New 'green' corrosion inhibitors based on rare earth compounds

A series of rare earth organic compounds pioneered by our group have been shown to provide a viable alternative to theuse of chromates as corrosion inhibitors for some steel and aluminium applications. For example we have shown thatthe lanthanum 4-hydroxy cinnamate offers excellent corrosion mitigation for mild steel in aqueous environments whilerare earth diphenyl phosphates offer the best protection in the case of aluminium alloys. In both cases the protectionappears to be related to the formation of a nanometre thick interphase occurring on the surface that reduces theelectrochemical processes leading to metal loss or pitting. Very recent work has indicated that we may even be able toaddress the challenging issue of stress corrosion cracking of high strength steels. Furthermore, filiform corrosion can besuppressed when selected rare earth inhibitor compounds are added as pigments to a polymer coating. There is little doubtfrom the work thus far that a synergy exists between the rare earth and organic inhibitor components in these novelcompounds. This paper reviews some of the published research conducted by the senior author and colleagues over the past10 years in this developing field of green corrosion inhibitors

Application of advanced experimental techniques for the microstructural characterization of nanobainitic steels

A 0.79C-1.5Si-1.98Mn-0.98Cr-0.24Mo-1.06Al-1.58Co (wt%) steel was isothermally heat treated at 350°C bainitic transformation temperature for 1 day to form fully bainitic structure with nano-layers of bainitic ferrite and retained austenite, while a 0.26C-1.96Si-2Mn-0.31Mo (wt%) steel was subjected to a successive isothermal heat treatment at 700°C for 300 min followed by 350°C for 120 min to form a hybrid microstructure consisting of ductile ferrite and fine scale bainite. The dislocation density and morphology of bainitic ferrite, and retained austenite characteristics such as size, and volume fraction were studied using Transmission Electron Microscopy. It was found that bainitic ferrite has high dislocation density for both steels. The retained austenite characteristics and bainite morphology were affected by composition of steels. Atom Probe Tomography (APT) has the high spatial resolution required for accurate determination of the carbon content of the bainitic ferrite and retained austenite, the solute distribution between these phases and calculation of the local composition of fine clusters and particles that allows to provide detailed insight into the bainite transformation of the steels. The carbon content of bainitic ferrite in both steels was found to be higher compared to the para-equilibrium level of carbon in ferrite. APT also revealed the presence of fine C-rich clusters and Fe-C carbides in bainitic ferrite of both steels.

Fabrication, microstructure and mechanical properties of high performance ferrite-bainite steels

Low cost ferrite and bainite(FB) steels offer the prospect of high ultimate tensile strength combined with high hole expansion ratio. The enhanced strain hardening and formabilityof FB steels were primarily associated with the fine ferrite matrix, the low residual stresses and dislocation densityand compatible deformation between both phases.This overview describes the various techniques to produce FB steels, and comparestheresulting microstructure, tensile propertiesand tretchflangeabilitywith conventional HSLA and DP steels.A new generation of ultrafine ferrite and nano-scalebainiteautomotive steelsisunder development forthe futuredemands of extremely high strength and ductilitythroughthe fabricationtechnologiesinvolvingphase transformationsandplastic deformation.

Approach for testing the material behavior in roll forming in a small scale

Roll forming of ultra-high strength steels (UHSS) and other high strength alloys is an advanced manufacturing methodology with the ability of cold forming those materials to complex three-dimensional shapes for lightweight structural applications. Due to their high strength, most of these materials have a reduced ductility which excludes conventional sheet forming methods under cold forming conditions. Roll forming is possible due to its low strains and incremental forming characteristic. Recent research investigates the development of high strength nano-structured aluminum sheet and titanium alloys, as well as their behaviour in roll forming with regard to formability, material behaviour and shape defects. The development of new materials is often limited to small scale samples due to the high preparation costs. In contrast, industrial application needs larger scale tests for validation, especially in roll forming where a minimum sheet length is required to feed the sample trough the roll forming machine. This work describes a novel technique for studying roll forming of a short length of experimental material. DP780 steel strips (500mm – 1300mm length) were welded between two mild steel carrier sheets of similar width and thickness giving an overall strip length of 2m. Roll forming trials were performed and longitudinal edge strain, bow and springback determined on the welded samples and samples formed of full length DP780 strip before and after cut off. The experimental results of this work show that this method gives a reasonable approach for predicting material behavior in roll forming transverse to the rolling direction. In contrast to that significant differences in longitudinal bow were observed between the welded sections and the sections formed of full length DP780 strip; this indicates that the applicability of this method is limited with regard to predicting longitudinal material behavior in roll forming.

Effect of tensile pre-strain on bending and unloading of automotive steels

In recent years, advanced high strength steels (AHSS) have been used in a wide range of automotive applications; they may have property variations through the thickness and the properties may also be dependent of prior processing including pre-straining. In order to model forming processes precisely using, for example, finite element analysis, it is important that material input data should adequately reflect these effects. It is known that shape defects in roll forming are related to small strains in material that has undergone prior deformation in a different strain path. Much research has already been performed on the change in the Young’s Modulus once a steel sheet has been plastically deformed,however many of these tests have only been conducted using tensile testing, and therefore may not take into account differences in compressive and tensile unloading. This research investigates the effect of tensile pre-straining on bending behaviour for various types of material;in bending, one half of the sheet will load and unload in compression and hence experience deformation under a reversed stress. Four different materials were pre-strained in tension with 1%, 3%, 7%, 11% and 25% elongation. Using a free bending test, moment curvature diagrams were obtained for bending and unloading. The results showed that the characteristics of the moment curvature diagram depended on the degree of pre-straining; more highly strained samples showed an earlier elastic-plastic transformation and a decreased Young's Modulus during unloading. This was compared to previous literature results using only tensile tests. Our results could influence the modeling of springback in low tension sheet operations, such as roll forming.

Multiscale microstructure engineering of steels

The development of modern steels is based on the tailoring of the microstructure to achieve the required properties. While historically this was performed at the micrometre scale length, there is now the scope to undertake this at the nanoscale or atom scale. The present paper reviews recent work related to the development of ultrafine and nanoscale microstructures in steel as well as changes at shorter scale lengths, such as cluster formation and solute effects. This includes the development of ultrafine ferrite through phase transformation, nanoscale and ultrafine bainite, precipitation and cluster strengthening and bake hardening of steels. A key element of the present work has been the use of atom probe tomography to unlock the nature of these structures.

Machinability and phase transformation study of nanobainite steels

There is an increasing demand for high strength materials with the development of technology and critical applications. Nano materials are newly developed materials with extremely high strength for this purpose. Nanobainite is a dual phase material containing alternate layers of bainitic ferrite in nano dimensions and retained austenite. Nanobainite is produced by isothermally holding austenitized steel at a temperature of 200°C or less, depending on the chemical composition, for 6 10 days until bainite forms and then cooling to room temperature using austempering. The experimental design consisted of face milling under 12 combinations of Depth of Cut (DOC)-1, 2 and 3mm; cutting speed-100 and 150m/min; constant feed-0.15mm/rev and coolant on/off. The machinability of the material is assessed by means of analysis, such as surface texture and microhardness. The assessment also involves microstructural comparisons before and after milling. Future work involves quantifying the microstructural phase before and after milling using XRD. The results obtained are used to assess the most favorable condition to cut this new variety of steel.

Springback investigation in roll forming of a V-section

To have fuel efficient vehicles with a lightweight structure, the use of High Strength Steels (HSS) and Advanced High Strength Steels (AHSS) in the body of automobiles is increasing. Roll forming is used widely to form AHSS materials. Roll forming is a continuous process in which a flat strip is shaped to the desired profile by passing through numerous sets of rolls. Formability and springback are two major concerns in the roll forming of AHSS materials. Previous studies have shown that the elastic modulus (Young's modulus) of AHSS materials can change when the material undergoes plastic deformation and the main goal of this study is to numerically investigate the effect of a change in elastic modulus during forming on springback in roll forming. Experimental loading-unloading tests have been performed to obtain the material properties of TRIP 700 steel and incorporate those in the material model used in the numerical simulation of the roll forming process. The finite element simulations were carried out using MSC-Marc and two different element types, a shell element and a solid-shell element, were investigated. The results show that the elastic modulus diminution due to plastic strain increases the springback angle by about 60% in the simple V-section roll forming analyzed in this study. © (2014) Trans Tech Publications, Switzerland.

Numerical modeling of dual phase microstructure behavior under deformation conditions on the basis of digital material representation

Development of a digital material representation (DMR) model of dual phase steel is presented within the paper. Subsequent stages involving generation of a reliable representation of microstructure morphology, assignment of material properties to component phases and incorporation of the model into the commercial finite element software are described within the paper. Different approaches used to recreate dual phase morphology in a digital manner are critically assessed. However, particular attention is placed on innovative identification of phase properties at the micro scale by using micro-pillar compression tests. The developed DMR model is finally applied to model influence of micro scale features on failure initiation and propagation under loading conditions.

On the definition of an kinematic hardening effect graph for sheet metal forming process simulations

The objective of this work is to develop a kinematic hardening effect graph (KHEG) which can be used to evaluate the effect of kinematic hardening on the model accuracy of numerical sheet metal forming simulations and this without the need of complex material characterisation. The virtual manufacturing process design and optimisation depends on the accuracy of the constitutive models used to represent material behaviour. Under reverse strain paths the Bauschinger effect phenomenon is modelled using kinematic hardening models. However, due to the complexity of the experimental testing required to characterise this phenomenon in this work the KHEG is presented as an indicator to evaluate the potential benefit of carrying out these tests. The tool is validated with the classic three point bending process and the U-channel width drawbead process. In the same way, the capability of the KHEG to identify effects in forming processes that do not include forming strain reversals is identified.

An analytical approach to predict web-warping and longitudinal strain in flexible roll formed sections of variable width

To reduce weight and improve passenger safety there is an increased need in the automotive industry to use Ultra High Strength Steel (UHSS) for structural and crash components. However, the application of UHSS is restricted by their limited formability and the difficulty of forming them in conventional stamping. An alternative method of manufacturing structural auto body parts from UHSS is the flexible roll forming process, which allows the manufacture of metal sheet with high strength and limited ductility into complex and weight-optimized components. One major problem in the flexible roll forming of UHSS is the web-warping defect, which is the deviation in height of the web area over the length of the profile. It has been shown that web-warping is strongly dependant to the permanent longitudinal strain formed in the flange of the part. Flexible roll forming is a continuous process with many roll stands, which makes numerical analysis extremely time intensive and computationally expensive. An analytical model of web-warping is therefore critical to improve design efficiency during the early process design stage before FEA is applied. This paper establishes for the first time an analytical model for the prediction of web-warping for the flexible roll forming of a section with variable width. The model is based on evaluating longitudinal edge strain in the flange of the part. This information is then used in combination with a simple geometrical model to investigate the relationship between web-warping and longitudinal strain with respect to process parameters.

Uniform elongation and the stress-strain flow curve of steels calculated from hardness using empirical correlations

An empirical relationship between the hardness and uniform elongation of non-Austenitic hypoeutectoid steels has been developed. This new hardness-elongation relationship was combined with previously developed correlations of hardness and strength (yield and ultimate tensile strength) to predict the stressstrain flow curve from a single hardness test. The current study considers both power law hardening behavior and exponential hardening behavior. Reasonable agreement was observed between the experimental and predicted flow curves of a high strength, low alloy steel. Additionally, an empirical correlation of the flow strength at instability with hardness is provided. © ASM International.