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Optimization of pulsed current in resistance spot welding of Zn-coated hot-stamped boron steels

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Abstract

Metallic coatings have been widely used for hot-stamped boron steel in automotive applications. Surface coating in hot-stamped boron steels has improved corrosion resistance. However, a thick coating layer degrades resistance spot weldability. In the case of a Zn-coated hot-stamped boron steel, the high contact resistance and material stiffness with low vaporization temperature of the alloyed layers result in a narrow current passage at the faying surface. Expulsion occurs at low current due to rapid heat development, resulting in a narrow weld current range. The pulsed current can control the heat input by applying a fast cool time during welding to improve the mechanical properties of the joint and acceptable current range. In this study, Zn-coated hot-stamped steels were resistance spot welded using various pulse current procedures, and welding condition was optimized via three pulsed current steps. Step 1: Contact area was controlled without nugget formation. Step 2: Nugget growth was minimized and contact area was maximized. Step 3: The maximum acceptable current range and nugget diameter were achieved. These welding conditions improved the acceptable current range and mechanical properties of spot welds due to increased spot weld size.

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Authors and Affiliations

  1. Advanced Forming Process R&D Group, Korea Institute of Industrial Technology, Ulsan, 44413, Korea

    Joo Yong Cheon, Jae Hun Kim & Changwook Ji

  2. Department of Mechanical Engineering, NMAM Institute of Technology Nitte, Karkala Udupi, 5754110, India

    Vijeesh Vijayan

  3. Department of Advanced Materials Engineering, Dong-Eui University, Busan, 47340, Korea

    Sivaprasad Murgun & Yeong Do Park

  4. Department of Mechanical Convergence Engineering, Hanyang University, Seoul, 133-791, Korea

    Ji Young Yu

Authors
  1. Joo Yong Cheon
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  2. Vijeesh Vijayan
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  3. Sivaprasad Murgun
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  4. Yeong Do Park
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  5. Jae Hun Kim
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  6. Ji Young Yu
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  7. Changwook Ji
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Corresponding author

Correspondence to Changwook Ji.

Additional information

Recommended by Associate Editor Tae June Kang

Jooyong Cheon is currently a researcher at the Ulsan Regional Division of Korea Institute of Industrial Technology in Ulsan, Korea. His current research interests spot welding and Arc welding.

Changwook Ji received his Ph.D. from the Pusan National University in Busan, Korea. He is currently a Senior Researcher at the Ulsan Regional Division of Koreainstitute of Industrial Technology in Ulsan, Korea.

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Cheon, J.Y., Vijayan, V., Murgun, S. et al. Optimization of pulsed current in resistance spot welding of Zn-coated hot-stamped boron steels. J Mech Sci Technol 33, 1615–1621 (2019). https://doi.org/10.1007/s12206-019-0313-2

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  • DOI: https://doi.org/10.1007/s12206-019-0313-2

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