Skip to main content
SpringerLink
Log in

Effects of welding current and torch position parameters on minimizing the weld porosity of zinc-coated steel

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This study involves an investigation of the effects of the welding current and torch position parameters, including the travel angle, torch-aiming position, and work angle, on reducing the weld porosity in the cold metal transfer (CMT) welding of hot-dip galvannealed steel in the lap-joint configuration. The effects of the welding parameters on the weld porosity are investigated through statistical analysis, high-speed imaging of the weld pool behavior, welding signal analysis, and scanning electron microscopy (SEM) analysis. The magnitude of the welding current influences the weld porosity and weld pool behavior because the current determines the arc force, the heat input, the amount of zinc vaporization, and the weld pool viscosity. The torch position parameters also have considerable effects on the weld porosity because they determine where the arc, arc force, and heat input are concentrated. A response surface model relating the welding parameters and the amount of weld porosity is estimated, and the optimum welding conditions and a suitable welding range are determined on the basis of the estimated model to minimize the weld porosity in the CMT welding of hot-dip galvannealed steel.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Yoichi T, Kazuhiro A (2004) Hot-dip galvanized steel sheet with excellent surface quality for automotive outer panels. JFE Technical. Report (4):55–60

  2. Pouraliakbar H, Hamedi M, Kokabi AH, Nazari A (2014) Designing of CK45 carbon steel and AISI 304 stainless steel dissimilar welds. Mater Res 17(1):106–114

    Article  Google Scholar 

  3. Ahsan MRU, Kim YR, Kim CH, Kim JW, Ashiri R, Park YD (2016) Porosity formation mechanisms in cold metal transfer (CMT) gas metal arc welding (GMAW) of zinc coated steels. Sci Technol Weld Joi 21(3):209–215

    Article  Google Scholar 

  4. Ahsan MRU, Kim YR, Ashiri R, Cho YJ, Eong CJ, Park YD (2016) Cold metal transfer (CMT) GMAW of zinc-coated steel. Weld J 95(4):120–132

    Google Scholar 

  5. Sarkari Khorrami M, Mostafaei MA, Pouraliakbar H, Kokabi AH (2014) Study on microstructure and mechanical characteristics of low-carbon steel and ferritic stainless steel joints. Mat Sci Eng A-Struct 608:35–45

    Article  Google Scholar 

  6. Ranjbarnodeh E, Pouraliakbar H, Kokabi AH (2012) Finite element simulation of carbide precipitation in austenitic stainless steel 304. I J Mech Appl 2(6):117–−123

    Google Scholar 

  7. Khalaj G, Pouraliakbar H, Jandaghi MR, Gholami A (2017) Microalloyed steel welds by HF-ERW technique: novel PWHT cycles, microstructure evolution and mechanical properties enhancement. Int J Pres Ves Pip 152:15–26

    Article  Google Scholar 

  8. Ashton RF, Wesley RP, Dixon CR (1975) The effect of porosity on 5086-H116 aluminum alloy welds. Weld. J. 54:95s–98s

    Google Scholar 

  9. Yu J, Cho SM (2017) Metal-cored welding wire for minimizing weld porosity of zinc-coated steel. J Mater Process Technol 249:350–357

    Article  Google Scholar 

  10. Kodama S, Furusako S, Miyazaki Y, Ishida Y, Saito M, Nose T (2013) Arc welding technology for automotive steel sheets. Nippon Steel Technical Report 103:83–90

    Google Scholar 

  11. Izutani S, Yamazaki K, Suzuki R (2013) New welding process, “J-Solution™ Zn,” suitable for galvanized steel in the automotive industry. R and D: R Dev Kobe Steel Eng Rep 63(1):54–59

    Google Scholar 

  12. Suzuki R, Kasai R (2013) Expansion of “MX-MIG process” as argon only gas shield welding method—for carbon steel. R and D: R Dev Kobe Steel Eng Rep 63(1):67–72

    Google Scholar 

  13. Pickin CG, Williams SW, Lunt M (2011) Characterisation of the cold metal transfer (CMT) process and its application for low dilution cladding. J Mater Process Technol 39(12):496–502

    Article  Google Scholar 

  14. Pang J, Hu S, Shen J, Wang P, Liang Y (2012) Arc characteristics and metal transfer behavior of CMT + P welding process. J Mater Process Technol 238:212–217

    Article  Google Scholar 

  15. Wilhelm G, Gött G, Schöpp H, Uhrlandt D (2010) Study of the welding gas influence on a controlled short-arc GMAW process by optical emission spectroscopy. J Phys D Appl Phys 43(43):434004

    Article  Google Scholar 

  16. Li J, Li H, Wei H, Gao Y (2013) Effect of torch position and angle on welding quality and welding process stability in pulse on pulse MIG welding-brazing of aluminum alloy to stainless steel. Int J Adv Manuf Tech 84(1–4):705–716

    Article  Google Scholar 

  17. Joaquin A, Elliott ANA, Jiang C, Rajan V, Hartman D, Karas C (2007) Gas metal arc welding of coated advanced high strength steel (AHSS)—developments for improved weld quality. SAE Technical Papers, (2007–01-1360)

  18. Pouraliakbar H, Pakbaz M, Firooz S, Jandaghi MR, Khalaj G (2016) Study on the dynamic and static softening phenomena in Al-6Mg alloy during two-stage deformation through interrupted hot compression test. Measurement 77:50–53

    Article  Google Scholar 

  19. Jandaghi MR, Pouraliakbar H, Shiran MKG, Khalaj G, Shirazi M (2016) On the effect of non-isothermal annealing and multi-directional forging on the microstructural evolutions and correlated mechanical and electrical characteristics of hot-deformed Al-Mg alloy. Mat Sci Eng A-Struct 657:431–440

    Article  Google Scholar 

  20. Pouraliakbar H, Jandaghi MR, Khalaj G (2017) Constrained groove pressing and subsequent annealing of Al-Mn-Si alloy: microstructure evolutions, crystallographic transformations, mechanical properties, electrical conductivity and corrosion resistance. Mater Design 124:34–46

    Article  Google Scholar 

  21. Jandaghi MR, Pouraliakbar H, Khalaj G, Khalaj M-J, Heidarzadeh A (2016) Study on the post-rolling direction of severely plastic deformed aluminum-manganese-silicon alloy. Arch Civ Mech Eng 16(4):876–887

    Article  Google Scholar 

  22. Jandaghi MR, Pouraliakbar H (2017) Study on the effect of post-annealing on the microstructural evolutions and mechanical properties of rolled CGPed aluminum-manganese-silicon alloy. Mat Sci Eng A-Struct 679:493–503

    Article  Google Scholar 

  23. Rokhlin SI, Guu AC (1993) A study of arc force, pool depression, and weld penetration during gas tungsten arc welding. Weld J 72:381s–390s

    Google Scholar 

  24. Quintino L, Liskevich O, Vilarinho L, Scotti A (2013) Heat input in full penetration welds in gas metal arc welding (GMAW). Int J Adv Manuf Tech 68(9–12):2833–2840

    Article  Google Scholar 

  25. Kim J-S, Kim I-J, Kim Y-G (2014) Optimization of weld pitch on overlay welding using mathematical method. Int J Precis Eng Manuf 15(6):1117–1124

    Article  Google Scholar 

  26. Lee H, An Y, Park H (2000) CO2 weldability of Zn coated steel sheet (1)—weld defects and its characteristics in welds. J Weld Join 18:64–68 (in Korean)

    Google Scholar 

  27. Moinuddin SQ, Sharma A (2015) Arc stability and its impact on weld properties and microstructure in anti-phase synchronised synergic-pulsed twin-wire gas metal arc welding. Mater Des 67:293–302

    Article  Google Scholar 

Download references

Acknowledgments

The authors are deeply grateful to Jeong Seok Kim, a research engineer at Hyundai Steel Company, for his assistance with the execution of the experiments.

Author information

Authors and Affiliations

  1. Technical Research Center, Hyundai Steel Company, 1480 Bukbusaneop-ro, Songak-eup, Dangjin, Chungcheongnam-do, 31719, South Korea

    Jiyoung Yu

  2. Research & Development Division, Hyundai Motor Company, 150 Hyundaiyeonguso-ro, Hwaseong, Gyeonggi-do, 18280, South Korea

    Dooyoung Kim

Authors
  1. Jiyoung Yu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Dooyoung Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jiyoung Yu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yu, J., Kim, D. Effects of welding current and torch position parameters on minimizing the weld porosity of zinc-coated steel. Int J Adv Manuf Technol 95, 551–567 (2018). https://doi.org/10.1007/s00170-017-1180-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-1180-6

Keywords

Search

Navigation