Thesis (M.S.)--Virginia Polytechnic Institute and State University, 1992. / Vita. Abstract. Includes bibliographical references (leaves 52-54). Also available via the Internet.

This thesis presents the results of experimental and numerical investigations carried out to assess the effects of tube bending and hydroforming on the crash performance of s-rail structures manufactured from three different advanced high strength steels, namely DDQ, HSLA350, and DP600. The main impetus for this project is to reduce vehicle weight through material substitution and, in order to do so, the effects of material strength on crashworthiness, as well as the interaction between forming processes and crash response must be well understood. To this end, in the current research, s-rails were fabricated through tube bending and hydroforming experiments conducted on DDQ, HSLA350, and DP600 steels with a nominal wall thickness of 1. 8mm, as well as HSLA350 steel with a nominal wall thickness of 1. 5mm. Impact experiments were subsequently performed on non-hydroformed and hydroformed s-rails to examine the effects of the forming processes and material substitution on the crushing loads and levels of absorbed energy. All forming and crash experiments were simulated using numerical finite element methods which provide additional insight into various aspects of the crash response of these structures. In particular, crash simulations were used to show the effects of work-hardening, material thickness changes, and residual stresses incurred during the forming operations. <br /><br /> The numerical tube bending simulations accurately predict the results of the tube bending and hydroforming processes for all materials, particularly for the DP600; the predictions for the DDQ material are the least accurate. Both simulations and experiments show that material thinning occurs on the tensile side of the bend, and material thickening on the compressive side of the bend; the level of thickness change is unaffected by material strength or initial material thickness. The low-pressure hydroforming process does not greatly affect the thickness and strain distributions of s-rails. <br /><br /> The crash simulations provide predictions that are in excellent accord with the measured results, with a maximum error of ±10% in the peak loads and energies; simulations of DP600 s-rails are the most accurate, while simulations of DDQ s-rails are the least accurate. Through simulations and experiments, it is shown that material thickness has the greatest effect on the crash performance of s-rail structures, while material strength plays a secondary role. A 20% increase in the wall thickness of HSLA350 s-rails amounts to a 47% increase in energy absorption. Substituting HSLA350 and DP600 steels in place of DDQ steel leads to increases in energy absorption of 31% and 64%, respectively, for corresponding increases in strength of 30% and 76%. Neglecting material strain-rate effects in the numerical models lowers the predicted peak loads and energies by roughly 15%. By performing a numerical parametric study, it is determined that a weight reduction of 22% is possible by substituting thinner-gauge DP600 s-rails in place of DDQ s-rails while maintaining the energy absorption of the structures.

This thesis presents the results of experimental and numerical investigations carried out to assess the effects of tube bending and hydroforming on the crash performance of s-rail structures manufactured from three different advanced high strength steels, namely DDQ, HSLA350, and DP600. The main impetus for this project is to reduce vehicle weight through material substitution and, in order to do so, the effects of material strength on crashworthiness, as well as the interaction between forming processes and crash response must be well understood. To this end, in the current research, s-rails were fabricated through tube bending and hydroforming experiments conducted on DDQ, HSLA350, and DP600 steels with a nominal wall thickness of 1. 8mm, as well as HSLA350 steel with a nominal wall thickness of 1. 5mm. Impact experiments were subsequently performed on non-hydroformed and hydroformed s-rails to examine the effects of the forming processes and material substitution on the crushing loads and levels of absorbed energy. All forming and crash experiments were simulated using numerical finite element methods which provide additional insight into various aspects of the crash response of these structures. In particular, crash simulations were used to show the effects of work-hardening, material thickness changes, and residual stresses incurred during the forming operations. <br /><br /> The numerical tube bending simulations accurately predict the results of the tube bending and hydroforming processes for all materials, particularly for the DP600; the predictions for the DDQ material are the least accurate. Both simulations and experiments show that material thinning occurs on the tensile side of the bend, and material thickening on the compressive side of the bend; the level of thickness change is unaffected by material strength or initial material thickness. The low-pressure hydroforming process does not greatly affect the thickness and strain distributions of s-rails. <br /><br /> The crash simulations provide predictions that are in excellent accord with the measured results, with a maximum error of ±10% in the peak loads and energies; simulations of DP600 s-rails are the most accurate, while simulations of DDQ s-rails are the least accurate. Through simulations and experiments, it is shown that material thickness has the greatest effect on the crash performance of s-rail structures, while material strength plays a secondary role. A 20% increase in the wall thickness of HSLA350 s-rails amounts to a 47% increase in energy absorption. Substituting HSLA350 and DP600 steels in place of DDQ steel leads to increases in energy absorption of 31% and 64%, respectively, for corresponding increases in strength of 30% and 76%. Neglecting material strain-rate effects in the numerical models lowers the predicted peak loads and energies by roughly 15%. By performing a numerical parametric study, it is determined that a weight reduction of 22% is possible by substituting thinner-gauge DP600 s-rails in place of DDQ s-rails while maintaining the energy absorption of the structures.

Test results are presented from an experimental program carried at the University of Texas at Austin aimed at evaluating the seismic performance of concrete columns reinforced with high-strength steel. Comparisons are made between the performance of columns reinforced with conventional Grade 60 steel, and the higher Grade 80. The high-strength steel used in this study is the result of a recent push in the U.S. to produce higher grade reinforcing bars with relatively high ductility. All steel used satisfied the specifications of ASTM A706. Column specimens were tested under constant axial load and reverse cyclic lateral loading until collapse. Columns performed in a similar manner, indicating that current limits on the yield strength of reinforcing bars in seismic applications could be raised to include Grade 80 A706 bars. Conclusions are drawn with respect to the effects of higher strength reinforcement on, member cracking, drift capacity, plasticity spread, plastic hinge performance, and strain demands on reinforcing bars. / text

Plain specimens of two batches of the commercial spring steel BS 251A58 of nominally identical processing but significantly differing levels of non-metallic inclusion levels, have been tested in rotating bending. The data produced has been analysed against some recent methods for the prediction of fatigue properties in high strength materials containing defects. The materials tested were specifically selected for their disparate cleanliness levels, yielding specimens with differing inclusion distribution and maxima. The morphology of critical inclusions is identical between the two material batches. Material microstructure is tempered martensite with ultimate tensile strength of approximately 2000 MPa, which renders it well above the strength level where sensitivity to defects causes variability in fatigue behaviour. Models have been selected from the literature for the prediction of fatigue limit using characterisation of the local microstructural state and the size and critical position of non-metallic inclusions. These models have been validated by the analysis of specific failures after fractographic analysis. It has been shown that these models are acceptably accurate and generally conservative. Difficulties in experimental work have precluded the planned measurement of crack growth rates during the current test work. These difficulties have yielded a superimposed mean stress to the rotating bend test. This mean stress has been quantified for each test and the result coupled with a parameter for mean stress correction. The validity of the mean stress correction has been proven in this work to be valid. More consistent results are observed for the mean stress corrected data. A statistical method for the prediction of maximum non-metallic inclusion size for a given number of specimens or components from small sample microsection analyses has yielded good results when compared to the fractographic observations. This work has investigated the effect of varying magnification level and number of fields surveyed on the accuracy of prediction and recommendations are made for the method for obtaining best accuracy. A 'unified' crack propagation life model from the literature has been applied which combines long and short crack growth regimes. The model has shown good correlation to the current data but only after fitting of constants and only within the low cycle regime. Relationships presented in the literature between constants and the material ultimate tensile strength were found to be inapplicable to the current material at this strength level.

The objectives of this thesis comprise of overcoming the challenges in designing lightweight welded structures such as material selection, choice of fatigue design methods, and increased performance by using improvement techniques. Material selection of welded joints is dependent on the filler and base material strengths. Partially and fully penetrated cruciform and butt welded joints were designed in under-matching, matching, and over-matching filler materials. Base material steel grades were S600MC, S700MC, and S960. Current design rules are developed for welds in steel up to yield strength of 700MPa. Therefore, design rules in Eurocode3, AWS d1.1, and BSK 07 were verified and recommendations for developing design rules for designing welded joints in S960 were concluded. Numerical methodology for estimating static strength of welded joints by simulating heat affected zone was also developed. Another objective of the thesis work was to overcome the challenges in selection of fatigue design methods. The available design curves in standards are developed for uniaxial stress states, however, in real life the welds in mechanical structures are subjected to complex multiaxial stress states. Furthermore; weld toe failures are frequently investigated, weld root failures are seldom investigated. Therefore, in this work the multiaxial fatigue strength of welded joints failing at the weld root was assessed using experiments and various nominal and local stress based approaches. Butt welded joints with different weld seam inclinations with respect to applied uniaxial loading were designed to assess the root fatigue strength in higher multiaxial stress ratio regime. The fatigue strength of multi-pass tube-to-plate welded joints subjected to internal pressure only and combined internal pressure and torsion in and 90° out of phase loading was also investigated. Test data generated in this thesis was evaluated together with the test data collected from literature. Last objective of the thesis included investigation of the increased performance in fatigue strength by post weld treatment methods such as HFMI. The behavior of residual stresses induced due to HFMI treatment during fatigue loading is studied. Numerical residual stress estimations and residual stress relaxation models are developed and the effect of various HFMI treatment process parameters and steel grade on the induced residual stress state is investigated. Specimens studied were non load carrying longitudinal attachments and simple plates. Residual stresses in both test specimens were measured using X-ray diffraction technique. / <p>QC 20170206</p>

[pt] Os aços de alta resistência avançados estão sendo desenvolvidos e usados para a indústria automotiva devido à sua excelente combinação de alta resistência e ductilidade, acarretando na minimização de custo e peso e maximização da segurança. A soldagem por fricção e mistura mecânica a ponto (Friction Stir Spot Welding – FSSW) é uma nova variante do processo de fricção e mistura mecânica (Friction Stir Welding – FSW), que é um processo de soldagem no estado sólido, e pode ser aplicada em uma variedade de indústrias que necessitam de soldagem a ponto como a indústria aeroespacial, automotiva, nuclear, óleo e gás, transporte e outras indústrias que necessitam fazer a junção dos metais usando, geralmente, uma configuração de sobreposição. O presente trabalho é um estudo exploratório para melhor compreensão da soldagem por fricção e mistura mecânica a ponto do aço TRIP 800. Diferentes corpos de prova foram produzidos usando velocidades de rotação da ferramenta de 1600, 2000 e 2400 rpm e tempos de espera de 2s e 3s. Além da caracterização metalúrgica e determinação de microdureza, ensaios de cisalhamento e cross-tension foram realizados para avaliar o desempenho mecânico das juntas. / [en] Advanced high strength steels (AHSS) are being developed and are being used for the automotive industry due to their exceptional combination of high strength and ductility, which leads to cost and weight savings and better safety. Friction Stir Spot Welding (FSSW) is a novel variant of Friction Stir Welding (FSW), which is a solid-state joining process without bulk melting and can be applied in a variety of industries that require spot welding such as aerospace, automotive, marine, nuclear, oil and gas, transportation industries and other industries that need to join metals together, generally using an overlap configuration. The present contribution is an exploratory study to a better understanding of a TRIP 800 friction stir spot welding. Different samples were produced using tool rotational speeds of 1600, 2000 and 2400 rpm and dwell time of 2s and 3s. Besides the metallurgical characterization and microhardness determination, lap-shear and cross-tensile tests were carried out to evaluate the mechanical performance of the joints.

Atualmente tubos de aço microligados são utilizados na construção de oleodutos e gasodutos para exploração e condução de petróleo e gás natural em águas profundas. Estas aplicações demandam a utilização de ligas metálicas que apresentem elevada resistência mecânica, boa soldabilidade e excelente resistência às falhas associadas ao hidrogênio devido ao trabalho em ambientes sour. O hidrogênio atômico oriundo da corrosão do aço entra na microestrutura do material através da superfície, devido à ação do H2S do meio que inibe a reação de recombinação do hidrogênio (H0+H0=H2) e sua consequente dissipação para o meio em forma de bolhas. O hidrogênio atômico permeia através do material se movendo por difusão através do reticulado cristalino onde interage com defeitos microestruturais denominados traps, tais como inclusões, precipitados, contornos de grão e discordâncias impedindo que este continue a se movimentar. O acúmulo de hidrogênio atômico nestes traps, ao atingir a concentração crítica, leva a ocorrência de falhas seja pela redução localizada da força de coesão dos átomos do reticulado, seja pela formação de tensões internas oriundas da formação de hidrogênio molecular. Diferenças microestruturais influenciam o mecanismo de difusão e aprisionamento do hidrogênio atômico, bem como a concentração crítica de hidrogênio molecular necessária para ocorrência das falhas associadas ao hidrogênio. A deformação plástica, inerente ao processo de conformação de tubos, gera discordâncias que atuam como traps de hidrogênio causando seu aprisionamento e influenciando, portanto, a difusão através do reticulado. O objetivo do presente trabalho é avaliar o efeito da deformação plástica sobre a permeabilidade ao hidrogênio em dois tubos API 5L X65, os quais se diferenciam, principalmente, por apresentarem diferentes teores Mn, levando a diferença microestruturais significativas. Para tanto foram empregados ensaios de permeabilidade de hidrogênio, utilizando metodologia adaptada do trabalho de Devanthan e Stachursky (1962), em amostras não deformadas e deformadas até 1% e 6% de alongamento. Os exames microestruturais mostraram diferenças na fração de perlita e no tamanho médio de grão entre os dois aços. Os resultados para as amostras não deformadas mostram que a permeabilidade e a difusividade aparente do hidrogênio são menores no aço com menor teor de Mn. A deformação plástica reduziu a difusividade aparente de hidrogênio nos dois materiais, sendo esta mais acentuada para o aço com maior teor de Mn. Entretanto, a permeabilidade de hidrogênio após deformação de 1% comportou-se de maneira distinta nos dois aços estudados. Este fato evidencia a influência da composição química e, consequentemente, da microestrutura, na permeabilidade e difusividade aparente de hidrogênio nos materiais submetidos à deformação plástica. / Currently microalloyed steel pipes are used to build pipelines for oil and gas exploration and conduction in deep waters. These applications demand alloys with high mechanical strength, weldability and excellent resistance to hydrogen assisted cracking due to work in sour environment. Atomic hydrogen produced during steel corrosion reaction enters in the microstructure from the metal surface due to the presence of H2S that hinders the hydrogen recombination reaction (H0+H0=H2), hence inhibiting hydrogen dissipation to the environment as bubbles. Atomic hydrogen permeates into the material moving through the lattice by diffusion, wherein it interacts with metallurgical defects such as inclusions, precipitates, grain boundaries and dislocations hindering its transport by diffusion. The accumulation of atomic hydrogen in these traps, upon reaching a critical concentration, leads to the occurrence of failures, either by the localized reduction of the cohesive strength of the atoms in the lattice, or by the build up of internal stresses arising from the formation of molecular hydrogen. Microstructural differences influence the mechanism of atomic hydrogen diffusion and entrapment, as well as the critical molecular hydrogen concentration required for the occurrence of hydrogen assisted cracking. Plastic deformation, which is inherent of pipeline forming process, creates dislocations that act as hydrogen traps, thus affecting hydrogen diffusion through the lattice. This work aims to evaluate the effect of plastic deformation in hydrogen permeation in two API 5L X65 pipeline with differences in chemical compositions especially regarding their Mn contents, which cause significant microstructural changes. Hydrogen permeation tests were performed, using a methodology adapted from the work of Devanathan and Stachursky (1962), in non-deformed and deformed samples up to 1% and 6% elongation. The microstructural characterization shows differences between the pearlite fractions of the two pipelines and in their average grain boundary sizes. The results of the permeation tests in the non-deformed samples showed that hydrogen apparent diffusivity and permeation are lower in the steel with lower Mn content. The plastic deformation reduced the apparent diffusivity of hydrogen in the two materials, however, the diffusivity reduction was more pronounced for the steel with higher Mn content. In addition, the changes in hydrogen permeation in samples deformed up to 1% were different for the two steels. This clearly shows the influence of chemical composition and microstructure in hydrogen permeation and apparent diffusivity in the plastically deformed materials.

Orientador: Marcelo dos Santos Pereira / Banca: Marcelino Pereira Nascimento / Banca: Rosinei Batista Ribeiro / Resumo: Este projeto é um estudo do efeito springback em quatro tipos de aços de alta resistência, sendo estes bifásico, baixo carbono, endurecível após pintura e com interstícios livres, aplicados atualmente como matéria-prima na produção de veículos. Neste contexto está inserido o desenvolvimento de novos aços avançados de alta resistência em consonância com o projeto ULSAB-AVC, que visa à produção de veículos seguros e econômicos para o século 21. A caracterização mecânica do efeito springback foi realizada por intermédio de ensaio de conformação mecânica, denominado dobramento de três pontos ao ar, como uma adaptação ao ensaio de flexão cilíndrica livre. Foram avaliadas também as propriedades mecânicas do material definidas pelo ensaio de tração, objetivando a determinação da resistência à tração, do limite de escoamento e do alongamento. Além disso, foi avaliada a caracterização microestrutural dos aços avançados, identificando e quantificando-se as fases presentes em coexistência por meio do processamento digital de imagens. Os resultados mostram que o efeito springback no aço bifásico, devido à sua alta resistência mecânica, apresenta as maiores taxas de springback e causa uma diminuição na "razão de aspecto" dos grãos que sofreram conformação mecânica e tentaram retornar às suas formas originais. Aços de baixo carbono e endurecíveis após a pintura, não sofrem efeito springback suficiente para causar alteração na forma dos grãos, sendo que a variação da "razão de aspecto" depende da combinação do alongamento e resistência mecânica destes aços. Já o aço com interstícios livres, devido a sua menor resistência mecânica, o efeito springback apresenta as menores taxas e a variação da razão de aspecto depende somente da capacidade de alongamento desse aço / Abstract: This is a study of the springback effect on four kinds of high strength steel, wich are dual-phase, low carbon, bake hardening and interstitial free, currently used as feedstock in the production of vehicles. In this context is inserted the development of new advanced high steel resistance in accordance with the project ULSAB-AVC, which aims to produce safe and economical vehicle for the 21st century. The mechanical characterization of the springback effect was performed by means of a test of mechanical conformation, called three-point air bending, done by adapting to unconstrained cylindrical bending test. Were also evaluated the mechanical properties of material defined by the tensile test, in order to determine the tensile strength, yield strength and the elongation. Furthermore, was performed the microstructural characterization of advanced steels by identificating and quantificating of present phases in coexistence by means digital image processing. The results indicates that the springback effect in dual-phase steel, due to its high mechanical strength, has the highest springback rates and causes a decrease in the "aspect ratio" of the grains that suffered mechanical conformation attempting to return to its original forms. Low carbon and bake hardening steels, have not enough springback effect to cause change in the shape of the grains and the change of the "ratio aspect" depends on the combination of both elongation and mechanical strength of these steels. Yet on the interstitial free steel, due to its lower mechanical strength, the springback effect has the lowest rates and the change in "aspect ratio" depends only on elongation capacity of the steel / Mestre

The production of advanced high strength steels (AHSS) for use in the automotive and construction industries requires complex control of runout table (ROT) cooling. Advanced high strength steels require coiling at temperatures below 500 °C in order to produce a complex multi-phase microstructure. The research described here will investigate the boiling conditions that occur for moving plate experiments when steel is cooled towards low coiling temperatures. Experiments were performed on a pilot-scale ROT located at the University of British Columbia using industrially supplied steel plates. Tests were performed for four different speeds (0.3, 0.6, 1.0 and 1.3 m/s) and three different initial plate temperatures(350, 500 and 600 °C). Each plate was instrumented with thermocouples in order to record the thermal history of the plate. The results show that cooling is more effective at slower speeds within the stagnation zone for surface temperatures over 200 °C. Outside the stagnation zone regardless of speed cooling is primarily governed by air convection and radiation with minor effects from latent heat caused by splashing water. The maximum peak heat flux value increases with decreasing speed and occurs at a surface temperature of approximately 200 °C, regardless of speed. Below a surface temperature of 200 °C, speed has a negligible effect on peak heat flux. The maximum integrated heat flux seems to vary with speed according to a second order polynomial.