Automotive Steel Sheets Research Articles

Comparative study of tensile properties and impact toughness of duplex lightweight steel

Herein, a comparative study regarding the tensile properties and impact toughness of duplex lightweight steel and its deformation behavior was conducted to broaden its application from automotive steel sheets to thick-plate applications at various temperatures using Fe-0.2C–15Mn–6Al and Fe-0.4C–15Mn–6Al hot-rolled steels as model alloys. These steels revealed duplex microstructures with a large fraction of γ austenite (>0.7), featuring elongated δ ferrite grains aligned with the rolling direction and nearly globular γ grains. Both steels demonstrated an exceptional balance of tensile strength and ductility despite their low temperatures ranging from −20 °C to −100 °C, which was attributed to the active dynamic strengthening mechanisms, such as transformation-induced plasticity (TRIP) and twinning-induced plasticity (TWIP). However, contrary to the promising tensile test results, the steels demonstrated low values of the impact absorbed energy at temperatures ranging from −60 °C to −196 °C. This difference was likely owing to the rapid deformation rates in the Charpy impact tests compared to tensile tests, leading to the evolution of significant damage indicated by deep parallel cracks within the δ grains, without significantly activating the TRIP effect. Therefore, despite the impressive low-temperature tensile properties of the duplex lightweight steel, its suitability for cryogenic thick-plate applications must be approached with caution owing to the potential for compromised mechanical properties under sudden impact conditions.

Non-Contact Evaluation of Deformation Characteristics on Automotive Steel Sheets

Non-Contact Evaluation of Deformation Characteristics on Automotive Steel Sheets

Effect of Zirconium Conversion Coating on Corrosion Resistance of Small-Defected Auto Steel Sheets

For the sake of environmental protection and energy conservation, traditional phosphate pretreatments have been gradually prohibited worldwide during automobile productions. As a promising substitute, the green and environment-friendly zirconate pretreatment technology is developing rapidly. However, because the thickness of zirconium conversion coatings is commonly ranged in nanoscale, its covering capability for small defects is inferior to that of phosphate film, which may have a detrimental impact on the service performance of automotive steel sheets. In this study, comparing the surface characteristics of cold rolled auto steel sheets before and after zirconate treatment, the effects of zirconium conversion coating on the surface defect transmission and the corrosion resistance of the sheet were investigated. The results showed that although the defects were detected and recognized after the treatment, the coating was able to grow normally at the surface of small defects and effectively improve the corrosion resistance of the defects. The surface corrosion resistance for some types of defects was basically equivalent to that of the intact surfaces.

Recent Development of Hot-Rolled AHSS for Lightweight Chassis

The development of ultra-high-strength automotive steel sheets for lightweight automobiles is still an effective strategy from the material point of view. In the case of cold-rolled steels for BIW(Body In White), it has been a long time since steel with 980MPa of UTS or higher were commercialized, and the use of 1.2GPa and 1.5GPa of cold-rolled steels is also increasing. However, in the case of hot-rolled steel for chassis, the increase in strength is not as fast as that of cold-rolled steel, because chassis parts are the lower structure of a vehicle and are very sensitive to durability.

An extended stress-based forming limit diagram focusing on the wrinkling phenomenon and the effect of the normal pressure on clamped surfaces

A novel wrinkling limit representation following the pattern of the conventional forming limit curves (FLCs) and the stress-based forming limit curves (SFLCs) as well as the application of the assumed criterion in finite element modelling are discussed in this manuscript. FLCs can partially refer to the wrinkling potential in the area left to the uniaxial tension line, but just like the SFLCs, cannot characterize the limits of the material behavior in a deeper sense, if negative in-plane stress and normal pressure act together on the sheet. This study predicts the wrinkling risk of clamped surfaces with a stress-based criterion through solving the analytical equations of the critical compressive stress causing wrinkling, and the corresponding blank holder pressure. The critical values were calculated based on the Wang and Cao’s theory using Hill48 anisotropic yield function coupled with the Swift hardening law. The results draw a novel wrinkling limit curve representation methodology, in which the minor stress responsible for wrinkling and its ratio to the major stress are distinguished in the function of the applied blank holder pressure. The applicability of the calculated curves was investigated using finite element simulations, which showed that this method provides the opportunity to quantitatively interpret how close a component is to the wrinkling limit. The calculated wrinkling tendencies were verified by standard cup drawing tests supplemented by round shape error measurements on three different automotive steel sheets. It can be stated that the obtained numerical conditions of wrinkling were fitted to the experiments fairly well.

Rapid evaluation of the critical condition for hydrogen-induced cracking in ultrahigh-strength automotive steel sheets: A semiquantitative investigation based on U-bend specimens

The production of automotive steel plates, which involves pickling, electroplating, and welding among other steps, introduces hydrogen. Additionally, during the service life of components fabricated using such plates, electrochemical corrosion occurs, and hydrogen atoms are introduced. The hydrogen atoms are adsorbed and diffused into the interior of the metal, accumulating at any defects. Automotive parts are commonly fabricated using cold forming techniques. The hydrogen embrittlement sensitivity of ultrahigh-strength automotive sheets (UHSSs) is influenced by the stress, concentration of diffusible hydrogen, and plastic strain resulting from the cold forming process. The standard methods for quantitative studies on the UHSS hydrogen embrittlement sensitivity, such as the constant-load testing and low-strain-rate testing, require a specialized equipment and extended experimental period, making them impractical for original automotive equipment manufacturers. This study focuses on the use of the quenching and partitioning (QP) steel QP1180, which contains residual austenite, and martensite steel MS1500, which has a low deformation ability but high strength, as research objects. The equivalent strain and stress were controlled by adjusting the bending radius and U-bend opening distance, while the diffusible hydrogen concentration was charged through immersion. The fracture time of the U-bend sample was recorded, and the critical diffusible hydrogen concentration for hydrogen-induced cracking was measured. Additionally, the stress distribution during the U-bending process was simulated using the finite-element method. To evaluate the hydrogen embrittlement resistances of QP1180 and MS1500, the area enclosed by the load stress and equivalent strain (bending radius) and fracture time were semiquantitatively determined. Finally, the hydrogen-induced delayed fracture space regions of QP1180 and MS1500 were determined in the three-dimensional space, with equivalent strain, load stress, and diffusible hydrogen concentration as coordinate axes. This provided a convenient and reliable means of determination of the critical conditions for a safe service and rapid evaluation of the hydrogen embrittlement sensitivity of ultrahigh-strength automotive sheets.

Microstructural Control and Alloy Design for Improving the Resistance to Delayed Fracture of Ultrahigh-Strength Automotive Steel Sheets

The demand for higher-strength automotive steel sheets has increased significantly for lightweight and safe body concepts. However, the increment of the steel strength is often limited by the potential occurrence of delayed fracture. This paper discusses proper microstructure control and alloy design to improve the resistance against the delayed fracture of ultrahigh-strength automotive steel sheets in order to increase the usable upper limit of their strength and provides basic data serving as a practical guide for solving the problem of delayed fracture in ultrahigh-strength automotive steel sheets. It is confirmed that grain refinement, the appropriate dual-phase structure of martensite with ferrite or retained austenite, and surface decarburization, increase the resistance to delayed fracture. In terms of alloy design, the effects of Nb, Mo, and B on the delayed fracture resistance of hot-stamped steels have been investigated. The results suggest that there are other reasons for Nb to improve delayed fracture resistance in addition to grain refinement and the ability to trap hydrogen by its precipitates, as has been conventionally believed. Regarding Mo, it was clearly demonstrated that the segregation of this element at the grain boundary plays a main role in improving the delayed fracture resistance.

Wear characteristics of the tool in the cold stamping process of ultra high strength steel sheets by establishing a novel wear test method based on the progressive die

Demands for lightweighting and crashworthiness of the vehicle body have increased. For this purpose, advanced high strength steel to the automobile body was regarded as a solution with respect to manufacturing cost and impact energy absorption. However, increasing the strength of the automotive steel sheet lead to a diversity of problems caused by the tool wear due to higher forming load than that of commonly used steel sheets. Hence, systematic wear experiment and evaluation methods are required to quantitatively and qualitatively evaluate the tool wear amount in the sheet metal forming process. In this study, a methodology is proposed to quantitatively evaluate the wear of sheet metal forming tool based on the experimental results. In order to carry out a systematic wear test and save the time and cost, the progressive die set was designed to be suitable for wear test. The designed testing machine can simultaneously test four types of punches made under various tooling conditions such as materials, shapes, and coatings. Through the measurement of the wear depth, roughness, and surface imaging of the punch and product roughness, which represent the wear characteristics, quantitative evaluation methods for tool wear in the sheet metal forming process are established. By referring to the wear test results, it is confirmed that it is appropriate to analyze the reasonable tool wear characteristics by using the proposed methodology for quantifying the tool wear in the sheet metal forming process.

Modelling of strain-induced martensite formation in advanced medium-Mn automotive sheet steel

The modelling of strain-induced martensite formation is simulated in advanced medium-Mn steel. The fraction of retained austenite (8%) embedded in the bainitic matrix is transforming into the strain-induced martensite during progressive static tensile tests. The originally elaborated technique and algorithms (using C++ language) are presented. The finite element method and LS-DYNA (LSTC Company, USA) have been deployed. The calculations of the stress-induced martensite start temperature were performed to characterize the austenite stability. The structural investigations using the SEM and EBSD have been conducted. The comparison of the experimental and numerical results has been made in terms of mechanical austenite stability.

Optimization of Surface Preparation and Painting Processes for Railway and Automotive Steel Sheets

The article deals with DIC (Digital Image Correlation) tests on steel plates used in the automotive and railway industries, as well as in the construction industry. The most critical part of DIC tests is the quality of proper surface preparation, painting, and random patterns. The paint mediates the deformation of the optical systems, and its quality is paramount. The authors’ goal in this research is to determine the optimal dye–cleaning–drying time parameters for DIC studies. Commercially available surface preparation and cleaning agents were tested alongside commercially available spray paints. Standard and specific qualification procedures were applied for the measurements. Once the appropriate parameters were determined, the results were validated and qualified by GOM ARAMIS tests. Based on the results, DIC measurements can be performed with higher accuracy and safety in laboratorial and industrial conditions, compared to the traditional deformation measurements executed by dial gauges or linear variable differential transformers.

Modelling of Phase Diagrams and Continuous Cooling Transformation Diagrams of Medium Manganese Steels

The aim of this manuscript was to study the influence of alloying elements on the phase transformation behavior in advanced high-strength multiphase steels. Continuous cooling transformation (CCT) and time–temperature–transformation (TTT) diagrams were calculated to analyze the stability of phases at variable time–temperature processing parameters. The analyzed materials were lean-alloyed transformation induced plasticity (TRIP) medium manganese steels. The simulations of the phase diagrams, the stability of the phases during simulated heat treatments, and the chemical composition evolution diagrams were made using Thermo-Calc and JMatPro material simulation softwares. The influence of alloying elements, i.e., Mn and C, were studied in detail. The computational and modelling results allowed the influence of alloying elements on equilibrium and non-equilibrium phase diagrams and microstructural and chemical composition evolutions to be studied. Good symmetry and correlation between computational softwares were achieved. The study allows for future optimization of the heat-treatment temperature and time conditions of modern medium-Mn automotive sheet steels.

Effect of forming on automotive sheet steel performance properties

In all industry sectors and in the automotive industry, in particular, structural materials that undergo various treatment methods are widely used. Various types of plastic deformation are widely used in the manufacture of products and structural elements made of low-carbon sheet steels. The authors studied the effect of the degree of technological deformation on the fatigue process parameters of flat low-carbon steels. It has been established that the preliminary deformation within the uniform limits causes an increase in fatigue resistance. The kinetic diagrams of the fatigue failure are used to estimate the change in durability from the rate of accumulation of fatigue damage at the cyclic deformation stage until the moment of origination and propagation of the fatigue crack. The ratio of the duration of fatigue failure stages of some sheet automotive steels depending on the degree of preliminary strain by stretching at a given amplitude stress of the cycle is revealed.

Investigation of Elastic Modulus Degradation and Recovery with Time and Baking Process for Deformed Automotive Steel Sheets

Investigation of Elastic Modulus Degradation and Recovery with Time and Baking Process for Deformed Automotive Steel Sheets

Publisher Correction to: A review of advances in resistance spot welding of automotive sheet steels: emerging methods to improve joint mechanical performance

Publisher Correction to: A review of advances in resistance spot welding of automotive sheet steels: emerging methods to improve joint mechanical performance

Effect of Minor Alloying Elements (C, Ni, Cr, Mo) on the Long-Term Corrosion Behaviors of Ultrahigh-Strength Automotive Steel Sheet in Neutral Aqueous Environment

This study examined the effects of minor alloying elements (C, Ni, Cr, and Mo) on the long-term corrosion behaviors of ultrahigh-strength automotive steel sheets with a tensile strength of more than 1800 MPa. A range of experimental and analytical results showed that the addition of Ni, Cr, and Mo decreased the corrosion current density and weight loss in electrochemical and immersion tests, respectively, in a neutral aqueous condition. This suggests that the minor addition of elements to steel can result in improved corrosion resistance even for long-term immersion periods. This is closely associated with the formation of thin and stable corrosion scale on the surface, which was enriched with the alloying elements (Ni, Cr, and Mo). On the other hand, their beneficial effects did not persist during the prolonged immersion periods in steel with a higher C content, suggesting that the beneficial effects of the minor addition of Ni, Cr, and Mo were overridden by the detrimental effects of a higher C content as the immersion time was increased. Based on these results, lower C and the optimal use of Ni, Cr, and Mo are suggested as a desirable alloy design strategy for developing ultrahigh-strength steel sheets that can be exposed frequently to a neutral aqueous environment.

Failure behaviour of Spot-welds on automotive steel sheets

Resistance spot welding is commonly employed methodology to join metals especially in the automobiles. A typical body in white structure of a car consists of 5000–7000 spot-welds. During service period of a car, the failure of joints under static and fatigue loads is of serious concern. The objective of present study is to examine the failure behaviour of resistance spot-weldments on different varieties of automotive steels. The failure of the spot-welds is a driven phenomenon. In current study attempts have been made to investigate different modes of failure of spot-welds under static as well as cyclic loads. Besides, microstructural development and microhardness distribution in the joints have been studied. The major findings from this work are: the joints under fatigue loading tends to fail primarily from heat-affected zone (HAZ) while on the other hand, joint failure subjected to static loading takes place at base metal (BM) or interfacial region of HAZ as well as BM. The joint failure subjected to static load is controlled by tensile strength of the as-received steel, however the joint failure subjected to fatigue load is dictated by inherent stress concentration present in interfacial region of the joints.

A review of advances in resistance spot welding of automotive sheet steels: emerging methods to improve joint mechanical performance

A review of advances in resistance spot welding of automotive sheet steels: emerging methods to improve joint mechanical performance

Fully Implicit Stress Update Algorithm for Distortion-Based Anisotropic Hardening with Cross-Loading Effect: Comparative Algorithmic Study and Application to Large-Size Forming Problem

A fully implicit stress integration algorithm is developed for the distortional hardening model, namely the e−HAH model, capable of simulating cross−hardening/softening under orthogonal loading path changes. The implicit algorithm solves a complete set of residuals as nonlinear functions of stress, a microstructure deviator, and plastic state variables of the constitutive model, and provides a consistent tangent modulus. The number of residuals is set to be 20 or 14 for the continuum or shell elements, respectively. Comprehensive comparison programs are presented regarding the predictive accuracy and stability with different numerical algorithms, strain increments, material properties, and loading conditions. The flow stress and r−value evolutions under reverse/cross−loading conditions prove that the algorithm is robust and accurate, even with large strain increments. By contrast, the cutting−plane method and partially implicit Euler backward method, which are characterized by a reduced number of residuals, result in unstable responses under abrupt loading path changes. Finally, the algorithm is implemented into the finite element modeling of large−size, S−rail forming and the springback for two automotive steel sheets, which is often solved by a hybrid dynamic explicit–implicit scheme. The fully implicit algorithm performs well for the whole simulation with the solely static implicit scheme.

Analysis of high strength composite structure developed for low-carbon-low-manganese steel sheet by laser surface treatment

In the present work, a high-strength composite steel structure developed by imparting laser surface hardening treatment on a low-carbon low-Manganese automotive steel sheet has been comprehensively analysed. The layered composite steel structure has been successfully developed by re-engineering the surface of the steel using diode laser hardening treatment up to a depth of 250–300 µm through its thickness. Hardness at the treated surface improved by 150% to that of its base due to formation of a mixture of hard phases constituting martensite and bainite along with retained ferrite. Indeed, coupling EBSD technique with Weibull distribution of various phase fractions determined by image quality helped analyse microstructure effectively. The tensile property of the layered composite steel sheet was found to yield significant improvements in both Yield Strength (YS) (40–44%) and Ultimate Tensile Strength (UTS) (19–21%) due to sandwich effect of composite layer constituting hardened layer and soft base accomplished by a strengthening mechanism associated with rule of mixtures concept. In fact, Young’s modulus of the composite steel sheet, determined from slope of tensile stress–strain diagram was found to be convergent with ultrasonic test result. Additionally, the crystallographic texturing effects of the hardened layer and untreated base measured using standard XRD technique re-confirmed their influence on Young’s Modulus and r-bar values obtained.

Recrystallisation before austenitization for improved microstructure and properties in automotive steel sheets with high product of strength and elongation

This study investigated the effect of recrystallization before austenitizing transformation (i.e., pre-recrystallization) on the microstructure and properties of 22Mn2Cr cold-rolled automotive steel sheets based on continuous annealing at 700 °C for various holding times. Subsequently, the samples were heated to an austenitizing temperature of ∼850 °C, which led to the formation of a fine austenite grains via nucleation at the dislocations during reheating. The austenite grain size was more refined when samples were pre-recrystallized at 700 °C for several minutes compared to those directly heated to 850 °C, which was attributed to combined grain refinement from recrystallization and austenite phase transformation. This refined austenite grain size led to a finer bainite grain size in the cooled final product. The strength of the steel decreased slightly (∼1200 MPa), but the elongation (∼19%) and product of strength and elongation (∼23 GPa%) were significantly enhanced by the pre-recrystallization treatment.