Introduction to Hot Stamping and Trends

By
Dr. Eren Billur, Post-doctoral Researcher
and
Dr. Taylan Altan, Director and Professor

Presented at ESI Hot Forming Die Engineering Seminar

October 15th, 2013

Center for Precision Forming (CPF)

www.cpforming.org / www.ercnsm.org
© Copyright Center for Precision Forming (CPF). All Rights Reserved.
 Center for Precision Forming - CPF

CPF is supported by NSF and 16 member

companies, interested in metal forming.

Interlaken
Technology Corporation

IMRA

2
 CPF – Current Projects

• Material Characterization
• Friction / Lubrication
• Process Simulation / Forming Al & AHSS
• Die Wear in Forming AHSS
• Edge Quality in Blanking / Shearing
• Hot Stamping of UHSS
• Servo Drive Presses and Hydraulic Cushions
3
 Sponsors & Partners of Hot Stamping Research

IMRA
TSG
Interlaken
Technology Corporation

Tooling Systems
Group

4
 Crashworthiness

Crumple Zone Passenger Zone Crumple Zone

5
Images from: media.Daimler.com
 Crashworthiness
Passenger Zone Roof rail Crumple Zone

A-pillars

B-pillars
Door beams

Intrusion Resistance Absorbing Energy

Ultra High Strength High Strength + Elongation
6
Ref: Hilfrich 2008.
 Summary of Hot Stamping

70 Mild Steels
L-IP
60 Conventional High
Better Formability

Aust. Strength Steels

Total Elongation (%)

TWIP
50 IF SS
Advanced High
40 Strength Steels
Mild
30 BH Higher Press Forces 2nd Generation
Al CMn TRIP AHSS
20 Al
(hs) Aluminum Alloys
10
MART
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 7
Ultimate Tensile Strength (MPa)
 Summary of Hot Stamping

70 Mild Steels
L-IP
60 Conventional High
Aust. Strength Steels
Total Elongation (%)

TWIP
50 IF SS
Advanced High
40 Mild Lightweight Potential for Strength Steels
BH Intrusion Resistance
30 2nd Generation
CMn Al AHSS
20 Al Higher Springback
(hs) Aluminum Alloys
10 MART
0
0 25 50 75 100 125 150 175 200 225 250
8
3
Specific Strength (MPa/(k g/m ))
 Summary of Hot Stamping

Heated >950 C
70 Austenite
Indirect Process:
2
60
Aust.
Total Elongation (%)

TWIP
50 IF SS
3-5 min.s Quenched in the die
40
Mild in Furnace >27 C/s Direct Process:
30 BH
CMn 1 TRIP Quenched
20
Mn-B Alloyed steel Martensite
10 (as delivered)
Ferrite & Pearlite MART
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 9
Ultimate Tensile Strength (MPa)
 Hot Stamping - Trends
Mass % of hot stamped
steel in BIW
Audi
A3
Volvo
XC90
44%
Volvo
Volvo
26%
VWV40
XC90
SAAB Golf VII
VW
9000 28%
Passat
19% 20%
7%
≈

1984 2003 2006 2012 2014

10
Ref: Lund 2009, Holzkamp 2011, Lindh 2011, Bielz 2012, Mattsson 2012, VW Media Services.
 Hot Stamping - Trends
Parts per year (in millions) >20
Parts/
550 Vehicle
500 8-10
6 Parts/
450 Vehicle
Parts/
450 million
Vehicle
400 per year
(2013)
350
300
4 Parts/
250 Vehicle
200 95 million
per year
150 8 million (2007)
3 million per year 210+ lines
100 per year (1997) around the world
50
0 (1987)
+55 planned

1987 1997 Year 2007 ’08 ’09 ’10 ’11 ’12 ’13 11
Ref: Oldenburg 2010, Hund 2011.
 Hot Stamping - Trends

Passenger
Zone

Deformation
Zone
(a) Front view (b) Side view
before crash after crash

12
Ref: Macek 2006, Image from: IIHS.
 Hot Stamping - Trends

22MnB5
1500 MPa
(215 ksi)

HSLA 340
(50 ksi)

Tailor Rolled Blanks Tailor Welded Blanks Tailored Hot

Stamping 13
Ref: Rehse 2006, Hilfrich 2008, Lee 2012, Images from: IIHS, VW Media Services.
 Hot Stamping - Trends

550 C 20 C

Tailored Heating Tailored Quenching Post Tempering

(Austenitizing) 14
Ref: Breidenbach 2009, Hedegärd 2011, Süß 2011, Steinhoff 2013. Image from: IIHS.
 Hot Stamping - Trends

900

800

700 A+F
Temperature ( C)

600
A+P
500 A+B
Ms
400
A+M
300
Mf
200

100
Time to cool (s) 8 27 40 80 133 266 1143 4000
Cooling Rate ( C/s) 100 30 20 10 6 3 0.7 0.2
15
Hardness (HV) 475 474 417 278 232 182 163 150
 Finite Element Simulation of Hot Stamping

Our simulations aim to predict the final properties of hot

stamped components:

1) Presence of defects: cracks, wrinkles or local necking,

2) Hardness distribution (both in uniform and in tailored parts),
3) Cooling channel analysis,
4) Distortion of the final part.

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 Finite Element Simulation of Hot Stamping

Fluid Mechanics
Heat transfer to the
Heat generation due to coolant medium.
plastic deformation.
Mechanical Field Thermal expansion.
Thermal Field
- Mechanical material Phase Microstructure - Thermal material
properties, transformation depends on properties,
- Volume change due depends on temperature. - Latent heat due to
to phase stress and strain. phase
transformation. transformation.
Microstructure Evolution
17
Ref: Åkerström 2006, Porzner 2012.
 Finite Element Simulation of Hot Stamping

Only needed in tailored parts

Air
Gravity Holding Forming Die Quenching Springback Quenching
Thermal + Thermal + Thermal +
Mechanical Thermal + Metallurgical Mechanical Metallurgical
Mechanical Mechanical

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 Predicting Defects

Crack prediction in a Side Member Reinforcement

Colors other than gray:

Thinning >20%. Part stamped at the participating
company

19
 Predicting Defects
Die Segment 1 Die Segment 2 Die Segment 3

Blank (Ti = 850 C)

20
Heated Dies (Ti = 450 C) Cooled Dies (Ti = 20 C)
 Predicting Defects

Crack / wrinkle prediction in a tailored part

With one-piece blankholder With two-piece blankholder
20 kN 15 kN 5 kN
Crack

Wrinkles in Non-symmetric No wrinkles or

the soft area draw-in cracks

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 Hardness Distribution

Die Quenching Optimization

Martensite phase fraction

1.00
0.85
0.71
0.57
0.42
0.28
0.14
0.00

Min = 0.00 4 seconds die quenching 10 seconds die quenching 22

Max = 1.00
 Hardness Distribution
Heat Transfer Coefficient (W/m 2C)
Air Quenching Stage 100
140
Convection
120
80 Radiation

Maximum Austenite (%)

100
60
80

60
40

40
20
20

0
0 10 20020 400 40 600
30 50 60800 70 1000
80 23
Ref: Shapiro 2009. Time (s) (C)
Temperature
 Hardness Distribution

Results

Hardened zone:
485 – 515 HV
Soft zone: 1500 – 1590 MPa
310 – 330 HV (~220 – 230 ksi)
920 – 1020 MPa
(~135 – 150 ksi)

Literature:
[George 2011] , 400°C dies = 790-840 MPa
[Feuser 2011], 450°C dies = ~850 MPa 24
 Cooling Channel Analysis

Cooling channel performance

1.3 mm 22MnB5 “roof rail”
Mass produced for a European car.

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 Cooling Channel Analysis

Cooling channel performance – tailored part

1.2 mm 22MnB5 “B-pillar”

1605 925 300

921.4 MPa
250
1600 920 Max
Maximum UTS (MPa)

Minimum UTS (MPa)

219 C

Temperature ( C)
200
1595 915
150
1589.4 MPa
1590 910
1590.3 MPa 100

1585 905
50
903.8 MPa Min
1580 900 20 C
1 2 3 4 5 6 7 8 9 10
0
0 20 40 60 80 100 120 140 160
Part # (Cycle) Time (s)

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 Distortion Analysis

Ongoing work: Distortion in Tailored Parts

strain

0.015
austenitisation

martensitic
0.01 transf ormation
+Initial,
undistorted grid

0.005

0 +Interstitial dissolved
carbon
+ carbon, tetragonal distorted
grid
Material 1 Material 2
200 400 600 800 1000 1200 temperature
-0.005
27
Ref: Porzner 2012.
 Summary and Conclusions

Several case studies were used to develop, calibrate and

validate material models, conversion factors and methods to
predict:

1) Defects (cracks, wrinkles, local necks),

2) Vickers hardness, yield and ultimate tensile strengths,
3) Cooling channel / heating cartridge performance,
4) Distortion in a non-uniform part.

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 What is next?

2000 1) New materials with

High Strength (USIBOR 2000, even higher strength:
MBW1900, HPF 2000) More lightweight potential
Engineering Stress (MPa)

1500 and increased

22MnB5 (USIBOR 1500, productivity.
MBW1500, HPF1470)
1000 2) New coatings: better
corrosion properties and
friction conditions.
500
High Elongation (DUCTIBOR 500, 3) New heating, forming
MBW500) and quenching methods
0 to improve productivity.
0 5 10 15 20
Engineering Strain (%) Competition: DP, TRIP, TWIP, and 29
Ref: Lanzerath 2011, Vietoris 2011, Ferkel 2012, Lee 2012. 3gAHS Steels with high YS and UTS.
 Deliverables / Hot Stamping

As of September 2013:
- 15 CPF Reports (Literature review and FE simulations),
(5 in the last 6 months) [confidential to members],
- 6 Stamping Journal R&D Updates
(+1 more in progress),
- 6 Conference Proceedings (+1 more submitted),
- 1 Book Chapter in “Sheet Metal Forming: Vol 2:
Processes and Applications”, (see next slide),
- And a new “Hot Stamping” book in progress! 30
 Questions / Comments?

For more information , please contact:

Dr. Eren Billur (billur.1@osu.edu), Ph 614-292-1785
Dr. Taylan Altan (altan.1@osu.edu), Ph-614-292-5063
Center for Precision Forming –CPF (www.cpforming.org)
339 Baker Systems,1971 Neil Ave,
Columbus, OH-43210
Non-proprietary information can be found at web sites:
www.cpforming.org
www.ercnsm.org
References can be sent upon request. 31