AHS Steels for Automotive Parts

Asst. Prof. Vitoon Uthaisangsuk, Dr.-Ing.

Department of Mechanical Engineering, Faculty of Engineering
King Mongkuts University of Technology Thonburi (KMUTT)
1
20-21June 2013
BITEC, Bangkok -Thailand
Outline
Automotive evolution
Car body structures
Automotive steels
Mild steels
High strength steels
Multiphase steels
Press hardened steels
2
Outline
Automotive evolution
Car body structures
Automotive steels
Mild steels
High strength steels
Multiphase steels
Press hardened steels
3
Materials used for car components - 1975
Source: Ducker Worldwide
Average 1975 vehicle weight
4
Source: Ducker Worldwide
Materials used for car components - 2007
Average 2007 vehicle weight
5
Source: Ducker Worldwide
Trend of materials usage
6
Source: WorldAutoSteel
Aim of automotive industries (mass reduction)
7
Aim of automotive industries (mass reduction)
Source: WorldAutoSteel
8
Source: WorldAutoSteel
Aim of automotive industries (mass reduction)
9
Role of HSS and AHSS for vehicle mass reduction
10
Growth of AHSS
11
Increasing of safety regulations
12
Evolution of North America crash tests
13
Safety concept
14
Safety concept
Source : http://www.autosteel.org
Safety concept
15
16
Safety concept
17
Strength comparison AHSS vs conventional HSS
Component material strength
DP
350/600
HSLA
350/450
Yield strength (MPa)
Conflict between mass reduction & safety regulations
Fuel economy / CO
2
emissions
Lower weight / lighter gauges

Safety
Higher strength / heavier gauges
Conflict between safety & fuel economy / CO
2
emissions
Seeking of new challenging materials
and manufacturing concept
18
Outline
Automotive evolution
Car body structures
Automotive steels
Mild steels
High strength steels
Multiphase steels
Press hardened steels
19
Steel sheet concept for automotive parts
Source : http://autospeed.com/cms/title_Steel-Identification-Using-Hardness-Testing/A_109717/article.html
20
Source : http://mercedes-benz-blog.blogspot.com/2010/03/new-mercedes-benz-e-class-cabriolet_2785.html
2010 The new Mercedes-Benz E-Class
21
Steel sheet concept for automotive parts
Source : http://boronextrication.com/tag/list-of-vehicles-with-boron-and-uhss
2011 Volvo V70 Body Structure
22
Steel sheet concept for automotive parts
23
Source: http://carskeleton.blogspot.com/2012_04_01_archive.html
Steel sheet concept for automotive parts
2012 Audi A3 body Structure
Source : http://www.autosteel.org
24
Steel sheet concept for automotive parts
25
Source : http://www.autosteel.org
Steel sheet concept for automotive parts
Cold rolled steels
26
Overview of cold rolled steel sheets
27
28
Strength evolutions of automotive steels
Source: http://www.metalformingfacts.com/industry-news/developments-gigapascal-strength-steels.html
Outline
Automotive evolution
Car body structures
Automotive steels
Mild steels
High strength steels
Multiphase steels
Press hardened steels
29
Mild steels
30
Best formability
High and Ultra high
strength steels
Mild steels
31
Mild steels for cold forming
32
max. C P S Mn Ti Al Si N
DC04 0,08 0,030 0,030 0,40 - 0,040 0,010 0,005
max. C P S Mn Ti Al Si N
DC04 0,08 0,030 0,030 0,40 - 0,040 0,010 0,005
>0,18
n
90
value
>1,6
r
90
value YS MPa UTS MPa A 80% A
g
%
140-210 270-350 >38% ~22 >0,18
n
90
value
>1,6
r
90
value YS MPa UTS MPa A 80% A
g
%
140-210 270-350 >38% ~22
Microstructure:
ferritic matrix
Carbides (few) and AlN
Mechanical properties:
Low yield strength and tensile strength
Low hardness
Very high total elongation
Great ductility and draw-ability
Specified value Typical value Specified value Typical value
Mild steels for cold forming
33
Microstructure:
Ferritic matrix
Precipitates (few) of micro-alloyed
elements
Mechanical properties:
Low yield strength and tensile strength
High n-value
High r-value
High uniform elongation
Great ductility and draw-ability
max. C P S Mn Ti Al Si N
DC06 0,02 0,020 0,020 0,25 0,3 0,040 0,010 0,002
max. C P S Mn Ti Al Si N
DC06 0,02 0,020 0,020 0,25 0,3 0,040 0,010 0,002
>0,22
n
90
value
>2,1
r
90
value YS MPa UTS MPa A 80% A
g
%
140-170 270-330 >41% ~25 >0,22
n
90
value
>2,1
r
90
value YS MPa UTS MPa A 80% A
g
%
140-170 270-330 >41% ~25
Specified value Typical value Specified value Typical value
Outline
Automotive evolution
Car body structures
Automotive steels
Mild steels
High strength steels
Multiphase steels
Press hardened steels
34
High strength steels
35
Increasing strength of steel sheets
36
High strength steel by solid solution strengthening
37
Solid solution strengthening (mixed crystal strengthening)
38
Influence of alloying elements on the yield point
substitutionally dissolved: P, Si, Cu, Mn, Mo, Ni, Al, Cr and interstitially dissolved: C, N
39
High strength steels by precipitation strengthening
Formation
40
Increasing the yield point of a-iron through different types of
precipitations
41
HS steels by work hardening (dislocation strengthening)
42
Dislocation density as a function of amount of deformation in pure iron
Degree of deformation
43
Evolution of dislocation structure in deformed tensile samples
44
The area
next to the Lders band is
nearly without dislocation
Dislocation in the area
of uniform elongation
Cell structure nearby
fracture
Conventional high strength steels: Micro alloyed steels
45
Micro alloyed steels: alloying concept
46
Metallurgical process during hot rolling
47
Micro alloyed steels: properties, typical applications
48
HSLA steels

49
Microstructure:
Ferritic microstructure with a little pearlite
Precipitates of micro-alloyed elements
Mechanical properties:
High yield strength
High tensile strength
Limited draw-ability and stretch-ability
max. C P S Mn Ti Al (min) Si Nb
HX340LAD 0,11 0,030 0,025 1,00 0,15 0,015 0,50 0,09
max. C P S Mn Ti Al (min) Si Nb
HX340LAD 0,11 0,030 0,025 1,00 0,15 0,015 0,50 0,09
~0,14
n
90
value
~1,0
r
90
value YS MPa UTS MPa A 80% A
g
%
340-420 410-510 >21% ~14 ~0,14
n
90
value
~1,0
r
90
value YS MPa UTS MPa A 80% A
g
%
340-420 410-510 >21% ~14
Specified value Typical value Specified value Typical value
Conventional high strength steel: High strength IF steels
50
High strength IF steels: alloying concept
51
High strength IF steels: properties, typical applications
52
Conventional high strength steels: Bake hardening (BH) steels
53
Schematic diagram of the bake hardening effect, by example of
the production of a car door
54
Increasing strength by bake-hardening
55
Bake-hardening behavior of different steel grades
56
Bake-hardening steels: properties, typical application
57
Outline
Automotive evolution
Car body structures
Automotive steels
Mild steels
High strength steels
Multiphase steels
Press hardened steels
58
Metastable iron - carbon (Fe-C) phase diagram
10 20 30 40 50 60 70 80 90 100
1 2 3 4 5 6 7 L Q
P S
O
G
K
F
D
C
E
N
B
A
I
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
M
L +
Fe C
3
L
H
Fe
3
C
(Cementite)
L +
L +
+ Fe C
3

+ Fe C
3
a
a
a

Cementite content in mass %

Carbon content in mass %
T
e
m
p
e
r
a
t
u
r
e
i
n

C
Source: Pitsch, W.; Sauthoff, G.; Hougardy, H.P. in:
Werkstoffkunde Stahl, Band 1: Grundlagen, Verein
Deutscher Eisenhttenleute, Springer-Verlag 1985
59
Transformation-Temperature-Time (TTT) diagram
60
Austenite
61
Bainite Ferrite - Martensite
62
Polymorphism of iron
63
Mechanical properties of different phases in steels
Phase Re , MPa Rm, MPa A, % Hardening, HV
Interstitial free condition
(Ferrite)
100-150 280 50 -
Ferrite (unalloyed)
Ferrite (0,7% Ni, 0,6% Cr)
Ferrite (13% Cr)
220
330
300
300
550
500
45
35
18
-
about 180
-
Pearlite 900 1000 10 -
Cementite 3000 - - -
Bainite ( 0,1% C) 400-800 550-1200 25 about 320
Martensite ( 0,1% C)
Martensite ( 0,4% C)
800
2400
1200
-
5
-
about 380
-
Austenite (18% Cr, 8% Ni) 300 600 40 -
Phase Re , MPa Rm, MPa A, % Hardening, HV
Interstitial free condition
(Ferrite)
100-150 280 50 -
Ferrite (unalloyed)
Ferrite (0,7% Ni, 0,6% Cr)
Ferrite (13% Cr)
220
330
300
300
550
500
45
35
18
-
about 180
-
Pearlite 900 1000 10 -
Cementite 3000 - - -
Bainite ( 0,1% C) 400-800 550-1200 25 about 320
Martensite ( 0,1% C)
Martensite ( 0,4% C)
800
2400
1200
-
5
-
about 380
-
Austenite (18% Cr, 8% Ni) 300 600 40 -
64
Homogeneity of grain structure - properties
65
Characteristics of AHSS
66
Microstructures of modern multiphase steels
Higher strength
67
Microstructures vs mechanical properties of modern multi-phase steels
Tensile strength in MPa
200 400 600 800 1200 1400 1600
0
10
20
30
40
50
s
t
r
a
i
n

i
n

%
perlite retained austenite
bainite martensite
TRIP TRIP
MS MS
1000
CP CP
DP DP
F+P
ferrite
68
Adjustment of multiphase structures of hot-rolled strip
69
Multiphase steels
70
Characteristics of Dual Phase (DP) steels
71
Dual Phase steels: materials concept
72
Multiphase steels
73
Characteristics of TRIP steels
74
TRIP steels: TRansformation Induced Plasticity
75
TRIP steels: The TRIP-effect
Strain
S
t
r
e
s
s

76
Multiphase steels
77
Characteristics of complex phase steels
78
Complex phase steels: materials concept
79
Stress-strain behavior of automotive steels
80
Outline
Automotive evolution
Car body structures
Automotive steels
Mild steels
High strength steels
Multiphase steels
Press hardened steels
81
Direct - indirect press hardening
82
Properties of press-hardened steel sheet
83
Temperature gradient during press hardening
84
Protection of blank surface
85
Demands on the surface coating
86
Changing of surface and microstructure
87
Trend of hot forming of steel
88
Hot stamping
89
Hot stamped of tailored blanks
90
Innovation Tailored Tempering
91
Press-hardened B-pillar
92
Body of Audi A4
93
Press-hardened parts in VW Passat
94
Example of a press-hardening plant
95
Heating of the blank
96
Blank B-Pillar after heating just before hot stamping
97
Hot stamping
98
Application of advanced high strength steels
99
Trend of advanced high strength steels
Japan
World
100
References
- Jody N. Hall, Evolution of advanced high strength steels in automotive
applications, General Motors Company, Chair, Joint Policy Council,
Auto/Steel Partnership, 2011.
- Wagner S., Schmid P., Forming of high strength steel sheet, IFU,
Stuttgart, 2012.
- Smith, W.F. and Hashemi, J., Foundation of metarials science and
engineering, 5th edition, McGraw-Hill, ISBN 978-007-131114-4.
- Bleck, W., Material Science of Steel, RWTH Aachen University, 2007,
ISBN: 3-86130-923-8.
101
Thank You
Thank You
102