On twist springback in advanced high-strength steels

The sheet metal components made of advanced high-strength steel (AHSS) become fairly attractive in reducing weight and enhancing operational performance of products. However the corresponding forming process often generates more severe springback. This paper aims to investigate the behavior of twist springback in advanced high strength sheet components, where a twist rail was considered and the corresponding die and measurement tool were developed. Finite element model of the twist rail was first validated through a try-out test and then is used to carry out a parametric study on the twist springback. The results lead to an in-depth understanding of how the design and process parameters, such as transition ratio of cross-section width, corner angle, drawbead depth and material strength grade, affect the twist springback, thereby providing some insights into sensitivity analysis for the design of products and corresponding processes.     

高强度汽车钢板冲压成形的主要问题及模具对策

目的研究汽车行业高强度钢板冲压成形时,开裂等缺陷的解决方法。方法通过分析高强度钢板在冲压成形过程中存在的主要问题的根源,应用板料成形CAE分析软件Dynaform对其成形工艺进行了分析与优化。结果确定了优化后的工艺参数和模具结构,结合模具调试实际,提出了高强度钢板冲压成形问题的模具设计和调试解决对策。结论通过CAE分析优化设计,以及模具调试的钳工精细化和TD处理,可以改善开裂、回弹等高强度钢板普遍存在的冲压成形缺陷。     

Life Assessment and Crack Growth Properties of Laser Cut Dual-Phase Steel

The effect of laser cut-edges has been studied as a method for producing an optimum fatigue life performance of advanced high-strength steel. During this study, DP600 high-strength steel laser cut-edges have been fatigue tested under S-N and E-N fatigue loading regimes. The cut-edge surface characteristic properties and internal metallurgical alterations have been observed to directly influence fatigue life of the steel. This paper has investigated the crack initiation and growth properties of the initial crack to mode two. It is shown that alterations in the surface properties can be harnessed so that beneficial properties can be produced to retard crack initiation. It was determined that the laser power and cutting speed can be used independently to produce the appropriate balance between microstructure and optimum surface properties. Optimal fatigue lives were attained by minimizing the laser cut-edge surface damage, maintaining the formation of wide area striations and by forming a uniform layer of martensitic material close to the cut-edge. These results suggest that laser cutting can be used to enhance the fatigue life to failure of fracture-sensitive steel grades.     

同时确定钢纤维高强混凝土的断裂韧度及拉伸强度

考虑钢纤维高强混凝土试件细观非均质性对宏观断裂的影响机制,将钢纤维掺量、长度、直径及钢纤维抗拉强度等细观层面的钢纤维特征参数,引入钢纤维高强混凝土宏观断裂模型的虚拟裂缝扩展量的具体计算公式,从而发展了考虑钢纤维特性的可同时确定钢纤维高强混凝土的断裂韧度与拉伸强度的模型及方法。采用变化参数为钢纤维掺量和混凝土水灰比的三点弯曲试件,基于所提模型,同时确定了钢纤维高强混凝土的断裂韧度与拉伸强度,确定值与试验拉伸强度值以及尺寸效应模型计算的断裂韧度吻合良好。基于测试数据离散性为钢纤维高强混凝土固有属性的事实,采用确定的断裂韧度及拉伸强度,建立起钢纤维高强混凝土塑性——准脆性——线弹性不同结构断裂模式的±20%全曲线,其可涵盖实验室条件下的所有试验数据。该文所提模型及方法适用于钢纤维高强混凝土及高强混凝土,可为钢纤维高强混凝土等复合材料真实断裂韧度与拉伸强度的确定,及个性化结构断裂破坏的预测等关键科技问题提供依据。     

Understanding the Effects of Mechanical and Laser Cut-Edges to Prevent Formability Ruptures During Automotive Manufacturing

The cut-edge condition has an important influence on the formability capacity of high-strength steel (HSS) automotive structures. XF350 and DP600 under examination were observed to display a decreased level of formability in the surface regions because mechanical punched edge hole-flanging capacity is dependent on ductility and the surface quality of the cut-edge produced. Formability was observed to be highly dependent not purely based on the properties of the steel but also the cut-edge properties. Hole expansion capacity (HEC)-forming experiments were performed on flat circular plates with mechanical and laser-cut holes to investigate the fracture and forming limits of HSS. The HEC properties of the cut-edges were determined using mechanical and laser-cutting processes using various cutting process parameters in which certain edge types displayed decreases in edge ductility. It was found that, by altering the processing parameters during the cutting process, the edge quality can be improved, and this has a positive effect on the formability capacity of steel components.     

高强韧低合金冷作模具钢6CrNiMnSiMoV的强韧化特性

研究了钢的微观结构，残余奥氏体的稳定性及力学性能随回火温度的变化，结果表明；钢的基体为细晶马氏体，且大部分具有位错亚结构；马氏体板条界上存在着较稳定的残余奥氏体薄膜；马氏体内均匀分布着大量固溶时未溶，５－５０ｎｍ大小的Ｖ４Ｃ３；２００－３００℃回火析出大量细小的ε－碳化物。这种微观结构对于获得高强韧性是理想。Ｓｉ使ε－碳化物溶解和渗碳体的形成温度提高到３００℃以上，故钢在２００－３００℃回火有良好     

高精度超高强钢长滑轨辊压制造技术

目的解决超高强钢辊压成形过程中回弹大、尺寸精度差、材料利用率低、生产效率低等问题,生产出高精度的超高强钢长滑轨产品,以满足市场需求。方法从截面形状、尺寸精度及冲孔要求三方面,对以DP980超高强钢材料成形的典型的滑轨产品进行了技术分析,针对该产品特性重点设计了冲孔方案,采用三步质量控制法对产品的成形过程及辊压模具设计进行了优化,最后采取多种方法对产品质量进行了全面检测。结果实际制造完成后的产品检测表明,通过优化模具设计及调整现场工艺,最终生产出的长滑轨各项指标均满足图纸要求,解决了超高强钢材料的成形难题。结论在超高强钢材料及尺寸较长产品的成形制造中,辊压成形技术相比其他成形工艺更加具有优势。     

汽车用先进高强钢本构模型与韧性断裂模型研究进展

轻量化是当前汽车行业全产业链共同面对的课题,提高先进高强钢使用比例是实现汽车轻量化的有效手段。对先进高强钢本构模型与韧性断裂模型的充分研究有助于提高先进高强钢开裂分析和预测的准确性,从而推动先进高强钢工程的应用进程。目前,在先进高强钢的研究过程中,学者们通常通过多种应变强化模型的线性组合,或结合微观结构与宏观力学行为进行多尺度分析来建立本构模型;通过多种应力状态下的准静态拉伸实验以及使用仿真与实验混合的方法来标定韧性断裂模型的参数。以第三代先进高强钢中的淬火配分（QP）钢为重点讨论对象,介绍了制备工艺与材料特性及其相关研究进展,并介绍了QP钢本构模型的研究现状、新近发展的非耦合韧性断裂模型以及考虑了应力三轴度和罗德角参数影响的韧性断裂模型在先进高强钢上的应用现状,最后指出了先进高强钢本构模型和韧性断裂模型未来的研究方向。     

DP800 双相高强钢折弯及回弹研究

目的针对高强度钢板成形过程中的回弹问题,研究工艺参数对回弹的影响规律,优选工艺参数组合,以获得回弹较小的V形件。方法采用dynaform软件对V形件进行成形及回弹的数值模拟,以摩擦因数、模具间隙、冲压速度、凹模圆角半径等工艺参数为自变量,以回弹前后水平距离差最大值为因变量,设计了四因素三水平的正交试验方案,研究多个工艺参数对回弹影响的规律。结果实验结果表明,V形件回弹值大小随着摩擦因数的增大呈现减小趋势;随着模具间隙、凹模圆角半径的增大,回弹值呈现增大的趋势;而冲压速度对V形件回弹的影响较小,且工艺参数影响V形件回弹大小的主次顺序为模具间隙、摩擦因数、凹模圆角半径、冲压速度。结论优选工艺参数组合为:摩擦因数为0.2、模具间隙为2.6 mm、冲压速度为1200 mm/s、凹模圆角半径为12 mm,此时回弹水平距离差最大值为0.566 mm,最大减薄率为1.40%;实际生产可以忽略冲压速度对回弹的影响,仿真结果对实际生产具有指导意义。     

高强度结构钢材单调荷载作用下的本构模型研究

钢材在单调荷载作用下的本构模型是进行结构分析的基础。为了更为准确地计算高强钢结构响应和分析构件的受力性能,为工程设计人员应用高强钢提供参考,该文在总结已有试验研究、开展大量拉伸试验的基础上,更新了高强钢多折线本构模型的参数,以Ramberg-Osgood模型为基础标定了适用于高强钢的非线性本构模型。通过和试验数据的对比,证明非线性本构模型能够很好地模拟高强钢在单调荷载作用下的应力-应变关系。为了兼顾准确性和效率,该文还提出了修正的多折线本构模型,在反映高强钢非线性的材料性能的同时本构模型也相对简单。     

窄间隙焊接侧壁熔合控制技术的研究现状

窄间隙焊接因采用窄且深的U型或者I型坡口,在焊接厚板时具有焊接效率高、焊接填充量少及焊接变形少等诸多优势,在大型厚壁高强钢结构制造领域具有很好的应用前景。由于窄间隙焊接中电弧与坡口侧壁几乎平行,造成电弧无法对侧壁直接加热,易出现侧壁未熔合缺陷,严重影响了大型高强钢结构的服役安全。通过对窄间隙焊接技术研究现状的分析整理,综述并比较常用的侧壁熔合控制技术与方案,分析了其优缺点。分析结果表明,目前已经开发了旋转电弧、双电弧、带状电极、复合热源及摆动电弧等多种侧壁熔合控制技术,在一定程度上解决了侧壁未熔合问题,并且在压力容器、厚壁管道等领域获得了应用。最后对该方向的研究进展进行了总结,并对其发展方向进行了展望。     

双丝埋弧焊FCB法单面焊双面成形工艺研究

埋弧焊FCB法单面焊双面成形工艺在船厂已有大量应用,针对国内单面焊工艺应用现状和高强钢的特点研制了高强钢双丝埋弧焊单面焊工艺配套焊丝与焊剂,同时系统分析了焊接规范、坡口形式、背面焊剂对焊道成形的影响。通过调整工艺使其接头性能达到技术要求,该技术有望实现埋弧焊FCB法单面焊工艺的国产化应用。     

基于爬壁机器人的EH36船用高强钢立焊工艺研究

目的 研究在爬壁机器人平台上进行EH36船用高强钢立焊的可行性及工艺参数。方法 通过在实验室搭建焊接实验平台来模拟EH36船用高强钢的实际焊接场景;在轮式爬壁机器人WRobot-50平台上进行船用EH36高强钢的立焊实验;对不同参数下的试样进行宏观形貌、微观组织及相关力学性能分析。结果 在电流为160 A、电压为24.5 V、焊接速度为0.6 m/min下,可以得到外观成形及微观组织都没有缺陷的立焊焊缝,其中焊缝的硬度较母材提高了约30%,屈服强度较母材约提高了4.3%,抗拉强度较母材约提高了9.0%。结论 爬壁机器人完全适用于船用EH36高强钢的立焊工艺,并且可以应用到船舶、石化等大型钢结构件的焊接工作中。     

Quantification of bake hardening effect in DP600 and TRIP700 steels

Recently developed advanced high-strength steels with multiphase microstructures show interesting bake-hardening (BH) properties. This research work aims to quantify the effect of BH on dual-phase (DP) and transformation induced plasticity (TRIP) steel. Different pre-strains from 0% to 10% with a subsequent BH annealing cycle with temperatures of 60–220 °C for varying BH holding times from 1 to 10,000 min were applied for both materials. Mechanical properties such as yield and tensile strengths, elongation and BH values in dependency of the BH parameters have been determined and related to specific microstructural features in order to characterize the age and strain hardening behavior.     

Effect of welding wire and groove angle on mechanical properties of high strength steel welded joints

Mechanical properties of high strength steel welded joints strictly depend on the welding process, the filler material composition and the welding geometry. This study investigates the effects of using cored and solid welding wires and implementing various groove angles on the mechanical performance of weld joints which were fabricated employing the gas metal arc welding process. It was found that weld joints of low alloy, high strength steels using low alloy steel cored welding wires exhibited higher tensile strength than that of low alloy steel solid wire and chromium‐nickel steel bare welding wire when the method of gas metal arc welding is employed. The effect of groove angle on the strength and toughness of V‐groove and double V‐groove butt‐joints was investigated. V‐groove joints, with higher tensile strength than double V‐groove joints in the whole range of groove angles, were superior in toughness for small groove angles, but impact toughness values of both joints were comparable for large angles. The effect of heat input and cooling rate on the weld microstructure and weld strength was also investigated by performing thermal analysis employing the commercial software ANSYS. It was concluded that cooling rate and solidification growth rate determined the microstructure of the weld zone which had great consequences in regard to mechanical properties.     

Investigation on lap-joint friction stir welding between AA6351 alloys and DP800 steel sheets

With continuous growth and stringent demand for weight reduction in automotive structures, the automotive industry has shown an increasing interest in dissimilar aluminium–steel welding. Dissimilar lap joint between AA6351 alloys of 2 mm thickness and DP800 advanced high-strength dual-phase steel of 1 mm thickness has been attempted and joined successfully by friction stir welding with different combinations of parameters. The experimental results of this research work clearly indicate that joining of advanced high-strength steel and aluminium in lap-joint configuration is quite feasible with friction stir welding. Microstructural characterization has been performed by X-ray diffraction (XRD) technique and scanning electron microscopy (SEM). An intermetallic compounds layer was found in the interface of steel and aluminium with thickness of less than \(7 \,\upmu \hbox {m}\) and it was identified as \(\hbox {Al}_{2}\mathrm{Fe}\) and \(\hbox {Al}_{3}\mathrm{Fe}\) by XRD method. Thermal cycle has been measured and correlated with the microstructure. Shear tensile test has been performed for determining the maximum failure load for different combinations of parameters. Finally, mechanical properties and microstructural observation are correlated with each other.     

Influence of temperature and hydrodynamic conditions on the corrosion behavior of AISI 316L stainless steel in pure and polluted H3PO4: Application of the response surface methodology

Phosphoric acid is mainly produced by the wet acid process, where corrosion problems could be intensified due to the presence of impurities in the phosphate ores. Operating temperatures and flowing conditions aggravate the aforementioned problems. This work studies the influence of temperature (25–60 °C) and hydrodynamic conditions (Reynolds numbers from 1456 to 5066) on the corrosion of AISI 316L stainless steel in pure and polluted phosphoric acid solutions, by means of cyclic potentiodynamic polarization curves in a hydrodynamic circuit. The effect of temperature is the same as that caused by impurities, that is, higher corrosion rates and hindered passivation and repassivation resistance of the alloy. Statistical analysis by means of surface response methodology proved that the effect of temperature on the corrosion parameters of AISI 316L is more influential than the Reynolds number effect. The Reynolds number seems to have no significant influence on the corrosion behavior of stainless steel. Furthermore, the influence of temperature on the corrosion rate is much higher than on the rest of the corrosion parameters analyzed, especially in polluted phosphoric acid solutions. AISI 316L stainless steel has a clear interest for the phosphoric acid industry as a component material of some equipment due to its good corrosion properties at the different temperatures and Reynolds numbers studied even in polluted media.     

Metallurgical and mechanical characterization of electron beam welded DP600 steel joints

Several new commercial advanced high-strength steels exhibit high strength and enhanced formability. These materials have the potential to affect cost and weight saving while improving performance. However, welding, by modifying the microstructure of the steel, has in general a detrimental effect on the mechanical properties of structural components. If high power density technologies are used, the result is that the mechanical properties of such kind of joints can be improved. This article presents a metallurgical and mechanical characterization of electron beam welded joints in advanced high-strength steel DP600. The experimental analysis was supported by a thermal numerical model obtained through the Sysweld^? code. Results show that mechanical properties of the electron beam welded joints are comparable with those of parent metal both in terms of static strength and ductility.     

冲压件成形仿真及其预成形模具方案设计

目的预测高强度钢板的冲压成形性。方法对使用高强度材料的左前地板2号横梁进行了数字仿真模拟,设计了一种提高板料抗破裂性能的带氮气弹簧的预成形模具。先根据仿真结果,在采用调整工艺参数的常规手段未果的情况下,分析了破裂原因,再根据成形模拟软件的使用要求,对氮气弹簧的技术特性进行了处理,保证能代入成形软件。结果再次成形模拟证明,采用氮气弹簧的预成形模具,能改善模具受力状态,使成形件不致破裂。结论预成形模具结构有助于改善特定形状冲压件的成形性。