* 5th Scientific Conference of Baghdad University. 25-27 Feb.

2003

*Corresponding author's. University of Baghdad, College of Engineering. Departments of Mechanical

Engineering. Al-Jadriya P.O/ 47024. Baghdad. Iraq

E-mail address: almukhtar@hotmail.de.

‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

INVESTIGATION OF SOME WELDING PARAMETERS IN

RESISTANCE SPOT WELDING OF AUSTENITIC STAINLEASS
STEEL

Dr. Kasim M. Daws, Dr. Abdul-Karim .A. Al-Douri, And Ahmed M. Al-Mukhtar
Dept . of Mech.
College of Engineering
University of Baghdad

ABSTRACT
Stainless steel has excellent mechanical properties and excessive corrosion resistance
permits to use in the jet engine manufacture. Austenitic stainless steel specimens of type AISI 321
in a strip form were welded in a lap-joint form under various welding parameters (weld current and
time) to show the effect of heat treatment (annealing and stress relieving) on the mechanical
properties. It was shown that the welding variable and heat treatment has effects on the weld nugget
properties. A metallurgical examination was made for weld area. This resulted in determination of
the phenomena of high temperature crack growth due to holding time temperature of 750 ˚C. The
delta-ferrite content increases with the heat input as confirmed by the magnetic scope examination.
Finally, the most common defects that could experimentally appear in spot welding were found and
detected. The authors believe that these phenomena are found for the first time and they did not
publish any thing like it in literature.

‫ﺍﻟﺨﻼﺼﺔ‬
‫ ﺘﻡ ﻟﺤﺎﻡ ﻋﻴﻨﺎﺕ‬.‫ﻴﻤﺘﻠﻙ ﺍﻟﻔﻭﻻﺫ ﺍﻟﻤﻘﺎﻭﻡ ﻟﻠﺼﺩﺃ ﺨﻭﺍﺹ ﻤﻴﻜﺎﻨﻴﻜﻴﺔ ﻤﻤﺘﺎﺯﺓ ﻭﺘﺄﻜﻠﻴﻪ ﻓﺎﺌﻘﺔ ﺘﺴﻤﺢ ﺒﺎﺴﺘﺨﺩﺍﻤﻪ ﻓﻲ ﺘﺼﻨﻴﻊ ﺍﻟﻤﺤﺭﻙ ﺍﻟﻨﻔﺎﺙ‬
‫( ﺒﺸﻜل ﺸﺭﺍﺌﻁ ﻭﺒﻭﻀﻊ ﺘﺭﺍﻜﺒﻲ ﻭﺒﻌﻭﺍﻤل ﻟﺤﺎﻡ ﻤﺘﻐﻴﺭﺓ )ﺘﻴﺎﺭ ﻭﺯﻤﻥ ﻟﺤﺎﻡ( ﻟﻤﻌﺭﻓﺔ‬٣٢١) ‫ﻤـﻥ ﺍﻟﻔﻭﻻﺫ ﺍﻟﻤﻘﺎﻭﻡ ﻟﻠﺼﺩﺃ ﺍﻻﻭﺴﺘﻨﺎﻴﺘﻲ‬
‫ ﻅﻬﺭ ﺃﻥ ﻋﻭﺍﻤل ﺍﻟﻠﺤﺎﻡ ﻭﺍﻟﻤﻌﺎﻤﻼﺕ ﺍﻟﺤﺭﺍﺭﻴﺔ ﻟﻬﺎ‬.‫ﺘﺄﺜﻴﺭ ﺍﻟﻤﻌﺎﻤﻼﺕ ﺍﻟﺤﺭﺍﺭﻴﺔ )ﺍﻟﺘﺨﻤﻴﺭ ﻭﺇﺯﺍﻟﺔ ﺍﻹﺠﻬﺎﺩ( ﻋﻠﻰ ﺍﻟﺨﻭﺍﺹ ﺍﻟﻤﻴﻜﺎﻨﻴﻜﻴﺔ‬
‫ﺍﻟﻔﺤﺹ ﺍﻟﻤﻴﺘﺎﻟﻭﺭﺠﻲ ﻟﻤﺴﺎﺤﺔ ﺍﻟﻠﺤﺎﻡ ﻭﻗﺩ ﻨﺘﺞ ﻋﻨﻪ ﺘﺤﺩﻴﺩ‬ ‫ ﺘﻡ ﺃﺠﺭﺍﺀ‬. (‫ﺘﺄﺜـﻴﺭ ﻋﻠـﻰ ﺨـﻭﺍﺹ ﻨﻘﻁﺔ ﺍﻟﻠﺤﺎﻡ )ﺍﻟﻤﻨﻁﻘﺔ ﺍﻟﻤﻨﺼﻬﺭﺓ‬
‫ ﻴﺯﺩﺍﺩ ﻤﺤﺘﻭﻯ ﺍﻟﺩﻟﺘﺎ ﻓﻴﺭﺍﻴﺕ ﻤﻊ ﺍﻟﺤﺭﺍﺭﺓ‬.‫ ﻡ‬٧٥٠ ‫ﺒﺴﺒﺏ ﺍﻟﻤﻜﻭﺙ ﻓﻲ ﺩﺭﺠﺔ ﺍﻟﺤﺭﺍﺭﺓ‬ ‫ﻅﺎﻫـﺭﺓ ﻨﻤـﻭ ﺍﻟﺘﺸﻘﻕ ﻓﻲ ﺍﻟﺤﺭﺍﺭﺓ ﺍﻟﻌﺎﻟﻴﺔ‬
‫ ﻤﻥ ﺍﻟﻤﻌﺘﻘﺩ ﻤﻥ‬.‫ ﺃﺨﻴﺭﺍ ﺘﻡ ﺘﺤﺩﻴﺩ ﺃﻫﻡ ﺍﻟﻌﻴﻭﺏ ﺍﻟﺘﻲ ﻴﻤﻜﻥ ﺃﻥ ﺘﻅﻬﺭ ﻓﻲ ﺍﻟﻠﺤﺎﻡ ﺍﻟﻨﻘﻁﻲ‬. ‫ﺍﻟﺩﺍﺨﻠﺔ ﻜﻤﺎ ﺘﻡ ﺘﺄﻴﻴﺩﻩ ﺒﺎﻟﻔﺤﺹ ﺍﻟﻤﻐﻨﺎﻁﻴﺴﻲ‬
.‫ﻗﺒل ﺍﻟﻤﺅﻟﻔﻴﻥ ﺃﻥ ﺘﺤﺩﻴﺩ ﻫﺫﻩ ﺍﻟﻅﻭﺍﻫﺭ ﻴﺘﻡ ﻷﻭل ﻤﺭﺓ ﻭﻟﻡ ﻴﺘﻡ ﻨﺸﺭ ﺸﻲ ﻤﺸﺎﺒﻪ ﻟﻬﺎ ﺴﺎﺒﻘﺎ‬

Keyword: Austenitic stainless steel. Spot-welding. Tensile strength test. Ferrite content. Crack
growth. Spot welding defects. Heat treatment. Delta ferrite.

INTRODUCTION
The need to excellent mechanical and corrosion resistance properties has led to increased use of
stainless steel metal. Austenitic stainless steel has found application in the more classical design of
jet engine manufacture. Resistance welding is a far more flexible method of joining metals and is
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

applicable to a great range of size, shape and materials. (Metals handbook.1971) Typically the
welding current is lower than using for aluminum alloy.
The most useful application of resistance welding (R.W.) is found in several important metal-
fabrication industries (Metals handbook.1958): -
-Aircraft: Fuselage, landing gear, exhaust rings, wing assemblies, tail assemblies and wheels.
-Automotive products: bodies, cabs, forms, seats brackets, levers, pans, wheels, housings, supports,
shock absorbers, and others. The modern automobile is essentially a resistance-welded structure
made up of thousands of individual work.
The R.S.W. is widely used in mass production of automobile appliances, metal furniture, and other
products made of sheet metal. If one considers that a typical car body has approximately 10.000
individual spot welds and that the annual production of automobiles throughout the world is
measured in tens of millions of units, the economic importance of resistance spot welding (R.S.W.)
is used can be appreciated (Mikel.1996). R.S.W. use in jet engine manufacture such as combustion
chamber and outer shell (Len Ground.1989. and Struart1997)
The objective of this work was to examine the influence of heat treatment on the spot weldability
of stainless steel as the effect of current and time on the mechanical properties and metallurgical
factors, and provide information about the defect of weld nugget.

EXPERIMANTAL PROGRAME
The experimental program comprised:
1- A set of lap specimen was welded under different conditions (weld time and current) and
constant electrode tip diameter was equal to 5.5mm. The annealing and stress relieving treatments
were applied.
2- A static tensile test was made to determine effect of the heat treatment on spot weldability. The
maximum load, which is a major factor from the design of view and the weld nugget area, was
determined for the heat-treated joints.
3- Cross section was made at the center of spot weld for specimens as welded, and for annealed
and stress relieved specimens. This was made to correlate the metallurgical factors with the
mechanical properties, through the metallurgical examination for the specimens. Moreover a
number of defects were investigated.
4- Micro-hardness tests were also applied along the faying surface (longitudinal) and along the
thickness of the weld nugget (traverse) respectively, for the mounted specimens in (5).

Material
The material employed in this investigation for all testing was a single sheet of austenitic
stainless steel (AISI. 321) with a nominal thickness (1.5mm). No surfaces coating were applied. The
stainless steels evaluated in this work are cold rolled sheet steel. Table (1) show the chemical
composition and mechanical properties.

Table (1). Chemistry (%) and mechanical properties

Steel
C Cr Ni Mn V Mo Si Ti Fe
Designation
AISI 321 0.05 19 8.8 1 0.06 0.5 0.72 0.46 Rem.

Tensile strength 0.2% offset Yield Reduction of

Elongation
(Mpa) strength area
600 205 Mpa 40% 50%
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

Welding Equipment
The resistance spot welding equipment employed in this investigation was a standard foot
operated, rocker arm spot welding (Bay Kay) single-phase machine, with transformer capacity (15
Kva) single phases (220 volt). Electrode was RWMA class 1 (pure copper) which have high thermal
and electrical conductivity. The electrodes were mechanized with a truncated tip face (16 mm
*5.5mm*30 deg).

Welding Process
Sets of welding specimens were made as follow; constraint the weld time and electrode pressure
and varying the weld current subsequently to obtain different weld joint properties. Then sets of
variables were made (weld time and weld current). Four welding times and currents were applied.
Sixteen sets of specimens were made, each set consist of three specimen for each time and current,
then each point on the curves represent the average of three specimens. In this work all joint were of
a single weld. Electrode force was set to be constant at (1617 N). Welding time was varied from
(15 to 60 cycle) and welding current range from (3.7 to 7.2 K.amp.).

TENSILE TESTING
The specimens used for tensile test are illustrated in Fig. 1. Static strength was measured using
the convential tensile shear lap specimens. Specimen details and testing methods conformed to
American Welding Society (AWS) practice (Boniface.1954).
All welds were tested in tensile shear, using a convential hydraulic tensile testing machine
(Adamel Lhomrgy Dy. 25) model EG04, was equipped with a digital readout for both load and
extension. The available function of the machine is to maintain both the peak load and break
extension for each type of specimen. Thus, the maximum load was recorded as measure of the weld
strength (Refs.7, 8). The chart speed set to be suitable for each type of specimen usually varies from
(2 - 10 mm/min), and depends upon the welding condition.
Lap Test: Fig.1 where two flat plates joint an overlapped section. For this work (1.5mm) thick
plates are (35*120mm) with are overlapping (35mm), the overlap distance was chosen to ensure
negligible edge effects. The geometry was approximated as closely as possible to pure shear made
on the joint. The geometry of specimens based on the AWS specimens. (Boniface.1954)

MICROHARDNESS TEST
It is necessary to determine the hardness over a small area of material. Therefore microhardness
tests are employed to examine the hardness variations through the weld nugget and heat effected
zone (HAZ) in both, traverse and longitudinal directions. Vickers hardness is employed, using a
conventional microhardness tester (JTT Digital micrometer taster, type JMT7 type A, Toshi INC.)
with (300gr) load. The weld metal hardness was average from two values at least. These tests were
done for the specimen in as welded conditions listed below: -
1- I=7.2 K.amp, T=60 cycle.
2- I=5.8 K.amp, T=45 cycle.
3- I=3.7 K.amp, T=30 cycle.
4- After annealing treatment (spc.1).
5- After stress relieving treatment (spc.1).
The specimens were prepared as the lap specimen mode and the cross-sectioned at the center of
spot and the mounted specimen then tested, in both traverses and longitudinal directions. The
starting point was from the unaffected zone toward the spot center longitudinally and then traversal
toward the nugget through the thickness of the sheet. The specimens were examined for
microhardness to the polished face as shown in the Fig.2.
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

MICROSTRUCTURS TEST
The same specimens of microhardness test were prepared for the metallurgical tests to reveal the
effects under welding condition and after heat treatment with the base line welding parameters (7.2
K.amp and T=60 cycle). The etching process was achieved on the specimen using on etching
solution for the weld metal, according to the AWS. The solution composition was 10 ml acetic acid,
15 ml hydrochloric acid (HCL), 10 ml nitric acid (HNO3), and two drops of glycerol.
Moreover, microscopic photographs were done to get clear metallurgraphical examinations for
few zones namely, fusion zone (cast nugget), heat effected zone, and the traverses region of the
HAZ with the fusion zone also was examined.

Ferrite Content
The percentage of ferrite content was measured (for same welded specimen condition as in microhardness
tests), by usin2g the ferrite scope M11 instrument manufactured by Fisher to detect the ferrite content for
stainless steel welds. The calibration process was carried out on standard specimens supplied by the
manufacture with the help of a sensing probe. Then after the sensing probe was passed over the test
specimens which the percentage ferrite content was investigated. The ferrite content examination was carried
for different zones of the spot nugget and base metal.

HEAT TREATMENT
Heat treatment was employed to spot-weld joint to investigate its effect on the mechanical properties of
spot weld joint. The type and the necessity for heat treatment of austenitic chromium-nickel steel weldments
depends to great extent upon the service condition to be encountered (Welding handbook.1958). The
annealing and stress relieving treatments which were applied to impart the greatest degree of stress relief
possible and reduce the residual stress developed due to the forge pressure and the rapid cooling the small
molten metal to surrounding cooled metal and ambient temperature. Specimens were heat treated in (Sola
Basic Lindberg) furnace.

Annealing Treatment
To obtain maximum softness and ductility, these steels were annealed after welded. Unlike the
unstablized grades, these steels did not require water quenching or other acceleration of cooling from the
annealing temperature to prevent subsequent intergranular corrosion (Metals handbook.1971 and welding
handbook.1958) air-cooling is generally adequate. Annealing was performed at 1010oC, for light section
might be held at this temperature for 3 minute per 2.5 mm. The time passed for thickness (1.5 mm) will be 2
min approximately then the weldments is cooled in air.

Stress Relieving Treatment

Stress relieving employed at temperature 750 oC with the same time as in annealing treatment. The rapid
heating and cooling at spot welding processes for stainless steel has been overemphasized. Stress relieving
generally advisable when the service environment is known or suspected to cause stress corrosion. By using
stabilized or extra low-carbon grades, heating at stress relieve temperature could avoid the intergranular
precipitates of chromium.

RESULTS AND DISCUSSION

Several tests were conducted for specimen configurations with electrode tip diameter (5.5 mm) as
detailed below.

Tensile Test Results

The AWS (Welding handbook. 1958) illustrated general result of the shear strength for the
tensile-shear specimen test at various weld current and time. Fig.3. The feature of these curves such
as the shape trend and behavior are compared with the experimental results of the present work. For
the lap-welded specimens the spot was submitted to combination of shear stress, which have the
greater effect and with a little amount of through thickness tensile stresses. The current and time
effect on the maximum strength moreover effect on the weld nugget area.
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

Heat Treatment
The type of the service media and condition determine the necessity for the heat treatments. For
some applications, heat treatment is used to impart the greatest degree of corrosion resistance
possible, while for other applications, heat treatment is only necessary for stress relieving. The
welding process includes high melting temperature in short time at a small area, which is
surrounded by a cooler metal. This will produce high stresses which invariably arise in any welded
structure have frequently been single out as the reason for annealing. However, the need for a stress
relief treatment in welded constructed of austenitic stainless steel has been over emphasized. The
heat treatment reduces the mechanical properties of weld metal. (Ref.2), as shown in the following
sections: -

Annealing of Spot Welded Joint

The main importance of annealing is its effect on the mechanical properties of the spot nugget as
shown in the tensile lap-test and the microhardness and metallurgical tests. This treatment has
relieved approximately 90% of stress. (Welding handbook.1958).

Effect of Current and Time

Figs.4-7 show the effect of current and time on the joint strength and weld area after the
annealing process. Generally, the joint strength (maximum load) and the weld nugget area increase
with the weld current up to maximum current value. A direct relationship of current with joint
strength and weld area agrees with feature of the AWS curves Fig.3. (Welding handbook.1958).
The weld area increases rapidly with weld current, from low current levels until expulsion occurs at
the higher levels. A similar behavior occurs with the weld strength. This result also agrees with
Sawhill (J.M. Sawhill et al.1977). From the heat formula (H=I2Rt), the current I is a squared
quantity. Therefore the change in current at a constant of time will increase in heat generation (heat
built up) with minimum losses in heat to surrounding metal and thus, this will increase in weld area
and the strength of weld joint (Welding handbook.1958). Following the above explanation, it can
explain why the current highly affects the heat generation to the extent greater than either resistance
or time. The response of strength to increase in current is regular for the aluminum alloys spot
welding. This finding agrees with observation made by Aidun (D.K. Aidun et al. 1980) for spot
welding of aluminum alloy. Because of induced stress due to rapid heating, cooling and the forge
pressure on the weld nugget, stress relieving treatment was made to investigate their effect on the
mechanical properties from the tensile test results, and their effects in the metallurgical and
microhardness test results.
Figs.8-11 show the effect of current and time on the joint strength and weld area after the stress
relieving treatment. The specimens have the same behavior as well as annealed joint.

METALLURGICAL EXAMINATION RESULTS

As stated previously, the base metal used in this study was stainless steel AISI 321. The base
matrix was austenite in structure with a smaller amount of ferrite as confirmed by the magnetic
scope examination. Because the fusion began rapidly at the interface of the two sheet surfaces and
moved towards the through thickness of the sheet metal, the weld metal have smaller amount of
ferrite which vary according to heat input. The microstructure for the as welded specimens consists
of fully austenitic weld beads and those containing some delta ferrite. The maximum content of
delta ferrite was at the center of the spot and decreased towards the outside, reaching minimum
values at the sheet metal itself at the far distance from the spot weld (approximate equal to 0.18%
ferrite). Also the amounts of the delta ferrite increase when the heat-input increases with the same
distribution in quantity, from the maximum at the center to the minimum towards the outside where
the high heat is dissipated. Table 2. The test of the heat treated specimen, showed that the amount
of the delta ferrite will be affected by the temperature of the treatment as shown for the base line
welding parameter which are 7.2 K.amp, current and 60 cycle weld time (spc.1). The high
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

temperature from the annealing treatment reduced the amount of ferrite to a minimum values less
than that was measured in the stress relieved specimen and the latter contained ferrite less than that
were measured in the as welded specimen as shown in table 1. Fig. 12 shows the metallurgical
examination for the as welded and heat-treated specimens. The delta ferrite when exposed for a long
time to temperatures ranging from about 650-950˚C will transform to intermetallic compound of
chromium and iron called the sigma phase (M.Kamaraj.1989). This phase may cause loss of
ductility and impact resistance.

HIGH TEMPERATURE CRACK GROWTH

The crack was adjacent to the weld during the post welding heat treatment and during service at
elevated temperature Fig. 12. The crack growth at high temperature in the weldments of austenitic
stainless steel, which occurred at the temperature of stress relieving treatment at 750oC, crack
growth takes place along the interface between the austenite and delta ferrite. This result agrees
with that stated by Kamaraj and Lancaster (M.Kamaraj.1989 and J.F.Lancaster.1970). Who studied
the crack growth in the temperature range of 600 to 800oC, moreover they have found that the crack
growth takes place at 600oC along the interface between the austenite and the arm of delta ferrite in
the weldments of 308 SS. Weld metal that solidifies as ferrite inherently much less susceptible to
cracking than that which solidifies as austenite. Mixed structures which contain more than 3%
ferrite at room temperature have in practice adequate resistance to hot cracking, but the fully
austenite weld metal with smaller amount of ferrite is very crack sensitive. Therefore after the stress
relieving treatment for the spot weld metal, the weld nugget metal have (1)% ferrite at temperature
of 750 oC, Table 1. At high temperatures sigma phase become more dominant in the crack growth
process. (M.Kamaraj.1989)

MICROHARDNESS TEST RESULTS

The procedure followed in this test for all the prepared specimens was taking reading of the
hardness by moving from the unaffected base metal, adjusted to HAZ, longitudinal towards the
center of the spot welds, and then toward the thickness of the sheet metal as traverse. The hardness
of the base metal has been measured in the region far away from the spot nugget, the results are
275, 210 and 240 HV for the as welded, annealed, and stress relieved specimens respectively. The
results concerning this test are presented in Figs. 13-17 longitudinally, and the Figs. 18-22 traversal.
It is seen that, from the longitudinal hardness measurement that higher hardness at the heat- affected
zone and drops to minimum values in the adjustment region, and then increases to higher values at
the center of the spot weld.
The hardness at the heat affected zone decreases as the heat input increases, while the hardness at
the center of the spot weld will increase. The decreasing in hardness in the HAZ is due to the
softening and reducing the stresses. The higher heat input will soften this region because the initial
contact will be in the HAZ and cause the flattened of asperities in the periphery of the spot nugget
as mentioned by the Pugachev (A.I.Pugachev.1968). Thus the stresses are concentrated in the
periphery of spot nugget. The longitudinal measurement of hardness results agree with that stated
by Dicknson and Natal (Dicknson.1987) for the mild steel. Moreover, Sawhill (J.M.Sawhill.1977)
showed the same results for the HSLA and Mn-Mo-Cb steels.
From the traverse hardness measurements the hardness will have the maximum values at the
center of weld nugget, then drops between the center and the heat-affected zone then, the increases
again at the heat-affected zone. The stresses are developed in thickness of the sheet metal because
the nugget growth through thickness of sheet. The compressive stresses are created in the outer shell
of molten nugget through thickness. Moreover, the forge pressure from the electrode force will
increase the compressive stress through the thickness of the sheet. The above discussion will
explain why the increase in the heat input will increase the hardness in the center of the spot weld
and at the heat-affected zone. The compressive stresses increase due to the increase in the
compression of the electrodes towards the thickness. The electrode pressure will not be sufficient to
balance the compressive stress within the spot due to the nugget growth. Moreover, the expulsion
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

of some of the highly plastic metal in the hot zone at the center of the spot will cause a higher stress
in the weld near the point from which the loss of metal occurs. This result agrees with that observed
by the Santella and Lindh, (M.L.Santalla.1998 and Lindh.1967) for the DQSK steels spot welding.
From another point of view, the temperature distribution of the heat input and the cooling rate will
vary the hardness along the spot nugget, thus the center and HAZ will have cooling rate with
respect to hardness measurement, higher than the middle region between the center and HAZ. The
hardness gradient along the spot nugget agrees with that observed by Santella (M.L.Santalla.1998)
who related that to variations in the cooling rates within the spot nugget. It can be shown clearly
that the hardness decreases after the annealing and stress relieving. This is due to the relief of the
residual stresses produced during the spot welding. The hardness results when annealing is lower
than that after the stress relieving.

SPOT WELDING DEFECTS

From the photographic examination it can be shown that the number of individual defects mostly
appears in the spot weld nugget. The cavity shapes in spot welds, which vary in size, depend upon
the welding parameters and on the type of these cavities, Figs. 23a & Fig.23b. The large cavity is
due to metal expulsion, it is the most conventional defects and is very serious and affects the weld
joint quality. For certain conditions of current and time, expulsion or splashing occur. Expulsion
occurs at (7.2 K.amp) current and (60 cycle) time. When welding is made at high setting the high
formation force of the weld of nugget well be produced against the electrodes. When the electrodes
force is not sufficient to balance the compressive stresses within the spot due to the nugget growth,
some of the highly plastic metal in the hot zone at the center of the spot nugget will be expelled.
The above results agree with those of Mirlin (G.A.Mirlin et al.1964) who has shown that formation
of splash is increased by excessive welding current and insufficient electrode compressive force at
the high welding settings. Splashing in spot welding weakens the cross section of the point being
welded, a cavity, which occurs from the heavy expulsion of molten metal, may extend over a very
large part of the fused area and must be regarded as a defect. (Welding handbook.1958) Fig. 24
shows the small shrinkage cavity, practically all the spot welds in metal thickness of the medium
and heavy gages have a shrinkage cavity in the center of the weld nugget. Fig. 25 shows the brittle
weld nugget, which are produced when insufficient fusion takes place at the faying surface due to
lower welding parameters. The stress relieving temperature exceeded 500 oC, the crack was
adjacent to the weld during the post welding heat treatment and during service at elevated
temperatures shown in Fig.12. The crack growth occurred in the weldments of austenitic stainless
steel at the temperature of stress relieving treatment at 750oC.

Table (2). The amount of delta-ferrite along the spot weld at different welding conditions and
under heat-treatment

Spec. No. Current Time Amount of the delta-ferrite from the

(K.amp.) (cycle) center of the spot weld. (%).
1 7.2 60 1.4 1.2 1 0.8 0.24 0.2
2 5.8 45 0.9 0.76 0.67 0.23 0.22 0.2
3 3.7 30 0.43 0.27 0.25 0.24 0.2 0.2
4 (annealed) 7.2 60 0.24 0.22 0.21 0.2 0.2 0.2
5 (stress relieved) 7.2 60 1 0.9 0.8 0.65 0.2 0.2
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

CONCLUSION
From the results obtained, the following conclusions may be drawn:
1- Heat treatment for austenitic stainless steel (0.05%C) effects the tensile strength and the
hardness of the spot nugget. The increase of heat treatment temperature will reduce the
mechanical properties of weld metal.
2- Hardness test across the interface and through thickness, showed peak values at the center of
fusion zone and the heat-effected zone, for all specimen, this was attributed to the effect of
cooling rate and developed stress and heat input in the fusion zone.
3- From the microstructure and magnetic test results the delta ferrite was found within austenite
matrix phase. This ferrite content was found to increase with the increase of heat input, and this
amount will decrease with increasing the temperature of heat treatment.
4- There are some of the individual defects were mostly appear in the spot weld nugget by
increasing the weld current at certain time or too long time of current flow, such as expulsion of
molten metal, and shrinkage cavities which occur at high machine setting.
5- The crack adjacent to weld metal at high temperature exceeding 700 ˚C during the post welding
heat treatment, it is growth at stress relieving temperature (750 ˚C) takes place a long the
interface between austenite and the arm of delta ferrite.

REFERENCES

• A.I.Pugachev, N.B.Demkin and V.I.Ryazantsev. (1968). ”Dimensions of Initial

Contact in Spot Welding of Light Alloys”. Welding Production.No4. Pp.13-15.
• Boniface E.Rossi. (1954). “Welding Technology”. McGraw HILL Book
Company.
• D.K.Aidun and R.W.Bennett. (1980). “ Effect of Resistance Welding Variables
on the Strength of Spot-Welded 6061-T6. Aluminum Alloy”. Welding
Journal.64 (12). Decem. Pp.15-25.
• Dicknson and Natal. (1987). ”Welding and Brazing and Soldering”. American
Welding Society, Vol.6. 9th edition.
• D.V.Lindh and J.L.Tocher. (1967). ”Heat Generation and Residual Stress
Development in Resistance Spot Welding”. Welding Journal. 46(8). August.
Pp.331s-358s.
• G.A.Mirlin,V. S,Savchenko and V.S.Shchedrov.(1964). ”Formation of
Splashing in Spot Welding and Methods of Prevention”. Welding Production.
4(5). Pp.7-12.
• J.M.Sawhill, Jr., H. Watanabe and J.M.Mitchell. (1977). ”Spot Weldability of
Mn-Mo-Cb-, V-N and SEA 1008 Steel”. Welding Journal. 56(7). July. Pp.
217s-223s.
• J.f.Iancaster. (1970). ”The Metallurgy of Welding, Brazing and Soldering”.
London, George Alden and Unwin LTD.
• Len Groud. (1980). ”The Welding”. Hodder and Straughton.
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

• Metals Handbook. (1971). ”Welding and Brazing”. American Welding

Society. 8th edition. Vol.6.
• Metals Handbook. (1958). “Welding Handbook”. American Welding Society
4th edition. Sec2.
• Mikell P.Groover. (1996) ”Fundamental of Modern Manufacturing”. Prentice
Hall.
• M.Kamaraj and V.M.Radhakrishnan. (1989). ”High Temperature Crack
Growth in Austenitic Weld”. Engineering Fracture Mechanics.33 (5). Pp.801-
811.
• M.L.Santalla, S.S.Babu, B.W.Riemer, and Z.Feng. (1998). ”Influence of
Microstructure on the Properties of Resistance Spot Welds”. 5th,International
Conference, on Trends in Welding Research, Pine Mountain, GA, 1-5, June
• Struart W.Gibson. (1997) ”Advanced Welding”. Former Lecture in Charge of
Welding Hiopwoodhall Collage, Macmillan.
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

120mm

35mm

A-Lap Specimen. 35mm

Fig.1. Geometry of tensile test specimen.

Longitudinal

Traversal

Fig. 2. The sequence and direction of microhardness measurements

Fig.3. General graphs of shear strength at various welding times and current settings. (Ref.5).
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

4000 15

w eld tim e w eld tim e

T = 1 5 (cycle) T = 1 5 (cycle)
T = 3 0 (cycle) T = 3 0 (cycle)
3000 T = 4 5 (cycle) T = 4 5 (cycle)
T = 6 0 (cycle) T = 6 0 (cycle)
10
M ax. Load ( N )

A rae( m m ^ 2 )
2000

1000

0 0

3000 4000 5000 6000 7000 8000 3000 4000 5000 6000 7000 8000
W eld C u rren t( A m p .) W eld C u rren t (A m p .)

Fig.4. Relationship of joint strength and welding Fig.5. Relationship of weld area and welding
current for lap test after anneling.del=5.5mm. current for lap test after anneling.del=5.5mm.

15
4000 w eld cu rre n t
w eld cu rren t
I= 3 .7 (K .am p .)
I= 3 .7 (K .am p .) I= 5 .8 (K .am p .)
I= 5 .8 (K .am p .) I= 6 .5 (K .am p .)
3000 I= 6 .5 (K .am p .) I= 7 .2 (K .am p .)
10
I= 7 .2 (K .am p .)
A rea( m m ^2 )
M ax. Load ( N )

2000

1000

0
0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
W eld T im e( C ycle )
W eld T im e( C ycle )
Fig.7. Relationship of weld area and welding
Fig.6. Relationship of joint strength and welding time for lap test after anneling.del=5.5mm.
time for lap test after anneling,del=5.5mm.

5000 15

w eld tim e w eld tim e

T = 1 5 (cycle) T = 1 5 (cycle)

4000 T = 3 0 (cycle) T = 3 0 (cycle)

T = 4 5 (cycle) T = 4 5 (cycle)

T = 6 0 (cycle) T = 6 0 (cycle)
10
A rea( m m ^2 )
M ax. Load ( N )

3000

2000
5

1000

0
0
3000 4000 5000 6000 7000 8000
3000 4000 5000 6000 7000 8000 W eld C u rrent( A m p . )
W eld C urrent( A m p . )
Fig.9. Relationship of weld area and welding
Fig.8. Relationship of joint strength and welding current for lap test after stress reliving,del=5.5mm.
current for lap test after stress reliving,del=5.5mm.
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

5000 15

w eld cu rre n t w eld cu rren t

I= 3 .7 (K .am p .) I= 3 .7 (K .am p .)

4000 I= 5 .8 (K .am p .) I= 5 .8 (K .am p .)

I= 6 .5 (K .am p .) I= 6 .5 (K .am p .)

I= 7 .2 (K .am p .) I= 7 .2 (K .am p .)
10
M ax. Load ( N )

A rea( m m ^2 )
3000

2000

1000

0 0

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
W eld T im e( C ycle ) W eld T im e ( C ycle )

Fig.10. Relationship of joint strength and welding Fig.11. Relationship of weld area and welding
time for lap test after stress reliving,del=5.5mm. time for lap test after stress reliving,del=5.5mm.

Center Heat Affected Base

Weld Zone Metal

Fig.12. Spot weld nugget microstructure for the base line welding
parameters (I=7.2K.amp. T=60 Cycle) A.as welded. B.stress relieved and
c.anneled specimen. X 200. Etching: 10ml acetic acid, 15ml hydrochloric
acid, 10ml nitric acid and 2 drops of glycerol.
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

240 240

230
230
H ard n ess ( H R V . )

H ard ness( H R V . )
220

220

210

210
200

190 200

0 .0 0 .2 0 .4 0 .6 0 .8 0 .0 0 .4 0 .8 1 .2
D istan ce( m m ) D istan ce( m m )

Fig.13. Longitudinal microharness from HAZ. Fig.14. Longitudinal microhardness from HAZ.
I=3.7K.amp.,T=30 cycle. I=5.8K.amp. ,T=45 cycle..

240 210

230 200
H ard n ess( H R V . )

H ard n ess (H R V .)

220 190

210 180

200 170

190 160

0 .0 0 .4 0 .8 1 .2 1 .6 2 .0 0 .0 0 .4 0 .8 1 .2 1 .6 2 .0
D istan ce( m m ) D istan ce( m m )

Fig.15. Longitudinal microhardness from HAZ. Fig.16. Longitudinal microhardness from HAZ.
I=7.2K.amp. ,T=60 cycle. I=7.2K.amp., T=60 cycle.after anneling.

230 210

220 200
H ard n ess( H R V .)

H ard ness( H R V .)

210 190

200 180

190 170
0 .0 0 .4 0 .8 1 .2 1 .6 2 .0 0 .0 0 .4 0 .8 1 .2 1 .6
D istan ce( m m ) D istance( m m )

Fig.17. Longitudinal microhardness from HAZ. Fig.18. Traverse microhardness from

I=7.2K.amp.,T=60cycle,after stress relieving. spot center,I=3.7K.amp ,T=30cycle.
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

220 240

216 230

H ard n esse( H R V . )
H ard ness( H R V . )

212 220

208 210

204 200

0 .0 0 .4 0 .8 1 .2 1 .6 0 .0 0 .4 0 .8 1 .2 1 .6
D istance( m m ) D istan ce( m m )

Fig.19. Traverse microhardness from Fig.20. Traverse microhardnesse from

spot center,I=5.8K.amp. ,T=45 cycle. spot center,I=7.2K.amp., T=60 cycle.

200 250

240

190
H ard n ess( H R V . )

H ard n ess( H R V .)

230

220

180

210

170 200

0 .0 0 .4 0 .8 1 .2 1 .6 0 .0 0 .4 0 .8 1 .2 1 .6
D istan ce( m m ) D istan ce( m m )

Fig.21. Traverse microhardness from spot center. Fig.22. Traverse microhardness from spotcenter.
I=7.2K.amp,T=60cycle,after anneling. I=7.2K.amp.,T=60cycle,after stress relieving.

Fig.23.A-Crosse –section
Through thickness show large
cavity due to metal expulsion.
X 100. B-fracture surface along
faying surface show the
expelled of plastic metal from
the hot zone, in which
produced cavity in the middle B
region of spot nugget. X 50.
Etching: 10ml acetic acid, 15ml
hydrochloric acid, 10ml nitric
acid and 2 drops of glycerol.
‫ﺍﻟﻤﺤﻭﺭ ﺍﻟﺭﺍﺒﻊ‬ 2003 ‫ﺍﻟﻤﺅﺘﻤﺭ ﺍﻟﻌﻠﻤﻲ ﺍﻟﺨﺎﻤﺱ ﻟﻜﻠﻴﺔ ﺍﻟﻬﻨﺩﺴﺔ ﻓﻲ ﺠﺎﻤﻌﺔ ﺒﻐﺩﺍﺩ‬

Fig.24. Small shrinkage cavity in the center of spot nugget. X100.

Etching: 10ml acetic acid, 15ml hydrochloric acid, 10ml nitric acid
and 2 drops of glycerol.

Fig.25. Show the insufficient fusion (small or brittle nugget), the Initial
nugget growth at faying surface and the sheet separation in the left of the
figure, this nugget will produce in the left of lobe curves. X200. Etching:
10ml acetic acid, 15ml hydrochloric acid, 10ml nitric acid and 2 drops of
glycerol.