SYMPOSIUM

Science and Technology of Welding and Joining of

Materials
TITLE OF THE PROJECT

“Statistical and metallurgy analysis of welded joint of three

DP-270 steels disimilar in thickness”

Authors:

Baltazar Hernández Víctor Hugo, Poiré de la Cruz David Ricardo, Reyes Calderón, Francisco
Vergara Hernández Héctor Javier, Vences Hernández Rogelio and Contreras Navarrete José de Jesús

Agosto 2024
 Index

1 Introduction

2 Methodology

3 Results

4 Conclusions

5 References
 Introduction
Figure 1 shows a typical metallographic image of a Dual Phase (DP) steel,
displaying its respective phases.

Ferrite
Martensite

Figure 1. DP Steel microstructure [1].

[1] Caprili, Silvia, et al. A new generation of high-ductile Dual-Phase steel reinforcing bars. Construction and Building Materials, 2018, vol. 179, p. 66-79.
 Controlling the quality of the resistance spot welding (RSW) process in Dual Phase
(DP) steels, through optimal welding parameters and evaluated using statistical
techniques, is of interest due to the wide range of DP steels that have been
developed.

Figure 2. Welding cycle of RSW [2].

[2] O. P. R. Cortés, “Evaluación de los parámetros del proceso de soldadura de puntos por resistencia (RSW) sobre las propiedades mecánicas y
metalúrgicas de un acero al carbono.” Tesis, 2012.
 The design of experiments was the chosen technique for the experimental evaluation
because it provides an experimental path and a way to assess the response of the
experimentation.

Figure 3. Two ways of experimental design.

[3] Valdés García, Roberto Carlos, Diseño y entrenamiento de una red neuronal para la estimación de daño en una estructura escolar bajo vibraciones,
Tesis, 2019.
 The RSW thermal cycle significantly influences the BM microstructure, resulting in
zones with varying properties, including the FZ, HAZ, and BM [4].

Figure 4. Weld metal zones of nugget [5].

[4] Svoboda, H., H.N. Lorusso, and A. Burgueño, “Soldadura de aceros dual phase en chapa fina: GMAW, PAW y RSW”. Soldagem & Inspeção, 2011. 16: p. 165-176.
[5] H. Zhang, A. Wei, X. Qiu, and J. Chen, “Microstructure and mechanical properties of resistance spot welded dissimilar thickness dp780/dp600 dual-phase steel joints,”
Materials and Design, vol. 54, no. 0, pp. 443–449, 2014.
 Methodology

7.Interpretacion de micrografias. 8. Medición de tamaño de grano.

9.Cuantificación de porciento de
fases.
 a) b)

• Zhang et al. [6] established a

correlation between weld nugget
c) D characteristics and tensile test
) outcomes.

Figura 12. Macrografías de las probetas: a) 3, b) 30, c) 39 y d) 48.

Figure 5. Macroscopic images of the samples

[6] Zhang, Hongqiang, et al. Resistance spot welding macro characteristics of the dissimilar thickness dual phase steels. Materials & Design 63 (2014): 151-158.
Table 1. Full factorial design 33.
Welding Welding
Thicknesses
current (A) time (ms)
(mm)
3500 500 0.48 / 0.98 5500 1000 0.98 / 1.7
3500 500 0.48 / 1.7 5500 1500 0.48 / 0.98
3500 500 0.98 / 1.7 5500 1500 0.48 / 1.7
3500 1000 0.48 / 0.98 5500 1500 0.98 / 1.7
3500 1000 0.48 / 1.7
3500 1000 0.98 / 1.7
3500 1500 0.48 / 0.98
3500 1500 0.48 / 1.7
3500 1500 0.98 / 1.7
4500 500 0.48 / 0.98
4500 500 0.48 / 1.7
4500 500 0.98 / 1.7
4500 1000 0.48 / 0.98
4500 1000 0.48 / 1.7
4500 1000 0.98 / 1.7
4500 1500 0.48 / 0.98
4500 1500 0.48 / 1.7
4500 1500 0.98 / 1.7
5500 500 0.48 / 0.98
5500 500 0.48 / 1.7
5500 500 0.98 / 1.7
5500 1000 0.48 / 0.98 Figure 6. Tensile data.
5500 1000 0.48 / 1.7
 Results (Taguchi)
Table 2. Taguchi orthogonal array L9.
Welding current Thickneses
Time (ms)
(A) (mm)

1 3500 500 0.48 / 0.98

2 3500 1000 0.48 / 1.7

3 3500 1500 0.98 / 1.7

4 4500 500 0.48 / 1.7

5 4500 1000 0.98 / 1.7

6 4500 1500 0.48 / 0.98

7 5500 500 0.98 / 1.7

8 5500 1000 0.48 / 0.98

9 5500 1500 0.48 / 1.7

 Table 3. Optimal level per factor.

Levels Welding Welding time Thicknesses

current (A) (ms) (mm)
1 3500 500 *
2 * * *
3 * * 2.68

Figure 7. Evaluation of the Taguchi method results.

 Results (FFD)

Figure 8. Pareto chart of standardized effects.

 • The normal probability plot is
used to verify that residuals are
normally distributed. Residuals
should approximate a straight
line on this plot, indicating
homogeneity of variance. [7].

Figure 9. Normal prob. plot.

[7] Kuehl, Robert O. Diseño de experimentos: principios estadísticos para el diseño y análisis de investigaciones. Thomson
Learning, 2001.
 FFD-derived mathematical model

I= welding current
T=Welding time
E=Thicknesses

T.D.

R² = 0.98
 Results (Weld nugget)
a) b)

c) d)

Figura 10. High-quality weld button images: a) Overall view of the weld, b) Fusion zone, c) Microstructure of the upper base material,
and d) Microstructure of the lower base material.
 Conclusions

The aim of this study was to identify optimal RSW process parameters for
enhancing the weldability of dissimilar-thickness DP steels.
• The employment of both full factorial design (FFD) and Taguchi methods in welding
experiments facilitated a more precise discretization of process variables and
resulted in optimized welding processes.
• A reduced current intensity combined with a decreased welding time leads to a
smaller heat-affected zone and a weld nugget with a desirable geometry.
• Thickness was the most significant factor influencing the geometry of resistance spot
welds.
 References
1. Caprili, Silvia, et al. A new generation of high-ductile Dual-Phase steel reinforcing bars. Construction and Building
Materials, 2018, vol. 179, p. 66-79.

2. O. P. R. Cortés, “Evaluación de los parámetros del proceso de soldadura de puntos por resistencia (RSW) sobre las
propiedades mecánicas y metalúrgicas de un acero al carbono.” Tesis, 2012.

3. Valdés García, Roberto Carlos, Diseño y entrenamiento de una red neuronal para la estimación de daño en una
estructura escolar bajo vibraciones, Tesis, 2019.

4. Svoboda, H., H.N. Lorusso, and A. Burgueño, “Soldadura de aceros dual phase en chapa fina: GMAW, PAW y RSW”.
Soldagem & Inspeção, 2011. 16: p. 165-176.

5. H. Zhang, A. Wei, X. Qiu, and J. Chen, “Microstructure and mechanical properties of resistance spot welded dissimilar
thickness dp780/dp600 dual-phase steel joints,” Materials and Design, vol. 54, no. 0, pp. 443–449, 2014.

6. Zhang, Hongqiang, et al. Resistance spot welding macro characteristics of the dissimilar thickness dual phase steels.
Materials & Design 63 (2014): 151-158.

7. Kuehl, Robert O. Diseño de experimentos: principios estadísticos para el diseño y análisis de investigaciones. Thomson
Learning, 2001.
Thanks for your
attention