La maîtrise du procédé de fabrication des aciers DP, en particulier le contrôle du cycle thermique est nécessaire afin pour l'obtention de microstructures biphasées et la reproductibilité des caractéristiques mécaniques et des propriétés d'usage attendues. Cette maîtrise passe par la mise en place de moyens de contrôle non destructifs de l'état microstructural en ligne permettant la détection d'irrégularités de la microstructure signes d'irrégularité du traitement thermique. Ce constat a donc conduit ARCELORMITTAL à mettre en place des moyens de contrôle non destructif en ligne permettant le contrôle de l'état microstructural par mesure magnétique. Pour que la mesure magnétique donne des informations précises sur l’état microstructural, une description mathématique fine des liens entre microstructure et propriétés magnétiques en ligne est recherchée. L'objectif fixé est d'arriver à prédire, sinon d'une façon quantitative, au moins d'une façon qualitative fine, la réponse magnétique à divers paramètres des microstructures d'aciers DP industriels dans le cadre d'une simulation micromagnétique magnéto-mécanique. Nous introduisons une formulation statique du couplage magnéto-mécanique basée sur la minimisation d’une fonctionnelle énergétique couplée à la résolution des équations de la mécanique des milieux continus. / The control of the manufacturing process of DP steels, in particular the control of the thermal cycle is necessary for obtaining Dual Phase microstructures and the reproducibility of the mechanical characteristics and the user properties. This control requires an online monitoring of the microstructural state. This allows the detection of irregularities of the microstructure and thus the irregularities of the heat treatment. This report thus led ARCELORMITTAL to set up an online non destructive evaluation of the microstructural state by magnetic measurement. So that magnetic measurement gives accurate informations on the microstructural state, a fine mathematical description of the links between microstructure and the online magnetic properties is required. The main objective is to manage to predict, if not in a quantitative way, at least in a fine qualitative way, the magnetic answer to various parameters of the industrial steel DP microstructures within the framework of a micromagnetism simulation. We introduce a static formalism of magnetomechanical coupling based on the energy functional minimization coupled with the resolution of the continuum mechanic equations.

The current research has considered the characterization of the high strain rate constitutive response of three steels: a drawing quality steel (DDQ), a high strength low alloy steel (HSLA350), and a dual phase steel (DP600). The stress-strain response of these steels were measured at seven strain rates between 0. 003 s^-1 and 1500 s^-1 (0. 003, 0. 1, 30, 100, 500, 1000, and 1500 s^-1) and temperatures of 21, 150, and 300 °C. In addition, the steels were tested in both the undeformed sheet condition and the as-formed tube condition, so that tube forming effects could be identified. After the experiments were performed, the parameters of the Johnson-Cook and Zerilli-Armstrong constitutive models were fit to the results. <br /><br /> In order to determine the response of the steels at strain rates of 30 and 100 s^-1, an intermediate rate tensile experiment was developed as part of this research using an instrumented falling weight impact facility (IFWI). An Instron tensile apparatus was used to perform the experiments at lower strain rates and a tensile split-Hopkinson bar was used to perform the experiments at strain rates above 500 s^-1 <br /><br /> A positive strain rate sensitivity was observed for each of the steels. It was found that, as the nominal strength of the steel increased, the strain rate sensitivity decreased. For an increase in strain rate from 0. 003 to 100 s^-1, the corresponding increase in strength at 10% strain was found to be approximately 170, 130, and 110 MPa for DDQ, HSLA350, and DP600, respectively. <br /><br /> The thermal sensitivity was obtained for each steel as well, however no correlation was seen between strength and thermal sensitivity. For a rise in temperature from 21 to 300 °C, the loss in strength at 10% strain was found to be 200, 225, and 195 MPa for DDQ, HSLA350, and DP600, respectively for the 6 o?clock tube specimens. <br /><br /> For all of the alloys, a difference in the stress ? strain behaviour was seen between the sheet and tube specimens due to the plastic work that was imparted during forming of the tube. For the DP600, the plastic work only affected the work-hardening response. <br /><br /> It was found that both the HSLA350 and DDQ sheet specimens exhibited an upper/lower yield stress that was amplified as the strain rate increased. Consequently the actual strength at 30 and 100 s^-1 was obscured and the data at strain rates above 500 s^-1 to be unusable for constitutive modeling. This effect was not observed in any of the tube specimens or the DP600 sheet specimens <br /><br /> For each of the steels, both the Johnson-Cook and Zerilli-Armstrong models fit the experimental data well; however, the Zerilli-Armstrong fit was slightly more accurate. Numerical models of the IFWI and the TSHB tests were created to assess whether the experimental results could be reproduced using the constitutive fits. Both numerical models confirmed that the constitutive fits were applied correctly.

The main purpose of this thesis is to improve the fundamental knowledge of non-isothermal tempering of martensite phase and its effects on the reduction in hardness (softening) with respect the base metal occurring at the heat affected zone (HAZ) of resistance spot welded dual-phase (DP) steels. This thesis also aims at understanding the influence of HAZ-softening on the joint performance of various DP steel grades. The tempering of martensite occurring at the sub-critical HAZ (SC-HAZ) of resistance spot welded DP600, DP780 and DP980 steels has been systematically evaluated by microhardness testing through Vickers indentation and the degree of tempering has been correlated to the HAZ-softening. From the joint performance analysis of similar and dissimilar steel grade combinations assessed through standardized testing methods, three important issues have been targeted: a) the joint strength (maximum load to failure), b) the location of failure (failure mode), and c) the physical characteristic of the weld that determines certain type of failure (weld nugget size). In addition, a partial tensile test has been conducted in order to evaluate the initiation of failure in dissimilar steel grade combinations. It has been shown that HAZ-softening lowered the weld size at which transition from interfacial to pullout failure mode takes place along with increased load-bearing capacity and higher energy absorption. Thus, it is concluded from mechanical testing that HAZ-softening benefits the lap-shear tensile joint performance of resistance spot welded DP steels by facilitating pullout failures through failure initiation at the SC-HAZ (tempered region). Instrumented nanoindentation testing was employed to further investigate HAZ-softening along the SC-HAZ by evaluating individual phases of ferrite matrix and tempered martensite islands. Although the ferrite matrix presented a slight reduction in hardness at nanoscale, higher reduction in hardness (softening) resulted for tempered martensite; thus confirming that tempered martensite is the major contributor to softening at micro-scale. A comparison between nanohardness and microhardness testing made at different distances from the line of lower critical temperature of transformation (Ac1) allowed revealing the actual extension of the SC-HAZ. In this regard, good correlation was obtained between nanohardness results along the SC-HAZ and the microstructural changes analyzed by electron microscopy (i.e., the tempering of martensite occurring at various distances far from Ac1 was correlated to low temperature tempering of dual phase steels). An in-depth analysis of the tempering of martensite phase at high temperature in DP steel subjected non-isothermal conditions i.e., rapid heating, extremely short time at peak temperature and rapid cooling (resistance spot welding), has been carried out mainly through analytical transmission electron microscopy (TEM). In addition, an isothermal tempering condition (i.e., slow heating and long time at peak temperature) in DP steel has been evaluated for complementing the analysis. Both non-isothermal and isothermal conditions have been correlated to the softening behaviour. TEM analysis of the base metal in the DP steel indicated that the morphology of the martensite phase is dependent on its carbon content, and its tempering characteristics are similar to that of equal carbon containing martensitic steel. The isothermally tempered structure is characterized by coarsening and spheroidization of cementite (θ) and complete recovery of the martensite laths; whereas precipitation of fine quasi-spherical intralath θ-carbides, coarser plate-like interlath θ-carbides, decomposition of retained austenite into elongated θ-carbides, and partial recovery of the lath structure were observed after non-isothermal tempering of DP steel. This difference in tempering behaviour is attributed to synergistic effect of delay in cementite precipitation due to higher heating rate, and insufficient time for diffusion of carbon that delays the third stage of tempering process (cementite coarsening and recrystalization) during non-isothermal. The finer size and the plate-like morphology of the precipitated carbides along with the partial recovery of the lath structure observed after non-isothermal tempering strongly influenced the softening behaviour of DP steel. The chemical analysis of θ-carbides through extraction replicas for three different DP steels revealed that the chemistry of the carbides is inherited from the parent DP steel during non-isothermal tempering at high temperature confirming that non-isothermal tempering DP steel is predominantly controlled by carbon diffusion.

The aim of this work is to nondestructively characterize the industrial dual phase (ferritic-martensitic) steels (DPS) by the Magnetic Barkhausen Noise (MBN) method. By quenching of AISI 8620 steel specimens having two different starting microstructures, from various intercritical annealing temperatures (ICAT) in the ferrite-austenite region, the microstructures consisting of different volume fractions of martensite and morphology have been obtained. The microstructures, strength properties and hardness values were determined by conventional metallographic and mechanical tests. The measurements of the Magnetic Barkhausen Noise (MBN) were performed by using both Rollscan and &amp / #956 / SCAN sensor connectors. A good correlation between the martensite volume fraction, hardness and MBN signal amplitude has been obtained. MBN emission decreased as the ICAT, therefore the volume fraction of martensite increased. Moreover, MBN emission decreased as the martensite morphology become thinner. It has been concluded that MBN method can be used for nondestructive characterization of industrial dual phase steels.

Quantitative relationships among processing parameters, microstructure, and material properties are of considerable interest in the context of development of robust processing routes that optimize the required material properties. As a result, the scientific literature contains a large number of experimental and theoretical studies on microstructure-properties relationships. Fracture sensitive mechanical properties such as ductility, ultimate tensile strength, fatigue life, and fracture toughness depend on the average microstructural parameters as well as the distributions of microstructural parameters and their extrema.Development of quantitative relationships between such material properties and microstructural distributions and extrema has received considerably less attention, particularly in the wrought metals and alloys. Accordingly, an important objective of this research is to perform a systematic investigation in this direction. The dependence of the fracture-sensitive mechanical properties on the microstructural distributions and extrema often leads to substantial variability in these properties: a set of specimens having the same average chemistry, the same average processing history, and the same average microstructural parameters such as volume fractions of different constituents can exhibit substantially different material properties. The present research (i) is concerned with high strength (~ 1000 MPa) high martensite (>50%) dual phase steel where the martensite is a topologically continuous phase (matrix) containing a dispersion of islands of ferrite, and (ii) focuses on understanding the microstructural origins of the variability in fracture sensitive mechanical properties, in particular variability in the room temperature uniaxial tensile ductility. The research involves quantitative microstructure characterization using stereology and digital image processing and quantitative fractography using scanning electron microscopy (SEM) and fracture profilometry. The analysis of the quantitative fractographic and microstructural data obtained in this research leads to useful guidelines for reducing the variability in the tensile ductility of the dual phase steel under investigation.

Building fuel efficient automobiles is increasingly important due to the rising cost of energy. One way to improve fuel efficiency is to reduce the overall automobile weight. Weight reductions using steel components are desirable because of easy integration into existing manufacturing systems. Designing components with Advanced High Strength Steels (AHSS) has allowed for material reductions, while maintaining strength requirements. Two Advanced High Strength steel microstructures investigated in this research utilize different strengthening mechanisms to obtain a desired tensile strength grade of 590MPa. One steel, HR590, utilizes precipitation strengthening to refine the grain size and harden the steel. The other steel, HR590DP, utilizes a dual phase microstructure consisting of hardened martensite constituents in a ferrite matrix. The steels are processed to have the same tensile strength grade, but exhibit different fatigue behavior. The central objective of this research is to characterize and compare the fatigue behavior of these two steels. The results show the dual phase steel work hardens at a low fatigue life. The precipitation strengthened microstructure shows hardening at low strain amplitudes, softening at intermediate strain amplitudes and little to no effect at high strain amplitudes. These different fatigue responses are characterized and quantified in this research. Additionally, observations showing the fracture surfaces and the bulk microstructure are analyzed.

The main purpose of this thesis is to improve the fundamental knowledge of non-isothermal tempering of martensite phase and its effects on the reduction in hardness (softening) with respect the base metal occurring at the heat affected zone (HAZ) of resistance spot welded dual-phase (DP) steels. This thesis also aims at understanding the influence of HAZ-softening on the joint performance of various DP steel grades. The tempering of martensite occurring at the sub-critical HAZ (SC-HAZ) of resistance spot welded DP600, DP780 and DP980 steels has been systematically evaluated by microhardness testing through Vickers indentation and the degree of tempering has been correlated to the HAZ-softening. From the joint performance analysis of similar and dissimilar steel grade combinations assessed through standardized testing methods, three important issues have been targeted: a) the joint strength (maximum load to failure), b) the location of failure (failure mode), and c) the physical characteristic of the weld that determines certain type of failure (weld nugget size). In addition, a partial tensile test has been conducted in order to evaluate the initiation of failure in dissimilar steel grade combinations. It has been shown that HAZ-softening lowered the weld size at which transition from interfacial to pullout failure mode takes place along with increased load-bearing capacity and higher energy absorption. Thus, it is concluded from mechanical testing that HAZ-softening benefits the lap-shear tensile joint performance of resistance spot welded DP steels by facilitating pullout failures through failure initiation at the SC-HAZ (tempered region). Instrumented nanoindentation testing was employed to further investigate HAZ-softening along the SC-HAZ by evaluating individual phases of ferrite matrix and tempered martensite islands. Although the ferrite matrix presented a slight reduction in hardness at nanoscale, higher reduction in hardness (softening) resulted for tempered martensite; thus confirming that tempered martensite is the major contributor to softening at micro-scale. A comparison between nanohardness and microhardness testing made at different distances from the line of lower critical temperature of transformation (Ac1) allowed revealing the actual extension of the SC-HAZ. In this regard, good correlation was obtained between nanohardness results along the SC-HAZ and the microstructural changes analyzed by electron microscopy (i.e., the tempering of martensite occurring at various distances far from Ac1 was correlated to low temperature tempering of dual phase steels). An in-depth analysis of the tempering of martensite phase at high temperature in DP steel subjected non-isothermal conditions i.e., rapid heating, extremely short time at peak temperature and rapid cooling (resistance spot welding), has been carried out mainly through analytical transmission electron microscopy (TEM). In addition, an isothermal tempering condition (i.e., slow heating and long time at peak temperature) in DP steel has been evaluated for complementing the analysis. Both non-isothermal and isothermal conditions have been correlated to the softening behaviour. TEM analysis of the base metal in the DP steel indicated that the morphology of the martensite phase is dependent on its carbon content, and its tempering characteristics are similar to that of equal carbon containing martensitic steel. The isothermally tempered structure is characterized by coarsening and spheroidization of cementite (θ) and complete recovery of the martensite laths; whereas precipitation of fine quasi-spherical intralath θ-carbides, coarser plate-like interlath θ-carbides, decomposition of retained austenite into elongated θ-carbides, and partial recovery of the lath structure were observed after non-isothermal tempering of DP steel. This difference in tempering behaviour is attributed to synergistic effect of delay in cementite precipitation due to higher heating rate, and insufficient time for diffusion of carbon that delays the third stage of tempering process (cementite coarsening and recrystalization) during non-isothermal. The finer size and the plate-like morphology of the precipitated carbides along with the partial recovery of the lath structure observed after non-isothermal tempering strongly influenced the softening behaviour of DP steel. The chemical analysis of θ-carbides through extraction replicas for three different DP steels revealed that the chemistry of the carbides is inherited from the parent DP steel during non-isothermal tempering at high temperature confirming that non-isothermal tempering DP steel is predominantly controlled by carbon diffusion.

Dual-phase (DP) sheet steels are a class of advanced high strength steels which boast a desirable combination of properties for the forming of automotive components, including: high strength, continuous yielding behaviour, and a high initial work hardening rate. The higher strength of DP steels relative to predecessors used to form automotive components allows for a reduction in part gauge, translating to the potential for reduced automobile weight, emissions, and fuel consumption. However, a form of premature failure during component forming known as `shear fracture' has become a prominent challenge to manufacturers' adoption of DP steels. Martensite particles in DP steel microstructures act as nucleation sites for the development of void damage during deformation, resulting in a deleterious effect upon formability and thought to contribute to the observed shear fractures. This dissertation contributes to the overall goal of offering guidance for the improvement of DP steel microstructures for more desirable fracture behaviour. Specifically, the role of non-ferritic phase/constituent (NFP) volume percent and spatial distribution in the accumulation of void damage in DP steels was investigated. Void damage accumulation in ten DP steel microstructural variants tested to failure under near plane-strain deformation was qualified and quantified in three dimensions using an X-ray micro-computed tomography technique. These results were correlated to the microstructural parameters of the variants, which clearly indicated the detrimental effects of NFP banding in DP steels. It was observed that DP microstructures with increased severity of NFP banding (generally aligned in the sheet rolling direction) incurred a reduced strain to failure. Often, microstructural variants with NFP bands aligned transverse to the major loading direction incurred a reduced strain to failure, accumulated a greater number of voids, and exhibited a larger void volume percent than a specimen with oppositely oriented NFP bands. Void damage spatial distribution was generally reflective of the spatial distribution of the most coarse NFP bands through the sheet thickness. In microstructural variants with NFP bands aligned transverse to the major loading direction, accumulated void damage was often observed to be highly elongated in the direction of NFP banding. / Thesis (Master, Mechanical and Materials Engineering) -- Queen's University, 2011-09-30 11:49:18.645

This thesis is devoted to the numerical investigation of mechanical behavior of Dual phase (DP) steels. Such grade of advanced high strength steels (AHSS) is favorable to the automotive industry due the unique properties such as high strength and ductility with low finished cost. Many experimental and numerical studies have been done to achieve the optimized behavior of DP steels by controlling their microstructure. Experiments are costly and time consuming so in recent years numerical tools are utilized to help the metallurgist before doing experiments. Most of the numerical studies are based on classical (local) constitutive models where no material length scale parameters are incorporated in the model. Although these models are proved to be very effective in modeling the material behavior in the large scales but they fail to address some critical phenomena which are important for our goals. First, they fail to address the size effect phenomena which materials show at microstructural scale. This means that materials show stronger behavior at small scales compared to large scales. Another issue with classical models is the mesh size dependency in modeling the softening behavior of materials. This means that in the finite element context (FEM) the results will be mesh size dependent and no converged solution exist upon mesh refinement. Thereby by applying the classical (local) models one my loose the accuracy on measuring the strength and ductility of DP steels. Among the non-classical (nonlocal) models, gradient-enhanced plasticity models which consider the effect of neighboring point on the behavior of one specific point are proved to be numerically effective and versatile tools to accomplish the two concerns mentioned above. So in this thesis a gradient-enhanced plasticity model which incorporates both the energetic and dissipative material length scales is derived based on the laws of thermodynamics. This model also has a consistent yield-like function for the interface which is an essential part of the higher-order gradient theories. The main issue with utilizing these theories is the implementation which limits the application of these theories for modeling the real problems. Here a straightforward implementation method based on the classical FEM and Meshless method will be proposed which due to its simplicity it can be applied for many problems. The application of the developed model and implementation will be shown on removing the mesh size dependency and capturing the size effect in microstructure level of dual phase steels.

abstract: Emission of CO2 into the atmosphere has become an increasingly concerning issue as we progress into the 21st century Flue gas from coal-burning power plants accounts for 40% of all carbon dioxide emissions. The key to successful separation and sequestration is to separate CO2 directly from flue gas (10-15% CO2, 70% N2), which can range from a few hundred to as high as 1000°C. Conventional microporous membranes (carbons/silicas/zeolites) are capable of separating CO2 from N2 at low temperatures, but cannot achieve separation above 200°C. To overcome the limitations of microporous membranes, a novel ceramic-carbonate dual-phase membrane for high temperature CO2 separation was proposed. The membrane was synthesized from porous La0.6Sr0.4Co0.8Fe0.2O3-d (LSCF) supports and infiltrated with molten carbonate (Li2CO3/Na2CO3/K2CO3). The CO2 permeation mechanism involves a reaction between CO2 (gas phase) and O= (solid phase) to form CO3=, which is then transported through the molten carbonate (liquid phase) to achieve separation. The effects of membrane thickness, temperature and CO2 partial pressure were studied. Decreasing thickness from 3.0 to 0.375 mm led to higher fluxes at 900°C, ranging from 0.186 to 0.322 mL.min-1.cm-2 respectively. CO2 flux increased with temperature from 700 to 900°C. Activation energy for permeation was similar to that for oxygen ion conduction in LSCF. For partial pressures above 0.05 atm, the membrane exhibited a nearly constant flux. From these observations, it was determined that oxygen ion conductivity limits CO2 permeation and that the equilibrium oxygen vacancy concentration in LSCF is dependent on the partial pressure of CO2 in the gas phase. Finally, the dual-phase membrane was used as a membrane reactor. Separation at high temperatures can produce warm, highly concentrated streams of CO2 that could be used as a chemical feedstock for the synthesis of syngas (H2 + CO). Towards this, three different membrane reactor configurations were examined: 1) blank system, 2) LSCF catalyst and 3) 10% Ni/y-alumina catalyst. Performance increased in the order of blank system < LSCF catalyst < Ni/y-alumina catalyst. Favorable conditions for syngas production were high temperature (850°C), low sweep gas flow rate (10 mL.min-1) and high methane concentration (50%) using the Ni/y-alumina catalyst. / Dissertation/Thesis / Ph.D. Chemical Engineering 2011