Advanced High Strength Steels Research Articles

A numerical investigation into the influence of the slide burnishing process on the real surface roughness and residual stress profiles of AHSS

Finite element models of the burnishing process for galvanized Advanced High-Strength Steels (AHSS) sheets were developed. To reduce the number of points that describe a real surface profile, optimization algorithms were implemented, considering three sequential stages: (1) surface profile filter, (2) mean line determination and, (3) eight roughness parameters validation. The finite element models developed accurately reproduce the experimental roughness profile, obtained with different burnishing forces. Also, the effect of the real surface roughness on the residual stress distribution was numerically investigated by considering the interaction between the coating layer present on the steel. The simulation showed that considering the real surface strongly influences the residual stress profile on the surface and to a certain depth.

Microstructural Evolution and Mechanical Properties of Nb‐Containing Medium‐Mn Low‐Density Steels

Microalloying of Nb has been commonly utilized to enhance the structure and mechanical properties of advanced high‐strength steel (AHSS), but its application in medium‐Mn low‐density steel has been relatively understudied. This study aims to investigate the evolution of nano‐scale precipitates and mechanical properties of Fe‐12Mn‐9Al‐3Cr‐1.4C‐0.02/0.04Nb low‐density steels. The findings reveal that the austenite grain size of 0.04Nb steels is approximately half that of 0.02Nb steels due to the precipitation of NbC particles. Moreover, the addition of Nb is found to elevate the formation energy of κ‐carbide, thereby impeding its growth and coarsening. Consequently, the intragranular κ‐carbides in 0.04Nb steels are consistently smaller than those in 0.02Nb steels, with no coarsened intergranular κ‐carbides detected in either steel variant after aging treatment at 723–823 K. Despite a slight reduction on precipitation strengthening of κ‐carbides with higher Nb content, the yield strength of 0.04Nb steels exceeds that of 0.02Nb steels by ≈71 MPa, mainly due to additional fine grain strengthening and dislocation strengthening. The strengthening mechanisms in the Nb‐containing low‐density steels are analyzed quantitatively. The role of Nb in regulating the microstructure and mechanical properties of medium‐Mn low‐density steels is comprehensively discussed, offering valuable insights for the alloy design of low‐density steel.

Deconstructing the Retained Austenite Stability: In Situ Observations on the Austenite Stability in One- and Two-Phase Bulk Microstructures During Uniaxial Tensile Tests

Given the critical role that metastable retained austenite (RA) plays in advanced high-strength steel (AHSS), there is significant interest in obtaining a comprehensive understanding of its stability, to achieve excellent mechanical properties. Despite considerable attention and numerous studies, the significance of individual contributions of various microstructural factors (size, crystallographic orientation, surrounding phases, etc.) on the stability of RA remain unclear, partly due to the difficulty of isolating the direct effects of these factors. In this study, we examined the influence of microstructural factors while minimizing the effect of chemical composition on the mechanical stability of RA. We accomplished this by comparing the austenite (γ) stability in two distinct microstructures: a two-phase RA/martensite microstructure and a one-phase γ microstructure, both with nearly identical γ compositions. We employed in situ high-energy X-ray diffraction during uniaxial tensile testing conducted at both room temperature and 100 °C, facilitating the continuous monitoring of microstructural changes during the deformation process. By establishing a direct correlation between the macroscopic tensile load, phase load partitioning, and the γ/RA transformation, we aimed to understand the significance of the microstructural factors on the mechanical stability of the RA. The results indicate that very fine RA size and the surrounding hard martensitic matrix (aside from contributing to load partitioning) contribute less significantly to RA stability during deformation than expected. The findings of this study emphasize the critical and distinct influence of microstructure on γ/RA stability.

The High-Cycle Tensile-Shear Fatigue Properties and Failure Mechanism of Resistance Spot-Welded Advanced High-Strength Steel with a Zn Coating.

Advanced high-strength steels (AHSSs) with Zn coatings are commonly joined by the resistance spot welding (RSW) technique. However, Zn coatings could possibly cause the formation of liquid metal embrittlement (LME) cracks during the RSW process. The role of a Zn coating in the tensile-shear fatigue properties of a welding joint has not been systematically explored. In this study, the fatigue properties of tensile-shear RSW joints for bare and Zn-coated advanced high-strength steel (AHSS) specimens were comparatively studied. In particular, more severe LME cracks were triggered by employing a tilted welding electrode because much more stress was caused in the joint. LME cracks had clearly occurred in the Zn-coated steel RSW joints, as observed via optical microscopy. On the contrary, no LME cracks could be found in the RSW joints prepared with the bare steel sheets. The fatigue test results showed that the tensile-shear fatigue properties remained nearly unchanged, regardless of whether bare or Zn-coated steel was used for the RSW joints. Furthermore, Zn mapping adjacent to the crack initiation source was obtained by an electron probe micro-analyzer (EPMA), and it showed no segregation of the Zn element. Thus, the failure of the RSW joints with the Zn coating had not initiated from the LME cracks. It was concluded that the fatigue cracks were initiated by the stress concentration in the notch position between the two bonded steel sheets.

Effect of initial microstructure on microstructure and properties of bainitic steels achieved by rapid heat treatment

Rapid heat treatment is essential in manufacturing advanced high-strength steels. The initial microstructure significantly influences the steel's microstructure and properties after rapid heat treatment. The present study investigated how the initial microstructure affected phase transformation, microstructure, and properties of bainite in high-carbon low-alloy steel during rapid heat treatment. Under rapid heating, ultrafine bainite (UB) sample with homogeneous composition exhibits the lowest austenitization temperature, while globular pearlite (GP) sample with poor composition homogeneity has a higher austenitization temperature. After rapid heat treatment, the compositional distribution of the initial microstructure was partially retained in the final sample. The increase of alloying elements inhibits the nucleation of bainitic ferrite, making it easier for bainitic ferrite to grow at low-alloy positions. Finally, a large amount of retained austenite is obtained in the alloying element-rich area. The difference in microstructure results in samples with different initial microstructures having similar strengths but differing plasticities. In samples with an initial lamellar pearlite (LP) microstructure, there was a substantial amount of thicker, filmy retained austenite, with an average thickness of 96.8 nm. This led to a small increase in Kernel Average Misorientation (KAM) with strain during the tensile process. This improvement in coordinated deformation during straining indicates that the sample has achieved excellent performance, with a tensile strength of 1483 MPa and a uniform elongation of 23 %. When the initial microstructure was GP, the sample contained a large amount of crumbly retained austenite with a low aspect ratio. This structure poorly coordinated deformation with higher strain, resulting in numerous microcracks.

Microstructural Evolution and Formation Mechanism of the Halo Ring in Resistance Spot Welded Third Generation Advanced High Strength Steel

Microstructural Evolution and Formation Mechanism of the Halo Ring in Resistance Spot Welded Third Generation Advanced High Strength Steel

Hydrogen Embrittlement of Advanced High-strength Steel S960MC Used in Transport and Vehicle Industry and the Influence of Potassium Thiocyanate during Hydrogenation

Advanced high-strength steels (AHSS) are currently facing a serious challenge from hydrogen embrittlement, which significantly affects their mechanical properties. Problems arise when hydrogen diffuses into the material and accumulates at grain boundaries, inclusions, or microcracks, degrading the material's characteristics. The main objective of the study is to investigate the effects of adding potassium thiocyanate (KSCN) to the sulfuric acid base solution during electrolytic hydrogenation using microalloyed martensitic AHSS grade S960MC. An increase in hydrogen diffusion into the examined material across its full surface is produced by adding thiocyanate ions to the electrolyte. This is the rationale behind the decision to add KSCN to the sulfuric acid base solution. The addition of KSCN to the base environment induced a considerable reduction in fracture strain, and the degradation was attributed to hydrogen buildup at grain boundaries, impurities and microcracks. These steels have an extensive list of applications in the automotive industry and are frequently used in the form of sheets for welding. Therefore, it is important to understand how their mechanical characteristics and behaviour vary in various circumstances, including hydrogen-rich environments.

Deformation-induced martensitic transformation kinetics in TRIP-assisted steels and high-entropy alloys

In this study, the sigmoidal kinetics of deformation-induced martensitic transformation (DIMT) in the transformation-induced plasticity (TRIP)-assisted alloys, including metastable high-entropy alloys (HEAs), austenitic stainless steels, and advanced high-strength steels (AHSSs) such as low-alloyed TRIP steels, medium-Mn steels, and quenching and partitioning steels, were studied using various models. To tune mechanical stability, the influences of stacking fault energy (SFE), chemical composition, austenite grain size, deformation temperature, strain rate, and stress state were considered. The novel Fe47Co30Cr10Ni5V8-xSix (x = 3, 4, and 6 at.%) alloys were the main investigated HEAs in the present work, in which silicon addition effectively led to lowering SFE and faster DIMT kinetics by promoting the formation of body-centered cubic α΄-martensite. The Olson-Cohen, Guimaraes (based on Johnson-Mehl-Avrami-Kolmogorov analysis), Shin, and Ahmedabadi models were analyzed and critically discussed. Moreover, a Hill-based sigmoid model was formulated as fα' / fsat = 1 – p / (p + εq) with the parameters p and q characterizing the stability of austenite, and fsat representing the saturated volume fraction of α΄-martensite. It was demonstrated that χ = p × q can be considered the sole austenite stability parameter. It was concluded that the proposed Hill-based model, demonstrating the highest accuracy among the studied models, can effectively simulate the kinetics of α΄-martensite formation.

Correlation between individual phase constitutive properties and plastic heterogeneities in advanced-high strength dual-phase steels

The present study comprehensively investigates the individual phase constitutive properties and plastic heterogeneities in advanced high-strength steels (AHSS), particularly DP590 and DP780 dual-phase (DP) steels. A machine learning-based model is implemented to identify the ferrite and martensite phases in the microstructures of DP590 and DP780. Then, the constitutive properties of ferrite and martensite phases are successfully obtained through a hybrid approach of in-situ neutron diffraction coupled with the crystal plasticity finite element method (CPFEM). The distinct microstructures between DP590 and DP780 result in different macroscopic and microscopic properties among the two materials. Owing to different martensite volume fractions (Vm) in DP590 (Vm = 8.3 %) and DP780 (Vm = 35.4 %), a noticeable dependency of plastic heterogeneities during deformation on martensite fraction and its spatial distribution is revealed. Compared to DP590, the deformed microstructure of DP780 exhibits a more heterogeneous distribution of stress and strain fields, along with significant formation of plastic strain localization leading to a remarkable increase in strain partitioning index. It shows that a lower fraction of martensite with its discrete distribution decreases martensite ability to hinder the ferrite deformation, thus strain localization is primarily concentrated within the ferrite phase as the predominant failure mode in DP590. In contrast, a higher martensite fraction in DP780 causes more pronounced strain localization which occurs in the ferrite and at the ferrite/martensite interface. In addition, interconnect distribution between martensite islands enhances the inhibition of martensite to ferrite deformation, thereby high strain gradient at their interface leads to prevalence of ferrite/martensite interface decohesion in DP780.

Achieving unexpected strength and ductility synergies in heterogeneous metastable lamellar steels

High-strength steel with excellent ductility is pivotal for the formability and safety of critical structural components. Here, a heterogeneous metastable lamellar steel, composed of alternating lamellar ferrite and austenite aligned with the rolling direction, was developed through an innovative combination of warm rolling and immediate annealing processes. This novel design overcomes the strength-ductility trade-off, achieving high ultimate tensile strength (∼1.2 GPa) and excellent uniform elongation (∼78%), pushing the product of ultimate tensile strength and uniform elongation to an ultra-high level (> 90 GPa %). The high tensile strength is attributed to ultrafine lamellar grains and significant work hardening induced by the hetero-deformation and transformation-induced plasticity (TRIP) effect. The exceptional ductility is a result of the synergy of multiple plasticity mechanisms, including (i) the inherent plastic deformation ability of lamellar microstructure and the hetero-deformation-induced hardening in the early deformation period, (ii) the persistent TRIP effect induced by the lamellar austenite with high mechanical stability and the elimination of strain localization caused by prolonged strain hardening due to the coordinated deformation of lamellar austenite and ferrite in the middle deformation period, and (iii) delamination cracking in the late deformation period. This approach adopted in current work offers a straightforward and economically feasible pathway for fabricating advanced high-strength steel with superior performance.

Stability of retained austenite and its effect on tensile properties and hole expansion performance of high-strength steel

Medium manganese steel has a ferritic matrix with retained austenite as the secondary phase at room temperature (RT). The effect of the transformation-induced plasticity (TRIP) of retained austenite on steel has earlier been found to result in an excellent combination of high strength and ductility, making it a promising candidate as a third-generation advanced high-strength steel (AHSS) for automotive applications. Therefore, extensive research has recently been conducted with the aim to increase the amount of retained austenite in steel, thereby enhancing the strength and ductility of the steel. However, an increase in the amount of retained austenite can be detrimental to the HER, which is due to its low mechanical stability and the transformation to martensite when forming holes by punching. However, there has been relatively little research on this topic.The impact of the mechanical stability of retained austenite on the tensile properties and hole expansion ratio (HER) of high-strength medium-Mn steel have been investigated in the present study. Samples were prepared using one-step austenite-reverted-transformation (ART) annealing, which resulted in steel with 24.7 % retained austenite and moderate mechanical stability. The steel showed also an excellent combination of strength and ductility. Samples were also prepared using two-step annealing, which showed a positive effect on the HER of the steel, regardless of the processing method used for the formation of a central hole on the samples. However, it slightly reduced the ductility of the steel. For all these samples, the impact of the retained austenite on the HER was found to be closely related to its mechanical stability and content in the steel.Retained austenite with poor stability transformed into hard martensite during the punching processing of holes. In contrast, the retained austenite with a relatively high stability showed a positive effect during the whole hole expansion deformation process. It decreased the stress concentration and, thereby, improved the HER. Thus, the present study has found that it is of the greatest importance to improve the stability of the retained austenite in high-strength medium-Mn steel, and to suppress its transformation to martensite during the punching of holes in the steel.

Insights into the microstructural evolution and strengthening mechanisms of friction stir spot welded advanced high strength ultrafine bainitic steel

Unlocking the full potential of advanced high-strength bainitic steels in spot-welding is a pivotal endeavor for harnessing their extraordinary mechanical properties in the automotive industry. This study suggests a shift in paradigm to address the inferior fusion weldability of this type of steel because of the formation of coarse martensite within the welded zone of weldments obtained by liquid-state welding, through the strategy of refining the martensite within the weld zone using the solid-state friction stir spot welding (FSSW) process. This paper delves into an in-depth investigation of the microstructural evolution and load-bearing capacity of a Fe-0.25C-3Cr-1.63Mn-1.5Si (wt%) ultrafine bainitic steel, having a remarkable tensile strength of 1.7 GPa, during the intriguing process of FSSW at rotational speeds of 600 to 2000 rpm. The research uncovers that the stir zone (SZ) undergoes dynamic recrystallization, resulting in a significantly refined microstructure. Regardless of the rotational speed employed, the high hardenability of the steel and rapid cooling during the process inevitably results in martensite formation within this region. However, a comprehensive microstructural characterization conducted by the electron backscatter diffraction (EBSD) analysis proves that the different thermal cycles induced by different rotational speeds lead into various prior austenite grain sizes, martensitic/bainitic packets and blocks attributes, and density of high-angle grain boundaries (HAGBs). Through the evaluation of strengthening mechanisms in different weld zones, the study sheds light on the key factors influencing strength. Block boundaries emerge as the primary contributor to SZ hardening, surpassing the role of geometrically necessary dislocations (GNDs) and solid solution strengthening. The load-bearing capacity observed during the tensile-shear test is governed by a delicate interplay between bonding width and crystallographic features (block size and HAGBs density) of the martensite formed within the SZ. The highest peak load was achieved under optimal welding conditions (rotational speed of 1000 rpm), which enabled the production of a sufficiently large bonding width, providing ample bonding area for load-bearing, along with an abundance of blocks and HAGBs to effectively impeding crack propagation.

Machine-Learning-Assisted Composition Design for High-Yield-Strength TWIP Steel

Twinning-induced plasticity (TWIP) steel is an ideal material for impact-resistant structures and energy absorption because of its high product of strength and elongation. However, compared with other advanced high-strength steels, the relatively low yield strength of TWIP steel is one of the important shortfalls that significantly limits its engineering applications. To enhance the comprehensive properties of TWIP steel, a machine learning design strategy that integrated comparative modelling, SHAP analysis, and multi-objective optimization were adopted in this study. Initially, various machine learning algorithms were compared for their predictive accuracy based on normalized data (273 entries) regarding the microstructure and properties of TWIP steel. Then, performance prediction models for yield strength, tensile strength, and elongation were established. SHAP analysis was subsequently employed to assess the significance and explicit laws of composition and microstructures in these three target properties, identifying key elements that enhance the overall performance. Furthermore, two new TWIP steels with high yield strengths and high products of strength and elongation were developed via multi-objective optimization. Under conventional hot forging + hot rolling + cold rolling + annealing processes, the two designed TWIP steels had yield strengths of 585 MPa and 560 MPa, tensile strengths of 1055 MPa and 1101 MPa, elongations of 55% and 58.5%, and products of strength and elongation of 58.0 GPa% and 66.4 GPa%, respectively. The yield strengths of the designed TWIP steels significantly improved while maintaining a reasonable product of strength and elongation. This work provides important references for the rational development of new TWIP steels.

Fabrication of Medium Mn Advanced High-Strength Steel with Excellent Mechanical Properties by Friction Stir Processing.

Friction stir processing (FSP) manufacturing technology was used to fabricate medium Mn advanced high-strength steel in this study. The mechanical properties and microstructure of the steel fabricated using FSP were investigated. The steel obtained a total elongation of 35.1% and a tensile strength of 1034.6 MPa, which is about 59% higher than that of the steel without FSP. After FSP, a gradient structure occurs along the thickness direction. Specifically, across the thickness direction from the base material zone to the transition zone and finally to the stirring zone, both the grain size and austenite fraction decrease while the dislocation density increases, which results from the simultaneous effect of severe plastic deformation and recrystallization during FSP. Due to the gradient structure, an obvious difference in the strain across the thickness direction of the steel occurs during the deformation process, resulting in significant hetero-deformation-induced (HDI) strengthening. The deformation mechanism analysis reveals that HDI strengthening and dislocation strengthening are the main factors in the improvement in the strength-ductility balance. The obtained knowledge sheds light on the process of fabricating medium Mn steels with excellent properties using FSP manufacturing technology.

Effect of Dewpoint on the Evolving Spectral Emissivity of Advanced High-Strength Steel During Intercritical Annealing

Effect of Dewpoint on the Evolving Spectral Emissivity of Advanced High-Strength Steel During Intercritical Annealing

Effect of alloying solutes on hydrogen segregation at pure iron Σ3(111) grain boundary: First-principles calculation

Hydrogen segregation behaviors at BCC-Fe Σ3 (111) grain boundary (GB) as well as the effects of alloying solutes were studied by the first-principles method. The segregation energy of alloying solutes at different periods presents a concave-down parabolic-like relationship with the atomic number, and the 4 d transition alloying solutes show a higher averaged segregation tendency. At the favorable trapping site, hydrogen segregation energy decreased by increasing the number of hydrogen atoms up to 0.85/Å2 in the plane vertical to the GB. Mo, Tc, Ru, Ta, W, Re, Os, and Ir strengthen GB and inhibit hydrogen segregation. Significantly, the interaction between alloying solutes and hydrogen segregation was elucidated by emphasizing the separation of the chemical and the mechanical contributions, and appropriate descriptors on hydrogen segregation energy influenced by alloying solutes were screened. This work offers theoretical backing to comprehend hydrogen segregation behaviors and the effects of alloying solutes to design advanced high-strength steels resistant to hydrogen embrittlement.

Effect of weld-line position on springback behavior in advanced high-strength steel tailor-welded blanks on hat-shaped bending application

In this study, both experiments and finite-element analysis are performed to elucidate the effect of weld-line position on the springback behavior of advanced high-strength steel tailor-welded blanks (AHSS-TWBs). AHSS-TWBs are fabricated from grade 590Y high-strength steel and 980Y advanced high-strength steel, each with a thickness of 1.2 mm. Gas tungsten arc welding is performed to obtain autogenous butt-weld joints. Three distinct weld-line position patterns are systematically analyzed to investigate the springback phenomenon via hat-shaped draw bending. Experiments on the AHSS-TWBs show that the weld-line position affects springback. The stress distribution changes with the weld-line position, thereby initiating variations in both the components of the bending moment and the corresponding springback angle. Depending on the weld-line position, different springback behaviors and bending moments are resulted on the components.

Local shear fracture properties in heat-affected zone of resistance spot-welded advanced high-strength steel

In the process of resistance spot welding of advanced high-strength steel (AHSS), the development of heat-affected zones (HAZs) considerably modifies the mechanical properties of the weld region. However, the limited reporting in the study of shear behavior in the HAZ hinders the accurate prediction of joint fracture and failure behavior. This study focused on the shear fracture behavior of resistance spot-welded AHSS. Given the limited extent of the HAZ, a miniature shear test was designed and shear fracture tests were conducted on JSC590, JSC980, and JSC1180. These tests facilitated the acquisition and compilation of data regarding the shear mechanical properties of diverse steel grades and their respective HAZs. A hardness-based empirical model for the strength coefficient and the strain-hardening exponent in Hollomon's law was introduced, and this model was subsequently integrated into finite element method calculations. The accuracy of the model was validated by shear strength reproductions, exhibiting errors within the range of 5.4%–13.5% and the averaged error was less than 10%. Further analyses confirmed that stress triaxiality at critical positions varied from 0 to 0.33, indicative of shear-dominant stress conditions. Moreover, the evolution of stress states revealed a notable association between the fracture surfaces across different stress states and steel grades. These findings fill the gap regarding the shear behavior of localized HAZs and expand the understanding of their mechanical behavior under various stress states. It will contribute to accurate fracture prediction by stress triaxiality based fracture criteria, such as Modified Mohr-Coulomb (MMC) model, applied to AHSS.

Characterization of Microstructure–Mechanical Properties Relationship in Dissimilar Resistance Spot Welding of the Advanced High-Strength Steel DP590 Steel to the Interstitial-Free Steel DC 06: EBSD Study

Characterization of Microstructure–Mechanical Properties Relationship in Dissimilar Resistance Spot Welding of the Advanced High-Strength Steel DP590 Steel to the Interstitial-Free Steel DC 06: EBSD Study

Understanding plasticity in multiphase quenching & partitioning steels: Insights from crystal plasticity with stress state-dependent martensitic transformation

This study develops a novel crystal plasticity (CP) model incorporating deformation-induced martensitic transformation (DIMT) and transformation-induced plasticity (TRIP) effect to predict the complex interplay between microstructural evolution and mechanical behavior in a third-generation advanced high-strength steel QP980. This model introduces phenomenological theory of martensite crystallography (PTMC) based TRIP theory and DIMT kinetics grounded on nucleation-controlled phenomenon. Notably, the DIMT model is improved by utilizing a geometric approach for calculating shear band intersections. A virtual multiphase representative volume element (RVE) based on the Voronoi tessellation is generated for the QP980 steel, which comprises ferrite, martensite, and retained austenite (RA). The study highlights how phase transformation affects mechanical properties, notably the strengthening from transformed martensite and the mechanical alterations in RA due to the TRIP effect. The DIMT kinetics dependent on stress states such as uniaxial tension (UT), uniaxial compression (UC), plane strain tension (PST), and equi-biaxial tension (EBT) are analyzed using the developed model. The role of microstructural surroundings on martensitic transformation is also examined. Furthermore, analysis under biaxial loading angles using the model reveals an asymmetric yield surface, with more pronounced changes in yield stress in the tensile region due to accelerated transformation behaviors, as opposed to the more gradual transformations in the compressive region. This study provides valuable insights into the deformation mechanisms of the third-generation advanced high-strength steels including relationship between plastic anisotropy, transformation kinetics, and microstructural evolution.