Patent Application
20230132518
This application relates to an arc welded joint excellent in terms of corrosion resistance which can preferably be used for the chassis members of an automobile and the like and to an arc welding method for forming the joint.
Nowadays, regarding the members used for an automobile body, there are increasing needs for not only increased strength and rigidity for the purpose of improving the safety and reliability of the automobile body but also decreased weight for the purpose of improving fuel efficiency. As a result, the thickness of a steel sheet for the members is being decreased by using a high strength steel sheet. On the other hand, for various members used for an automobile, and particularly, for chassis members (for example, a lower arm and the like), from the viewpoint of the strength and rigidity of members, a steel sheet having a thickness larger than that of a steel sheet used for an automobile body is used. Therefore, by increasing the strength of a steel sheet used for chassis members, thereby realizing an additional decrease in the thickness of a steel sheet, it is possible to realize an additional decrease in the weight of an automobile body. Consequently, it is possible to realize an improvement in fuel efficiency while the strength and rigidity of members are maintained.
Generally, members used in a corrosive environment are subjected to a rust prevention treatment such as chemical conversion coating and electrodeposition coating to achieve corrosion resistance after welding has been performed. However, there may be a case where rust or corrosion is observed in a weld and a portion in the vicinity of the weld as time passes. In the case of a member which has been subjected to electrodeposition coating as described above, corrosion tends to start at a weld, extends in the weld and a wide region surrounding the weld while being accompanied by coating film blister as time passes, and progresses also in the thickness direction. In the case where corrosion progresses in such a way, there is a decrease in the thickness of the weld and a portion in the vicinity of the weld, which results in a decrease in the strength of not only the weld but also the member. That is, in the case where corrosion occurs in members whose weld is subjected to a load (for example, the chassis members of an automobile and the like) and progresses, there may be a case where the member fractures.
In the case where electrodeposition coating is performed, after chemical conversion coating (for example, a zinc phosphate treatment or the like) is first performed on a base steel sheet and a weld metal as a pretreatment to improve the adhesion property of an electrodeposition coating film to the base steel sheet and the weld metal, electrodeposition coating is performed. A zinc phosphate treatment, which is widely used as an example of chemical conversion coating, is a technique in which zinc phosphate crystal grains are grown on the surface of the base steel sheet and the weld metal to improve the adhesion property of a coating film in electrodeposition coating. However, in the case of the conventional technique, even when chemical conversion coating is performed on a member before electrodeposition coating is performed, coating film blister often occurs in a weld and a wide region surrounding the weld as time passes. That is, in the case of the technique where electrodeposition coating is performed after chemical conversion coating described above has been performed as a pretreatment, it is difficult to completely inhibit corrosion starting at a weld from occurring.
Therefore, investigations are being conducted regarding a technique in which a steel sheet having a plated layer (for example, a zinc-based plated layer and the like) is used. Although, in the case of a steel sheet having a plated layer, it is not possible to avoid an increase in manufacturing costs compared with the case of an ordinary steel sheet due to additional costs caused by a plating treatment, it is possible to expect the effect of improving corrosion resistance due to a plated layer.
However, even in the case of members for which a steel sheet having a plated layer is used, an arc welding method is used as a joining method as in conventional cases. Therefore, in a weld which is subjected to a high temperature due to arc plasma (hereinafter, referred to as “arc”), which is a heat source, since a plated layer is vaporized, a local un-plated portion is exposed. Therefore, it is not possible to expect a significant improvement in corrosion resistance commensurate with an increase in cost due to the use of a steel sheet having a plated layer.
As described above, although various manufacturing techniques have been developed to improve the corrosion resistance of members, all of such techniques have both advantages and disadvantages. Therefore, from the viewpoint of improving corrosion resistance while inhibiting an increase in manufacturing costs, investigations are being conducted regarding a technique for more effectively preventing corrosion starting at a weld from occurring and progressing.
Examples of a conventionally known starting point in a weld at which corrosion occurs include the following.
(a) slag adhering to a weld (mainly the surface of a weld bead)
(b) welding fume adhering to a weld
(c) oxide formed on the surface of a steel sheet subjected to a high temperature due to welding
Even when a member having the adhering substance described in item (a) or (b) above or the oxide described in item (c) above in a weld is subjected to chemical conversion coating, the formation of a region which is not coated with a chemical conversion coating layer formed of zinc phosphate crystal grains starts at the adhering substance or the formed substance, and such a region is locally retained.
In addition, in such a region which is not coated with a chemical conversion coating layer, even when electrodeposition coating is performed, since there is insufficient formation of a coating film, and since there is an insufficient adhesion property of a coating film, there is a significant deterioration in corrosion resistance. As a result, there is a decrease in thickness due to corrosion occurring and progressing. Therefore, investigations are being conducted regarding a technique for preventing the formation of the adhering substance described in item (a) or (b) above or the oxide described in item (c) above.
For example, Patent Literature 1 discloses a technique in which, after arc welding has been performed and before electrodeposition coating is performed, a weld and a portion in the vicinity of the weld is subjected to a spraying treatment or an immersion treatment by using a non-oxidizing acidic solution having a pH of 2 or less at a temperature of 30° C. to 90° C. This technique is a technique for removing the slag described in item (a) above, the welding fume described in item (b) above, and the oxide described in item (c) above by dissolving a weld bead and a steel sheet with the non-oxidizing solution.
However, in the case of the technique disclosed in Patent Literature 1, since it is necessary to wash away the acidic solution before electrodeposition coating is performed, the manufacturing process of members becomes complex. In addition, since a member having a desired shape is formed of steel sheets having various shapes which are overlapped and welded together, an acidic solution which is retained in gaps between the overlapped steel sheets causes severe corrosion. Moreover, since a large amount of acidic solution is used, breakdown and corrosion tend to occur in manufacturing equipment due to the equipment being exposed to a corrosive environment, and it is necessary to ensure the safety of operators by preventing fume from scattering.
Patent Literature 2 discloses a technique in which the amounts of oxidizing gases (that is, CO2 and O2) contained in a gas for shielding a weld (hereinafter, referred to as “shielding gas”) when arc welding is performed are decreased. This technique is a technique for inhibiting the formation of slag when welding is performed, the oxidization of a welded heat affected zone, and the adhesion of welding fume.
However, in the case where the amounts of oxidizing gases in a shielding gas are decreased, a weld bead becomes unstable due to an arc becoming unstable, which results in poor weld penetration. Since such a weld defect causes a decrease in joint strength, it is difficult to apply the technique disclosed in Patent Literature 2 to members such as chassis members which are required to have sufficient strength and rigidity.
Patent Literature 3 discloses a technique in which the formation of slag is inhibited by decreasing the total of the contents of Si and Mn in a welding wire used in arc welding and the contents of Si and Mn in a steel sheet used.
However, in the case where the Si content and the Mn content are decreased from the viewpoint of inhibiting slag formation, it is not possible to avoid a decrease in the strength of a steel sheet. That is, in the case of the technique disclosed in Patent Literature 3, since a steel sheet having a large thickness has to be used to achieve sufficient strength of members, it is difficult to realize a weight reduction of an automobile body.
Patent Literature 4 discloses a technique in which, even in the case of a weld bead containing slag, welding fume, and oxides, a chemical conversion coating layer is sufficiently formed by controlling the chemical composition of a treatment solution used in chemical conversion coating. In this technique, the formation of a chemical conversion coating layer is facilitated by performing a surface treatment with a surface conditioning solution containing a zinc phosphate colloid. Moreover, by performing chemical conversion coating with a zinc phosphate treatment solution containing F in an amount of 100 mass ppm or more, slag, welding fume, and oxides are dissolved and removed, which results in an improvement in the adhesion property of an electrodeposition coating film.
However, in the case of the technique disclosed in Patent Literature 4, since a zinc phosphate treatment solution containing fluorine, which is designated as a poisonous substance, is used, it is necessary to decrease the fluorine content in liquid waste generated from the treatment solution to a level satisfying environmental standards, when the liquid waste is discharged from a factory. Therefore, large liquid waste disposal equipment is necessary in addition to the manufacturing equipment for members.
PTL 1: Japanese Unexamined Patent Application Publication No. 9-20994
PTL 2: Japanese Unexamined Patent Application Publication No. 8-33982
PTL 3: Japanese Unexamined Patent Application Publication No. 8-33997
PTL 4: Japanese Patent No. 5549615
The disclosed embodiments have been completed to solve the problems of the conventional techniques, and an object of the disclosed embodiments is to provide an arc welded joint excellent in terms of corrosion resistance which can preferably be used for various steel-made members (for example, the chassis members of an automobile and the like) which are subjected to electrodeposition coating before use and an arc welding method for forming the joint.
To solve the problems described above, the present inventors conducted investigations regarding the reasons for a deterioration in corrosion resistance in a weld of a steel-made member which has been subjected to electrodeposition coating (hereinafter, referred to as “coated steel-made member”).
A deterioration in the corrosion resistance of the weld of the coated steel-made member is caused by slag and welding fume adhering to the weld (that is, a weld bead and a welded heat affected zone) and oxides formed on the surface of a steel sheet subjected to a high temperature due to arc welding. Generally, in the case where a zinc phosphate treatment is performed as chemical conversion coating before electrodeposition coating is performed on a member which has been manufactured by a steel sheet subjected to work, the steel sheet is dissolved due to the etching function of the zinc phosphate treatment solution. In addition, since there is an increase in pH in a local region at a solid-liquid interface due to hydrogen ions being consumed due to the dissolution of the steel sheet, zinc phosphate crystal grains (that is, a chemical conversion coating layer) are precipitated on the surface of the steel sheet. However, since slag, welding fume, and other kinds of oxides exist on the weld of the steel sheet, there is a deterioration in dissolubility in a zinc phosphate treatment solution. As a result, it is difficult for zinc phosphate crystal grains to be precipitated. Therefore, since a chemical conversion coating layer is not sufficiently formed on a weld, it is not possible to achieve a sufficient adhesion property of a coating film when electrodeposition coating is performed thereafter. This is the reason why there is a deterioration in the corrosion resistance of the weld of a coated steel-made member.
That is, in the case where it is possible to sufficiently precipitate zinc phosphate crystal grains in a weld, since it is possible to improve the adhesion property of an electrodeposition coating film, it is possible to improve the corrosion resistance of the weld.
Therefore, the present inventors conducted investigations regarding a technique with which it is possible to improve corrosion resistance by densely precipitating zinc phosphate crystal grains on a weld. As a result, it was found that, to improve the corrosion resistance of the weld, decreasing the amount of slag adhering to the weld is most effective. However, in the case of a member manufactured by using a high strength steel sheet and a high strength welding wire, since there is an increase in the contents of Si, Mn, Ti, and the like due to the member having a high alloy chemical composition, there is a problem of an increase in the amount of slag formed in the weld.
By inhibiting the oxidation of Si, Mn, Ti, and the like contained in a steel sheet and a welding wire, it is possible to solve such a problem. That is, by using a shielding gas containing oxidizing gases in decreased amounts, since it is possible to inhibit the oxidation of such elements, it is possible to decrease the amount of slag formed. However, in the case where the contents of oxidizing gases in a shielding gas are decreased, since a cathode spot severely moves around when arc welding is performed, the arc becomes unstable. As a result, there are new problems of oxygen incorporation into a weld pool due to atmospheric air entrainment and a deterioration in weld bead shape.
On the other hand, in the case where an increase in the strength of a coated steel-made member is intended, it is not possible to avoid an increase in the contents of Si, Mn, Ti, and the like.
From the results of investigations conducted by the present inventors, inhibiting the formation of slag adhering to the weld bead to sufficiently precipitate a chemical conversion coating layer while maintaining arc stability to form a weld bead having a good shape is effective for improving the corrosion resistance of a member. Moreover, it is possible to further improve corrosion resistance by promoting the precipitation of a chemical conversion coating layer as a result of the following.
(A) decreasing the amount of welding fume adhering to a weld bead toe
(B) decreasing the amounts of oxides formed on the surface of a steel sheet due to welding
(C) removing oxides (so-called mill scale) formed on the surface of a steel sheet in a process for manufacturing the steel sheet
The disclosed embodiments have been completed on the basis of the findings described above.
That is, the disclosed embodiments include an arc welded joint, having a slag-coverage area ratio SRATIO (%) of 15% or less, wherein SRATIO is calculated by using equation (1), where an area of a surface of a weld bead formed by performing arc welding on a steel sheet is defined as a weld bead surface area SBEAD (mm2) and, of the weld bead surface area SBEAD, an area of a region covered with slag is defined as a slag surface area SSLAG (mm2) and having a weld bead width ratio WRATIO (%) of 60% or more, wherein WRATIO is calculated by using equation (2) from a maximum value WMAX (mm) and a minimum value WMIN (mm) of a weld bead width in a direction perpendicular to a welding line of the weld bead.
In the arc welded joint according to the disclosed embodiments, it is preferable that a cleaning region, in which oxides formed on a surface of the steel sheet are removed due to formation of a cathode spot when the arc welding is performed, be formed so as to be adjacent to a weld bead toe and that a minimum value MMIN (mm) of a distance M (mm) in the direction perpendicular to the welding line between an outer edge of the cleaning region and the weld bead toe (hereinafter, referred to as “cleaning width”) be 0.5 mm or more.
In addition, the disclosed embodiments include an arc welding method for manufacturing an arc welded joint, the arc welded joint having a slag-coverage area ratio SRATIO (%) of 15% or less, wherein SRATIO is calculated by using equation (1), where an area of a surface of a weld bead formed by performing arc welding on a steel sheet is defined as a weld bead surface area SBEAD (mm2) and, of the weld bead surface area SBEAD, an area of a region covered with slag is defined as a slag surface area SSLAG (mm2), and having a weld bead width ratio WRATIO (%) of 60% or more, wherein WRATIO is calculated by using equation (2) from a maximum value WMAX (mm) and a minimum value WMIN (mm) of a weld bead width in a direction perpendicular to a welding line of the weld bead.
In the arc welding method according to the disclosed embodiments, it is preferable that the arc welding be performed with reverse polarity as in a case of common CO2 welding and MAG welding, that a cleaning region, in which oxides formed on a surface of the steel sheet are removed due to formation of a cathode spot, which is an electron-emitting source, be formed so as to be adjacent to a weld bead toe, and that a minimum value MMIN (mm) of the cleaning width M (mm) be 0.5 mm or more. Moreover, it is preferable that Ar gas be used as a shielding gas.
Moreover, it is preferable that a short circuit intermittently occur between the steel sheet and a welding wire and that such a short circuit occur at an average short circuit frequency FAVE (Hz) of 20 Hz to 300 Hz with a maximum short circuit cycle TCYC (s) of 1.5 s or less. Moreover, it is preferable that pulse current be used as welding current of the arc welding and that X (A·s/m) calculated by using equation (3) from peak current IPEAK (A), base current IBASE (A), peak time tPEAK (ms), rise time tUP (ms), and fall time tDOWN (ms) of the pulse current and a distance L (mm) between the steel sheet and a contact tip satisfy a relational expression 50≤X≤250. In the arc welding method according to the disclosed embodiments, a solid wire may be used as the welding wire.
S
RATIO=100×SSLAG/SBEAD (1)
W
RATIO=100×WMIN/WMAX (2)
X=(IPEAK×tPEAK/L)+(IPEAK+IBASE)×(tUP+tDOWN)/(2×L) (3)
Here, the cleaning region described above is a region in which, by performing arc welding with the steel sheet being set at the cathode and with the welding wire being set at the anode (that is, with so-called reverse polarity), a cathode spot, which is an electron-emitting source, is formed on the steel sheet, and in which a phenomenon (so-called cleaning), in which oxides formed on the surface of the steel sheet are removed due to electron emission occurring in such a manner, occurs. Moreover, “s” used in the unit of X (A·s/m) denotes “seconds”, and the unit of tPEAK, tUP, and tDOWN (ms) is “milliseconds”(= 1/1000 seconds).
According to the disclosed embodiments, since it is possible to improve the corrosion resistance of the welds of various kinds of members such as chassis members, it is possible to improve the rust prevention performance of members made of a high strength steel sheet and members which are used in a strongly corrosive environment. According to the disclosed embodiments, it is possible to manufacture various kinds of members by using a high strength steel sheet having a tensile strength of, for example, 440 MPa or higher (for example, a steel sheet of a 440 MPa class, a steel sheet of a 590 MPa class, and a steel sheet of a 980 MPa class) and to improve the corrosion resistance thereof, which has a significant effect on the industry. In addition, by using a high strength steel sheet, it is also possible to decrease the thickness of the members.
Hereafter, with reference to
Here, the present embodiment is intended for arc welding performed on at least two steel sheets, and
In the disclosed embodiments, for example, as illustrated in
As illustrated in
O2->2[O] (4)
CO2->CO+[O] (5)
When oxygen generated due to such a decomposition reaction is dissolved in a molten metal 7 or a weld pool 8 (refer to
To solve such a problem, a welding wire 1 and a steel sheet 3 to which non-ferrous metals such as Si, Mn, Ti, and the like are added as deoxidizing agents are used. That is, by discharging oxygen which is generated due to a reaction expressed by formula (4) or formula (5) in the form of slag formed of SiO2, MnO, TiO2, and the like, a reaction between oxygen and iron is inhibited.
Slag which has been discharged to the surface of the weld pool 8 is aggregated in a subsequent cooling process, allowed to adhere to the surface of the weld bead 6 and a weld bead toe 9 (that is, a weld bead) (refer to
Here, the weld bead toe 9 and the weld bead start/finish end portions 10 will be described with reference to
Therefore, in the disclosed embodiments, by using a shielding gas containing mainly Ar gas, there is a decrease in the amount of O2 and CO2 mixed in, which results in the formation of slag being inhibited. Specifically, when the area of the surface of the weld bead 6 is defined as a weld bead surface area SBEAD (mm2) and, of the weld bead surface area SBEAD, the area of the region covered with slag is defined as a slag surface area SSLAG (mm2), a slag-coverage area ratio SRATIO (%) calculated by using equation (1) is set to be 15% or less. Moreover, since the aggregation of slag on the surface of the weld bead 6 is inhibited in the case where there is a decrease in the amount of slag formed, it is preferable that the slag-coverage area ratio SRATIO be 9% or less or more preferably 5% or less.
Furthermore, the lower the amount of non-conducting slag formed, the better the chemical conversion coatability and the electrodeposition coatability. Therefore, since it is preferable that the slag-coverage area ratio SRATIO be as small as possible, there is no particular limitation on the lower limit of the slag-coverage area ratio SRATIO. It is preferable that the slag-coverage area ratio SRATIO be 0.1% or more.
S
RATIO=100×SSLAG/SBEAD (1)
To prevent slag from being non-uniformly distributed on the surface of the weld bead 6, it is necessary to stabilize the shape of the weld bead 6.
Therefore, in the disclosed embodiments, a weld bead width ratio WRATIO (%) calculated by using equation (2) from the maximum value WMAX (mm) and the minimum value WMIN (mm) of a weld bead width (refer to
Here, there is no particular limitation on the upper limit of the weld bead width ratio WRATIO. It is preferable that the weld bead width ratio WRATIO be 100% or less.
W
RATIO=100×WMIN/WMAX (2)
It is preferable that arc welding be performed with the steel sheet 3 being set at the cathode and with the welding wire 1 being set at the anode (that is, with so-called reverse polarity). By using the reverse polarity, since a cathode spot, which is an electron-emitting source, is formed on the steel sheet 3, a region 4 (a so-called cleaning region), in which oxides (for example, mill scale formed in the manufacturing process of the steel sheet 3, oxides formed due to heat input when welding is performed, and the like) formed on the surface of the steel sheet 3 are removed, is formed.
In the case where a distance in a direction perpendicular to the welding line between the outer edge of the cleaning region 4 and the toe of the weld bead 6, that is, a cleaning width M (refer to
On the other hand, in the original portion of a steel sheet which is not affected by welding heat, it is not possible to expect that there is an improvement in chemical conversion coatability or electrodeposition coatability due to a cleaning function. In addition, in the case where a region in which cathode spot formation occurs is wide, arc discharge becomes unstable. Therefore, it is preferable that the maximum value MMAX (mm) of the cleaning width M (mm) be 8.0 mm or less.
By performing arc welding with reverse polarity, the welding wire 1 is set at the anode, and the steel sheet 3 is set at the cathode. Then, as a result of a welding voltage being applied through the welding wire 1, which is continuously fed through the center of the welding torch 2 to the steel sheets 3, a portion of shielding gas, which is fed from inside the welding torch 2, is ionized to form plasma. Consequently, the arc 5 is formed between the welding wire 1 and the steel sheets 3. The remaining shielding gas (that is, the portion of the gas, which is not ionized and which flows from the welding torch 2 to the steel sheets 3) seals the arc 5, the molten metal 7, and the weld pool 8 from outside air (refer to
The front end of the welding wire 1 is melted by the heat of the arc 5 to form molten metal 7, and the droplet of the molten metal 7 is transported to the weld pool 8 by an electromagnetic force, gravity, and the like. At this time, a state in which the molten metal 7 is separated from the weld pool 8 (refer to
In the case of arc welding utilizing Ar gas as a shielding gas, since the amount of oxygen which is mixed in the molten metal 7 and the weld pool 8 is significantly small, the effect of preventing the formation of slag is realized. However, since a cathode spot severely moves around, there is a disadvantage in that the weld bead 6 tends to meander or to have a wavy shape. Here, the chemical composition of the Ar gas described above is a chemical composition containing Ar in an amount of 99.0% or more in terms of volume fraction. Such a shielding gas containing mainly the Ar gas described above is also referred to as an “Ar shielding gas”.
To eliminate such a disadvantage, in arc welding, the cycle at which a short circuit occurs between the welding wire 1 and the steel sheet 3 (hereinafter, referred to as “short circuit cycle”) and the frequency with which such a short circuit occurs (hereinafter, referred to as “short circuit frequency”) are specified in the disclosed embodiments. Specifically, it is preferable that the maximum value of the short circuit cycle TCYC (s) be 1.5 s or less and that the average value of the short circuit frequency (average short circuit frequency) FAVE (Hz) be 20 Hz to 300 Hz.
By specifying the maximum value of the short circuit cycle and the average short circuit frequency to realize stable droplet transfer, since it is possible not only to inhibit the formation of slag but also to realize stable arc discharge, it is possible to form a weld bead 6 in which the slag-coverage area ratio SRATIO and the weld bead width ratio WRATIO are within the ranges described above.
In the case where the volume of the droplet formed from the front end of the welding wire 1 is excessively large or small, the weld pool 8 becomes unstable. Specifically, in the case where the average short circuit frequency FAVE is less than 20 Hz, large droplets are transferred to the weld pool 8, or droplet transfer modes other than a short circuit transfer mode (for example, streaming transfer mode and the like) are mixed irregularly. In addition, in the case where the average short circuit frequency FAVE is more than 300 Hz, although the size of droplets is small, arc reignition due to a short circuit occurs excessively often. For such reasons, in any of such cases, since the weld pool 8 is disturbed, it is difficult to eliminate the meandering or wavy shape of the weld bead. That is, by controlling the average short circuit frequency FAVE to be 20 Hz to 300 Hz, it is possible to control the volume of a droplet which is transferred to the weld pool 8 in one short circuit cycle to be about the same as that of a sphere having a diameter equal to that of the welding wire 1. As a result, it is possible to stabilize droplet transfer.
To eliminate a variation in the volume of a droplet which is transferred to the weld pool 8 in one short circuit cycle so that there is an improvement in the uniformity of the weld bead, it is more preferable that the average short circuit frequency FAVE be 35 Hz or more or even more preferably 50 Hz or more. In addition, in the case where the average short circuit frequency FAVE is large, there may be a case where droplets having small volumes are scattered in the form of a large number of spatters at the times of a short circuit and reignition. Therefore, it is more preferable that the average short circuit frequency FAVE be 250 Hz or less or even more preferably 200 Hz or less.
In addition, in the case where the maximum short circuit cycle TCYC is more than 1.5 s, since droplet transfer becomes unstable, the weld bead width and a penetration depth become unstable. That is, by controlling the maximum short circuit cycle TCYC to be 1.5 s or less, it is possible to form a weld bead 6 having a good shape. The term “maximum short circuit cycle TCYC” denotes the maximum value of a short circuit cycle in a welding pass for forming an arc welded joint. This means that any of the short circuit cycles in a welding pass does not exceed 1.5 s.
By specifying the average short circuit frequency FAVE and the maximum short circuit cycle TCYC as described above, regular and stable droplet transfer is possible in arc welding utilizing an Ar shielding gas. Here, to control the average short circuit frequency FAVE described above to be 20 Hz or more, it is more preferable that the maximum short circuit cycle TCYC be 1.0 s or less or even more preferably 0.2 s or less. In addition, it is sufficient that the maximum short circuit cycle TCYC be within a range in which the average short circuit frequency FAVE becomes 300 Hz or less, and it is preferable that the maximum short circuit cycle TCYC be 0.004 s or more.
The term “average short circuit frequency FAVE” denotes the average value of a short circuit frequency in a welding pass for forming an arc welded joint. That is, when a change in the arc voltage in a welding pass is measured by using a measuring device (for example, oscilloscope and the like) to count the number of times that the arc voltage becomes zero, the average short circuit frequency FAVE is defined as a value obtained by dividing the number of times by the time (s) required for the welding pass (number/s=Hz).
Here, examples of preferable welding conditions include welding current: 150 A to 300 A, arc voltage: 20 V to 35 V, Ar gas flow rate: 15 Liter/min to 25 Liter/min, distance L between the steel sheet 3 and a contact tip (hereinafter, referred to as “CTWD”): 5 mm to 30 mm, and the like. Here, the welding current and the arc voltage are represented by their respective average values in a welding pass.
Moreover, there is no particular limitation on the methods used for controlling the average short circuit frequency and the maximum short circuit cycle to be within the ranges described above. For example, by performing current waveform control utilizing pulse current as illustrated in
X=(IPEAK×tPEAK/L)+(IPEAK+IBASE)×(tUP+tDOWN)/(2×L) (3)
In the case where the value of X (A·s/m) calculated by using equation (3) is excessively small, there may be a case where the arc 5 sways and/or droplet transfer becomes unstable. On the other hand, in the case where the value of X is excessively large, there may be a case where the welding wire 1 plunges in the weld pool 8 or a case where a grown droplet flies apart at the time of a short circuit, resulting in a deterioration in weld bead shape, spatter adhesion, and the like. Therefore, it is preferable that the value of X satisfy the relational expression 50≤X≤250 or more preferably 60≤X≤230. It is even more preferable that the value of X be 80 or more and that the value of X be 200 or less. Here, “s” used in the unit of X (A·s/m) denotes “seconds”, and the unit of tPEAK, tUP, and tDOWN (ms) is “milliseconds”(= 1/1000 seconds).
In addition, in the case where the value of the distance L between the steel sheet 3 and the contact tip is excessively small, since severe wear occurs in the welding torch 2, welding becomes unstable. In the case where the value of the distance L between the steel sheet 3 and the contact tip is excessively large, the arc 5 sways. Therefore, it is preferable that the value of L be 5 mm to 30 mm or more preferably 8 mm to 20 mm.
In the case where the value of IPEAK is excessively small, since it is not possible to achieve sufficient heat input, there is a deterioration in weld bead shape. In the case where the value of IPEAK is excessively large, burn through occurs, and there is an increase in the number of spatters. Therefore, it is preferable that IPEAK be 250 A to 600 A. It is more preferable that IPEAK be 400 A or more and that IPEAK be 500 A or less.
In the case where the value of IBASE is excessively small, arc becomes unstable. In the case where the value of IBASE is excessively large, burn through occurs. Therefore, it is preferable that IBASE be 30 A to 120 A. It is more preferable that IBASE be 40 A or more and that IBASE be 100 A or less.
In the case where the value of is excessively small, it is not possible to achieve sufficient heat input. In the case where the value of tPEAK is excessively large, burn through occurs. Therefore, it is preferable that tPEAK be 0.1 ms to 5.0 ms. It is more preferable that tPEAK be 1.0 ms or more and that tPEAK be 4.5 ms or less.
In the case where tUP or tDOWN is excessively small, arc sway is induced. In the case where tUP or tDOWN is excessively large, there is a deterioration in weld bead shape. Therefore, it is preferable that each of tUP and tDOWN be 0.1 ms to 3.0 ms. It is more preferable that each of tUP and tDOWN be 0.5 ms or more and that each of tUP and tDOWN be 2.5 ms or less.
When the base time of the pulse current is defined as tBASE (ms), although tBASE is not used in equation (3), which is used for calculating the value of X, in the case where tBASE is excessively small, there is an excessive decrease in the size of a droplet. In the case where tBASE is excessively large, there is an excessive increase in the size of a droplet. In any of such cases, welding becomes unstable. Therefore, it is preferable that tBASE be 0.1 ms to 10.0 ms. It is more preferable that tBASE be 1.0 ms or more and that tBASE be 8.0 ms or less.
Furthermore, in the disclosed embodiments, it is not necessary that a short circuit occur in every cycle of the pulse current. It is sufficient that a short circuit occur once in one to several pulses. In addition, as long as a short circuit occurs once in one to several pulses, there is no particular limitation on the pulse frequency of the pulse current.
In the disclosed embodiments, the purpose of using the pulse current is (1) to promote the stable growth of the droplet in the base time while inhibiting the arc from swaying by applying lower current and (2) to promote a short circuit in the peak time and the fall time by pushing down the grown droplet to the weld pool by using electromagnetic force and the shearing force of the Ar shielding gas without separating the grown droplet from the wire.
In the disclosed embodiments, it is not necessary to feed oxygen or to add special elements. Therefore, by using a solid wire, which is less expensive than a flux-cored wire, as a welding wire, it is possible to realize a decrease in process costs.
Here, the solid wire which can preferably be used in the disclosed embodiments has a wire chemical composition containing C: 0.020 mass % to 0.250 mass %, Si: 0.05 mass % to 1.50 mass %, Mn: 0.50 mass % to 3.0 mass %, P: 0.020 mass % or less, S: 0.03 mass % or less, and a balance of Fe and incidental impurities. It is preferable that the diameter of the solid wire be 0.4 mm to 2.0 mm.
The arc welded joint and arc welding method according to the disclosed embodiments will be described in detail in accordance with examples.
By performing lap fillet welding (refer to
Here, the weld bead surface area SBEAD and the slag surface area SSLAG were derived by taking the image of the surface of the region of the weld bead 6 excluding the weld bead start/finish end portions 10 (having a length of 15 mm each) from directly above and by measuring the projected areas of the weld bead and slag viewed from above. In the case of a weld bead 6 having a length of less than 130 mm, the image of the surface of the full length of the weld bead 6 excluding the weld bead start/finish end portions 10 was taken. In the case of a weld bead 6 having a length of 130 mm or more, the image of the surface of a portion (having a length of 100 mm) of the weld bead 6 excluding the weld bead start/finish end portions 10 was taken. The slag-coverage area ratio SRATIO was derived by using equation (1) above from the weld bead surface area SBEAD and the slag surface area SSLAG derived as above. The derived slag-coverage area ratio SRATIO is given in Table 3.
Similarly, the maximum value WMAX and minimum value WMIN of the weld bead width were measured by taking the image of the surface of the region of the weld bead 6 excluding the weld bead start/finish end portions 10 (having a length of 15 mm each) and by analyzing the taken image. In the case of a weld bead 6 having a length of less than 130 mm, the image of the surface of the full length of the weld bead 6 excluding the weld bead start/finish end portions 10 was taken. In the case of a weld bead 6 having a length of 130 mm or more, the image of the surface of a portion (having a length of 100 mm) of the weld bead 6 excluding the weld bead start/finish end portions 10 was taken. The weld bead width ratio WRATIO was derived by using equation (2) above from the maximum value WMAX and minimum value WMIN of the weld bead width measured as above. The derived weld bead width ratio WRATIO is given in Table 3.
In addition, similarly, the maximum value MMAX and the minimum value MMIN of the cleaning width were measured by taking the image of the surface of the region of the weld bead 6 excluding the weld bead start/finish end portions 10 (having a length of 15 mm each) and by analyzing the taken image. In the case of a weld bead 6 having a length of less than 130 mm, the image of the surface of the full length of the weld bead excluding the weld bead start/finish end portions 10 was taken. In the case of a weld bead 6 having a length of 130 mm or more, the image of the surface of a portion (having a length of 100 mm) of the weld bead 6 excluding the weld bead start/finish end portions 10 was taken. Each of the measured maximum value MMAX and the minimum value MMIN of the cleaning width is given in Table 3.
The evaluation of “corrosion resistance” given in Table 3 was performed as follows. First, after having removed the electrodeposition coating layer by immersing the arc welded joint which had been subjected to the corrosion test in a removing solution, the corrosion product was removed in accordance with ISO 8407. Subsequently, in the case where the weld bead start/finish end portions 10 (having a length of 15 mm each) of the weld bead 6 were included, the image of the surface of the region excluding the weld bead start/finish end portions 10 was taken, and the maximum corrosion width HMAX from the weld bead toe 9 was measured by analyzing the taken image. The evaluation of corrosion resistance was made in accordance with the following criteria, and the evaluation results are denoted by reference signs A to C and F.
Here, in Table 3, “reference sign A” denotes a case of “a maximum corrosion width HMAX from the weld bead toe of less than 3.0 mm”. “Reference sign B” denotes a case of “a maximum corrosion width HMAX from the weld bead toe of 3.0 mm or more and less than 4.5 mm”. “Reference sign C” denotes a case of “a maximum corrosion width HMAX from the weld bead toe of 4.5 mm or more and less than 6.0 mm”. “Reference sign F” denotes a case of “a maximum corrosion width HMAX from the weld bead toe of 6.0 mm or more”. The rank denoted by reference sign A is the highest followed by those denoted by reference signs B and C in this order, and the rank denoted by reference sign F is the lowest.
Here, as illustrated in
The evaluation results are given in Table 3.
As indicated by Tables 2 and 3, it is clarified that, in the case of welding Nos. 5 to 15, which were examples of the disclosed embodiments, since SRATIO was 15% or less, and since WRATIO was 60% or more, arc welded joints excellent in terms of corrosion resistance were obtained.
Of these examples of the disclosed embodiments, in the case of welding Nos. 7 to 15, since MMIN was 0.5 mm or more, arc welded joints excellent in terms of corrosion resistance at a higher level were obtained.
In contrast, in the case of welding Nos. 1 and 2 where SRATIO was more than 15%, and in the case of welding Nos. 3 and 4 where WRATIO was less than 60%, that is, in the case of the comparative examples, there was a deterioration in phosphatability and electrodeposition coatability, which resulted in a deterioration in the corrosion resistance of the arc welded joints.
In addition, as indicated by the data of welding Nos 5 to 15, which were the examples of the disclosed embodiments, it is clarified that arc welded joints excellent in terms of corrosion resistance were obtained regardless of whether a welding wire for an ultra-high tensile strength steel sheet (wire code W1 in Table 4) or a welding wire for a mild steel sheet (wire code W2 in Table 4) was used.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-072716 | Apr 2020 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2021/010961 | 3/18/2021 | WO |
