Coating Technology to Improve the Performance of Resistance Welding Electrodes for Zn-Mg-Al Alloying Coated Steel Sheets
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PosMAC (POSCO Magnesium Aluminum alloy Coating product) is a ternary alloy-coated steel (Zn- 3%Mg-2.5%Al) developed by POSCO utilizing proprietary technology to achieve high corrosion resis- tance. However, the weldability of PosMAC is lower than that of standard steel sheets due to reactions between Cu-based electrodes and the coated layer during resistance welding. This interaction leads to the formation and growth of CuZn compounds, which causes uneven wear on the electrodes and shortens their lifespan. In this study, we produced the coating using the High Velocity Oxygen Fuel (HVOF) process with various types of WC-based powders. We evaluated both coated and uncoated electrodes by measuring frac- ture strength at 100 spot points after spot welding. Additionally, we assessed the final coating electrode through projection resistance welding at a dual fan component manufacturer. The HVOF-sprayed WC- 12Co coating demonstrated promising results in both spot and projection resistance welding tests. Notably, in projection welding tests with the coated electrode, its lifespan was found to be ten times longer than that of the commercially available uncoated electrode.
Abstract
PosMAC (POSCO Magnesium Aluminum alloy Coating product) is a ternary alloy-coated steel (Zn- 3%Mg-2.5%Al) developed by POSCO utilizing proprietary technology to achieve high corrosion resis- tance. However, the weldability of PosMAC is lower than that of standard steel sheets due to reactions between Cu-based electrodes and the coated layer during resistance welding. This interaction leads to the formation and growth of CuZn compounds, which causes uneven wear on the electrodes and shortens their lifespan. In this study, we produced the coating using the High Velocity Oxygen Fuel (HVOF) process with various types of WC-based powders. We evaluated both coated and uncoated electrodes by measuring frac- ture strength at 100 spot points after spot welding. Additionally, we assessed the final coating electrode through projection resistance welding at a dual fan component manufacturer. The HVOF-sprayed WC- 12Co coating demonstrated promising results in both spot and projection resistance welding tests. Notably, in projection welding tests with the coated electrode, its lifespan was found to be ten times longer than that of the commercially available uncoated electrode.