The nature and scope of this thesis can be divided into four categories: • FORMING PARAMETERS • Identification of various laser forming parameters in order to produce specimens of similar dimension (radius of curvature). • TEMPERATURE AND MICROSTRUCTURE • To study the effect of maximum temperature reached during the forming operation on the microstructure of the various specimens. • FATIGUE LIFE • Compare the fatigue life of the specimens produced by various laser parameters to that of the original material, and also the fatigue life of mechanical formed specimens. • RESIDUAL STRESS PROFILE Determine if the laser forming process induces detrimental residual stress magnitudes in the specimens. The main objective of this thesis was to gain an understanding of the way in which laser forming affects the fatigue performance and residual stress magnitude / distribution of dual phase steel. Although lasers have been used successfully in various manufacturing processes (welding, cutting, marking, etc.), little information is available on the influence of laser forming on many automotive alloys such as dual phase steel. The first part of the work involved a literature review of the process and factors affecting the laser forming process. It became clear from the literature overview that laser forming of sheet material thicker than 1mm is complex in nature. The variables that can influence the process are complicated and their interaction with each other is not easily controlled. The main parameters that were thus controlled in this study are as follows: • Laser power (P) • Laser head travel speed (v) • Laser beam size (mm) The chapters that follow the literature review, deals with the laser forming process of dual phase steel and the production of fatigue specimens using various laser parameters. It was found that the following laser parameters resulted in specimens with approximately the same radius of curvature: Laser power KW Beam diameter mm Interval spacing % Overlap Scanning velocity m/min Line Energy J/m 5 20 10 50 2,5 2000 3,1 14 10,5 25 2 1550 1,5 7,5 7,5 0 1,2 1250 From the results obtained from fatigue testing specimens produced with the above settings, it is clear that the laser forming process has the potential to be employed as a production stage in the manufacture of wheel centre discs while maintaining adequate fatigue strength. Large beam diameters which cause heat penetration through the thickness of the specimen and hence microstructure breakdown should be avoided, since it was shown that these specimens exhibited impaired mechanical properties than those produced with a smaller laser beam diameter. The microstructural changes observed during the forming process needs to be considered since the mechanical properties of the material changes with a change in microstructure. A dramatic change in microstructure was observed; therefore it is of crucial importance that microstructural evaluation plays an important part in deciding optimum laser parameters for the forming process of ferrous alloys. During residual stress analysis, trends were observed between measurements taken at the same location of the samples; regardless whether measurements were taken on the laser irradiated side or the reverse side of the specimen. The only difference was the magnitude of the relieved residual stress. In most cases the obtained relieved residual stress was much smaller in magnitude than that of the original plate (in the bulk of the material). The surface indicated a slight tensile residual stress for most samples evaluated. A good correlation in distribution profile was obtained between microhardness and relieved residual stress distribution at the ‘middle of sample’ location. This indicates that an increase in hardness indicates an increase in residual stress magnitude for the laser formed specimens. In conclusion, this research has proved that it is possible to deform metal plate of a 3,5mm thickness with a CO2 laser system. The research also established the effect of process parameters on the final product’s shape/bend angle and characterised the effect of the laser forming process on the material’s mechanical properties and structural integrity.