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Assessment of Rate-Dependency and Adiabatic Heating on the Essential Work of Fracture of Press-Hardening Steels
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.ORCID iD: 0000-0001-5120-6533
Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, Plaça de la Ciéncia, 2, 08243 Manresa, Spain.ORCID iD: 0000-0002-9446-4388
Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, Plaça de la Ciéncia, 2, 08243 Manresa, Spain.ORCID iD: 0000-0001-5227-6859
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.ORCID iD: 0000-0001-5280-0710
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2025 (English)In: Metals, ISSN 2075-4701, Vol. 15, no 3, article id 316Article in journal (Refereed) Published
Abstract [en]

The automotive industry is currently in a paradigm shift transferring the fleet over from internal combustion vehicles to battery electric vehicles (BEV). This introduces new challenges when designing the Body-In-White (BIW) due to the sensitive and energy-dense battery that needs to be protected in a crash scenario. Press hardening steels (PHS) have emerged as an excellent choice when designing crash safety parts due to their ability to be manufactured to complex parts with ultra-high strength. It is however crucial to evaluate the crash performance of the selected materials before producing parts. Component testing is cumbersome and expensive, often geometry dependent, and it is difficult to separate the bulk material behaviour from other influences such as spot welds. Fracture toughness measured using the essential work of fracture method is a material property which has shown to be able to rationalise crash resistance of Advanced High Strength Steel (AHSS) grades and is thereby an interesting parameter in classifying steel grades for automotive applications. However, most of the published studies have been performed at quasi-static loading rates, which are vastly different from the strain rates involved in a crash. These higher strain rates may also lead to adiabatic self-heating which might influence the fracture toughness of the material. In this work, two PHS grades, high strength and very high strength, intended for automotive applications were investigated at lower and higher strain rates to determine the rate-dependence on the conventional tensile properties as well as the fracture toughness. Both PHS grades showed a small increase in conventional mechanical properties with increasing strain rate, while only the high-strength PHS grade showed a significant increase in fracture toughness with increasing loading rate. The adiabatic heating in the fracture process zone was estimated with a high-speed thermal camera showing a significant temperature increase up to 300 degrees Celsius.

Place, publisher, year, edition, pages
MDPI, 2025. Vol. 15, no 3, article id 316
Keywords [en]
press-hardening steel, fracture toughness, rate dependence, essential work of fracture, adiabatic heating
National Category
Solid and Structural Mechanics
Research subject
Solid Mechanics
Identifiers
URN: urn:nbn:se:ltu:diva-111986DOI: 10.3390/met15030316ISI: 001452551600001OAI: oai:DiVA.org:ltu-111986DiVA, id: diva2:1943895
Funder
EU, Horizon 2020, 814517
Note

Validerad;2025;Nivå 2;2025-04-02 (u5);

Full text license: CC BY 4.0;

Available from: 2025-03-12 Created: 2025-03-12 Last updated: 2025-04-02Bibliographically approved
In thesis
1. Evaluation of Crashworthiness and Fracture Toughness at High Deformation Rates for Advanced High Strength Steel sheets
Open this publication in new window or tab >>Evaluation of Crashworthiness and Fracture Toughness at High Deformation Rates for Advanced High Strength Steel sheets
2025 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Gradually more stringent environmental and safety regulations in the transport sector have made third generation Advanced High Strength Steel (3rd-gen AHSS) grades and new generations of press hardening steels (PHS) cost-effective and natural substitutes in the automotive industry. Increasing the strength of steel allows for potentially downgauging the sheet thickness while maintaining or improving structural performance, and thus reducing the weight of the vehicle. 3rd-gen AHSS and PHS grades have been continuously adapted by the automotive industry for body-in-white parts and energy-absorbing safety components. However, the limited ductility of these higher-strength materials can make them more prone to cracking, which in turn has a negative impact on the folding behaviour of safety structures in a crash. For further introduction of new high-strength steel grades in the design and production of safety parts, proper calibrated material models are needed, and their crash behaviour must be investigated and quantified. Plane stress fracture toughness measured with the Essential Work of Fracture (EWF) method has recently emerged as a viable material parameter to rationalise edge crack resistance and crashworthiness. EWF offers a small-scale laboratory methodology capable of characterising important fracture characteristics of modern automotive steel grades. Hence, EWF together with well-instrumented crash tests in the laboratory are powerful tools for estimating the crashworthiness and quantifying energy absorption. However, much of the published fracture toughness data is based on quasi-static conditions, which do not reflect the conditions in a crash typically involving high deformation rates. To characterise the material for crash scenarios and validate simulation models, further investigation is necessary at higher deformation rates. In this PhD thesis, the crashworthiness and fracture characteristics of 3rd-gen AHSS and PHS grades at higher deformation rates were investigated. The crashworthiness and energy absorbing capacity were evaluated by studying dynamically loaded axially crushed crash boxes both experimentally using full-field deformation measurements and numerically by finite element analysis using a commercially available damage model. Stereo high-speed imaging allowed for more efficient evaluation of crash performance with fewer components and aided in model validation. Furthermore, the rate dependence of fracture toughness and the underlying mechanisms were explored, revealing that crack propagation resistance after crack initiation significantly influences fracture toughness at higher loading rates. It was also experimentally shown that there is significant adiabatic heating in the fracture process zone using the EWF methodology at higher loading rates, which can influence the value of fracture toughness.

Place, publisher, year, edition, pages
Luleå: Luleå University of Technology, 2025
Series
Doctoral thesis / Luleå University of Technology 1 jan 1997 → …, ISSN 1402-1544
Keywords
Advanced High Strength Steel, Fracture toughness, Crashworthiness
National Category
Solid and Structural Mechanics
Research subject
Solid Mechanics
Identifiers
urn:nbn:se:ltu:diva-111999 (URN)978-91-8048-789-4 (ISBN)978-91-8048-790-0 (ISBN)
Public defence
2025-05-07, E231, Luleå University of Technology, Luleå, 09:00 (English)
Opponent
Supervisors
Available from: 2025-03-13 Created: 2025-03-12 Last updated: 2025-04-28Bibliographically approved

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Jonsson, SimonLarsson, FredrikKajberg, Jörgen

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