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Tailor welded blanks (TWB) afford better utilization of sheet steel for automotive and other applications. However, forming behaviour can be complicated because of the interactions between the different sheet steels comprising the TWB and the welding processes used. At Dofasco we have studied a matrix of different steel types, sheet thicknesses, and welding processes (i.e. mash seam, laser and electron beam) in order to gain an understanding of forming behaviour of tailor welded blanks. Simulative forming tests such as hole expansion, stretch bend, stretch dome and tensile tests were used. Finite element simulations using the FTICASE code were used to determine mechanisms for part failures. In addition, weld “service” characteristics such as corrosion performance and fatigue life were evaluated. Microscopic examinations included microhardness, metallography, and tests for weld porosity and zinc entrapment.

An accurate and reproducible mechanical Hat-channel test for evaluating flaking performance of Galvanneal sheet products has been implemented at Dofasco. Effective test conditions have been established and a flaking performance rating system has been set up. Good correlation between Hat-channel and production press performance has been achieved. The flaking mechanism of Galvanneal with good and poor adhesion was examined. The effect of lubricant on flaking has also been investigated.