Effect of Liquid Metal Embrittlement Indent Cracks on Zinc Coated 3rd Generation AHSS Mechanical Performance

Abstract

Third-generation advanced high-strength steels (3G-AHSS) are typically galvanized to prevent corrosion of the outer body structure. However, the zinc coating on the surface, combined with the locally elevated temperatures generated during the resistance spot welding (RSW) process, can provide the prerequisites for liquid metal embrittlement (LME). This work uses two strategies to control LME crack formation: current pulsation and varying the electrode geometry. These two methods were compared to a baseline welding schedule for a 3G-980-GI coated AHSS. The effectiveness of each method was discussed in terms of the overall weld cracking index and local cracking index. The results showed that increasing the current pulses results in a slower energy input into the weld, which can help to reduce LME crack formation. Introducing more pulses (five to seven pulses) reduced LME crack formation while maintaining the same welding time. Regarding the electrode geometry, the results showed an increase in LME cracking index for currents below the expulsion level Imax-10% when the electrode face diameter increased, whereas at the current level Imax-200A, the electrode radius was the most important factor to control LME crack index. For the current level above the expulsion, Imax+10%, a drastic decrease in the LME cracking index was observed when a large electrode surface diameter was used. The electrode radius was not a significant factor in controlling LME. The mechanical properties of selected conditions were examined using the lap shear test and the results showed no significant effect of LME cracks on the shear tensile strength. The location of the failure indicated that most of the cracks are located in the indented area (type A), which does not influence the lap shear strength.