Article
Metallurgy & Metallurgical Engineering
Christina Hofer, Manfred Stadler, Thomas Kurz, Verena Maier-Kiener, Alexander Mayerhofer, Thomas Hebesberger, Ronald Schnitzer
Summary: Ultrahigh strength steels are widely used in the automotive industry for weight reduction and increased safety. Cathodic corrosion protection is required to expand the application fields of martensitic steels. Microstructural analysis can evaluate crash performance and local formability.
STEEL RESEARCH INTERNATIONAL
(2021)
Article
Chemistry, Physical
Filip Votava, Hana Jirkova, Ludmila Kucerova, Stepan Jenicek
Summary: Press-hardening, also known as hot stamping, is a manufacturing process for producing car body parts with high mechanical properties and safety requirements. In this study, a special combined tool with heated and cooled parts, including a 3D printed component, was used to investigate the variation of microstructures and mechanical properties in relation to the cooling process in the tool. Two steels, 22MnB5 and an experimental high-strength steel, were studied by adjusting the cooling process in the tool and conducting microscopic analyses, mechanical tests, and hardness measurements.
Article
Chemistry, Physical
Shixin Peng, Jie Zhou, Jie Peng, Heping Deng, Fanjiao Gongye, Jiansheng Zhang
Summary: Hot tensile tests were conducted on the GH3625 superalloy to analyze its flow behavior and investigate the effect of temperature and strain rate on grain growth. Two prediction models, the work hardening model and the modified Arrhenius model, were used to accurately predict the stress of flow curves. The best deformation condition for hot stamping of GH3625 was determined to be at temperatures of 800-850 degrees C and strain rates of 0.1-10 s(-1). A successfully hot stamped part of GH3625 was produced with improved tensile and yield strength compared to the original sheet.
Article
Chemistry, Physical
Shuang Liu, Songyuan Ai, Mujun Long, Yi Feng, Jingjun Zhao, Yan Zhao, Xiang Gao, Dengfu Chen, Mingtu Ma
Summary: This study investigates the effects of Nb and V microalloying on ultra-high strength hot stamping steel (UHSHSS) through thermodynamic calculations and experiments. The research explores the appropriate process parameters and analyzes the influence of Nb and V elements on the quenching microstructures, grain sizes, and mechanical properties of UHSHSS. The results show that the addition of Nb and V elements promotes the refinement of the quenched structure and grain size, leading to improved elongation and strong-plastic properties of UHSHSS.
Article
Materials Science, Coatings & Films
Khatereh Maleki, Daniella M. Pallisco, Joseph R. McDermid, Nabil D. Bassim
Summary: This study has determined the mechanism for micro-crack formation in Zn-coated DHPF PHS and revealed the relationship between the coating microstructure and micro-cracks.
SURFACE & COATINGS TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Ireneusz Wrobel
Summary: This paper presents the results of numerical simulations of distortions in drawpieces generated during hot stamping production, dividing distortions by shape and based on industrial experience. Numerical compensation of hardening distortions was proposed to meet shape and dimensional tolerances, with results confirmed by experimental studies. Conclusions and recommendations for process analysis were also elaborated.
Article
Engineering, Mechanical
Leonardo Pelcastre, Evan Kurnia, Jens Hardell, Justine Decrozant-Triquenaux, Braham Prakash
Summary: The use of hardfacing materials in press hardening tools can enhance durability and improve process economy, by depositing new material on the tool through welding. The friction stability of hardfacing materials is closely related to the temperature of the workpiece material, affecting the formation and structure of material transfer layers onto tool steels.
Article
Materials Science, Multidisciplinary
Diego Tolotti de Almeida, Kleber Eduardo Bianchi, Joao Henrique Correa de Souza, Milton Sergio Fernandes de Lima, Thomas Gabriel Rosauro Clarke, Fabio Pinto da Silva, Hardy Mohrbacher
Summary: This study investigates and compares the fatigue performance of laser-welded joints of two press hardening steels: a standard 22MnB5 and a variant modified by NbMo alloying. The results indicate that joint geometry aspects and intrusion-generated damage mechanism are the main causes of poor fatigue life. The NbMo modified alloy performs better than the standard steel. Laser-welded joints of press hardened steels could offer favorable fatigue performance if tight quality limits are used in the manufacturing procedures, surpassing that of conventional and high strength structural steels.
Article
Materials Science, Multidisciplinary
Jisung Yoo, Min Chul Jo, Min Cheol Jo, Seongwoo Kim, Sang-Heon Kim, Jinkeun Oh, Seok Su Sohn, Sunghak Lee
Summary: The addition of Mo can reduce the effects of hydrogen embrittlement in 32MnB5 steel and improve its resistance by decreasing hydrogen diffusivity and changing crack propagation path. Experimental results show that the addition of Mo significantly reduces ductility loss in H-charged steel, indicating higher hydrogen embrittlement resistance.
Article
Engineering, Manufacturing
J. Venema, J. Hazrati, S. B. Zaman, D. T. A. Matthews, E. Atzema
Summary: Severe tool wear occurs in hot stamping, primarily due to compaction galling where fractured particles from the part's coating become compacted on the tools. Investigation of AlSi coating fracture reveals a strong correlation between fracture, strain, and temperature. I-type coating fractures widen and eventually lead to II-type fractures along the coating-substrate interface.
INTERNATIONAL JOURNAL OF MATERIAL FORMING
(2022)
Review
Multidisciplinary Sciences
Ireneusz Wrobel, Adam Skowronek, Adam Grajcar
Summary: The production of ultra-high strength automotive components requires a multi-directional approach, and hot stamping combines forming and heat treatment processes. This paper reviews the basics of hot stamping, technological lines, materials, and heat treatment profiles, while also discussing the numerical modeling process. It further explores the important aspects of process automation, including the use of digital twins for simulation and optimization.
Article
Materials Science, Characterization & Testing
Tanya Aycan Baser, Oguz Gurkan Bilir, Ahmet Onayli, Alperen Bayram, Burak Barutcuoglu, Mustafa Uzunboy, Ersoy Erisir
Summary: This study investigates the effect of decarburization on fatigue crack origination and growth in uncoated 22MnB5 steel press hardened parts. The decarburization layer was analyzed and found to have two distinct zones indicating complete and partial decarburization. High cycle fatigue tests were performed on decarburized and polished samples, showing that polished condition outperforms the decarburized condition. Fractographic investigations reveal that decarburization is responsible for crack origination and affects crack propagation through full and partial decarburization zones.
Article
Engineering, Manufacturing
Maria Emanuela Palmieri, Francesco Rocco Galetta, Luigi Tricarico
Summary: Ultra-high-strength steels combined with tailor-stamping technologies have become increasingly popular in automotive body production due to their crashworthiness improvements and part weight reduction benefits. In this study, USIBOR(R)2000 steel is compared to its predecessor USIBOR(R)1500 steel for the manufacturing of an automotive B-Pillar using a tailored tool tempering approach. Finite Element (FE) simulations were performed to study the effects of quenching time and tool temperature on the mechanical properties of the part. Experimental evaluations were conducted to validate the simulation results using the Geeble-3180 physical simulator.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2022)
Article
Materials Science, Multidisciplinary
Hardy Mohrbacher, Linda Bacchi, Gloria Ischia, Stefano Gialanella, Michele Tedesco, Fabio D'Aiuto, Renzo Valentini
Summary: Press hardening steel commonly uses titanium microalloying to protect boron from nitrogen, ensuring the hardenability effect during die quenching. Additional microalloying elements, such as niobium and vanadium, have been found to improve toughness, bendability, and hydrogen embrittlement resistance. A new press hardening steel incorporates all three microalloying elements and shows enhanced performance compared to standard grade steel.
Article
Nanoscience & Nanotechnology
Seok-Hyun Hong, Doyub Kim, Sunghak Lee, Sung-Joon Kim
Summary: This study investigates the mechanisms of Zn-assisted liquid metal embrittlement (LME) in hot press forming (HPF) steels through laboratory-scale simulation tests and examines the relationship between microstructural evolutions of the Zn coating and LME cracking.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2023)
Article
Materials Science, Multidisciplinary
Din Bandhu, E. Venugopal Goud, Jay J. Vora, Subhash Das, Kumar Abhishek, Ramendra Kumar Gupta, Ashish Thakur, Soni Kumari, K. Devaki Devi
Summary: This study performed butt welding experiments using the processes of resistance metal powder welding (RMD) and gas metal arc welding (GMAW), and conducted macroscopic and microscopic analysis of the welds. The results showed that RMD welding produced better weld quality, smaller heat-affected zone, and finer grain refinement.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Article
Green & Sustainable Science & Technology
Felipe Marin, Adriano Fagali de Souza, Alexandre Mikowski, Luis Henrique Guarnieri Fontanella, Paulo Soares, Luis Norberto Lopez de Lacalle
Summary: The hybrid manufacturing process of combining initial machining and posterior laser powder bed fusion (LPBF) can reduce costs and manufacturing time. This research investigates the properties of the melting interface zone (MIZ) in hybrid parts and assesses the influence of LPBF process energy density on the MIZ and mechanical properties. The results show high-quality interphase even with low energy density, and the costs and manufacturing time were reduced by about 50%.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2023)
Article
Automation & Control Systems
Francisco Javier Amigo, Gorka Urbikain, Luis Norberto Lopez de Lacalle, Pablo Fernandez-Lucio, Octavio Pereira, Asier Fernandez-Valdivielso
Summary: Machining processes on heat-resistant superalloys, such as turbine cases, rings, or shafts, are challenging and time-consuming. The use of high-feed turning technique, specifically the PrimeTurning (TM) tool, has shown potential in reducing machine downtimes and improving surface roughness. However, a deeper understanding of the high-feed turning process is required to prevent tool failures and reject parts. Experimental tests on Inconel 718 alloy revealed that a cutting-edge angle of 30 degrees reduces the likelihood of notches and improves surface roughness, while increasing the cutting-edge angle without adjusting the feed rate may result in tool fractures due to chip overload.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Jun Zha, Nagore Villarrazo, Gonzalo Martinez de Pisson, Yipeng Li, Huijie Zhang, Luis Norberto Lopez de Lacalle
Summary: This study proposes an evolutionary method to improve the machining accuracy of curved surfaces by including compensation for the machining error and making corrections after the manufacturing programming is fully developed. The experimental results show that this method effectively increases surface accuracy and reduces errors, demonstrating its potential to enhance the quality and productivity of manufacturing highly accurate curved surfaces.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
Benat Inigo, Ander Ibabe, Luis Norberto Lopez de Lacalle, Gorka Aguirre
Summary: This study proposes an artefact-based fast and automated solution for mapping volumetric errors in medium size 3-axis machine tools. It enables the calibration of a 1m3 workspace in less than 1 hour without prior knowledge of temperature variations. By performing continuous measurements for seven days and identifying a volumetric error variation model, this study estimates uncertainties of individual parameters and motion errors using residual errors and propagates them to the TCP through Monte Carlo simulations. The model is used to understand the changes in volumetric positioning error over time and its generation within the kinematic chain of the machine.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Correction
Green & Sustainable Science & Technology
Felipe Marin, Adriano Fagali de Souza, Alexandre Mikowski, Luis Henrique Guarnieri Fontanella, Paulo Soares, Luis Norberto Lopez de Lacalle
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Alejandro Pascual, Naiara Ortega, Soraya Plaza, Luis Norberto Lopez de Lacalle, Eneko Ukar
Summary: This study presents an XRCT-based FEM methodology to assess the influence of porosity defects on the mechanical behavior and failure of L-PBF AlSi10Mg components. The defects are evaluated through XRCT scanning and porosity analysis, followed by FEM modeling. Tensile tests and further XRCT inspections are conducted to examine the relationship between fracture level and porosity.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Multidisciplinary
F. J. Amigo, G. Urbikain, L. N. Lopez de Lacalle, O. Pereira, P. Fernandez-Lucio, A. Fernandez-Valdivielso
Summary: The hottest parts of aerospace components often require machining of heat-resistant materials. New high-feed machining strategies have been introduced to improve productivity rates, but tracking tool wear is crucial for timely replacement. High pressure cooling and cryogenic techniques are used to assist the machining of aggressive materials while reducing environmental impact. This study presents a prediction cutting model for high feed turning of Nimonic (c) C-263 superalloy, considering tool wear and the benefits of reducing side cutting edge angle. The wear prediction model shows good agreement with experimental results and reveals the significant increase in tool life achieved by reducing the side cutting edge angle.
Article
Chemistry, Analytical
Endika Tapia, Leonardo Sastoque-Pinilla, Unai Lopez-Novoa, Inigo Bediaga, Norberto Lopez de Lacalle
Summary: Industrial communication protocols are important for interconnecting systems and machines in industrial environments. In this study, we evaluated the performance and complexity of OPC-UA, Modbus, and Ethernet/IP protocols when used with machine tools. Our results show that Modbus has the best latency figures, and the complexity of communication varies depending on the protocol used.
Article
Chemistry, Physical
Nagore Villarrazo, Soraya Caneda, Octavio Pereira, Adrian Rodriguez, Luis Norberto Lopez de Lacalle
Summary: This research examines the feasibility of using cryogenic cooling combined with MQL lubrication, known as CryoMQL technology, as a cutting fluid in the industrial environment. The study aimed to determine whether the energy savings achieved by this technology compensate for the increased environmental impact. Milling tests on carbon steel AISI 1045 were conducted to analyze the tool life, cutting edge wear, and energy consumption of the two technologies. The results demonstrated that CryoMQL not only increased tool life but also improved productivity and allowed for a more environmentally friendly process.
Article
Materials Science, Multidisciplinary
Kiran Wakchaure, Rakesh Chaudhari, Ajaykumar Thakur, Kishan Fuse, Luis Norberto Lopez de Lacalle, Jay Vora
Summary: Submerged friction stir welding (SFSW) was used to weld 6 mm thick 6061Al-T6 alloy plates under different water temperatures. The results showed that submerged samples had finer grain size and higher microhardness, and defect-free joints were obtained. Moreover, water temperature had a significant effect on the welding results, with joints welded at 80 degrees C exhibiting the highest tensile strength and microhardness.
Article
Thermodynamics
Sakshum Khanna, Sagar Paneliya, Parth Prajapati, Rakesh Chaudhari, Jay Vora, Hussam Jouhara
Summary: This study demonstrates a modified synthesis route for fabricating n-hexacosane-impregnated graphene nanosheets (GrPCM) nanocomposite. The exfoliation of graphene sheets during the hydrothermal and sonication process increases the surface area for improved impregnation and interaction with n-hexacosane. The GrPCM nanocomposites exhibited enhanced thermal stability, higher thermal conductivity, and improved latent heat compared to pure PCM materials. The findings suggest that GrPCM3 is an excellent composite material for efficient heat transfer processes.
THERMAL SCIENCE AND ENGINEERING PROGRESS
(2023)
Article
Engineering, Manufacturing
Jay Vora, Yug Shah, Sakshum Khanna, Vivek K. Patel, Manoj Jagdale, Rakesh Chaudhari
Summary: This study identified current, pulse-off-duration (Toff), and pulse-on-duration (Ton) as vital input factors for the WEDM process of Ti6Al4V. Empirical models were generated and validated using ANOVA, showing a significant impact of these factors on material removal rate (MRR) and surface roughness (SR). Additionally, the use of expanded graphite (EG) nano-powder was found to improve the WEDM process, increasing MRR by 45.35% and reducing SR by 36.16%.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2023)
Article
Chemistry, Physical
Jay Vora, Rudram Pandey, Pratik Dodiya, Vivek Patel, Sakshum Khanna, Vatsal Vaghasia, Rakesh Chaudhari
Summary: This study investigates and optimizes the bead geometries of SS-309L using a GMAW-based WAAM process. The Box-Behnken design approach is used for trials, and regression models are developed. The optimized parameters yield a maximum BH of 9.48 mm and a minimum BW of 5.90 mm for single-layer depositions.