Prototyping of Straight Section Components Using Incremental Shape Rolling

Flexible Roll Forming (FRF) allows the forming of components with a variable cross-section along the length of the component. However, the process has only limited application in the automotive industry due to wrinkling in the flange which currently prevents the forming of high strength steels and limits the part shape complexity. This paper presents a new forming technology, Incremental Shape Rolling (ISR), where a pre-cut blank is clamped between two dies and then a single forming roll is used to incrementally form the material to the desired shape. The new process is similar to some Incremental Sheet Forming (ISF) approaches but with the difference that Incremental Shape Rolling (ISR) allows the manufacture of longitudinal components from high strength metal sheets. In this work, a numerical model of the ISR of a straight section is developed. Experimental prototyping trials are performed and are used to validate the numerical model which is then applied to analyse the new forming process. The results show that in ISR, tensile residual strains are developed in the flange. Flange wrinkling is observed and directly linked to the number of forming passes that are used in the process.

Microstructural Characteristics and Strengthening Mechanisms of Ferritic–Martensitic Dual-Phase Steels: A Review

Ferritic–martensitic dual-phase (DP) steels are prominent and advanced high-strength steels (AHSS) broadly employed in automotive industries. Hence, extensive study is conducted regarding the relationship between the microstructure and mechanical properties of DP steels due to the high importance of DP steels in these industries. In this respect, this paper was aimed at reviewing the microstructural characteristics and strengthening mechanisms of DP steels. This review article represents that the main microstructural characteristics of DP steels include the ferrite grain size (FGS), martensite volume fraction (MVF), and martensite morphology (MM), which play a key role in the strengthening mechanisms and mechanical properties. In other words, these can act as strengthening factors, which were separately considered in this paper. Thus, the properties of DP steels are intensely governed by focusing on these characteristics (i.e., FGS, MVF, and MM). This review article addressed the improvement techniques of strengthening mechanisms and the effects of hardening factors on mechanical properties. The relevant techniques were also made up of several processing routes, e.g., thermal cycling, cold rolling, hot rolling, etc., that could make a great strength–ductility balance. Lastly, this review paper could provide substantial assistance to researchers and automotive engineers for DP steel manufacturing with excellent properties. Hence, researchers and automotive engineers are also able to design automobiles using DP steels that possess the lowest fuel consumption and prevent accidents that result from premature mechanical failures.

Overview on the digitized production of welded steel structures

This paper presents a concept and practical topics involved in digitized production. The term “production” denotes the design, fabrication, and service life of a product, which in this case elaborates on welded steel structures. This includes the required information for guiding all the process stages of the chosen material back to its re-melting, following the material flow in a fully digitized form. This concept enables an increase in production quality at a higher level while minimizing the risk of human errors. Automation of the short-run production of steel structures for demanding applications is also a key goal, together with securing a cost-efficient process. Typically, such structures are fabricated from high- or ultra-high-strength steels. Though challenging, reaching these aims seems to be realistic by applying advanced fatigue design methods, using high-quality robotic welding and receiving information about the real loading of the structure.

The role of robotics in additive manufacturing: review of the AM processes and introduction of an intelligent system

Purpose Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components. AM technologies have received an enormous attention from both academia and industry, and they are being successfully used in various applications, such as rapid prototyping, tooling, direct manufacturing and repair, among others. AM does not necessarily imply building parts, as it also refers to innovation in materials, system and part designs, novel combination of properties and interplay between systems and materials. The most exciting features of AM are related to the development of radically new systems and materials that can be used in advanced products with the aim of reducing costs, manufacturing difficulties, weight, waste and energy consumption. It is essential to develop an advanced production system that assists the user through the process, from the computer-aided design model to functional components. The challenges faced in the research and development and operational phase of producing those parts include requiring the capacity to simulate and observe the building process and, more importantly, being able to introduce the production changes in a real-time fashion. This paper aims to review the role of robotics in various AM technologies to underline its importance, followed by an introduction of a novel and intelligent system for directed energy deposition (DED) technology. Design/methodology/approach AM presents intrinsic advantages when compared to the conventional processes. Nevertheless, its industrial integration remains as a challenge due to equipment and process complexities. DED technologies are among the most sophisticated concepts that have the potential of transforming the current material processing practices. Findings The objective of this paper is identifying the fundamental features of an intelligent DED platform, capable of handling the science and operational aspects of the advanced AM applications. Consequently, we introduce and discuss a novel robotic AM system, designed for processing metals and alloys such as aluminium alloys, high-strength steels, stainless steels, titanium alloys, magnesium alloys, nickel-based superalloys and other metallic alloys for various applications. A few demonstrators are presented and briefly discussed, to present the usefulness of the introduced system and underlying concept. The main design objective of the presented intelligent robotic AM system is to implement a design-and-produce strategy. This means that the system should allow the user to focus on the knowledge-based tasks, e.g. the tasks of designing the part, material selection, simulating the deposition process and anticipating the metallurgical properties of the final part, as the rest would be handled automatically. Research limitations/implications This paper reviews a few AM technologies, where robotics is a central part of the process, such as vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, DED and sheet lamination. This paper aims to influence the development of robot-based AM systems for industrial applications such as part production, automotive, medical, aerospace and defence sectors. Originality/value The presented intelligent system is an original development that is designed and built by the co-authors J. Norberto Pires, Amin S. Azar and Trayana Tankova.

Pulse spray gas metal arc welding of advanced high strength S650MC automotive steel

With an increasing demand for safer and greener vehicles, mild steel and high strength steel are being replaced by much stronger advanced high strength steels of thinner gauges. However, the welding process of advanced high strength steels is not developed at the same pace. The performance of these welded automotive structural components depends largely on the external and internal quality of weldment. Gas metal arc welding (GMAW) is one of the most common methods used in the automotive industry to join car body parts of dissimilar high strength steels. It is also recognized for its versatility and speed. In this work, after a review of GMAW process and issues in welding of advanced high strength steels, a welding experiment is carried out with varying heat input by using spray and pulse-spray transfer GMAW method with filler wires of three different strength levels. The experiment results, including macro-microstructure, mechanical properties, and microhardness of weld samples, are investigated in detail. Very good weldability of S650MC is demonstrated through the weld joint efficiency > 90%; no crack in bending of weld joints, or fracture of tensile test sample within weld joint or heat affected zone (HAZ), or softening of the HAZ. Pulse spray is superior because of thinner HAZ width and finer microstructure on account of lower heat input. The impact of filler wire strength on weldability is insignificant. However, high strength filler wire (ER100SG) may be chosen as per standard welding practice of matching strength.

First-Principles Calculations of Thermal and Electrical Transport Properties of bcc and fcc Dilute Fe–X (X = Al, Co, Cr, Mn, Mo, Nb, Ni, Ti, V, and W) Binary Alloys

The adiabatic shear sensitivity of ultra-high-strength steels is closely related to their thermal conductivity. Therefore, it is essential to investigate the effects of alloying elements on the thermal conductivity of ultra-high-strength steel. In this study, the variation in the scattering behavior of electrons with respect to temperature and the mechanism of three-phonon scattering were considered for obtaining the contributions of electrons and phonons, respectively, to the thermal conductivity of alloys while solving the Boltzmann transport equation. By predicting the effect of ten alloying elements on the electronic thermal conductivity (κe), it was found that, at 1200 K, the doping of iron with Ni and Cr endowed iron with κe values of 24.9 and 25.7 W/m K, respectively. In addition, the prediction for the lattice thermal conductivity (κL), which was performed without considering point defect scattering, indicated that elements such as Al, Co, Mn, Mo, V, and Cr demonstrate a positive effect on the lattice thermal conductivity, with values of 3.6, 3.7, 3.0, 3.1, 3.9, and 3.8 W/m K, respectively. The contribution of κL is only 5–15% of the total thermal conductivity (κtotal). The alloying elements exhibited a similar effect on κtotal and κe. Δκi; the change in thermal conductivity with respect to κ0 owing to the alloying element i was evaluated according to the total thermal conductivity. These values were used to understand the effect of the concentration of alloying elements on the thermal conductivity of iron. The Δκi values of Ni, Co, and W were 6.44, 6.80, and 6.06, respectively, indicating a reduction in the thermal conductivity of iron. This paper provides theoretical guidance for the design of ultra-high-strength steels with a high thermal conductivity.