recent developments in sheet steels from a forging ... · recent developments in sheet steels from...
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Recent Developments in Sheet Steels
from a Forging Perspective and Outlook
C J Van Tyne
Advanced Steel Processing and Products Research Center
Colorado School of Mines
Golden, CO USA
Forging Technical Conference
September 12, 2018
Long Beach, CA
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ASPPRC
Concentrating on research at the
interface between producers and users of steel.
CSMCSMCSM
Advanced Steel
Processing and
Products Research
Center
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ASPPRC Sponsors
AK Steel
Algoma
AMG Vanadiu
ArcelorMittal
Baoshan Iron and Steel
Bekaert
Blount International
Caterpillar Incorporated
CBMM North America
Chevron Energy
Climax Molybdenum
Deere and Company
Essar Steel Algoma
Evraz Inc. NA
FCA US LLC
General Motors Corporation
Gerdau
Gestamp
Kobe Steel
Los Alamos National Laboratory
Nexteer Automotive
Nucor Steel
POSCO
Precision Castparts Corp
Saudi Basic Industries
SSAB Americas
Tata Steel Europe
Ternium Mexico
Timken Steel
Thyssenkrupp Steel
United States Steel Division, of USX
voestalpine Stahl GmbH
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• Major developments in sheet steels over last
decade.
• Possible opportunities for forging companies
• Objectives:
1) Justify why forgers should be aware of sheet
steel metallurgy.
2) Describe some of the recent developments.
3) Speculate about possible opportunities in the
coming years.
Background and Objectives
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• Microalloyed forging steels
• Major opportunity of forging companies
• Low total cost manufacturing
• Good for certain markets
• Where were microalloyed steels first developed
and used in a major way?
A Bit of History
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• A major large scale use was in steel plate in
early 1970s although patents in 1939-41.
• Produced by Japan for use in the 800 mile
Alaskan pipeline.
• Pipe made by the UOE process using a large
hydraulic press.
Microalloyed Steels
Gray MJ and Siciliano F. High Strength Microalloyed Linepipe. Microalloyed Steel Institute; 2009.
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• Steel metallurgy continues to evolve to meet the
needs of society.
• There is significant time from initial idea/patent
to large scale use.
• Forging steels may develop from research done
on other steel products.
Implications
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• Automotive industry uses large quantities of
steel.
• Vehicles need to become lighter and stronger.
• Lighter to increase fuel economy and to reduce
emissions.
• Stronger to improve passenger safety.
• Steel Companies are developing sheet steels
with high strength and higher toughness.
• Higher strength means less steel and lighter vehicle
• Higher strength often means less toughness
Drivers of Recent Developments in Sheet
Steels
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• First Generation
Automotive Sheet Steels
www.tf.uni-kiel.de/matwis/amat/iss/kap_9/advanced/t9_2_1b.html
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• Second Generation
Automotive Sheet Steels
Suwanpinij P, The Synchrotron Radiation for Steel Research, Adv in Mat Sci and Engr, 2016.
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• Third Generation (Gen3) Steels
Automotive Sheet Steels
Hall, J. N., 2011, “Evolution of Advanced High Strength Steels in Automotive Applications”,
presented in Great Designs in Steel Seminar, May 18th, 2011
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Fundamental Requirement of Gen3 Steel
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• DP (Dual Phase) steels are a mixture of ferrite
and martensite. First generation.
• Strength from martensite
• TE from ferrite
DP Steels
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• TRIP (Transformation Induced Plasticity) Steels
• High end of First Generation Steels
• When deformed (in use) austenite transforms to
martensite increasing plastic behavior thus increasing
toughness
Steels with Retained Austenite
D.K. Matlock and J.G. Speer, “Design Considerations for the Next Generation of Advanced High Strength Sheet Steels,”
Proceedings of the The 3rd International Conference on Structural Steels, 2006, pp. 774-781.
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• Q&P steels concept developed by ASPPRC.
• Processing to increase retained austenite.
• Reported: 1500 MPa, 17% TE
Quench and Partitioned (Q&P) Steels
D.K. Matlock, V.E. Bräutigam, and J.G. Speer, “Application of the Quenching and Partitioning (Q&P) Process to a
Medium-Carbon, High-Si Microalloyed Bar Steel,” Proceedings of Thermec’2003, Trans Tech Publications, Inc,
Uetikon-Zurich. Switzerland, 2003, pp. 1089-1094.
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• TBF (TRIP aided Bainitic Ferrite) Steels
• Interrupted Austempering process
• Prior forging enhances properties
• Reported:
• 1000 MPa
• 30% TE
TBF Steels
B. C. De Cooman, “Structure–Properties Relationship in TRIP Steels Containing Carbide-Free Bainite,”
Current Opinion in Solid State and Materials Science, vol. 8, pp. 285–303, 2004.
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Q&P and TBF steels
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• Laboratory steels (not production).
• Research work to date has focused on sheet
steels with lower C content than most forging
steels.
• TE is not toughness, but a rough indication.
• Production runs of:
• QP980 980 MPa 20% TE
• QP1180 1180 MPa 14% TE
Caveats
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• These sheet steel compositions not yet ready for
many forging applications.
• The idea of having retained austenite to
increase strength and improve toughness is key.
Forging Outlook
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• To get retained austenite need careful control of
post forging heat treatment.
• Can be done in heat treat shop after forging, but
there would be added expense.
• Like microalloyed forging steels, control of time
and temperature directly off the press should be
considered.
Forging Outlook
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• Development of appropriate steel chemistries.
• Post forging time temperature control
• Continuous heat treatment conveyors?
• Forgings are thicker than sheet. Heat extraction?
• Precise timing needed.
• Effective quenching needed.
• Many research and technical details to be
resolved before actual implementation.
Challenges
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• Many new sheet steel (concepts) developed to
increase strength and TE (toughness)
• DP, TRIP, Q&P, TBF
• Not yet ready for forging applications
• These concepts (production schemes) may be
coming to the forging industry.
• Will require precise time and temperature
control post forging.
Conclusions
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Thank You