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A Numerical and Experimental Investigation

into Hot Stamping of Boron Alloyed Heat
Treated Steels

ARTICLE in STEEL RESEARCH INTERNATIONAL · JANUARY 2009

Impact Factor: 0.49 · DOI: 10.2374/SRI07SP094-79-2008-77-84

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 Metal Forming

A Numerical and Experimental Investigation into Hot Stamping of Boron Alloyed

Heat Treated Steels

Malek Naderi, Vitoon Uthaisangsuk, Ulrich Prahl, Wolfgang Bleck

Department of Ferrous Metallurgy, RWTH Aachen University, Aachen, Germany, uthai@iehk.rwth-aachen.de

Hot stamping of steel sheets using water or nitrogen cooling media was studied on a laboratory scale. Sheets of grade 22MnB5 boron
steels in three different thicknesses were investigated and the results of experimental hot stamping tests were considered. Microstructural
analysis, linear and surface hardness profiling as well as tensile tests of formed samples were carried out. After hot stamping, mostly fully
martensitic microstructures, which yield ultra high strength levels, were produced. It is concluded that die cooling media, i.e., water or nitro-
gen, have a significant effect on material properties after hot stamping. Using liquid nitrogen as coolant in the punch instead of water in-
creases yield strength by 50 to 65MPa. Moreover, the evolution of the temperature and force during the hot stamping process was simu-
lated by using a coupled thermomechanical FEM program. The results of numerical simulation and experimental results are in good
agreement.

Keywords: Hot stamping, FE Simulation, 22MnB5 steel, Thermomechanical Process

DOI: 10.2374/SRI07SP094-79-2008-77-84; submitted on 10 May 2007, accepted on 20 July 2007

Introduction stamping were considered in detail. Simulation of the high

Ultra high strength steel sheets are used in automotive
industries to reduce the weight of an automobile and to
improve car safety. Many car components and structural
members can be made significantly lighter by using ultra
high strength steel sheets. It is clear that by increasing the
strength of steel sheet, its formability deteriorates. Thus,
various types of ultra high strength steel sheets with con-
trolled microstructure as well as innovative processes are
developed.
A forming method called die quenching, hot forming, hot
stamping or hot pressing is employed for fabricating
automobile structural components having strength of 1500
MPa or more [1-4]. By this method, the strength of a steel
sheet is increased through quenching after short time heat-
ing in the austenite temperature region within a die which
is maintained at room temperature.
The main advantages of hot stamping are the excellent
shape accuracy of the components and also the possibility
of producing ultra high strength parts without any spring
back. Because of the microstructure transformation of
austenite to martensite within the stamping operation, the
spring back effect is avoided.
The current material, which is used by hot stamping
process, is 22MnB5 boron steel. It is known with different
trade names such as BTR165 [4] and Usibor1500 [5].
They mainly do not have different chemical compositions
but different coatings.
The hot stamping process appeared at the end of the
nineties, since then many papers contributed in developing
the process. Some of them focused on material properties
and coatings [6-8]. Some others tried to improve the effi-
ciency of the process [5, 9, 10]. Moreover, simulation of
the process and material characterization has been consid-
ered [7, 11-17].
In the present research, the hot stamping process was
simulated experimentally and numerically on a laboratory
scale. The material properties of the formed parts after hot
temperature forming process was performed by using the
FE program ABAQUS. The predicted press force and
temperature evolutions were compared to experimental
results in order to verify the used FE-model. In conclusion,
an acceptable agreement between experiment and simula-
tion can be found.
Experimental Set-up
The investigated material is industrially processed sheets
of 22MnB5 steel grade. The uncoated plates were pro-
vided in three different thicknesses of 1mm, 1.5mm and
2.8mm. The chemical analysis of the 22MnB5 steel is
given in Table 1.
Table 1. Chemical analysis of the investigated steel (in mass%).
C Si Mn P S Cr Ti B N
0.23 0.22 1.18 0.015 0.001 0.16 0.04 0.003 0.005
The CCT diagram of the investigated steel has been de-
termined by dilatometry tests, microstructural investiga-
tions and hardness measurements [8]. It is shown that the
cooling rates higher than 25°C/s result in fully martensitic
microstructure.
Two sets of cold stamping and quench hardening as well
as hot stamping experiments were performed. Hot stamp-
ing and cold stamping plus water quench hardening sched-
ules are illustrated schematically in Figure 1. The experi-
mental set-up of hot stamping facilities in department of
ferrous metallurgy (IEHK) is shown in Figure 2. The
press is a SCHENCK PEZ0673 machine with maximum
press force of 1000 KN. The mould assembly includes a
water or nitrogen cooled punch and a non-cooled die. The
die and the punch were made by X165CrMoV12 tool steel.

steel research int. 79 (2008) No. 2 77

Metal Forming

The cooling system is just in the punch so that quenching

is started as soon as forming begins. The furnace is a nor-
mal non-protected atmosphere with maximum heating
temperature of 1600°C. The samples are rectangular
blanks, with length and width of 105×105mm with differ-
ent thicknesses. The imposed stamp depth was 20mm and
the distance between the punch and the die before the tests
was fixed to 20mm.

Figure 3. Schematic of contact positioning of thermocouples to the

blank, the die and the punch.

Figure 1. Schematic of the processes. (a) Hot stamping and (b)

cold stamping plus water quench hardening.

Figure 4. Schematic of the measured parts of deformed blanks, a)

hardness test sample cut for the edge and the bottom of formed
blanks and b) Linear and surface hardness’s test sample geometry.

Figure 2. Hot stamping facilities in IEHK including press, furnace

and water cooling system.

The temperature evolution of the blank, the die and the

punch during press hardening was recorded digitally by
using three Pt/Pt-Rh10% thermocouples. One thermo-
couple was soldered to the die, 10mm beneath the contact
surface. The other was soldered to the punch, 10mm above
the contact surface. The third thermocouple was soldered
to the blank 20mm far from the edge of the blank. Every
0.2 seconds, the temperature was recorded. The schematic Figure 5. Schematic of the tensile test samples, a) three samples
representation of the thermocouples positioning is illus- were cut from the base of each formed blanks and b) tensile sam-
trated in Figure 3. ple geometry a DIN 50114 [18].

The effect of heating and cooling processes on the hard-

ness of the formed sheets was considered by using Vickers
hardness tests (HV0.8) methods. These hardness tests were
performed on polished samples by using a programmable
hardness test machine. This machine can scan the surface
of the sample and measure the hardness at each point. The
rectangular samples taken from the bottom were used for
investigation of hardness maps, and the linear samples
taken from the edge were used for linear hardness tests.
The interval between each test point is 0.3mm, Figure 4.
Determination of the mechanical characteristics were
carried out using tensile tests for thin sheet metals accord-
ing to DIN 50114 [18] at room temperature. All tolerances
refer to DIN ISO 2768 [19]. The specimen geometry and
the position of taking the samples from the deformed
blanks are shown in Figure 5. The measuring gauge length
is 25mm, which is adjusted by an accurate imaging system.
Thus, the total elongation A25 was determined.

78 steel research int. 79 (2008) No. 2

 Metal Forming

FEM Modelling Boundary conditions considered in the thermal analyses

are contact heat transfer between blank and tools and con-
Hot stamping is a thermo-mechanical forming process. In vection and radiation for non-contact surfaces. A convec-
this case, a non-linear, temperature-dependent, hardening tive heat transfer coefficient of 7 W/m2°C was used. The
function is required for describing plastic deformation of dependency between contact pressure and contact heat
sheet metal in the simulation [20]. The used material transfer coefficient has been investigated [21]. It was
model is a temperature and strain rate dependent elastic- shown that the cooling rate of a blank is decreased by
plastic model. Influence of phase transformation and trans- increasing contact pressure. Thus, the contact heat transfer
formation plasticity was not considered in the model. coefficient is not constant during cooling down of the hot
However, temperature distributions on blank and tools and blank (quenching stage). By the simulation of hot stamp-
thermal as well as mechanical contact behaviour between ing using a water cooled punch, thermal contact conduc-
blank and tools were taken into account. It is assumed that tance was taken equal to 1280 W/m2°C for the forming
the transverse anisotropy vanishes and an isotropic yield stage and 200 W/m2°C for 4 seconds after forming. In the
condition can be used. A coupled thermal and mechanical simulation of hot stamping using a nitrogen cooled punch,
analysis based on explicit time integration was used in this a higher value of 2000 W/m2°C for the forming stage but
work, wherein each stage was performed with different the same value of 200 W/m2°C for 2.4 seconds after form-
time step periods. The estimation of the time step period is ing were used. In addition, latent heat released according
based on the geometry of the initial mesh and the material to the formation of martensite was also taken into account.
properties of the element in the model. In a multiple hot The martensite start temperature Ms of 22MnB5boron steel
stamping process, the duration of the forming stage is was determined and is equal to 410°C. The latent heat
shorter than the total process time. After or before the from the transformation from austenite to martensite was
forming stage, additional scaling of the thermal stage estimated to be 58.5 kJ/kg [22].
analysis is possible which further reduces computational
time.
Here, modelling of simultaneous forming and quenching
was performed. The process was subdivided into three
steps in the simulation. The first step is cooling down of
the hot blank by transferring from the furnace (6-8 sec-
onds). In the second step, the hot forming begins. The
third step is a quenching stage due to heat transfer between
blank and tools. The modelled blank, die and punch are
corresponding to the experimental set-up. Because of
symmetry conditions only one quarter of blank and tools
and symmetry constraints were applied. The blank was
modelled with 8-node brick elements and the tools were
considered to be rigid and modelled with a 3D analytical
surface. The finite element mesh of blank, punch and die
used in the simulation of the blank with 1mm thickness is
presented in Figure 6. The mechanical contact between
blank and tools was defined using the kinematic contact
method and friction. The friction force was modelled as a
rate-independent friction model with a static friction coef-
ficient of μ = 0.1. The punch had a velocity of 40 mm/s
and the forming depth was 20 mm. Total experimental
process duration was about 50 to 60 seconds depending on
the thickness of the blank and on the cooling system. The Figure 6. FE mesh used for the simulation of 1mm blanks.
actual forming stage was completed after approximately 1
second, after which tools and blank remained in contact
for further cooling.
Simulation was performed for the hot stamped sheets
with 1mm thickness in two different conditions, at which The Young’s modulus and Poisson’s ratios as a function
the punch was cooled by water or nitrogen. The austeniza- of temperature were taken from the literature [23]. Iso-
tion of the blank in the furnace has not been simulated. thermal compression and quenching tests at different tem-
The initial temperature of blank and tools, at which the peratures between 500°C and 900°C and different strain
punch was cooled by water, were 933°C and 20°C, respec- rates of 0.05s-1 to 10.0s-1 were carried out for 22MnB5 hot
tively. When using a nitrogen cooled punch, the initial rolled plate steel, in order to determine the flow stress
temperature of the 1mm blank, the die and the punch were curve. These loading conditions were close to those ap-
950°C, 25°C and -50°C, respectively. As punch and die pearing during hot stamping. In all of the tests, samples
were modelled with a rigid surface, the temperature evolu- were austenitized at 900°C for 5 minutes and quenched at
tion of the tools was not calculated. Nevertheless, actual a rate of 50°C/s to the temperature at which the compres-
temperatures measured in the experiment for punch and sion test was performed. More information about the iso-
die were used in the simulation for each step. thermal compression tests are given in [24].

steel research int. 79 (2008) No. 2 79

Metal Forming

In Figure 7a stress-strain curves for the forming stage
for different temperatures from 550°C to 900°C at strain
rate of 1.0s-1 are presented, whereas Figure 7b shows the
flow curves for 650°C at different strain rates between
0.1s-1 and 10.0s-1. These flow curves were used to describe
the plastic behaviour of the material depending on tem-
perature and deformation rate for the hot stamping simula-
tion.
Results and Discussion
Materials. The microstructure of the as-delivered steels
consists of 73-77 percent ferrite, the remaining part being
pearlite. The ferrite grain size (dm) in the sheets with 1 mm
thickness is approximately 11 µm and in the 2.8mm sheets
it is about 7.8µm. In the thinner sheets pearlite is located at
ferrite grain boundaries, while in the thicker sheets pearlite
is elongated in rolling direction as individual regions,
Figure 8. Hardness varies between 170-200 HV10.

Hot Stamping. The sheets with 1mm and 1.5mm thick-

ness were austenitized at 950°C for 10min and at 900°C
for 15min, respectively. The thicker blanks, 2.8mm, were
heat treated at 950°C for 15min. These treatments were
applied not only for hot stamping experiments but also for
cold stamping plus quench hardening experiments. For the
case of nitrogen as a coolant, the punch was cooled to
-50°C. A typical force-time diagram for the thickest blank
(2.8mm) in various conditions of stamping is shown in
Figure 9. In the figure, WCP and NCP are the abbrevia-
tions for the type of cooling process used, punch using
water or nitrogen as a coolant, respectively.

Figure 7. Flow curves of 22MnB5 steel corresponding to the Figure 9. Force evolution of 22MnB5-2.8mm during stamping
isothermal compression tests, (a) at different deformation tempera- processes. WCP stands for water cooled punch and NCP stands
tures with strain rate of 1.0 s-1 and (b) at deformation temperature for nitrogen cooled punch.
of 650°C and under different strain rates [24].

Thickness Treatment Martensite Bainite Ferrite

(mm) (%) (%) (%)
900ºC, 15’-WCP 80 20 <1
1.0 950ºC, 10’-WCP 100 <1
950ºC, 10’-NCP 100 <1
900ºC, 15’-WCP 98 2 <1
1.5 950ºC, 10’-WCP 98 2 <1
950ºC, 10’-NCP 96 4
950ºC, 15’-WCP 100
2.8
950ºC, 15’-NCP 97 3

Figure 8. Light optical microscopy images of as-delivered 22MnB5 Table 2. Phase fractions of 22MnB5 steel after hot stamping.
steels in rolling direction with thickness of (a) 1mm and (b) 2.8mm. WCP - Water cooled punch; NCP - Nitrogen cooled punch.

80 steel research int. 79 (2008) No. 2

 Metal Forming

The main problem in laboratory hot stamping experi- with higher carbon values, i.e., the previously pearlite
ments in the present research is the manual transfer of hot zones, are characterised by harder martensite.
blanks form the furnace to the mould assembly. It causes
different delay, while the blank is air cooled. Due to this
problem, there are different initial deformation tempera-
tures which affect the cooling rate in the mould and proba-
bly phase transformations which take place during cooling.
Two diagrams related to temperature evolution of the
mould assembly and the blank with 1mm thickness are
illustrated in Figure 10. The above mentioned problem
can be seen in the following diagrams. For instance, for
the blank which is hot stamped by the water cooled punch,
the transfer time took about 8 seconds (Figure 10a), while
for the nitrogen cooled punch this transfer period of time
took about 6.8 seconds (Figure 10b). This fact will defi-
nitely affect the later phenomena like phase trans-
formations and cooling rates. Besides, the reproducibility
of the process would be a challenge. It is also observed
that the cooling rate in the hot stamped blank with the
nitrogen cooled punch is almost double that of the water
cooled punch.

Microstructural Evaluation. The quantitative and

qualitative measurements of the present phases in the
stamped blanks were done by LOM and SEM techniques.
The contribution of each phase in the final microstructure
of hot stamped blanks is summarized in Table 2.
Cold stamping and water quench hardening of the
blanks with different thicknesses resulted in fully marten-
sitic microstructure.
Some selected LOM and SEM images corresponding to
hot stamped samples are represented in Figure 11. For
better identification of phases, the SEM images are given
in negative format. It is observed that hot stamping of the
blanks regardless of the thickness resulted in almost fully
martensitic microstructure. The martensite laths or packets Figure 10. Temperature evolution during hot stamping processes
are fine. Isolated islands of bainite can be easily distin- of 22MnB5-1mm, (a) water cooled punch and (b) nitrogen cooled
guished in Figure 11b. punch.

Linear and Surface Hardness Profile. As mentioned

previously, linear hardness and surface hardness meas-
urements were carried out by Vickers hardness in the
HV0.8 scale. The interval between each measuring points
was fixed to 0.3 mm. The collections of linear hardness
and surface hardness profiles of 22MnB5 steel with the
thickness of 2.8 mm in various conditions are plotted in
Figure 12a and Figure 13. The linear hardness values of
the hot stamped blanks in different thicknesses are com-
pared in Figure 12b. The indicated numbers in the graph
show the average of all hardness values. It can be seen that
the lower thickness results in higher average hardness
values. At some specific points which have very good
contacts or bending points, hardness values have been
raised rapidly. The hardness maps show the hardness val-
ues higher than 450 HV10 which indicate fully martensitic
microstructures after stamping. It is also observed that
both cold stamping and water quench hardening and hot
stamping by using nitrogen as coolant result in a mostly
Figure 11. Light optical and scanning electron microscopy images
heterogeneous distribution of hardness values. Different of hot stamped 22MnB5 blanks; (a) and (b) 1 mm - 950°C, 10min
hardness zones can occur due to non-homogeneous disso- + hot stamping-WCP; (c) and (d) 1.5 mm - 950°C, 10 min + hot
lution of carbon during austenization treatment. The zones stamping-WCP. B = bainite.

steel research int. 79 (2008) No. 2 81

Metal Forming

Mechanical Properties. Tensile tests were performed to

study mechanical properties. For each condition, three
parallel specimens were examined. The mean values of
experimental results are given in Table 3. The yield and
the ultimate tensile strength of the hot stamped samples
vary between 990 to 1080 MPa and 1400 to 1500 MPa,
respectively. With these values of yield and tensile
strength the hot stamped blanks are listed in the range of
ultra high strength steels. It should be mentioned that no
spring back was detected in the hot stamped blanks. The
spring back was considered visually by using light optical
microscopy. The details are not illustrated here.
As mentioned in the literature [25], the ability of a mate-
rial to have both a good ductility or formability and a high
strength is best quantified with the TS×A80. The mechani-
cal properties and also TS×A25 of 22MnB5 steel with dif-
ferent thicknesses are illustrated in Figure 14. In this fig-
ure, not only the mechanical properties are compared but
also the formability index of the steel in different thick-
nesses is demonstrated. It is seen, however the variation of
yield and tensile strength by thickness are not very sensi-
tive but the formability index variations are very consider-
able. This factor by increasing the thickness from 1 mm to
2.8 mm is approximately doubled.

Numerical Simulation. The experimental measurement

and numerical calculation of the temperature evolution in
the middle of the blank with a thickness of 1 mm is repre-
sented for water and nitrogen cooling in Figure 15. In
general, a good agreement of temperature evolution be-
tween experiment and simulation can be observed for the
Figure 12. Linear hardness profiles of 22MnB5 steel along the half whole process. A few seconds after beginning of the third
of the hot stamped samples, (a) 2.8 mm blanks in different stamp-
ing conditions and (b) comparison of the hot stamped samples for
stage, when forming is completed and the blank and the
different thicknesses. The indicated numbers show the average of tools remain in contact, a slightly faster cooling was ob-
the hardness values. tained in the experiment. This could be caused by the
actual contact situation between blank and tools, which
can strongly influence heat transfer. In addition, the effect
of oxide layers was not considered here. Temperatures of
the other points on the blanks should be measured and
compared to the numerical results. Different thermal con-
tact conductance for different zones on the blanks should
be considered.
For further investigation, temperature evolution in punch
and die has to be taken into account by using a thermal
element for the tool modelling. On the right hand side of
Figure 13. Surface hardness maps of 22MnB5 of 2.8 mm thick-
Figure 15a and 15b the calculated temperature distribution
ness after (a) cold stamping + 950°C – 15 min + water quench, on the blank (a half model) with a thickness of 1 mm at the
and (b) 900°C - 15min + hot stamping – nitrogen cooled punch. end of the simulation by a total process time of 46.3 sec-
onds is shown in case of water and nitrogen cooling, re-
Table 3. Mechanical properties of 22MnB5 steel after different spectively. The highest temperature value can be observed
conditions of hot stamping. WCP - water cooled punch; NCP - in the middle of the blank around the flange area. In this
nitrogen cooled punch.
area, there is a small gap between the blank and tools in
the simulation and therefore, the heat transfer could not
E- take place completely. The effect of released latent heat
Thickness Rp0.2 Rm Au A25
Treatment Modul
(mm)
(GPa)
(MPa) (MPa) (%) (%) due to martensitic transformation during quenching can
900ºC, 15’-WCP 198 987 1397 2.6 3.8 also be observed in the temperature-time diagrams in Fig-
1.0 950ºC, 10’-WCP 198 1024 1418 2.6 3.7 ure 15. The curves show a small bend at the temperature of
950ºC, 10’-NCP 188 1076 1413 1.7 2.1 400°C.
900ºC, 15’-WCP 194 1035 1485 3.4 6.7
1.5
Figure 16 shows the calculated pressing force from the
950ºC, 10’-WCP 210 1010 1478 3.4 6.3
950ºC, 10’-NCP 176 1075 1480 3.2 5.4 simulation and the determined force from the experimental
950ºC, 15’-WCP 241 987 1493 3.6 8.1 results in case of water cooling during the forming stage in
2.8
950ºC, 15’-NCP 211 1050 1490 3.2 7.4 comparison. The reaction force on the punch is defined

82 steel research int. 79 (2008) No. 2

 Metal Forming

here as the pressing force. An ac-

ceptable agreement between ex-
periment and simulation was found
as well. From the time 1.2 to 1.5
seconds after the beginning of the
stamping stage, the calculated force
slightly overestimates the experi-
mental force. In that time range, the
contact surfaces between blank and
tools are partly opened, whereas
only the areas of edge radius of the
punch and die are in contact with
the blank and a small sliding takes
place in the simulation. Therefore,
the friction coefficient can play an
important role here. In addition, the
deviation between experimental and
calculated results could also be
caused by local material hardening
and to locally differing cooling rates Figure 14. Mechanical properties of 22MnB5 steel after hot stamping. The results are
depending on the contact situation separated by thickness.
during the process. On the upper
side of Figure 16, the equivalent
stress distribution on the blank at
the end of simulation is illustrated.

Summary and Conclusion

It is shown that industrial hot

stamping can be simulated on a
laboratory scale. Three different
sheet thicknesses of 1 mm, 1.5 mm
and 2.8 mm from 22MnB5 steel
grade were investigated. It can be
concluded that higher tensile
strength as well as higher ductility
or higher formability index values
are obtained as the thickness of
sheet increases.
The die cooling media, i.e., water
or nitrogen, have a significant effect
on material properties after hot
stamping. Using liquid nitrogen as
coolant instead of water in the
punch increases the yield strength
by 50 to 65 MPa.
In addition, numerical simulation
of the hot stamping process was
performed by using an ABAQUS
program with a coupled thermo-
mechanical explicit code. Force and
temperature evolution during form-
ing and quenching could be pre-
dicted in acceptable agreement with
experimental data. The numerical
results can be strongly influenced
by the actual contact situation be-
tween blank and dies. An observa-
tion of this contact area in the ex- Figure 15. Measured and calculated temperature in the middle of the 1 mm blank and
periments is necessary, in order to calculated temperature evolution using (a) water cooling punch and (b) nitrogen cooled
verify the simulation. punch.

steel research int. 79 (2008) No. 2 83

Metal Forming
Figure 16. Measured and calculated pressing force from the
analysis of the 1mm blank and calculated stress distribution.
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