Concentration mg/m3

3 2.5 2 1.5 1 0.5 0 Copper fumes zinc CMT dip transfer arc Standard dip transfer arc Pulsed dip transfer arc

BASE ELEMENTS FOR DESIGNING GALVANIZED STEEL STRUCTURES

Mihaela POPESCU Carmen OPRIS

Fig. 1. Emissions values in MIG brazing with CMT manual process [8] The inferior limit of application of the CMT process is reduced compared with conventional solutions with short arc and short-circuit transfer, which ensures the significant extension of the welding domain. Thermal power, respectively the welding energy at the CMT process is lower, compared with other processes. In the case of conventional processes, with short arc and short-circuit transfer, the wire executes feed motion, until the short-circuit is produced. The process is accompanied by abundant, uncontrolled sputtering [3]. In case of the CMT process, the previous presented situations may be avoided, since the welding wire executes an advancing-retreat movement towards the part to be welded, with high frequency. This is the main difference between CMT process and the conventional MIG/MAG process. Oscillation frequency of the wire varies in time, depending on the short-circuit formation, but the average is about 70 Hz. Metal transfer is done almost without welding current, while at the short arc welding conventional process, the short-circuit transfer is due to a higher welding current. The CMT process is extremely flexible, uses the process controller for the technologic monitoring of the working parameters, ensuring information regarding the main steps of the process. It is possible, thus, for the first time to combine the CMT process with the pulsed arc process. This is the reason why welding energy and penetration influence favourably the geometry of the welded joint [2,5,6].

Abstract: The paper presents the Cold Metal Transfer process, its performances and applications for the weldbrazing of galvanized sheets. Prior to welding, the sheets were investigated using thermo gravimetric and thermo differential analysis Welded joints were submitted to tensile testing, and examined with the optical microscope. Key words: galvanized microstructure, tensile tests sheets, CMT process,

1. INTRODUCTION
One new joining method for galvanized plates is the Cold Metal Transfer (CMT) process, developed by Fronius, obtaining what can be called joining drop by drop. The advantages of using this joining process are as follows: low thickness materials can be joined, under 0,8 mm; high diameters of the filler wire with low welding currents can be used (wire with 1,2 mm, may be welded stable with a current IS = 65A); good welding position; heat introduced in the piece is approx. 30% lower than the MIG/MAG classic process; low deformations; the process is suitable for complete mechanization. As the CMT process functions with less heat input, it almost incidentally has another added advantage: lower pollutant emissions. As shown by numerous test results, the concentrations of pollutant investigated in CMT brazing are far below those encountered in MIG brazing nearly 90% less copper fumes and as much as 63% less zinc that with conventional dip-transfer arc technology (figure 1) [8]. Joining of galvanized sheets is part of category of joints that cannot be obtained using classic processes, but can be done using weld-brazing. Joining process with welding/weld-brazing, with low thermal input, Cold Metal Transfer (CMT) is based on a completely new technologic concept, associated with specific equipments.

2. EXPERIMENTAL RESEARCH
Before being weld-brazed, two types of galvanized plates were examined, using thermo gravimetric and thermo differential analysis: probe 1 was covered by galvanization, and probe 2 was Cr 3+ passivation covered plate [4]. These experiments were made to determine the purity of the probe, as well as the thermal decomposition reactions that appear when the temperature increases. On the other hand, by thermo differential analysis the solid phase reactions between iron and zinc can be noticed as well as exothermic and endothermic phenomena. Figures 2 and 3 present the results obtained following the mentioned analysis. 363

The samples were afterwards weld-brazed, joining plates 1 mm thick. CuSi3 filler wire (DIN 1733) was used, with the chemical composition in table 1. Shielding gas was a Ar+30%He+1%CO2 mixture, which was used to allow the increase of arc power and consequently the welding speed. A higher welding speed is necessary in order to deteriorate the less possible the zinc layer. Therefore the arc power increases by introducing helium in the shielding gas, because of the high ionization potential, allowing thus the increase of the welding speed and obtaining good mechanical properties of the joint. After weld-brazing, the samples were submitted to tensile testing [2, 6, 7]. Fig. 2. The thermo gravimetric and thermo differential analysis of the galvanized plate Table 1. Properties of CuSi3 wire Typical composition in % Al < 0,01 Si 2,80 - 4,00 Mn 0,75 - 1,50 Sn < 0,20 Zn < 0,20 Pb < 0,02 Fe < 0,30 P < 0,02 Others total < 0,40 DIN 1733 SG-Cu Si 3 Material Nr. W.2.1461 BS 2901 part 3 C 9 AWS A 5.7 ER Cu Si - A CuZn5; CuZn10; CuZn15; CuSi2Mn; CuSi3Mn Filler wire for joining Copper, Copper-Silicon and Copper-Zinc alloys. Suitable for joning of steel to Copper and for surfacing of steel. High temperature and corrosion resistance. Very commonly used for galvanized steel.

Classification

Fig. 3. The thermo gravimetric and thermo differential analysis of the galvanized and Cr3+ passivation covered plate Symbols in figures 2 and 3 are as follows: TG (TGA) - thermo gravimetric analysis DTG - TG derivative DTA - differential analysis Determinations were made using a METTLER thermal analysis device, and the process to reduce the weight depending on temperature is represented by means of DTG. Testing for galvanized steel was conducted for 20 minutes at 500C, at the speed of 5C/min. It can be noticed, depending on temperature, the reduction of weight, as it follows. Both probes are approximately similar from the weight loss point of view. So, the zinc layer is completely damaged around the value of 420C (melting temperature of zinc). However the weight reduction is more accentuated in the case of non passivated probe. In the case of probe 1 which is passivated, the loss of weight is not significant up to the temperature of 260C, and in the other case the weight loss is significant starting with the temperature of 200C. In the case of probe 2 a strong exothermic reaction appears at the temperature of 496C. It is also worth mentioning the existence of inflexion points: probe 1 at the temperature of 405C and 448C, and as regards probe 2 at the temperature of 480C and 501C. These analysis show that the degradation of the zinc layer is reduced when it is passivated, having thus a higher resistance at processing at elevated temperatures in the environment. One can estimate that when welding these galvanized steels, the zing layer is less damaged if the Cr 3+ passivation operation is conducted. 364

Base materials Remarks

Tensile testing of the galvanized weld-brazed sheets is presented in figure 4. Following the tensile tests, samples 2, 3, 4 were broken in the base material, which confirms that the welding regimes were adequate, and samples 1 and 5 were broken in the joint, brittle fracture caused by the presence of hard intermetallic phases of iron and zinc. Results of the tensile tests are presented in table 2.

Fig. 4. Tensile test of the samples

Table 2. Results of the tensile tests Sample 1 2 3 4 5 Rm [daN/mm2] 310 370 370 350 260 Remarks Break in the joint Break in the base material Break in the base material Break in the base material Break in the joint

contributing thus to the increase of the weld-brazed joints resistance. At microscopic level this joining method does not have a significant influence on the materials structure in the heat affected zone. This is due to the low heat induced in the components by the high speed weld-brazing process. In the heat affected zone we can find an area characterized by a fine grain size, which hasnt suffered the increase of the grain size due to overheating (fig. 6).

Microstructural examinations were conducted on the samples, for both the welded joint and the base material. In the weld-brazed joint one can observe the dendritic crystallization of the eutectoid in an solid solution matrix. Brazing alloy that was used is CuSi3, which presents a structure formed by an solid solution of copper dissolved in silicon and an eutectoid mechanical mixture formed of the phase and the intermetallic compound Cu33Si7 (fig. 5) [2].

Fig. 6. Microstructure of the heat affected zone Also, because of the low heat input induced by the CMT process, one can see that the zinc layer has not been damaged in the area adjacent to the joint, which means that the anticorrosive protection of the galvanized sheets was not affected by the weld-brazing process. The thickness of the zinc layer is practically the same, as can be seen in figure 7.

a.

b. Fig. 5. Microstructural examination a. weld-brazed joint, b. weld-brazed joint-base material One can observe an area of copper diffusion in the base material, with approximate 8m thickness. The presence of this diffusion area in the base material ensures a good bond between the brazing alloy and the base material,

Fig. 7. Area adjacent to the CMT joint

3. CONCLUSION
The destructive tests program conducted on the samples demonstrates the quality of weld-brazed joints, emphasizing the copper diffusion area, as well as the fact that the zinc layer was not affected by the CMT process. 365

Being a colder process overall, CMT makes a number of work-steps superfluous. Freedom from spatter, for instance, means no post-weld machining. Not even when 100 % CO2 shielding gas is used in the welding of steel. Being able to butt-weld light-gauge sheets means there is no need for weld-pool backing support. High gap bridge ability means better process manageability and therefore suitability for automation. And thanks to the multiprocess capabilities of the welding machine, you can also perform MIG/MAG standard and pulsed-arc welding as well as CMT. On top of all this, there are all the savings that result from the loss-free gas supply to the torch, the automatic cooling-unit cut-out, low open-circuit power, high efficiency, modular (and thus highly flexible) system principle, easy servicing, updates via laptop etc. All the attributes that feature in the digital MIG/MAG systems do sterling service here as well [3, 5, 6]. Working with Fronius systems is definitely a very safe bet indeed. They all come with IP 23, earth fault-current watchdog, temperature-controlled fan. An additional benefit with the CMT systems is that because there is no spatter, fewer welding fumes are generated, which leads to less soiling at the workplace [1 8].

[7] YU, Z.S., LI, R.F., ZHOU, F.M., WU, M.F., QI, K., QIAN, Y.Y., Joint evolution and strengthening mechanism in arc brazed galvanized steel with CuSi3 filler, Material Science and Technology, 2004,vol 20, no. 11, ISSN 0267-0836, pp. 14791483. [8] xxx : Fronius

REFERENCES
[1] BOUAIFI, B., Low heat process enhance jointing of coated sheet metals, Welding Journal, 2003, 82(1), ISSN 0043-2296, pp. 26-31 [2] POPESCU, M., OPRIS, C., BRAN, I., Possibilities of applying the CMT (cold metal transfer) process for joining some components from agriculture, Buletin AGRO-AGIR, 2010, Anul II, No IV, pp 175-180, ISSN 1224-7928 [3] POPESCU, M., MAGDA, A., MOCUTA, G.E., DEMIAN, C., PERIANU, I.A., GROZA, D.: Comparative approach of MIG/MAG Brazing and CMT galvanized steel joining processes for automotive applications, Scientific Bulletin of the POLITEHNICA University of Timisoara Transactions on Mechanics, Fasc. 2, 2008, Tom 53(67), ISSN 1224-6077, pp. 29-36 [4] POPESCU, M., MOCUTA G.E., PADUREAN, I., Galvanized plates behaviour during the exploitation temperature variations, METALURGIA, 2010, no. 2, p. 21-23, ISSN 0461-9579 [5] QUINTINO, L., PIMENTA, G., IORDCHESCU, D., MIRANDA, R.M., PEPE, N.V., MIG Brazing of galvanized thin sheet joints for automotive industry, Material and Manufacturing Processes, 2006, vol. 21, issue 1, ISSN 0361-8773, pp. 63-73 [6] VERSTAPPEN, H.G.J.M., SUSTEREN, van S.J., OOJI, van W.J., Durability of powder coated hotdip galvanized steel, Journal of Coatings Technology, 2002, vol 74, nr. 7, ISSN 1547-0091, pp. 43-54 366

CORRESPONDENCE
Mihaela POPESCU, Prof. Assoc. Eng. Politehnica University of Timisoara Mechanical Engineering Faculty No. 1, M. Viteazul Bvd, Timisoara 300222, Romania mihaela.popescu@mec.upt.ro Carmen OPRIS, Assist. Ph.D. Eng. Politehnica University of Timisoara Mechanical Engineering Faculty No. 1, M. Viteazul Bvd, Timisoara 300222, Romania carmen.opris@mec.upt.ro