Direct contact heating for hot forming die quenching (HFDQ)

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F&P Manufacturing Inc., a Tier 1 automotive part manufacturer, is expanding its capabilities to include hot forming/die quenching (HFDQ). In this process, steel sheets, called "blanks," are heating to approximately 1000C, which austentizes the steel and transforms a protective Al-Si coating into a permanent Al-Si-Fe layer that provides long-term corrosion protection. The hot blanks are then transferred to a cooled die, where they are simultaneously quenched and formed into shape. Almost all hot stamping lines heat the blanks with roller hearth furnaces. This technique has several shortcomings, however, which has motivated F&P to pursue an alternative technique in which blanks are heated by bringing them into contact with a hot surface. This approach would require significantly less floor space and consume far less energy compared to roller hearth furnaces, and could also produce parts having tailored microstructures through controlled, non-uniform heating. Preliminary research carried out by the University of Waterloo and F&P resulted in a lab-scale prototype that demonstrated the feasibility of this approach. The objectives of the proposed research are to develop a pilot-scale apparatus that combines direct contact heating and forming on a single hydraulic press. This process will eliminate the need for roller hearth furnaces, thereby realizing dramatic reductions in capital and operating costs, and improvements in process efficiency. Moreover, the highly-controlled blank heating realized through this process will facilitate tailoring and improve part quality. These improvements will give F&P a crucial advantage over international competitors. Reduced costs and improved part quality will also benefit F&P's customers, and exemplifies the innovation needed to ensure the ongoing viability of Canada's automotive sector. Finally, this research will equip two highly qualified personnel with skills in engineering design, manufacturing, and experimentation, which are all in demand by Canadian industry.