Weld quality & hold time

When engineers plans the welding process parameters, the weld nugget size is the key factor to optimize. But weld quality is not only about the weld nugget size. It is also important to get high weld strengths and good material properties around the weld. In this case study, we present the influences of the hold time on the hardness distributions after welding. Also the effects of hardness on the performance of weld strengths were tested.

hardness distribution in the welded part

Hardness after welding

Hardness distribution after welding is critical for the performance of welds. The hold time can affect the cooling rate thus change the hardness distribution after welding.

We ran a set of simulation with different hold time(100ms, 150ms, 200ms) to investigate their effect on the microstructures. The material used in this simulation is DP600 with GI coating. The machine settings are weld time=300ms, F=4kN, I=7.75kA (AC). The welding processes were simulated by SORPAS 2D.welding v14.0.

Cooling rate & Hold time

The nodal temperature curves show different cooling rates affected by different hold time. They would result in different microstructures thus different hardness distributions after welding.

nodal temperature curve showing cooling rate
Nodal temperature curve by different hold-time

Hardness distribution

Below images show hardness distributions resulted from different cooling rates by different hold time. All three cases used the same weld time, current and force, so they had the same weld nugget size.

Hardness distribution with hold time 100ms/150ms/200ms
Hardness distribution with hold time 100ms/150ms/200ms

Weld strength and Hardness

To see the performance of different hardness distribution, we simulated tensile shear testing by SORPAS 3D.testing v6.10. Fracture occurred at different locations during the weld strength testing. Different hardness distribution from different cooling rates resulted in different fracture behaviors.

fracture behavior with different hold time by SORPAS 3D.testing
Fracture during tensile shear test

The weld strength curves show different performance of the welds affected by different hold time. Shorter hold time resulted in lower hardness thus lower strength. Longer hold time resulted in higher hardness thus higher strength but more rapid fracture. An optimal hold time would result in the best performance of the weld with large elongation and high enough strength.

load-elongation curve by SORPAS 3D
Load-elongation curve with different hold time