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The Next Generation of Advanced High Strength Steels
– Computation, Product Design and Performance
First-Year Progress Update on the DOE ICME 3GAHSS Project
Louis G. Hector, Jr., Technical Fellow
General Motors R&D, Warren, MI 48316
Ron Krupitzer, Vice President
Steel Market Development Institute
2000 Town Center, Suite 320
Southfield, MI 48075-1123
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Award to USAMP through Sec. Chu’s Office (DOE): February, 2013
• http://energy.gov/articles/energy-department-investments-develop-lighter-stronger-
materials-greater-vehicle-fuel
DOE Funding: $8,571,253 ($6,000,000 DOE funding (70%), $2,571,253 industry funding)
Duration: Four Years (February 1, 2013 – January 31, 2017)
Approach: Integrated Computational Materials Engineering + 3GAHSS Alloy Development
New ICME Project on Third Generation
Advanced High Strength Steels (3GAHSS)
Recipients, Sub-recipients, and Key Contractors
• USAMP: Chrysler, Ford, General Motors
• A/SP and SMDI: AK Steel, ArcelorMittal, Nucor Steel, Severstal
North America, and US Steel Corporation
• Universities: Brown University, Clemson University, Colorado
School of Mines, Michigan State University, University of Illinois
• National Lab: PNNL
• Engineering Companies: EDAG, LSTC
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Candidate Automotive Components
for ICME 3GAHSS Project E
lon
ga
tio
n (
%)
Tensile Strength (MPa)
Current Materials
Gen 3 Steel Targets
Weight Reduction
(Gage and/or
Geometry)
Rails
DOE Steel Targets
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(a) …use computers (with minimal experimental
inputs) to “design” multi-phase steel
microstructures that achieve desired strength
and ductility targets (for example).
(b) …generate constitutive models that accurately account
for the multi-scale physical phenomena in an advanced steel
under an arbitrary strain path.
(c) …pass models onto metal forming and CAE engineers
for formability and performance predictions in commercial FE codes. (d) …predict formability and failure
limits.
ICME Constitutive Model Development for
3GAHSS
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LP
Start with
QP980
ST 2.1 Experimental:
Nanometric to Grain
Scale Mechanical
Tests/Texture (EBSD)
(years 1-4)
ST 2.2 Experimental:
Coupon-Level Tests for
Flow Behavior,
Formability, Failure
Fracture (years 1-4)
ST 2.8 Computational:
Microstructural Design
and Analysis of
3GAHSS
(years 1-2)
ST 2.3 Computational :
Atomistics for
Defects/Strengthening/
Hardening (years 1-4)
ST 2.4 Computational:
Crystal Plasticity
For Mechanical
Properties of Phases in
Microstructure (years
1-4)
ST 2.9 Experimental
Design and
Manufacture of
3GAHSS (years 1-4)
ST 2.5 Evolutionary
Yield Function
(years 1-4)
ST 2.6 Computational:
Microstructure-Based
Finite Element
Approach for Bulk
Sheet YS, UTS, TE, UE
and Formability (years
1-4)
ST 2.10 Computational:
Development and
Validation of Macroscopic
Constitutive Models for
Deformation and Fracture
-PamStamp,\LS-DYNA,
ABAQUS (years2-4)
ST 2.7 Computational:
Failure/Fracture
Models
(years 3-4)
Phase II Integration,
design, cost analysis,
and model and
property database with
3GAHSS
Task 2 - ICME Constitutive Model
Development Path for 3GAHSS
Brown
Brown
CSM
Michigan State UIUC Michigan State
Clemson
PNNL
PNNL + A/SP
A/SP
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Experimental: Nanometric to Grain Scale
Mechanical Tests/Texture (EBSD)
• Brown University, School of Engineering
– Prof. Sharvan Kumar
– Prof. Allan Bower
– Dr. Hassan Ghassemi-Armaki
– Dr. Hyokyung Sung
• Purpose:
– Measure flow properties of individual steel phases
with state-of-the-art micropillar compression
– Measure texture information with Electron Backscatter
Diffraction (EBSD); measure austenite transformation
kinetics.
• Integration:
– Provide experimental data for inputs to atomistic and
crystal plasticity (microstructural) simulations and
model validation.
ST 2.1 Experimental:
Nanometric to Grain
Scale Mechanical
Tests/Texture
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As Received
100 mm
As Received As Received
0.0 0.1 0.2 0.3 0.4 0.50
200
400
600
800
1000
Str
ess (
MP
a)
Strain
5%
10%
20%
30%
40%
50%
Fracture
Interrupted tests
10 % strain
201LN
Neutron diffraction
estimated values
AK steel corp.
Austenite
Martensit
e
Martensite
Evolution with
Strain in 201LN
Experimental: Nanometric to Grain Scale
Mechanical Tests/Texture (EBSD)
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Micropillar Deformation in As-Rec. Austenitic 201LN
Single Slip
System
436
316
124
0.00 0.01 0.02 0.03 0.04 0.050
200
400
600
800
1000
1200
Str
ess (
MP
a)
Strain
436
316
124
316
436 124
Multiple Slip
Systems
0.00 0.01 0.02 0.03 0.04 0.050
200
400
600
800
1000
1200
Str
ess (
MP
a)
Strain
003
033
113
115
113
115
003 033
003
033
115 225
113
Experimental: Nanometric to Grain Scale
Mechanical Tests/Texture (EBSD)
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Experimental: Coupon-level Tests for Flow
Behavior, Formability, Failure/Fracture
• Clemson University,
- Prof. Fadi Abu-Farha
• Purpose:
– Perform macro-scale measurements, including:
• Uniaxial tensile testing
• Hydraulic bulge test (balanced biaxial)
• Controlled biaxial testing (cruciform)
• Austenite-to-martensite transformation at different conditions
• Shear testing
• Formability testing -Nakajima/Marciniak
• Tension-compression testing
• Edge fracture (hole expansion test, center hole specimen tension
test)
• Other (draw bend / stretch bending test, springback, etc.)
• Integration:
– Provide experimental data for input to and crystal plasticity
(microstructural) simulations and homogenized
constitutive model validation.
ST 2.1 Experimental:
Coupon-Level Tests for
Flow Behavior,
Formability, Failure
Fracture
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Digital Image Correlation Simple Tension of Q&P980 (@45o, 23oC) Stationary color bands appear on the tensile bar surface.
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Digital Image
Correlation
Formability
test of Q&P
980 steel
stretching with
a cylindrical
punch @ 23oC.
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Computational: Atomistics for
Defects/Strengthening/Hardening
• University of Illinois
– Prof. Dallas Trinkle
– Dr. Michael Fellinger
• Purpose:
– Using electronic structure methods, compute
material properties, elastic constants, hardening
parameters of 3GAHSS phases/chemistry.
– Compute dislocation core structures, then
energetics of core/solute interactions for e.g.
Critical Resolve Shear Stress (CRSS), and
(possibly) other hardening parameters.
• Integration:
– Provide computed inputs to crystal plasticity
modeling effort to reduce number of experimental
inputs; reduce dependencies upon data fitting.
ST 2.1 Computational:
Atomistics for Defects
/ Strengthening /
Hardening
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Computational: Atomistics for
Defects/Strengthening/Hardening
Stacking-fault energy surfaces: bcc {110} and {112}, and fcc {111}
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Computational: Atomistics for
Defects/Strengthening/Hardening
Energy (eV)
FCC
BCC
Volume
Bain path
calculations
including C are
in progress
Screw dislocations in bcc Fe: Initial geometry and force-constant calculations
Bain transformation from fcc to bcc
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Computational: Crystal Plasticity for Mechanical
Properties of Phases in Microstructure
• Michigan State University
– Prof. Farhang Pourboghrat
• Purpose:
– Generate and then mesh a realistic 3D RVE
of 3GAHSS for use in crystal plasticity
simulations.
– Develop evolutionary yield function for FE
simulations.
• Integration:
– Apply Brown-measured data to facilitate
crystal plasticity simulations. ST 2.1 Computational:
Crystal Plasticity for
Mechanical Properties of
Phases in Microstructure
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Computational: Crystal Plasticity for Mechanical
Properties of Phases in Microstructure
Using Brown University Generated Microstructural Data
to Generate a 3D Representative Volume Element (RVE)
or
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Computational: Crystal Plasticity for Mechanical
Properties of Phases in Microstructure
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Computational: Microstructural Design
and Analysis of 3GAHSS
• Colorado School of Mines
– Professor David Matlock
– Professor John Speer
• Purpose:
– Develop recipes for 3GAHSS that meet
DOE targets for mechanical properties,
mass and cost savings.
• Integration:
– Provide recipes to make 3GAHSS coupons.
ST 2.8 Computational:
Microstructural Design
and Analysis of 3GAHSS
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Exceptional Strength Targets - High Ductility 1500 MPa/25% TE
• Steel Type: Quenching and partitioning (Q&P) steel
• Processing:
• Austenite: 820 °C, 2 min.
• Quench: 180 °C
• Partition: 400 °C, 100 s
Example: SEM of Q&P steel 0.3C–3Mn–1.6Si
sample austenitized at 820°C for 120 s, quenched
to 200°C, and partitioned at 400°C for 30 s.
E. De Moor, J.G. Speer, D.K. Matlock, J.H. Kwak, and S.B. Lee, “Effect of Carbon and Manganese on the
Quenching and Partitioning Response of CMnSi Steels,” ISIJ Intl. Vol. 51, no. 1, 2011, pp.137-144.
Computational: Microstructural Design
and Analysis of 3GAHSS
Under development
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• Steel Type: Medium Mn, Duplex TRIP steel
• Processing:
Intercritical anneal: 600 °C, 96 h
Reversion anneal: 640 °C, 16 h
High Strength - Exceptional Ductility Targets: 1200 MPa/30% TE
Example: SEM of Medium Mn (7.1-Mn) steel
annealed for 168 hr. at 600 °C followed by water
quenching – selected to illustrate features
anticipated in10-Mn microstructure
P. J. Gibbs: “Design considerations for the third generation advanced high strength steels”, Ph.D Thesis,
Colorado School of Mines, 2013
Computational: Microstructural Design
and Analysis of 3GAHSS
Under development
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Design and Manufacture of 3GAHSS Steel Sheets
• To validate length scale material models, 3GAHSS
heats are being made and rolled.
– AK Steel used CSM recipes to cast two heats which are
being processed into sheet.
– Mechanical property test results and microstructural
analysis will be used to validate the material models
• Refined and validated models will eventually be
used to predict 3GAHSS chemistry and
microstructure with mechanical properties that
meet the DOE 3GAHSS targets
AK Steel 3GAHSS Heat
ST 2.9 Design and
Manufacture of 3GAHSS
Steel Sheets
• Auto/Steel Partnership
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Task 3: Forming – Component-Scale
Performance Prediction and Validation
• Auto/Steel Partnership
• Purpose:
– To identify applicable forming models and
validate these models using component-
scale forming trials.
• Integration:
– Integration of forming models with the
length scale material models of Task 2 and
Task 5 design optimization.
– Use of 3GAHSS heats from Sub-Task 2.9
for forming and performance model
validation Task 3: Forming –
Component-Scale
Performance Prediction
and Validation
Images courtesy of Severstal.
Hardening Yield FLD
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Task 3: Forming – Component-Scale
Performance Prediction and Validation
• Forming simulations: begin with the BAO QP980 steel
and then progress to 3GAHSS from Sub-Task 2.9.
• Outputs to the forming simulation: to be compared to
forming trials with components such as a T-shaped
and/or U-bend component.
• The validated models will be integrated with the length
scale material models from Task 2 and the Task 5
Design Optimization
Draw stretch sample
Stretch bend sample
Image courtesy of
Severstal.
Image courtesy of ArcelorMittal
R&D East Chicago.
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Task 4 ‘Assembly’ and Task 6 ‘Integration’
• Livermore Software And Technology
Corporation
• Auto/Steel Partnership
• Purpose:
– Task 4: To assemble validated length scale
material models sufficient to predict
3GAHSS chemistry and microstructures that
can meet the DOE FOA target mechanical
properties.
– Task 6: To integrate the length scale
material models with forming models,
performance models, design optimization
and technical cost modeling into the ICME
model.
Task 4 ‘Assembly’ and
Task 6 ‘Integration’
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Status: Task 5 ‘Design Optimization’ and
Task 7 ‘Technical Cost Modeling’’
• EDAG Corporation
• Auto/Steel Partnership
• Purpose:
– Task 5: To optimize a baseline assembly
consisting of four or more AHSS components
using 3GAHSS mechanical properties
– Task 7: To develop a technical cost model that
includes material and manufacturing costs.
• Integration
– Design optimization will be coupled with forming
and performance simulations from Task 3
• Determine the feasible 3GAHSS gauges and
shapes for weight optimized assembly.
Task 5 ‘Design
Optimization’ and
Task 7 ‘Technical Cost
Modeling’’
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Status: Task 5 ‘Design Optimization’ and
Task 7 ‘Technical Cost Modeling’’
• The baseline assembly is the body structure of a
four-door, mid-size sedan.
– Bill of materials (alloys and grades) - Complete
– Component and assembly weights - Complete
– Load cases have been defined
• Side barrier impact
• Pole impact
• Roof crush
• Front impact
• Rear impact
• Seat belt anchorage strength
– Currently assessing baseline assembly
performance against defined load cases
– Design optimization with 3GAHSS will begin
with the completion of the baseline assembly
performance assessment.
• Preliminary Technical Cost Model - Complete
Body Structure: Baseline Mid-Size sedan
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“The Endgame”
Task 2.
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Acknowledgement
This material is based upon work supported by the Department of Energy National Energy Technology Laboratory under Award Number No. DE-EE0005976.
This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Such support does not constitute an endorsement by the Department of Energy of the work or the views expressed herein.
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Thank You For Your Attention!
Questions?
“…one cannot be but
impressed by the potentialities
of an implement of research so
fine-grained that it reveals the mode
of association of the atoms themselves.”
Edgar Bain, United States Steel Corp. (ca. 1920s)
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North American
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