Press Hardening of High-Carbon Low-Density Steels

In this study, sheets of experimental high-carbon low-density steels (LDSs) with a thickness of 1.7 mm were processed in a combined tool designed for press-hardening. Press hardening, also known as hot stamping or hot press forming, is a manufacturing process used to create car body parts with exceptional mechanical properties and safety standards. These components often require tailored properties, meaning different mechanical characteristics in various parts of the component. LDSs have a lower specific density than conventional steels, so their use would be particularly suitable in automotive applications. Combined tools achieve distinct mechanical properties within a single part through thermomechanical processing. Simultaneous forming and heat treatment create tailored zones of high strength and ductility within the sheet metal. The hardened zone provides crashworthiness, while the more ductile zone absorbs kinetic energy and converts it into deformation energy. Hot stamping enables forming complex geometries from high-strength sheets with limited cold formability, a capability that can also be exploited for the aluminium-alloyed LDS under investigation in this work. Three different high-carbon LDSs with differences in chemical composition were subjected to this experiment, and the hardness, microstructure, and mechanical properties of the two areas of each sheet were evaluated. The aim is to determine their suitability for processing by press hardening and to try to achieve tailored properties (i.e., differences in ductility and strength across one part) as in a typical representative of 22MnB5 boron steel, where a strength limit of 1500 MPa at 5% ductility is achieved in the cooled part and 600 MPa at 15% in the heated part. Tailored properties were also achieved in the investigated LDS, but with only relatively small differences between the two tool areas. The omega profiles were produced by press hardening without visible defects, and it was possible to process the steels without any difficulties.