This thesis deals with the topic of procedural parameters influence on the properties of welded joint in zinc-coated deep-drawing steels in laser welding with wobbling. First part of the thesis serves as an overview of laser welding technology, welding of steel with protective zinc layer and weld quality testing. Second part is dedicated to a proposal, process flow and evaluation of an experiment. Seven trial lap welding joints of DC04+ZE steel have been welded using different welding parameters. Specimens from these trial welds were used for metallurgical testing by macro-etch examination and for tensile strength break testing to get mechanical properties of welded joints.

This diploma thesis deals with the experiment of welding galvanized sheets using fiber laser. The experiment is based on testing of welds lap joints with different gap between the welded parts. Theoretical part of this diploma thesis describes the principles and different types of lasers, laser welding technology, welding defects, galvanizing and inspection of welded joints. In the experimental part of the thesis welding tests and analysis of the results of the experiment have been realised and evaluated.

The unique combination of high specific strength and ductility in third generation advanced high-strength steels (3G-AHSSs) has garnered significant attention from top automotive steel industries. These materials are being considered as potential options for making lighter body components due to their strength and ability to tolerate thinner material cross-sections. However, galvanizing these steels through the continuous hot-dip galvanizing process is challenging, because the main alloying elements such as Mn, Si, Al, and Cr tend to selectively oxidize on the steel surface during the annealing process before being immersed in the galvanizing bath containing Zn(Al, Fe). The presence of these oxides extensively covering the substrate surface can negatively impact reactive wetting, coating adhesion, and overall coating quality. In this study, the selective oxidation kinetics and reactive wetting of a series of Fe-(2-10)Mn-(0.00/0.01/0.03)Sb (at. pct) were determined and a model was proposed for analyzing oxide growth during intercritical annealing prior to galvanizing. Annealing heat treatments were carried out at 676, 725, 775, and 825 ˚C for 60-480s holding time in a N2-5vol pct H2 process with a dew point of –10 ˚C. MnO was formed on all samples after annealing. It was determined that the annealing conditions (temperature and isothermal holding time) affected the external oxide thickness and depth of the oxidation zone, which in turn influenced the MnO growth rate. With increasing the bulk Mn content of the alloy, the Mn elemental flux to the external surface increased, resulting in an increase in the oxidation parabolic rate constant. The average activation energy of internal oxidation for the Fe-2Mn, Fe-6Mn and Fe-10Mn alloys were determined to be 216±15 kJ/mol, 178 ± 18 kJ/mol and 152 ±10 kJ/mol, respectively, which are consistent with the activation energy of oxygen diffusion through MnO interfaces and the bulk diffusion of oxygen in austenite. Moreover, the average activation energy for external oxide growth was ~113±18 kJ/mol, which was attributed to the diffusion of Mn cations along the grain boundaries of the external Mn oxides. It was determined that micro addition of Sb to the Fe-Mn alloys led to a reduction in the oxidation rate constant, external oxide thickness, and internal oxidation zone, which was attributed to Sb segregation at both the external and internal oxide interface, resulting in the reduction of oxygen permeability. The reduction was more significant in the Fe-10Mn alloys, primarily attributable to the increased Sb segregation at the interfaces. The research showed that when the bulk Mn content increased, more antimony (Sb) segregated at both the internal and external oxide/substrate interface. As a result, the oxygen present at these interfaces decreased. This is attributed to the reduction of Sb solubility in α-Fe with increasing Mn and positive interactions between Sb and Mn. Advanced Atom Probe Tomography (APT) analysis confirmed that as more Sb segregated at the interfaces, the excess oxygen reduced due to site competition between O and Sb. Additionally, Sb surface segregation kinetics for Fe-(0.01/0.03)Sb and Fe-2Mn-(0.01/0.03)Sb at.% were determined based on the modified Darken model and linear heating followed by isothermal annealing. After the annealing, Sb segregation was detected on the surface of both the Fe-xSb and Fe-2Mn-xSb alloys, which increase with increasing temperature and holding time. The segregation rate, as determined from the Darken curves, was higher in Fe-Sb alloys compared to Fe-2Mn-Sb alloys, which can be attributed to variations in the crystal structure and the density of defects within the metal matrix. Additionally, the activation energy for Sb diffusion in both Fe-Sb and Fe-2Mn-xSb alloys were determined to be approximately 193±18 kJ/mol closely aligns with the activation energy of Sb bulk diffusion in α-Fe. Simulated galvanizing treatments were conducted on Fe-(2-10)Mn-(0.00/0.03)Sb at.% alloys. It was found that Sb segregation at the external/oxide interface resulted in a decrease in the size and thickness of the external oxide particles, which can facilitate better contact between the zinc bath and the substrate. Furthermore, it was found that Sb segregation at the interface between the external oxide and substrate led to a decrease in the stability of the interfacial region. This effect was attributed to an increase in the local atomic spacing near the interface, caused by Sb segregation. As a result, a local strain was observed near the interface. This localized strain significantly reduced the energy needed to separate the oxide from the metal matrix, contributing to decreased stability of the interfacial region. The higher bulk manganese (Mn) content led to increased segregation of antimony (Sb), resulting in a greater local strain within the interfacial region. These effects, in turn, enhanced the kinetics of the aluminothermic reduction reaction and assisted oxide lift-off. Furthermore, the closely packed Fe-Al intermetallics at the coating/steel interface increased as a result of adding Sb to the steel. In addition, no Sb segregation was observed at interfacial layer/metal interface. This absence of segregation can be attributed to the dissolution of segregated Sb into the liquid zinc. It was determined that Sb, which segregated at the external oxide/substrate interface during annealing, dissolved into the zinc bath and disrupted its bond with iron. This disruption occurred due to the higher electronegativity of Sb compared to Fe with Zinc, as well as the sufficient solubility of Sb in liquid zinc. / Thesis / Doctor of Science (PhD) / The unique combination of high specific strength and ductility exhibited by third-generation advanced high-strength steels has captured the attention of automotive industries. However, challenges arise when attempting to galvanize these steels through continuous hot-dip galvanizing processes. The selective oxidation of alloying elements during annealing can have detrimental effects on reactive wetting and coating adhesion. The objective of this research was to improve the coating quality of Mn-containing steels by introducing micro-additions of Sb. Sb segregation to the surface and interfaces began to occur during annealing. Segregated Sb resulted in a reduction of the oxidation rate. Sb segregation at oxide interfaces also contributed to decreased oxygen permeability. Upon immersion in the liquid zinc bath, both Sb and Fe dissolved into the zinc, leading to the formation of an interfacial layer on the surface, which indicates successful reactive wetting. The findings of this research provide valuable insights for improving galvanizing processes and enhancing coating quality, specifically in the context of third-generation advanced high-strength steels.

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In response to more stringent global CO2 emissions, automotive manufacturers have increased the use of advanced high strength steels (AHSS). Ultra-high strength steels are often used within the body-in-white (BIW) for safety critical parts and structural reinforcements, such as roof rails and side impact beams. Currently, the most commonly used press hardened steel (PHS) grade for these applications is 22MnB5, with a typical composition of 0.22C 1.2Mn 0.25Si 0.005B (wt%). Automotive OEMs have expressed a desire to use Zn-based coatings as they are compatible with the current painting system and have the potential to provide robust cathodic protection. The steel blanks generally undergo direct hot press forming (DHPF) to achieve the necessary martensitic microstructure and target mechanical properties, but this presents challenges for Zn-coated 22MnB5. The adoption of Zn-based coatings within the automotive industry has been inhibited by the prospect of liquid metal embrittlement (LME) resulting from DHPF, as well as the desire to provide robust cathodic protection. Previous literature has reported that a zinc ferrite (α-Fe(Zn)) coating with a global Zn content of at least 30 wt% will provide cathodic protection to the underlying substrate. The main goal of this work was to determine the microstructural evolution and electrochemical properties of galvanized (GI70 – 70 g/m2/side) 22MnB5 substrates as a function of the annealing time at a typical austenization temperature of 900°C. It was found that the Zn-based coatings annealed at 700°C consisted to a mixture of small volume fraction of α-Fe(Zn) and Г-Fe3Zn10. After heating to 900°C, the coating comprised varying volume fractions of α-Fe(Zn) and Zn(Fe) liquid, which transformed to Г-Fe3Zn10 after solidification. The relative fraction of Г Fe3Zn10 was found to decrease with increasing annealing time until the coating completely transformed to α-Fe(Zn) after annealing at 900°C for 240 s. GDOES results found that, when the sample was annealed at 900°C for 240 s, the global Zn content of the coating was less than 30 wt%. Coatings comprising varying fractions of Г-Fe3Zn10 were subjected to uniaxial tensile tests to determine how the coating microstructure affected the mechanical properties in comparison to the uncoated substrate material. It was found that the uncoated substrate material met the mechanical property requirements of σ(UTS)min ≥ 1500 MPa regardless of annealing time. However, σ(UTS) was found to decrease with increasing annealing times for the GI70 coated samples until the target mechanical properties were not met when the sample was annealed at 900°C for 180 s. This was attributed to increased coating thicknesses leading to a decrease in the martensitic cross-sectional area to support the load. Furthermore, the coatings were subjected to a variety of electrochemical characterization techniques, including potentiodynamic and galvanostatic polarization scans, potentiostatic scans, and electrochemical noise tests. Potentiodynamic polarization scans indicated a higher driving force for cathodic protection when the coating contained some fraction of Г-Fe3Zn10. Furthermore, a limiting current density for these samples was observed, demonstrating that Г-Fe3Zn10 corrodes at a slower rate in comparison to α Fe(Zn). Galvanostatic polarization measurements indicated that, when the fraction of Г Fe3Zn10 within the coating was below 15 vol%, the protective properties of the phase were not exhibited. XRD and TEM analysis revealed the formation of three corrosion products on the surface: simonkolleite, hydrozincite, and akaganeite. It was found that, when samples contained greater than 15 vol% Г-Fe3Zn10 in the coating, the predominant corrosion products were a combination of simonkolleite and hydrozincite. When the Г Fe3Zn10 content was below this value, the dominant corrosion product was found to be akaganeite. Furthermore, substrate attack was observed on a sample annealed at 900°C for 420 s when the coating layer was intact, indicating that the α-Fe(Zn) only containing coating obtained at this time does not provide cathodic protection. Based upon the current results, it was determined that a minimum volume fraction of 15 vol% Г-Fe3Zn10 must be present within the coating layer to obtain robust cathodic protection. Furthermore, it was determined that the processing window to develop cathodically protective Zn based coatings while mitigating LME is extremely narrow. This is a result of the fact that it is necessary for at least 15 vol% Г-Fe3Zn10 to be present within the coating microstructure at room temperature, which is liquid at the forming temperatures of 900°C. From the current findings, it was found that it is unlikely that a cathodically protective Zn-based coating can be obtained for DHPF steel parts using 22MnB5 as a substrate material. This is due to the high forming temperature resulting in liquefication of the coating and the rapid cooling rates necessary to achieve the target mechanical properties of σ(UTS)min ≥ 1500 MPa. Thus, it is recommended that the current substrate material be altered such that the part may be formed below the peritectic temperature of 782°C. / Thesis / Master of Applied Science (MASc)

Made available in DSpace on 2016-04-18T21:36:00Z (GMT). No. of bitstreams: 4 Danieli Cristina Pedroso1.pdf: 893786 bytes, checksum: 0b49df9c67021da69e5f47f5170c5703 (MD5) Danieli Cristina Pedroso2.pdf: 3031650 bytes, checksum: bbf4b2dc04de906b1c5596adb5c76bb8 (MD5) Danieli Cristina Pedroso3.pdf: 2597659 bytes, checksum: 1a3e7d52a670d6eb3f003b1583e76702 (MD5) Danieli Cristina Pedroso4.pdf: 198943 bytes, checksum: 16b69ef67e7c298a9fc35b695825e236 (MD5) Previous issue date: 2009-08-17 / In this work the causes of rejection of lots of artifacts from the company Produto para Linhas Preformados, PLP, were analyzed which are made of steel SAE 1010 and SAE 1020 and zinc coated by hot-dip galvanizing. Lots of samples from different manufacturers were selected, with different chemical composition and geometry, but belonging to rejected lots and approved lots in accordance with usual market standards. The rejections are due to problems related to the adhesion of the layer of zinc. The samples were submitted to optical microscopy test, scanning electron microscopy and X-ray diffractions for comparative checking of between the structures of zinc formed layers by hot -dip galvanizing. To verify the corrosion in coating failure, corrosion tests were performed in three different environments: urban environment considered to be low-polluted; environment simulating sea water, salt spray. There is no failure evidence between the zinc coating and the substrate structure; irregular coatings and not very well defined phases were found in the rejected parts. In regions with failures, the results show a behavior similar to the literature with the rapid formation of rust at the beginning of the exposure followed by a show oxidation. / Neste trabalho foram analisadas as causas da rejeição de lotes de artefatos da empresa Produto para Linhas Preformados, PLP, fabricados com aços SAE 1010 e SAE 1020 e zincados por imersão a quente. Foram selecionadas amostras de lotes de fabricantes diferentes, com composição química e geometrias distintas, pertencentes a lotes rejeitados e a lotes aprovados de acordo com normas usuais de mercado. As rejeições se devem a problemas relacionados a aderência da camada de zinco. As amostras foram submetidas a exames por microscopia óptica, microscopia de varredura e análises por difração de raio-X para verificação comparativa entre as estruturas das camadas de zinco formadas no processo zincagem por imersão a quente. Para verificar a corrosão nas falhas de revestimento de zinco, foram realizados ensaios de corrosão em três ambientes diferentes: ambiente considerado urbano de baixa poluição; ambiente simulando água do mar; câmara de névoa salina. Não há indício de relação entre a falha nos revestimentos de zinco e a estrutura do substrato; revestimentos irregulares e com fases não muito bem definidas foram encontrados nas peças rejeitadas. Nas regiões com falha, os resultados evidenciam um comportamento semelhante ao da literatura, com formação rápida de ferrugem no início da exposição das peças seguida por uma oxidação lenta.

O mercado siderúrgico vive um momento de grande competição e as empresas produtoras necessitam, cada vez mais, atuar internamente sobre seus custos para garantir lucratividade e rentabilidade. A motivação deste trabalho foi a redução de custos de produção de arames de aço para o setor agropecuário, por meio de estudo de viabilidade técnica do emprego de aço ao carbono produzido via aciaria elétrica, em lugar de aço produzido via aciaria a oxigênio – atualmente utilizado em algumas usinas siderúrgicas. As qualidades de aços estudadas são produzidas através de aciaria elétrica, dando origem aos tarugos que são laminados a quente para obtenção do fio-máquina que segue para os processos posteriores de trefilação e galvanização, em que se obtém os arames de aço. As composições químicas propostas neste trabalho devem garantir que as especificações de propriedades mecânicas permaneçam sendo atendidas. Foram realizados levantamento e análise de histórico de dados, análises de composição química, caracterização microestrutural, ensaios de tração e de enrolamento. Fundamentado nos resultados atingidos, mostra-se que a metodologia proposta para avaliação de propriedades mecânicas é válida. O presente estudo aponta também que é viável tecnicamente o emprego de aço ao carbono semelhante ao SAE1045, obtido via aciaria elétrica, na produção de arames de aço galvanizados para o setor agropecuário, mantendo o atendimento a todas as especificações e com possibilidade de redução de custos de produção. / The steel market is experiencing a period of great competition and manufacturing companies need, increasingly, to act internally on their costs to ensure lucrativeness and profitability. The motivation of this work was to reduce the cost of production of steel wires for the agriculture sector, by studying the technical feasibility use of a carbon steel produced by electric arc furnace, replacing the oxygen furnace steel – currently used in some mills. The studied steels are manufactured in an electric arc furnace, giving rise to the billets that are hot rolled to obtain the wire rod to follow the subsequent process of drawing and galvanizing, where the wires of steel are made. The chemical compositions proposed in this paper must guarantee that the mechanical properties described in the technical standards continue be met. Data, chemical composition, microstructure, tensile strength and winding properties were surveyed and analyzed. Based upon the results achieved, it is shown that the proposed method for assessment of the mechanical properties is valid. This study also indicates that it is technically feasible the use of carbon steel similar to SAE1045, obtained by electric arc furnace, to manufacturing galvanized steel wires for the agriculture sector maintaining compliance to all technical standards and with the possibility of reducing costs.