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Revival of Arc Welding Methods for Body-in-White Assembly - CMT Technology

as an Enabler for High Quality & Cost Efficient Solutions

Conference Paper · April 2009

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Mr. Johnny K. Larsson

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 Joining in Automotive Engineering
Bad Nauheim, 28-30 April 2009

Revival of Arc Welding Methods for Body-in-White Assembly

CMT Technology as an Enabler for High Quality & Cost Efficient Solutions

Johnny K Larsson
Volvo Car Corporation

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 1
 9th EAC&E: “Joining in Automotive Engineering”

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

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 2
 9th EAC&E: “Joining in Automotive Engineering”

Joining Techniques Used in Automobile Manufacturing

Resistance Welding Laser Welding Shielded Arc Welding Arc Splash Welding
Spot, Seam, Projection CO2, Nd/Yr:YAG, Fiber MIG, MAG, TIG Bolt, Stud

Brazing Hybrid Joining

Arc, Laser

Process Related Product Related

Adhesive Bonding

Clinch Joining Riveting, Screws Punch Elements Hemming

Self-piercing, Blind, FDS Bolts, Nuts, Inserts

Tº

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
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 9th EAC&E: “Joining in Automotive Engineering”

Gas Metal Arc Welding (GMAW)

Preconditions

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

Main obstacles and drawbacks

Substantial heat input  Parts’ distorsion  Deteriorated accuracy & quality

Restricited process window  Reduced availability
Difficult to robotize  Labour intense  Cost increase
Requires destructive testing for QA  Additional personnel  Cost increase

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 4
 9th EAC&E: “Joining in Automotive Engineering”

Gas Metal Arc Welded Side Door Hinges

Flexible Door Assembly Station for Volvo S60/V70/S80

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 5
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Typical Arc Welding Body Applications [Volvo V70]

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”

“Cheaper than LBW – Better Quality than GMAW”

► What Methods for High Volume Production are Available ?

► Structural vs. Non-Structural
► Fulfilling VCC Weld Quality Criteria
► Suitable for NDT
► Investment and Running Costs [Productivity, Availabililty etc.]
► Evaluation of Pros and Cons
 Process aspects
 Product aspects

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 7
 9th EAC&E: “Joining in Automotive Engineering”

Performance Validation of Alternative Methods

► Process Requirements ► Product Requirements

 Line energy, which influences  Static strength

Minimum base plate thickness  Fatigue behaviour

Parts distorsion  Crash performance

Removal of coatings
 Robustness

Gap bridgeability

Sensibility to offset position

Sensibility to variable gap

Sensibility when welding around corners

Sensibility to different welding positions
 Weld spatter
 Paintability / corrosion
 Accessibility
 Availability

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 8
 9th EAC&E: “Joining in Automotive Engineering”

Conceivable Arc Welding Methods Available for BIW Assembly

Plasma Plasma Keyhole Plasma MIG TOP-Tig

SuperMIG

Cold Arc Super Pulse Cold Metal Transfer [CMT]

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
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 9th EAC&E: “Joining in Automotive Engineering”

Cold Metal Transfer (CMT) Technology

The wire motion is

reversed and the process
begins all over again.

The rearward movement

of the wire assists
droplet detachment
during the short circuit.
When the filler metal The short circuit current
dips into the weld pool, is kept small.
the arc is extinguished.
The welding current is
During the arcing period, lowered.
the filler metal is moved
towards the weld pool.

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 10
 9th EAC&E: “Joining in Automotive Engineering”

Boron Steel Components in the V70 Body Structure

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

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
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 9th EAC&E: “Joining in Automotive Engineering”

USIBOR© Coated Hot Stamped Components

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

Press hardened conditions

Diffusion of Al
 Yield strength 1,050-1,100 MPa
into basic
 Tensile strength 1,500-1,550 MPa material
 Elongation 5-7%
Diffusion of Fe
Thickness approx. 45 µm and change of microstructure into the coating

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 12
 9th EAC&E: “Joining in Automotive Engineering”

Previous Recommendations for GMAW of USIBOR©

Robotized welding

 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

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 13
 9th EAC&E: “Joining in Automotive Engineering”

Extended Utilization of USIBOR© Coated Parts

Projekt Artikelnr Namn Material Material
Y283/Y352 30754552 A-PILLAR INNER LOWER LH Usibor WSS-M1A322-A3
Y283/Y352 30754553 A-PILLAR INNER LOWER RH Usibor WSS-M1A322-A3
Y283/Y352 30754725 BUMPER BEAM REAR Usibor WSS-M1A322-A3
Y283 30754623 SIDE INNER CANTRAIL LH Usibor WSS-M1A322-A3
Y283 30754624 SIDE INNER CANTRAIL RH Usibor WSS-M1A322-A3
Y283/Y352 30754990 A-PILLAR LOWER REINF.LH Usibor WSS-M1A322-A3
Y283/Y352 30754994 PATCH REINF LOVER .LH Usibor WSS-M1A322-A3
Y283/Y352 31213329 PATCH REINF UPPER .LH Usibor WSS-M1A322-A3
Y283/Y352 30754991 A-PILLAR LOWER REINF.RH Usibor WSS-M1A322-A3
Y283/Y352 30754995 PATCH REINF LOVER .RH Usibor WSS-M1A322-A3
Y283/Y352 31213330 PATCH REINF UPPER .RH Usibor WSS-M1A322-A3
Y283/Y352 30766004 REINF. B-PILLAR LH Usibor WSS-M1A322-A3
Y283/Y352 30791171 PATCH REINF. B-PILLAR LH Usibor WSS-M1A322-A3
Y283/Y352 30766005 REINF. B-PILLAR RH Usibor WSS-M1A322-A3
Y283/Y352 30791172 PATCH REINF. B-PILLAR RH Usibor WSS-M1A322-A3
Y352 31213777 SIDE INNER CANTRAIL LH Usibor WSS-M1A322-A3
Y352 31213778 SIDE INNER CANTRAIL RH Usibor WSS-M1A322-A3

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 14
 9th EAC&E: “Joining in Automotive Engineering”

Comparative Welding Trials on USIBOR® utilizing CMT Technology

with Conventional GMAW as Reference

VCC Materials Combinations:

• 1.2 mm USIBOR 1500 P / 1.2 mm BOLOC02 [shot-blasted] fillet (PB incl. 30°vertical)
fillet (PC incl. 30°vertical)
• 1.2 mm USIBOR 1500 P / 1.0 mm RP260 50G50G HD fillet (PB incl. 30°horizontal)
• 1.5 mm USIBOR 1500 P / 1.5 mm USIBOR 1500 P fillet (PB)
• 1.45 mm DP600 50G50G HD / 1.75 USIBOR 1500 P fillet (PB)
FoE Materials Combinations:
• 2.0 mm USIBOR 1500 P / 1.2 mm USIBOR 1500 P slot
• 1.2 mm USIBOR 1500 P / 2.0 mm USIBOR 1500 P slot

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 15
 9th EAC&E: “Joining in Automotive Engineering”

Comparative Welding Trials on USIBOR®

1.2 mm USIBOR 1500 P / 1.0 mm RP260 50G50G HD [1]

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

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 16
 9th EAC&E: “Joining in Automotive Engineering”

Comparative Welding Trials on USIBOR®

1.2 mm USIBOR 1500 P / 1.0 mm RP260 50G50G HD [2]

CMT
• It is possible to find a welding range !!!

Process parameters used

• Synergie law 1053
• Shielding gas 82% Ar + 18% CO2 = ATAL 5
• Shielding gas nozzle 20-22 mm
• Filler metal EN 440 = G3Si1, diameter 1.0 mm

Process settings used for the process tolerance trials

• wfs = 4 m/min, v = 14 mm/s

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 17
 9th EAC&E: “Joining in Automotive Engineering”

Comparative Welding Trials on USIBOR®

1.45 mm DP600 50G50G HD / 1.75 mm USIBOR 1500 P [1]

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

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 18
 9th EAC&E: “Joining in Automotive Engineering”

Comparative Welding Trials on USIBOR®

1.45 mm DP600 50G50G HD / 1.75 mm USIBOR 1500 P [2]

CMT
• It is possible to find a welding range !!!

Process parameters used

• Synergie law 1053
• Shielding gas 82% Ar + 18% CO2 = ATAL 5 (AirLiquid)
• Shielding gas nozzle 20-22 mm
• Filler metal EN 440 = G3Si1, diameter 1.0 mm

Process settings used for the process tolerance trials

• wfs = 8,5 m/min, v = 16 mm/s

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 19
 9th EAC&E: “Joining in Automotive Engineering”

CMT IR-Test at VCT; Scope & Layout [Station 11-62-070]

Today’s Situation; Spatter in gas nozzle & burn through welding faults (MTR, MTBF)
 During 18 weeks there were 99 stops with an average of 5 min/stop.
 Average stop during one week 27,5 min.
 Average stop for a year, 1265 min (46 weeks production).
 Total cost for production losses over a year, 1,77MSEK (1,265min x 1400kr, from BB cost tools)
 MTR = 5 min
 MTBF = 19,5 tim (8+8+5,5 work hours / day)

Workload for the robot 3603 (CMT-Welding IR-test) in Y286/5

Description Robot nr Name of seam Seam length (mm)

Front RH robot 3603 Windscreen flange RH 45

Front RH robot 3603 A-pillar Uniside RH 30

Front RH robot 3603 A-pillar Amazon member RH 15

11-62-070 Front RH robot 3603 Amazon member RH 120

Front RH robot 3603 Preweld upr door hinge A-pillar RH 64

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

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 20
 9th EAC&E: “Joining in Automotive Engineering”

Re-working Operations

Number of Car Bodies

 



Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
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 9th EAC&E: “Joining in Automotive Engineering”

Amount of Faults before and after the CMT Installation [week 0837; day 4]

Technical issues  Reduced availability

Quality issues; e.g. spatter First week of production
utilizing the CMT equipment

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 22
 9th EAC&E: “Joining in Automotive Engineering”

CMT Experience

 CMT is a significant colder welding method compared to short arc GMAW

 Easier to obtain a nice joint appearance
 Voltage compensation factor (%) will give a 3D lobe
 Common calibration & maintenance routines can be used
 CMT is sensitive for touching the upper sheet during welding (default offset 1mm)
 Requires other welding angles compared to traditional GMA welding
 Easier to program since (wire) stick out does not affect the result
 Not spatter-free, but very few spatters which stick to the car body
 Possibility to increase cleaning intervals off nozzles due to less spatter
 Penetration might be a problem when welding in thick materials (max 3mm)

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”

Future Development and New Challenges

 Investigate possible station time reduction / weld redistribution through

an increased welding speed by CMT technology

 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

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 24
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To be continued…..

Johnny K Larsson, Technical Specialist BIW Joining Technologies

Issue date: 2009-04-30, Security Class: Open
Page 25