, Z140
3603 11-62-070 135_6114 Amazon member 30640473 Body side outer 0,77 V1159, Z100 30640457 Sidembr upr otr 0,87, V1357 Z140
3603 11-62-070 135_6054 Preweld upr doorhinge A-pillar descending 30640469 Reinf, hinge upr 1.80, V1340 30640467 Reinf, A-pillar lwr 1.50 V1478, Z140 30640473 Body side outer 0.77, V1159, Z100
Re-working Operations
Amount of Faults before and after the CMT Installation [week 0837; day 4]
CMT Experience
Johnny
Dept: Dept:81331,
K Larsson, Joel
Technical
Lundgren
Specialist BIW Joining Technologies
Issue date: 2009-04-30, Security Class: Open
Page 23
9th EAC&E: “Joining in Automotive Engineering”
The Plasmatron© process is a plasma method with single gas shield and
modified nozzle design. Efficiency is high and superior welds can be
achieved on aluminium with thin oxide layers
Plasma-MIG [“Super-MIG™”] hybrid technology is a competitive
process to conventional MIG welding and brazing. New plasma-MIG
hybrid equipment presents 2-3 times higher welding speed compared to
MIG welding
To be continued…..