Low Carbon Steel Sheets Research Articles

Effect of Laser Power on Weld Formability and Residual Stress of Unequal Thickness 410 Ferritic Stainless Steel/RCL540 Low-Carbon Alloy Steel

In this paper, the butt joint of unequal thickness 410 ferritic stainless steel and RCL540 low-carbon alloy steel sheets are realized by laser welding. The effects of different laser powers on weld formability, mechanical properties, and residual stress in the welding process are investigated. It is observed that with increasing laser power, the heat accumulates at the bottom of the molten pool and weld metal, causing the ratios of upper and lower melt widths to decrease. The tensile test results show that all specimens fractured in the weak zone of the base metal on the stainless steel side at 10 mm from the weld seam. The residual stress distributions of the specimens are calculated using ABAQUS 2022 software and compared with the measurements of the blind-hole method. It is found that the stainless steel side produces tensile stresses, with the power increase offset by compressive stresses in the base metal. When the laser power is 1200 W, the welded joint has the best weld formability and mechanical properties and the least residual stress. The upper and lower melt width ratio is 1.17, the maximum microhardness of the weld metal is 374.7 HV, the maximum test force and tensile strength are 5617.5 N and 468.12 MPa, respectively, and the minimum values of the transverse and longitudinal stresses are −45.8 MPa and −106.4 MPa, respectively.

Production Optimization of Premium Food Can with Distortion Printing under Waving Requirement

This research aims to propose a novel approach for evaluating and minimizing scraps in an industrial production of premium food cans with distortion printing. Beyond conventional formability criteria, a waving requirement is introduced to ensure aesthetic quality of the printed graphics. The research focuses on real production conditions, specifically involving double-cold-reduced (DR) low-carbon steel sheets and chromium-coated tin-free steel with a thickness of 0.16 mm. The sheets are laminated on both sides with a plastic film prior to undergoing distortion printing on the exterior. Subsequently, a blank is subjected to a drawing-redrawing process to form a food can. To address challenges associated with characterizing these thin sheets, a material parameter identification method is proposed and demonstrated. The thickness profile and flange length are identified as key criteria for this identification process. Measurements of thickness distribution and flange length are obtained using digital image correlation (DIC) and microscopy techniques. Within the manufacturing system, uncertainties related to material properties and forming processes can result in scraps or defects. To analyze these processes, finite element analysis (FEA) is employed and validated through experiments. For the evaluation of scrap rates, uncertainty propagation is conducted using a metamodeling technique, specifically employing radial basis function (RBF) neural networks. The study concludes by offering process optimization recommendations aimed at reducing the scrap rate.

Effect of strain path and short-term post-annealing on the microstructure, texture, and mechanical anisotropy of low-carbon steel

In this research, the effect of strain path and short-term post-annealing on the microstructure, texture, and mechanical anisotropy of low-carbon steel was investigated. Asymmetric unidirectional rolling (AUR) and asymmetric cross rolling (ACR) were applied on Fe-0.072C steel. The ACR-processed sheet revealed a very limited number of new grains compared to the AUR-processed sheet, which was due to the dynamic recovery induced by strain path change. The average ferrite grain size of the post-annealed AUR- and ACR-processed samples was 11.5 and 14.1 μm, respectively. The dominant recrystallization in the annealed AUR-processed sheet was discontinuous static recrystallization, while that in the annealed ACR-processed sheet was continuous static recrystallization. The weak typical rolling textures (γ-fiber and α-fiber) at the midthickness of both rolled sheets demonstrated that the shear deformation effectively contributed to the formation of the shear textures during asymmetric cold rolling. The ACR decreased the intensity of the overall texture more than the AUR process due to the changes in the reference frame of deformation after each pass, which destabilized ideal texture components. The results showed that Goss and {111}〈112〉 components were continuous and discontinuous static recrystallization textures in the asymmetrically cold-rolled low-carbon steel sheet during the annealing treatment, respectively. The annealed AUR-processed sheet revealed a weaker texture as compared to the annealed ACR-processed sheet. The significant changes in the preferred orientations of the annealed AUR-processed sample led to weaker texture intensity compared to the annealed ACR-processed sheet. The hardness of the annealed AUR-processed sheet (183.8 HV) was higher than that of the annealed ACR-processed steel (156.9 HV), which was owing to the larger grain size and also the elimination of the γ-fiber texture in the annealed ACR-processed sheet. The strength along the rolling direction was lower than that along the transverse direction in the AUR-processed sheet. However, in the ACR-processed sheet, the values of strength were similar along three different tensile directions. As an important conclusion, if both high-strength and low-anisotropy are needed in the low-carbon steel sheets, it's better to apply ACR rather than AUR. In addition, if both high toughness and low anisotropy are essential, it's better to use AUR followed by post-annealing rather than ACR + post-annealing. The length of the intermediate stage of work hardening in the annealed ACR-processed sample was much less than the annealed AUR-processed sheet due to the presence of harder orientations (〈111〉 and 〈110〉) along rolling and transverse directions in the annealed ACR-processed sample. Finally, the fracture behavior of deformed and post-annealed steel sheets for both strain paths was ductile and shear ductile.

Strict convexity of yield surfaces of some weakly-textured materials

Let Sym0 be the space of traceless symmetric second-order tensors. We say that a polycrystalline elastic–plastic material is weakly-textured if its yield function f:Sym0→R is the sum of a texture-independent isotropic part fiso and an anisotropic part which is linear in the relevant texture coefficients. Let c>0 and S≔f−1(c)⊂Sym0 be the yield surface of the weakly-textured material in question. We present a sufficient condition (*), namely that ∇2f(S) be positive definite for each S∈S, for a smooth yield surface S to be strictly convex in Sym0. We apply this sufficient condition to weakly-textured materials with yield functions that satisfy the following conditions: (i) the yield functions f and fiso are smooth; (ii) ∇2fiso(S) is positive definite for each S in Siso≔fiso−1(c)⊂Sym0. We prove that the yield surface S⊂Sym0 of such weakly-textured material is strictly convex if the texture coefficients in f are sufficiently small. As illustration for practical applications, by appealing to condition (*) we study the strict convexity of the yield surface pertaining to a weakly-textured orthorhombic aggregate of cubic crystallites which has a quadratic yield function of the type proposed by Hill in 1948. Moreover, we show that all 35 samples of cold-rolled and annealed low-carbon steel sheets studied by Stickels and Mould have their quadratic yield functions and corresponding yield surfaces strictly convex.

Fatigue Properties of Zinc Coated Low Carbon Steel Sheet Joints by the Means of Spot Welding

Fatigue Properties of Zinc Coated Low Carbon Steel Sheet Joints by the Means of Spot Welding

Effects of Weld Heat Input on Mechanical Characteristics of Low Carbon Sheet Steels

This study focuses on examining the variation in mechanical characteristics of low-carbon sheet steels when they are subjected to heat input from Tungsten Inert Gas (TIG) welding. The weld heat input parameters, such as welding speed and current, were controlled through the TIG welding process. A finite element analysis was performed to evaluate the couple field thermomechanical effects of the weld heat line, using the Gauss heat flux approach for thermal heat variation across the weld heat-affected zone. The numerical study yielded results for weld heat-affected deflection, residual stress, and modal analysis through the finite element model. It was found that the ductility decreased and hardness increased in the fusion zone, as a function of weld current and speed. The residual stresses and their zone of influence, as determined by weld line parameters, were found to be key factors affecting deflection and natural frequencies in structural aspects of low carbon sheet steels.

Surface Characteristics and Corrosion Tendency of TIG-Welded Low Carbon Steel Sheet Affected Cold Galvanizing and Processed by Immersion in Sodium Chloride Solution

Surface Characteristics and Corrosion Tendency of TIG-Welded Low Carbon Steel Sheet Affected Cold Galvanizing and Processed by Immersion in Sodium Chloride Solution

Joining thin galvanized low carbon steel sheet to AA6056-T4 by resistance spot welding and adhesive weld bounding

Multimaterial assemblies made by resistance spot welding (RSW) process offer a cost-efficient lightweight solution for automotive body-in-white production. However, joining different materials, such as steel (Fe) and aluminum (Al), brings issues due to their different physical properties and low weldability. The present work investigated the evolution of the weld between a thin galvanized low carbon steel sheet and an AA6056-T4 aluminum alloy from macroscopic observations to the evolution of the intermetallic compound layer (IMC) during RSW. Comparisons between homogeneous Al-Al RSW, Fe-Al RSW and Fe-Al adhesive weld bonding for different mechanical solicitations were also realized. Observations showed that the interface for short welding periods is composed of a thin and discontinuous IMC layer. The interface also presents defects that facilitate crack initiation and propagation, leading to an interfacial fracture mode. The different mechanical tests carried out demonstrated that the Al-Al and Fe-Al welds reached a similar maximum tensile load under the shear–tensile test. However, Fe-Al assemblies under cross-tensile test showed poor mechanical properties. The use of an adhesive layer with an Fe-Al spot weld seems to be a potential solution, as it is easily implementable on production lines and improves the mechanical properties of Fe-Al assemblies.

The influence of rolling at subcritical temperatures on the low-carbon steel structure and properties formation

Problem. In practice, the rolling of a low-carbon steel sheet due to significant heat losses ends in the austenite – ferrite two-phase structure region, which leads to the metal heterogeneous structure formation, that decreases the sheet steel properties of the and its ability to be drawn.
 Adverse temperature conditions characteristic of traditional hot rolling technology can be prevented by metal processing in the single-phase ferrite structure region below the critical point Ar1. Rolling of a thin sheet in the subcritical temperature range will ensure obtaining a uniform metal structure, which determines the level of its mechanical properties, as well as the quality of stamped parts
 Goal. The purpose of the work is study the rolling modes influence at subcritical temperatures on the low-carbon steel structure and properties formation.Methodology. The microstructure of 08ps steel samples was studied using a metallographic and electron microscope JSM-840 with a "Link-860/|500" microanalysis system, the 08ps steel samples cross-section fine structure was studied using an electron microscope JEM - 200Сx. The metal mechanical properties complex was determined by standard tensile test methods.Results. The 08ps steel structure and properties after rolling at subcritical temperatures were studied. The comparative analysis of the fine structure of the initial blank and deformed samples of low-carbon steel was carried out. It was established that changes are observed in the structure of the deformed samples and the initial blank, which indicate the polygonization and recrystallization processes implementation and do not provide the of metal mechanical properties level provided for by DSTU 2834-94.Originality. Тhe thin structure of a 08ps steel sheet deformed in the subcritical temperature range with air cooling was studied. The development differs in the temperatures of the beginning and end of rolling, as well as the cooling rate in the post-deformation period. It allows to expand theoretical ideas about the patterns of 08ps deformed steel structure formation and to use them in practice. Practical value. The results of the work can be applied in determining rational processing modes, which involve rolling at subcritical temperatures, to increase the complex metal properties and obtain high-quality parts by cold stamping.

Application of the process of joining sheet by mechanical cold forming (clinching) using dissimilar materials

In the metalworking industry in general, the need to join components made of sheet metal is very common. The automotive sector, for example, needs to join components made of sheet metal to assemble vehicle bodies. The aeronautical sector needs to join sheets, mainly aluminum, when assembling aircraft. In white goods, there is a need to join low-carbon steel sheets that make up a wide range of household appliances, as well as other sectors such as metal structures, packaging and others. The joining of sheet metal components can be done through some permanent joining process, such as welding and riveting; or by some type of detachable connection, made by screw, nut, stud, pin, among others. A joining technique that has been gaining ground in the industry is plastic deformation joining. Groche et al. (2014) reviewed this technique and present the various existing variations. The most common is known as clinching union. According to Varis (2006), it emerged in the 1980s in an automotive industry in the assembly of chassis. The technique consists of cold joining sheets through the action of a punch that plastically deforms the sheets against a die. The deformation produces an interlook region that joins the sheets, giving the appearance of a spot weld. Sarmento and Pereira (2012) cite the main advantages of this technique: (I) it allows joining a vast amount of materials including metals with non-metals; (II) lower distortions, embrittlement and residual stress; (III) high process repeatability and simple quality control, and (IV) safe working environment.

Determining the optimal reduction ratio in temper rolling in terms of residual stress distribution across thickness

Materials with compressive stresses on the surface withstand fatigue failures, cracking, galling, and corrosion. This compressive stress at the surface can be created by temper rolling. The rolling process must be conducted with an appropriate reduction to obtain the desired benefit from temper rolling. A 1% thickness reduction is usually applied to endow flatness and surface texture to the strip, and this reduction is sufficient to eliminate the discontinuous yielding phenomenon. In this study, 2.5-mm-thick low-carbon steel sheet (DC01 grade) samples were annealed at approximately 600°C for 5 minutes, temper-rolled at room temperature at various reduction ratios subsequently, and the residual stresses formed along the thickness by rolling were investigated. This study has revealed that a 1% reduction ratio is insufficient for developing compressive stresses on the surface, but this can only be achieved with a 1.5% reduction ratio. When the reduction ratio was increased to 1.8%, tensile stresses began to occur inside, along with compressive stresses on the surface. It was observed that at a reduction ratio of 2%, the situation was reversed again; tensile stresses began to regenerate at the surface, and this became more pronounced up to a 10% reduction ratio.

熱間圧延中の低炭素鋼板の酸化皮膜の変形に及ぼすマンガンの影響

In hot rolling process of low carbon steel sheets, oxide scale formed on the sheets may result in surface defects on the rolled products. The major phase of the scale is wustite FeO, which shows sufficient plasticity to follow the sheet deformation only at elevated temperature. However, thick scale is cracked, fragmented and indented to the sheets by the rolling even at elevated temperature because scale surface is instantly cooled by cold rolls to brittle temperature. Therefore, thick scale should be removed by descalers just before the rolling. It is reported that manganese decreases the eutectoid temperature between ductile wustite and brittle magnetite. Therefore, manganese may have a positive effect to widen wustite window to lower temperature and to suppress surface defects. In this study, 0mass% and 2mass% manganese bearing steel sheets with controlled scale on surface were hot rolled in a laboratory. The sheets were reduced 30% in thickness by unlubricated rolling at temperature between 1173 K and 1373 K. Scanning electron microscopy on longitudinal section showed that manganese decreases crack depth and increases spacing between scales indented to the steel. It is concluded manganese makes the scale on steel more ductile and suppresses surface defects.

An Investigation into the Friction of Cold-Rolled Low-Carbon DC06 Steel Sheets in Sheet Metal Forming Using Radial Basis Function Neural Networks

This article presents the friction test results for cold-rolled low-carbon DC06 steel sheets, which are commonly processed into finished products using sheet metal forming methods. A strip drawing test with flat dies was used in the experimental tests. The strip-drawing test is used to model the friction phenomena in the flange area of the drawpiece. The tests were carried out using a tester that enabled lubrication with a pressurised lubricant. The friction tests were carried out at different nominal pressures, oil pressures, and friction conditions (dry friction and oil lubrication). Oils destined for deep-drawing operations were used as lubricants. Neural networks with radial base functions (RBFs) were used to explore the influence of individual friction parameters on the value of the coefficient of friction (COF). Under lubrication with both oils considered, the value of the COF increased with decreasing oil pressure. This confirms the correctness of the concept of the device for reducing friction in the flange area of the drawpiece. The developed concept of pressurised lubrication is most effective at relatively small nominal pressures of 2–4 MPa. This range of nominal pressures corresponds to the actual nip pressures when forming deep-drawing steel sheets. Under conditions of dry friction, the values obtained for the COF rise above 0.3, while under lubrication conditions, even without pressure-assisted lubrication, the COF does not exceed 0.2. As the nominal pressure increases, the effectiveness of the lubrication exponentially decreases. It was found that the Sq parameter carries the most information regarding the value of the COF. The RBF neural network with nine neurons in the hidden layer (RBF-8-9-1) and containing the Sq parameter as the input was characterised by an R2 of 0.989 and an error of 0.000292 for the testing set.

The Effect of Electrode Geometry and Pre-heating Treatment on Resistance Spot Welding Strength

Resistance spot welding (RSW) is one of the most significant and common metal joining methods used in industries. The present paper discusses the comparative performance of resistance spot welding electrodes of nontraditional design with the traditional one of 8 mm contact diameter in welding a 1.5 mm thick low carbon steel sheet used in automobile structural bodies and bridges. The modified electrode tip surface center was machined to have three different holes of 2, 3, and 4 mm depth and three different diameters of 2, 4, and 6 mm producing nine different hollow electrode dimensions. As well as the influence of pre-heating temperature on the mechanical properties of the weld joint was investigated by considering the other main parameters of welding time, current, and force are constant. The shear tensile test and torsion test examinations are carried out to investigate the mechanical properties. Also, to interrupt the results, a macrograph examination was conducted to determine the nugget size formation. The results show that the increase or decrease in the strength of the weld joint is greatly influenced by the proper selection of the modified electrode geometries. Also, the results indicated that the maximum improvement in shear tensile strength and torsional strength is about 140% and 150% compared to the traditional one. Furthermore, pre-heating processes helped decrease the contact resistance at the faying surfaces and improve the weld tensile strength and torsional strength to about 141% and 171% at 200 oC. Moreover, improvement may be achieved by slightly increasing pre-heating temperatures

Strength enhancement and uniform strain distribution through cross route-constrained groove pressing

Constrained groove pressing (CGP) is one of the severe plastic deformation techniques for sheet metals to impose large plastic strain and produce ultrafine-grained (UFG) structures without any change in dimensions. Cross route-constrained groove pressing (Cross-CGP), an advanced version of the conventional CGP process, involves two CGP cycles with an equivalent strain of 2.32 per cycle where the square sample is rotated by 90° after performing every cycle of CGP. The strain path in the sheet during conventional CGP and cross-CGP significantly affects the homogenization of mechanical properties. Sheets of low carbon steel are processed through conventional-CGP and cross-CGP routes. The ability to sustain the maximum strain has been increased in the cross-CGP process due to uniform strain distribution. The tensile strength and hardness in the sheet processed through cross-CGP are higher than that of conventional CGP, especially at higher pass numbers. Tensile behavior and hardness in two different orientations (parallel and perpendicular to the groove direction) have been found to be almost the same in the cross-CGP processed sheet.

Analysis of the Lubrication Performance of Low-Carbon Steel Sheets in the Presence of Pressurised Lubricant

Abstract In sheet metal forming processes, friction increases the force parameters of the forming process and produces a deterioration in the quality of the surface of the components. The basic way to reduce the unfavourable impact of friction is to lubricate the sheet metal surface with commercial oils. This article presents the results of experimental studies and analysis of variance (ANOVA) of the friction of DC01 low-carbon steel sheets using a strip drawing test. For these tests, a special device was built containing countersamples with a flat surface made of 145Cr6 steel covered with a protective AlTiN coating. Lubricants of different viscosities were fed into the contact zone under forced pressure. The effect of contact pressure on the value of the coefficient of friction was also determined. The predicted R² of 0.9227 was in reasonable agreement with the adjusted R² of 0.9411 confirming that the ANOVA model was reliable. It was found that increasing the lubricant pressure had a beneficial effect in reducing the value of the coefficient of friction. The higher the contact pressure, the more effectively the pressurised oil reduced the value of the coefficient of friction.

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.

Application of Artificial Neural Networks to the Analysis of Friction Behaviour in a Drawbead Profile in Sheet Metal Forming.

Drawbeads are used when forming drawpieces with complex shapes to equalise the flow resistance of a material around the perimeter of the drawpiece or to change the state of stress in certain regions of the drawpiece. This article presents a special drawbead simulator for determining the value of the coefficient of friction on the drawbead. The aim of this paper is the application of artificial neural networks (ANNs) to understand the effect of the most important parameters of the friction process (sample orientation in relation to the rolling direction of the steel sheets, surface roughness of the counter-samples and lubrication conditions) on the coefficient of friction. The intention was to build a database for training ANNs. The friction coefficient was determined for low-carbon steel sheets with various drawability indices: drawing quality DQ, deep-drawing quality DDQ and extra deep-drawing quality EDDQ. Equivalents of the sheets tested in EN standards are DC01 (DQ), DC03 (DDQ) and DC04 (EDDQ). The tests were carried out under the conditions of dry friction and the sheet surface was lubricated with machine oil LAN46 and hydraulic oil LHL32, commonly used in sheet metal forming. Moreover, various specimen orientations (0° and 90°) in relation to the rolling direction of the steel sheets were investigated. Moreover, a wide range of surface roughness values of the counter-samples (Ra = 0.32 μm, 0.63 μm, 1.25 μm and 2.5 μm) were also considered. In general, the value of the coefficient of friction increased with increasing surface roughness of the counter-samples. In the case of LAN46 machine oil, the effectiveness of lubrication decreased with increasing mean roughness of the counter-samples Ra = 0.32-1.25 μm. With increasing drawing quality of the sheet metal, the effectiveness of lubrication increased, but only in the range of surface roughness of the counter-samples in which Ra = 0.32-1.25 μm. This study investigated different transfer functions and training algorithms to develop the best artificial neural network structure. Backpropagation in an MLP structure was used to build the structure. In addition, the COF was calculated using a parameter-based analytical equation. Garson partitioning weight was used to calculate the relative importance (RI) effect on coefficient of friction. The Bayesian regularization backpropagation (BRB)-Trainbr training algorithm, together with the radial basis normalized-Radbasn transfer function, scored best in predicting the coefficient of friction with R2 values between 0.9318 and 0.9180 for the training and testing datasets, respectively.

Tensile and fatigue behavior of novel dissimilar resistance spot welds of AA5754 to steels: interplay of intermetallic layer, weld nugget diameter and notch root angle

AA5754 sheet was resistance spot welded (RSW) to high-strength low-alloy (HSLA) steel sheet and low carbon steel (LCS) sheet respectively using multi-ring domed (MRD) electrodes and multiple solidification weld schedules. The confluence of the intermetallic compound layer, weld nugget diameter, and notch root angle are delineated. The results demonstrated that elevated Mn content (0.634%) in the HSLA steel promoted the formation of a thinner and more uniform IMC layer in AA5754-HSLA stack-ups when compared to the LCS, comprised of a lower Mn content (0.130%), in the AA5754-LCS stack-ups. Diluting the alloy content by changing the HSLA sheet to LCS sheet in AA5754-steel RSWs softened the aluminum weld nugget. Fatigue results demonstrated that fatigue life in Al-steel spot welds is greater when compared to the aluminum sheet joined to itself in the tensile shear configuration. Fatigue life was greater for the positive polarity AA5754-HSLA steel RSWs than for the AA5754-LCS. While weld nugget diameter dominates weld fatigue life, manipulation of the weld notch root angle enables additional fatigue life control. To enhance fatigue life, a large notch root angle is beneficial.

Effects of Partial Replacement of Si by Al on Cold Formability in Two Groups of Low-Carbon Third-Generation Advanced High-Strength Steel Sheet: A Review

Partial replacement of Si by Al improves the coatability (or galvanizing property) of Si-Mn advanced high-strength steel (AHSS) sheets. In this paper, the effects of the partial replacement on the microstructure, tensile property, and cold formability are reported for the low-carbon third-generation AHSS sheets, which are classified into two groups, “Group I” and “Group II”. The partial replacement by 1.2 mass% Al increases the carbon concentration or mechanical stability of retained austenite and decreases its volume fraction in the AHSSs, compared to Al-free AHSSs. The partial replacement deteriorates the tensile ductility and stretch formability in the AHSSs with a tensile strength above 1.2 GPa. On the other hand, it achieves the same excellent stretch-flangeability as Al-free AHSSs. A complex addition of Al and Nb/Mo further enhances the stretch-flangeability. The cold formabilities are related to the heat treatment condition and microstructural and tensile properties, and the stress state.