Morphology and microstructure studies of the zincalume steel joints using metal inert gas (MIG) process

The lap joint of Zincalume G550 steel is welded by Metal Inert Gas (MIG) welding and ER70S-6 filler wire. 16.5 - 17.5 v of welding voltage and 3 - 4.5 m/min of wire-speed are set in parameters under the 70 A of constant welding current. The welded specimens were cold-mounted and cut with a cutting machine and the cross-section of the joints was ground with three different abrasive papers (220,1000,2000) and etching with Ferric Chloride (FeCl₃). The microstructure of the joint surface is investigated. The fine (at FZ) and coarse grains (at HAZ) are identified clearly. In experimental testing, it can be seen that high welding voltage and low wire speed produced high heat energy, which can be led to the creation high volume of perlite structure in the weld zone and the grain size of the HAZ (heat affected zone) was much bigger than FZ (fusion zone) during the MIG process. The welding voltage is a direct relationship with forming microstructure that the phase transformation increases when the welding voltage increases. However, low wire speed can be expanded the size of the weld region where the fine grains are observed. In the FZ, the perlite structure (a-Ferrite and cementite) moved between the FZ and the HAZ, and the cementite grain much formed under the high-temperature end of the FZ.