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Forming AHSS: Playing by new rules
Advanced high-strength steels spur unconventional thinking about formability
By Tim Heston
July 15, 2008
Advanced high strength steels spur stampers to think about metal forming in new ways.
Published in...
Mention a certain material is predicted to overtake mild steel as the
auto sector's most popular material in 10 years, and people take
notice.
That's been Peter Ulintz's experience in recent years. As advanced
product engineering manager for Cleveland-based stamper Anchor
Manufacturing Group, Ulintz has toured the country giving seminars
on what many believe eventually will become a preferred metal for
automotive and other industries: advanced high-strength steels. At a
recent seminar at the METALFORM tradeshow in Birmingham, Ala.,
Ulintz picked up a prop on his podium. "See? I'm waving a red flag.
They're coming, and you'd better be ready for them."
AHSS has been gaining ground in an automotive industry hunting Advertising Information
for all the weight savings it can while satisfying or surpassing safety
The Fabricator® standards. The material could be called the next step in steel's
evolution toward exhibiting the high-strength, lightweight The shop floor at MBtech Autodie in Grand
Rapids, Mich., has more than 30 presses for
Subscribe to FAB characteristics of more expensive materials, like aluminum and
die tryout. In recent years the company has
magnesium. made great strides building dies for AHSS.
View This Issue Challenges arise, however, from a formability standpoint—hence
Ulintz's red flag. The varieties of AHSS do exhibit high formability, but in entirely different ways from legacy materials.
According to sources, it's more than just high amounts of springback; instead, metal formers need to throw out the
old rulebooks. AHSS has spurred stampers to think about metal forming in new, unconventional ways.
Related TechCells
Redefining High Strength
Hydroforming Daniel Schaeffler pointed to his wedding band. A metallurgist and
president of Engineering Quality Solutions, a Southfield, Mich.-
Coil Processing based consultancy, Schaeffler admitted the band was only 18 karat,
not pure gold—but for good reason.
Press Feeding "Pure gold is like any pure metal," he said."It's extremely formable. It
has no strength."
Tool and Die The same holds true for pure iron. But mix that formable element
with"impurities" like carbon and manganese, and the story changes.
The material, mild steel, has less formability but higher strength than
pure iron. To further increase steel strength historically has required Figure 1
Tags adding primarily carbon and manganese. This decreases formability This shows stress-strain curves for certain
and weldability to a point where, unfortunately, it isn't practical for grades of HSLA, DP, and TRIP steels with
n-value, martensitic- forming complex parts calling for yield strengths greater than 275 to 350-MPa (50-KSI) yield strength. Source: A.
345 MPa (40 or 50 KSI). Konieczny,
steels, k-value, hsla,
high-strength-steel, high- Above this strength level, steelmakers add very small amounts of
strength-low-alloy, elements like titanium, vanadium, and niobium (also called columbium) to the melt, and adjust the steel mill
processing to use much less carbon and manganese to produce a steel of a given strength level. Compared to
formability, dual-phase,
conventional CMn steels, these high-strength, low-alloy (HSLA) steels (also known as microalloyed steels) generally
die-design , complex- have increased strength, better formability, and better weldability.
phase, ahss
Until recently the nature of the strength-formability trade-off has remained the same: Making a material stronger
reduced formability. HSLA steels reduced that trade-off. But to make steel of still higher strength and lower weight—
as the automotive industry is demanding—requires that trade-off to be reduced further, or even eliminated.
To accomplish this required a new approach to alloy development and, in turn, forming. This led in recent years to a
new class of steels—AHSS. The various grades are grouped under the AHSS umbrella not because they share
microstructures, but because they alter the relationship between ductility and strength. According to a report from a
2006 AHSS workshop in Arlington, Va.,"The typical trade-off between strength and ductility has been taken as gospel
by generations of faculty, students, and engineers. The ability to increase both of these properties simultaneously
with AHSS is indeed a technical paradigm shift of the highest order."
Because this fundamental trade-off changes, so do the rules for metal forming. Yes, the steels do exhibit high
formability, allowing the stamping of high-strength materials with tensile strengths, in some cases, of 700 MPa and
above, values so high that stampers wouldn't have bothered to put them through a press a decade ago. However,
the steels respond to deformation in unconventional ways, and this is the root of the challenges associated with
AHSS.
Metallurgists classify most AHSS into first and second generations. The first generation includes dual-phase (DP),
transformation-induced plasticity (TRIP), complex-phase (CP), and martensitic steels. The second generation
includes those with a corrosion-resistant austenitic matrix, such as twinning-induced plasticity (TWIP) and lighter-
weight steels with induced plasticity (L-IP). Some even classify emerging multi- and nanophase materials into a third
generation.
According to Schaeffler, DP steels—a family of high-strength steels with similar weldability and better formability as
an HSLA steel of similar strength—are likely to continue dominating the AHSS market."In general, the amount of
dual-phase applications is going to dwarf everything else combined," he said."With TRIPs and others, there are many
more ingredients in the cake, and that means potential weldability issues and probably a higher price tag. But in the
right application, [using TRIPs and other, more expensive steels] will be worth it."
Dueling With Dual-Phase
Consider a DP blank formed in a drawing die. The blank is deformed
into the desired product shape, but perhaps with some springback,
side-wall curl, or edge cracking that wouldn't be expected with traditional HSLA or mild steel. What happened?
The material's unique makeup—starkly different from earlier generations of steel—is to blame. DP's microstructure
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which means you need even more blank holder pressure. And in some instances, you cannot do it with nitrogen
cylinders. You may need to be in a hydraulic or toggle press," depending on how large and thin the part is.
Ulintz added that edge condition becomes extremely important when edge stretching is involved."You need to have
clean edges in order to be able to stretch the flanges. AHSS material has reduced edge stretchability. In a low-
carbon or HSLA application, we might not need to pay that much attention to the condition of the sheared edge,
because there's enough ductility in the material to form a flange or expand a hole, or whatever else it is we're doing.
But because the advanced high-strength steels have a high sensitivity to edge stretching, the edge condition is
critical." All the stress will locate at any imperfection, be it a hot spot from laser cutting or a burr from a trim die.
AHSS also changes things for the die maintenance department. Ulintz mentioned a recent study cited in the
International Steel and Iron Institute's AHSS Design Guidelines which showed that burr growth doesn't happen in the
conventional way with AHSS, because AHSS appears to fracture differently and is less ductile than HSLA."What
ends up being the criteria for die maintenance is punch wear," Ulintz said,"rather than burr generation."
Put another way: The tools wear without significant burr growth on the part, which means die maintenance personnel
have to play by new rules.
Ulintz concluded that most AHSS development challenges boil down to strong and light, two adjectives that have
remained a dichotomy throughout most of metal forming's history.
"One of the advantages of going to the advanced high-strength steels is that automakers can down-gauge. Now you
complicate the issue. I used to have a 2-mm-thick HSLA material, and I'm going to down-gauge to a 1.8-mm-thick
advanced high-strength steel. The material is thinner, but the die has to be designed and built as though it were three
to four times thicker."
Thinner material requires more robust dies and presses. How's that for counterintuitive thinking?
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Additional Information
Author
Tim Heston
Senior Editor
FMA Communications Inc.
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