Abstract
The usage of advanced high strength steel (AHSS) in automotive body structures is projected to grow significantly in the next 5–10 years with the introduction of new safety and fuel economy regulations. This is due to their superior mechanical properties and weight savings potential. These new materials pose significant manufacturing challenges, particularly for welding and stamping. Due to the high strength nature of AHSS materials, higher weld forces and longer weld times are often needed to weld these advanced steels. In this paper, the weldability of 1.4 mm electro galvanized (EG) Dual Phase 780 (DP780) welded to a 1.6 mm Electro Galvanized (EG) Transformation Induced Plasticity 780 (TRIP780) is discussed. Also, weld current lobes, mechanical properties (shear and cross tension), metallographic cross-section and micro-hardness profile in a two-metal stack-up are discussed. Weld Lobes and a full factorial Design of Experiment (DOE) was conducted. Weld current and hold time are the chosen factors for the DOE. Based on the DOE data analysis, weld current was the significant factor for tensile load and hold time was the significant factor for the cross tension load. There were no interaction effects observed between weld current and hold time o for tensile and cross tensions loads.
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