Abstract
Al-Si coated press hardened steels have shown great potential in the lightweight of automobile, while simultaneously face the challenge in welding process and fatigue performance. Based on the fatigue tests, it can be found that the fatigue cracks are all initiated from the surface coating. The fracture and surface morphology observation results reflect that the cracks in coating are formed during the hot stamping process and the followed die quenching, acting as the pre-existed cracks for the subsequent fatigue failure. Therefore, the fatigue cracks can be initiated via these pre-existed ones with the continuous load mainly due to the extremely high stress concentration in the region near the crack tip, eventually lead to the failure.
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