Physical and Numerical Simulation of Hot Stamping for Hybrid Steel-Composite Lightweigh t Bodies

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Following development a new one-step integrated forming, curing and joining process for manufacturing Press Hardened Steel (PHS) and CFRP hybrid parts (2017-18), a new experimental steel chemistry was cast in collaboration with the Steel & Metals Institute at Swansea University (UK). The experimental steel chemistry contains a novel combination of Si, Al, P, Nb and B additions in order to optimise microstructural evolution, marked by retention of austenite within a bainitic ferrite matrix, during a new Transformation Induced Plasticity (TRIP) assisted PHS part manufacturing process. Crucially, the steel chemistry maintains industrial manufacturer friendless. Development of the new TRIP assisted PHS technology was developed, involving press hardening experiments, mechanical testing and microstructural characterisation of formed parts in order to determine and optimise the relationship between process parameters, microstructure and mechanical properties. Following optimisation, the new TRIP assisted PHS technology was combined with the new one-step process for PHS-CFRP hybrid parts. The technology permits economical manufacturing of lightweight parts for safety-critical automotive applications, in turn promoting safer and lighter vehicles. The results are to be published over two journal papers and one conference paper (currently under peer-review).