Fatigue and Impact Behavior of Friction Stir Processed Dual-Phase (DP600) Steel Sheets
Abstract
:1. Introduction
2. Materials and Methods
3. Results and Discussion
3.1. Microstructural Evolution
3.2. Mechanical Properties
3.2.1. Hardness
3.2.2. Tensile Test
3.3. Fatigue Behavior
3.3.1. S-N Curve
3.3.2. Fracture Surfaces
3.4. Impact Behavior
4. Conclusions
- With position-controlled FSP, thin (1.1 mm) DP600 steel sheets were successfully processed without macro-damage, cracking, or deformation discontinuities. During steady-state processing, the processing temperature reached 915 ± 20 °C;
- Through the intense thermo-mechanical treatment of FSP, the microstructural modification raised the hardness of the DP600 steel from 178 HV 0.5 to approximately 292 HV 0.5;
- It was found that the deformation behavior of DP600 steel is dominated by work hardening. This behavior remained unchanged after FSP. FSP also significantly improved the yield strength from 301 MPa to 811 MPa and the tensile strength from 621 MPa to 1054 MPa. However, the increase in strength was accompanied by a decrease in uniform elongation from 21.3% to 5.8% and elongation at break from 34.7% to 13.0% in the process direction;
- By applying FSP to DP600 steel, the AR fatigue limit was increased from 360 MPa to 440 MPa. FSP was found to be ineffective for the morphological characteristics of fracture surfaces;
- The finite-life fatigue fracture surfaces of the as-received samples were characterized by the formation of fine bulges due to the variation in the crack propagation path in the vicinity of the martensite particles/clusters. After FSP, the transformation of the martensite particles into coarser lath martensite also transformed the fracture surface into a step-like morphology;
- DP600 steel exhibited a high peak contact force of approximately 37.6 kN with a displacement of approximately 10.7 mm in the drop-weight impact test. FSP reduced these values to about 33.6 kN and 6.8 mm, respectively. The energy absorption capability of the DP steel decreased from 239 J to 183 J;
- FSP can be considered a practical tool for automotive lightweighting and part-specific feature development applications where DP600 steel is used due to its ability to provide simultaneous improvements in static and fatigue strength combined with an adequate impact energy absorption performance.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
Abbreviations and Symbols
°C | Celsius degree |
Ac1 | Temperature at which austenite begins to form during heating |
Ac3 | Temperature at which transformation of ferrite to austenite is completed during heating |
AHSS | Advanced high-strength steel |
AR | As-received |
ASTM | American Society for Testing and Materials International |
BIW | Body-in-white |
C1 | Basquin’s law coefficient |
C2 | Basquin’s law exponent |
DP | Dual-phase |
EBSD | Electron backscatter diffraction |
EDM | Electric discharge machining |
F | Force |
FSP | Friction stir processing |
FSP/W | Friction stir processing/welding |
FSW | Friction stir welding |
FSSW | Friction stir spot welding |
g | Gram |
HAZ | Heat-affected zone |
Hz | Hertz |
HV | Hardness Vickers |
IPF | Inverse pole figure |
J | Joule |
K | Strain-hardening coefficient |
kg | Kilogram |
kN | Kilo Newton |
mm/s | Millimeter per second |
m/s | Meter per second |
N | Number of cycles to failure |
n | Strain-hardening exponent |
MPa | Mega Pascal |
PD | Processing direction |
RD | Rolling direction |
rpm | Repeat per minute |
s | Second |
s−1 | Per second |
SEM | Scanning electron microscope |
SPD | Severe plastic deformation |
SZ | Stir zone |
TD | Transverse direction |
TMAZ | Thermo-mechanically affected zone |
WC | Tungsten carbide |
X | Displacement |
σ | Stress amplitude |
σy | Yield strength |
σUTS | Tensile strength |
εu | Uniform elongation |
εf | Elongation at break |
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Chemical Composition (mass %) | C | Mn | P | Ti | Al | Nb | S | Si | Cr |
---|---|---|---|---|---|---|---|---|---|
DP600 | 0.14 | 0.5 | 0.1 | 0.22 | 0.030 | 0.09 | 0.015 | 0.5 | 0.77 |
Condition | Tensile Direction | σy (MPa) | σuts (MPa) | Ɛu (%) | Ɛf (%) | K (MPa) | n |
---|---|---|---|---|---|---|---|
AR | (RD) | 301 ± 6 | 621 ± 13 | 21.3 ± 0.5 | 34.7 ± 2.1 | 1135 | 0.24 |
(TD) | 335 ± 1 | 640 ± 10 | 18.0 ± 0.8 | 31.0 ± 1.2 | 1212 | 0.21 | |
Processed | (PD) | 811 ± 48 | 1054 ± 56 | 5.8 ± 0.2 | 13.0 ± 2.0 | 1714 | 0.14 |
(TD) | 682 ± 35 | 925 ± 23 | 5.1 ± 0.4 | 5.4 ± 0.9 | 1915 | 0.15 |
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Yilmaz, M.; Ozturk Yilmaz, I.; Saray, O. Fatigue and Impact Behavior of Friction Stir Processed Dual-Phase (DP600) Steel Sheets. Metals 2024, 14, 305. https://doi.org/10.3390/met14030305
Yilmaz M, Ozturk Yilmaz I, Saray O. Fatigue and Impact Behavior of Friction Stir Processed Dual-Phase (DP600) Steel Sheets. Metals. 2024; 14(3):305. https://doi.org/10.3390/met14030305
Chicago/Turabian StyleYilmaz, Mumin, Imren Ozturk Yilmaz, and Onur Saray. 2024. "Fatigue and Impact Behavior of Friction Stir Processed Dual-Phase (DP600) Steel Sheets" Metals 14, no. 3: 305. https://doi.org/10.3390/met14030305