The effect of prestrain and bake hardening on the low-cycle fatigue properties of TRIP steel

The scope of this study was to examine the effects of plane strain prestrain, induced via cold-rolling, and subsequent automotive paint bake hardening cycle on both tensile and fatigue properties of a hot rolled TRIP780 multiphase steel. Strain-life data has been generated for as-received (0% prestrain), 10% and 20% prestrained samples, in both baked and unbaked conditions. Cold rolling  increased the number of strain reversals to failure at high cyclic strain amplitudes with no effect at low strain amplitudes. Bake hardening increased the number of reversals to failure at high cyclic strain amplitudes. The prestrained material exhibited partial cyclic softening, with some residual strength increase. The residual strength increase was attributed to the austenite to martensite transformation that occurred during the prestraining process.

Contact pressure prediction in sheet metal forming using finite element analysis

Tool wear has become a significant issue associated with the forming of high strength sheet steels in the automotive industry. In order to combat this problem, recent research has been devoted to utilizing the contact results obtained from current sheet metal forming software predictions, in order to develop/apply tool wear models or tool material selection criteria for use in the stamping plant. This investigation aims to determine whether a specialized sheet metal forming software package can correctly capture the complex contact conditions that occur during a typical sheet metal stamping process. The contact pressure at the die radius was compared to results obtained using a general-purpose finite element software package, for a simple channel-forming process. Although some qualitative similarities between the two predictions were observed, it was found that significant differences in the magnitude and distribution of the contact pressure exists. The reasons for the discrepancies in results are discussed with respect to the simplifications and assumptions adopted in the finite element model definitions, and with regards to other results available in the literature.

Accuracy and precision assesment of stochastic simulation tools for springback variation

The sheet forming industry is plagued by inherent variations in its many input variables, making quality control and improvements a major hurdle. This is particularly poignant for Advanced High Strength Steels (AHSS), which exhibit a large degree of property variability. Current FE-based simulation packages are successful at predicting the manufacturability of a particular sheet metal components, however, due to their numerical deterministic nature are inherently unable to predict the performance of a real-life production process. Though they are now beginning to incorporate the stochastic nature of production in their codes. This work investigates the accuracy and precision of a current stochastic simulation package, AutoForm Sigma v4.1, by developing an experimental data set where all main sources of variation are captured through precise measurements and standard tensile tests. Using a Dual Phase 600Mpa grade steel a series of semi-cylindrical channels are formed at two Blank Holder Pressure levels where the response metric is the variation in springback determined by the flange angle. The process is replicated in AutoForm Sigma and an assessment of accuracy and precision of the predictions are performed. Results indicate a very good correspondence to the experimental trials, with mean springback response predicted to within 1 ° of the flange angle and the interquartile spread of results to within 0.22°.

Numerical investigation of high and low pressure tube hydroforming

Hydroforming is one option to reduce vehicle weight while increasing component stiffness and rigidity. This typically involves using a fluid to form a component with high internal pressure. Tube hydroforming has gained increasing interest in the automotive and aerospace industries because of its many advantages such as part consolidation, good quality of the formed part etc. The main advantage is that the uniform pressure can be transferred to whole part at the same time. In low pressure hydroforming, the internal pressure is significantly and the hydroformed section length of line stays almost the same as the circumference of the blank tube. This paper details the comparison between high and low pressure hydroforming. It is shown that the internal pressure and holding force required for low pressure hydroforming process is much less than that of high pressure. Also stress and thickness distribution are more uniform and the process is highly suitable for the forming of advanced high strength steels.

Formation of ultrafine ferrite by dynamic strain-induced transformation

In the current study, the role of dynamic strain induced transformation on ferrite grain refinement was investigated using different thermomechanical processing routes. A Ni-30Fe austenitic model alloy was also employed to study the evolution of the deformation structure under different deformation conditions. It was shown that the extreme refinement of ferrite is more likely due to the formation of extensive high angle intragranular defects in the austenite through deformation. Among the different thermomechanical parameters, the deformation temperature had a significant effect on the intragranular defect characteristics. There was a transition where the cell dislocation structure changed to laminar microband structures with a decrease in the deformation temperature. Moreover, the ultrafine grained structure was also successfully produced through static transformation using warm deformation process; in other words, concurrent deformation and transformation are not necessary for ultrafine ferrite formation.

Numerical investigation of ramp and constant pressurization system during tube crushing process

The requirement for the automotive industry at present and even more so in the future is to simultaneously develop materials, economic forming processes and techniques for weight reduction of the component. To fulfil this need steel manufacturers have developed Advanced High Strength Steels which have high strength and good formability. Due to high strength, material thickness can be reduced without compromising the function of the component. High pressure hydro forming is one process that can be used to produce complex components from these materials. However, reduction in material thickness of these steels does not result in a large decrease of internal fluid pressure and die closing force during tube hydro forming and hence the higher strengths of these steels will require higher pressures. Tube crushing is a process in which the component can be formed with low pressures. In this paper numerical comparison of ramp and constant pressurization system during tube crushing for a TRIP steel is studied. It is proposed that ramp pressure is the best option to obtain a part with accurate geometrical shape from tube crushing with less die closing force. The stress and thickness distribution of the part during tube crushing were critically analysed.

Experimental and numerical evaluation of forming and fracture behaviour of high strength steel

Car manufacturers are under pressure to reduce vehicle mass while maintaining comfort and passenger safety for current and future vehicles. To meet this demand the steel industry has developed Advanced High Strength Steels (AHSS) that promise higher strength and improved formability compared to conventional steel grades. Even though significant research has already been performed to evaluate the material properties and forming behaviour of most AHSS types, only a limited literature is available on their necking and fracture behaviour and the effect on formability. This paper examines and compares the thinning, necking and fracture behaviour of two AHSS and one conventional steel type, namely TRIP, DP and HSLA. Uniaxial, plane and biaxial strain conditions are investigated by tensile, cup drawing and stretch forming tests and by using numerical methods. The test results indicate that significant differences exist in necking and fracture behaviour between all three steel types.

A study of the strengthening mechanism in the thermomechanically processed TRIP/TWIP steel

The strengthening mechanism responsible for the unique combination of ultimate tensile strength and elongation in a multiphase Fe-0.2C-1.5Mn-1.2Si-0.3Mo-0.6Al-0.02Nb (wt%) steel was studied. The microstructures with different volume fraction of polygonal fenite, bainite and retained austenite were simulated by controlled thermomechanical processing. The interupted tensile test was used to study the bainitic ferrite, retained austenite and polygonal ferrite behavior as a function of plastic strain. X-ray analysis was used to characterize the volume fraction and carbon content of retained austenite. TEM and heat-tinting were utilized to analyze the effect of bainitic fenite morphology on the strain induced transformation of retained austenite and retained austenite twinning as a function of strain in the bulk material. The study has shown that the austenite twinning mechanism is more preferable than the transformation induced plasticity mechanism during the early stages of deformation for a microstructure containing I5% polygonal ferrite, while the transformation induced plasticity effect is the main mechanism in when there is 50% of polygonal ferrite in the microstructure. The baillitic fenite morphology affects the deformation mode of retained austenite during straining. The polygonal fenite behavior during straining depends on dislocation substructure tonned due to the deformation and the additional mobile dislocations caused by the TRIP effect. TRIP and TWIP effects depend not only on the chemical and mechanical stability of retained austenite, but also on the interaction of the phases during straining.

Electron back scattered diffraction (EBSD) characterization of warm rolled and accumulative roll bonding (ARB) processed ferrite

An interstitial free (IF) steel was severely deformed using accumulative roll bonding (ARB) process and warm rolling. The maximum equivalent strains for ARB and warm rolling were 4.8 and 4.0, respectively. The microstructure and micro-texture were studied using optical microscopy and scanning electron microscopy equipped with electron back scattered diffraction (EBSD). The grain size and misorientation obtained by both methods are in the same range. The microstructure in the ARB samples after 6 cycles is homogeneous, although a grain size gradient is observed at the layers close to the surface. The through thickness texture gradient in the ARB samples is different from the warm rolled samples. While a shear texture (⟨110⟩//rolling plane normal direction (ND)) at the surface and rolling texture at the center region is developed in the ARB  samples, the overall texture is weak. The warm rolled samples display a sharp rolling texture through the thickness with increasing the sharpness toward the center. These differences are attributed to the fact that the central region of ARB strip is comprised of material that was once at the surface. The ARB process  can suppress the formation of shear bands which are conventional at warm rolled IF steels. EBSD study on the sample with 6th cycle of ARB following the annealing at 750 ◦C verified a texture gradient through the thickness of the sheet. The shear orientations at the surface and at the quarter thickness layers can be identified even after annealing. The overall weak texture and existence of shear orientations make ARB processed samples unfavorable for sheet metal forming in compare with warm rolled samples.

Microstructure and mechanical properties of thermomechanically processed TRIP steel

The strengthening mechanism responsible for the unique combination of ultimate tensile strength and elongation in a multiphase Fe-0.2C-1.5Mn-1.2Si-0.3Mo-0.6Al-0.02Nb (wt%) steel was studied. The microstructures with different volume fractions of polygonal ferrite, bainite and retained austenite were simulated by controlled thermomechanical processing. The interrupted tensile test was used to study the bainitic ferrite, retained austenite and polygonal ferrite behaviour as a function of plastic strain. X-ray analysis was used to characterise the volume fraction and carbon content of retained austenite. Transmission electron microscopy was utilised to analyse the effect of bainitic ferrite morphology on the strain induced transformation of retained austenite and retained austenite twinning as a function of strain in the bulk material. The study has shown that the austenite twinning mechanism is more preferable than the transformation induced plasticity (TRIP) mechanism during the early stages of deformation for a microstructure containing 15% polygonal ferrite, while the transformation induced plasticity effect is the main mechanism when there is 50% of polygonal ferrite in the microstructure. The bainitic ferrite morphology affects the deformation mode of retained austenite during straining. The polygonal ferrite behaviour during straining depends on dislocation substructure formed due to the deformation and the additional mobile dislocations caused by the TRIP effect. Operation of TRIP or twinning mechanisms depends not only on the chemical and mechanical stability of retained austenite, but also on the interaction of the phases during straining.

Characteristics of the deformed and recrystallised grains obtained after hot plane strain compression of a model Fe-30wt%Ni alloy

The development of physically-based models of microstructural evolution during hot deformation of metallic materials requires knowledge of the grain/subgrain structure and crystallographic texture characteristics over a range of processing conditions. A Fe-30wt%Ni based alloy, retaining a stable austenitic structure at room temperature, was used for modelling the development of austenite microstructure during hot deformation of conventional carbon-manganese steels. A series of plane strain compression tests was carried out at a temperature of 950 °C and strain rates of 10 s-1 and 0.1 s-1 to several strain levels. Evolution of the grain/subgrain structure and crystallographic texture was characterised in detail using quantitative light microscopy and highresolution electron backscatter diffraction. Crystallographic texture characteristics were determined separately for the observed deformed and recrystallised grains. The subgrain geometry and dimensions together with the misorientation vectors across sub-boundaries were quantified in detail across large sample areas and the orientation dependence of these characteristics was determined. Formation mechanisms of the recrystallised grains were established in relation to the deformation microstructure.

EBSD and TEM investigation of the hot deformation substructure characteristics of a type 316L austenitic stainless steel

The evolution of crystallographic texture and deformation substructure was studied in a type 316L austenitic stainless steel, deformed in rolling at 900 °C to true strain levels of about 0.3 and 0.7. Electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) were used in the investigation and a comparison of the substructural characteristics obtained by these techniques was made. At the lower strain level, the deformation substructure observed by EBSD appeared to be rather poorly developed. There was considerable evidence of a rotation of the pre-existing twin boundaries from their original orientation relationship, as well as the formation of highly distorted grain boundary regions. In TEM, at this strain level, the substructure was more clearly revealed, although it appeared rather inhomogeneously developed from grain to grain. The subgrains were frequently elongated and their boundaries often approximated to traces of {111} slip planes. The corresponding misorientations were small and largely displayed a non-cumulative character. At the larger strain, the substructure within most grains became well developed and the corresponding misorientations increased. This resulted in better detection of sub-boundaries by EBSD, although the percentage of indexing slightly decreased. TEM revealed splitting of some sub-boundaries to form fine microbands, as well as the localized formation of microshear bands. The substructural characteristics observed by EBSD, in particular at the larger strain, generally appeared to compare well with those obtained using TEM. With increased strain level, the mean subgrain size became finer, the corresponding mean misorientation angle increased and both these characteristics became less dependent on a particular grain orientation. The statistically representative data obtained will assist in the development of physically based models of microstructural evolution during thermomechanical processing of austenitic stainless steels.

FEA comparison of high and low pressure tube hydroforming of TRIP steel

The increasing application of hydroforming for the production of automotive lightweight components is mainly due to the attainable advantages regarding part properties and improving technology of the forming equipment. However, the high pressure requirements during hydroforming decreases the costs benefit and make the part expensive. Another requirement of automotive industries is weight reduction and better crash performance. Thereby steel industries developed advanced high strength steels which have high strength, good formability and better crash performance. Even though the thickness of the sheet to form the component is reduced, the pressure requirement to form the part during expansion is still high during high pressure hydroforming. This paper details the comparison between high and low pressure tube hydroforming for the square cross-section geometry. It is determined that the internal pressure and die closing force required for low pressure tube hydroforming process is much less than that of high pressure tube hydroforming process. The stress and thickness distribution of the part during tube crushing were critically analysed. Further, the stress distribution and forming mode were studied in this paper. Also friction effect on both processes was discussed.

Influence of processing on the roll forming characteristics of recovery annealed steel

Roll forming (including corrugating) of high strength steel has for many years been treated as an art rather than a science. This work, by using analysis at both the microscopic and standard mechanical level, has demystified the production of these high strength steels, and has helped point the direction for further development of these efficient construction products.

Effects of aging bake hardenable steel in sheet metal forming

Bake hardening steels are being used as body panels in modern cars. These steels are stronger through an ageing process after baking in the paint ovens, which allows the thickness of the steel to be reduced without reducing the denting performance. The current study examined whether the steel ages at room temperature prior to forming which would deteriorate the formability. The work developed a new test and provided insight into acceptable levels of natural ageing which could be tolerated in the manufacturing process.