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Hole Expansion of Dual‐phase and Complex‐phase AHS Steels ‐ Effect of

Edge Conditions

Article  in  Steel Research International · April 2010

DOI: 10.2374/SRI08SP110

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 MaterialsTechnology

he Hole Expansionof Dual-phase AHSSteels- Effectof EdgeConditions

and Complex-phase
tf-

te.
Its Anna Kareloval), Qhristian Krempaszkyl), Ewald Werner2), Prodromos Tsipouridis2), Thomas Hebesberger3),
Andreas Pichler3)
NS
't ChristianDopplerLaboraioryof MaterialMechanicsof High PerformanceAlloys;
he Garchingb. München,Germany
of 2)Lehrstuhlfür WerkstoffkundeundWerkstoffmechanik, Technische Universität
München;Garchingb. München,Germany;
ne 3)voestalpineStahlLinzGmbH,B3E Researchand Development; Linz,Austria

)1y
'o- Hole expansion is one of the most importantpropertiesdescribingthe formabilityof steel sheets, especiallythose used in automotive
he industry.In order to determineand emphasizethe influenceof hole edge conditionsand hole surfacequalityon the resultsof standardized
to hole expansiontests, differenthole preparaiionmethodssuch as hole punching,hole drillingand wire cuttingwere appliedto the
industriallyproduceddual-phaseand complex-phasesteel grades DP800 and CP800. Resultsof hole expansiontestingwere discussed

rk with respectto the impactof deformationintroducedinto the materialduring the hole preparationand io the materialmicrostructureand
x- mechanicalproperties.The damagecharacteristics of every methodas well as the fracturesurfaceswere investigatedin detail via light
5n optical microscopy (LOM) as well as scanning electron microscopy(SEM). Qualitativeand quantitativeanalyses of microstructure
\ia combined with microhardnessmeasurementswere used for the interpretationof the results and are correlatedwith the mechanicar
n-
propertiesand the formabilitycharacteristics
of the investigatedsteelgrades.
M
NS
fe Keywords: AHSS,formability,
holeexpansion,
edgecondition,
microstructure,
fracture
vl-
)rt DOI:.1O.23741SR|0BSP1
10; submittedon 3 July 2008,acceptedon 4 November2008
ne
of

Introduction composition and the special manufacturing process, these

In the need for safer and lighter cars, automobile and
ien steel producers are rapidly introducing new Advanced
nd
1
High Strength Steels(AHSS) for body structures.Because
m, of their inherent high strength, attractive crash energy
z. management properties and good formability, the effrcient
lss use of AHSS suchas dual-phase,complex-phase and TRIP
(transformation induced plasticity) steels,will significantly
ls:
d), contribute to vehicle light weighting and fuel economy.
Compared to conventionalmicro-alloyedsteels,AHSS
exhibit a superior combination of high strengthwith good
formability. This combination arises primarily from their
high strain hardening capacity as a result of their lower
yield to ultimate tensile strength ratio. Reduced
of formability is one of the consequenceswhen selecting
nd
88,
conventional steelswith higher strength.
The family of high strength steelsbasedon multi-phase
microstructures typifies the development of improved
!", material concepts to enhance formability. Among these,
(et
dual-phase (DP) steels, whose microstructure consists
mainly of ferrite and martensite, are gaining the widest
95. acceptance among the automakers. They provide an
58 excellent combination of strength and ductility and
4l
moreover are widely available due to the relative ease of
manufacture. Complex-phase (CP) steels represent the
61. transition to steelswith very high ultimate tensile strengths.
They provide a higher level of yield strength at tensile
t.
strength levels equal to those of dual-phasesteelsand are
). therefore an excellent choice for applications where the
0 combination of high strength and ductility together with
high energy absorption and high residual deformation
capacity is required. Due to the controlled chemical
steels posses a very fine microstructure consisting of
fenite and a higher volume fraction of hard phases(bainite,
martensite)than DP steels.
As the concept of formability of the newly developed
advanced steel grades is very broad, a wide range of
mechanical tests has been developed in order to
characterize and classify the mechanical properties of
these materials. Whereas deep drawability aan be
quantified by the strain hardening and uniform elongation
measures obtained from tensile tests, edge stretchability
(or stretch flangeability) can be characterizedby shifting
the geometric instability (local necking) to much higher
strains, as it is realized in hole expansion testing. The
stressfield in the formed edge is similar to the stressfield
in the shearededge during flanging operations.
High strength steels have the tendency to crack under
the applied loading in the surface locations, because
processingmethods such as punching, drilling or shearing
and hole flanging capacity are dependent on the local
ductility of the material, as well as on the surfaceand edge
quality of the hole. It was found that the hole expansion
property is strongly related to the microstructure.
AHSS grades gain their well known improved total
elongations from microstructures with unique differences
in morphology, hardnessand amounts of low temperature
transformation products. Unfortunately, these micro-
structures reduce local elongations or local ductility that
affect hole expansion, stretch flanging, and bending. It is
therefore desirable to emphasize the importance of the
local ductility compared to the total elongation, when the
steel is used for applications where stretch flangeability is
the major factor limiting forming [1-4].

steel researchint. 80 (2009)No. 1 71

MaterialsTechnology

Material Production and Experimental Procedure Standardlight optical microscopy (LOM) and scanning
electron microscopy (SEM, LEO1450 and/or TOPCON
The sheetmaterialstestedwere industriallyproducedby SM-520 field emission gun) were used to analyze the
voestalpineStahl Linz GmbH, Austria. Two AHSS grades microstructuresof the investigatedmaterials. Specimens
with a sheet thickness of 1,2 mm, based on similar for metallographicanalysiswere conventionallyprepared.
chemical composition, however possessing different Since the microstructureof investigatedAHSS grades is
microstructuresand mechanicalproperties,were selected fine and complex, severaletching techniquescomprising
for the investigations.The dual-phasesteel is denotedas different etching agents such as LePera, Beraha I and
DP800, the complex-phasesteel as CP800. Chemical Kalling I [5] were used for complementary analyses.
compositionsare listed in Table 1. The alloying concept Quantitative characteristics of the microstructure were
involves a common base (C, Mn, Cr, Si) composition. subsequentlydeterminedby line intercept measurements
Both grades were heat treated in a Hot Dip Galvanizing in a light optical microscope, considering ferrite as a
line with processingparameterslisted in Table 2. matrix phaseand maftensite,bainite and retained austenite
as the second phase [6, 7]. The fraction of retained
austenite was determined using a magnetic volumetric
method.The measuringmethodmakesuse of the different
Table 1. Chemicalcompositionof the investigated
DPB00and magnetic behaviour of ferrite (ferromagnetic below the
CP800(in wt. %).
Curie-temperature) and austenite (paramagnetic). The
fraction of the retained austenite is, on this base,
Grade C Si Mn+Cr+Mo P Fe determinedby relating the value of the magnetic saturation
DP8OO 0.138 0 .1 4 0.01 Bal. of the specimento the magneticsaturationof a reference
CP8OO 0.140 0.14 - 2.5 0.011 Bal. samplel8l.
The mechanicalpropertiesof investigatedsteelsin the
as annealedconditionwere measuredon a Roell-Korthaus
Table 2. Processingparametersof the HDc{reated cold rolled RKM 250 testing machine. The tensile specimenswere
DPB00and CPB00steels. machined with their tensile axis parallel to the rolling
direction.
Grade ProcessinAconditions In order to broadenthe information about the material
DP8OO T , , . - 8 0 0 " C tt , , - 5 0 s ;C p - l 2 K . / s T
, e a - 4 2 5 ' C ; T 7 , ,4 o 0 ' C properties,microhardnessmeasurementswere performed
CP8OO T,,,: 840"C; t"":75s; Cn- 70K./s,Toe:425'C; T?.-460'C on a Reichert-JungMicro Duromat 4000E machinewith a
testing load of 2p (19,6133mN), an indentationspeedof
0.2p/s and a holding time of 15 s. To measurethe mean
Table 3. Microstructuralcharacteristicsof the investigatedsteel
material hardness and to verify the microhardness
grades (F: Ferrite; M: Martensite;B: Bainite;TM: Tempered
Martensite;RA: RetainedAustenite).
measurements,standard Vickers hardness measurements
(HV10) were also performed according to DIN EN ISO
6501-1.
Ferrite
Ferrite Maftensite Bainite/TM RA Specimensfor hole expansiontestingwere preparedand
Grade grain size
t%l l%l I%l tested according to ISO/TS 16630:2003(E) (metallic
t%l frrml materials- method of hole expandingtest). Steel sheets
DP8OO 65.8 28 o-L 1.8 were cut along the rolling direction into squarespecimens
CPSOO 31.4 L t. 4 48.4 2.8 0.8 of 100x100mm'. According to the standard,a hole with
initial diameterd6of 10 mm (+ 0.02) was introducedin the
centreofthe specimens.Threedifferentproceduresofhole
Table 4. Vickers microhardness(HV0.2) of "soft" and "hard"
preparationwere employed,i.e. standardmethods,such as
phasesof DP800and CPB00and overallhardness(HV10)of the
materials. hole punching and hole drilling as well as a new method,
wire cutting. The burr was subsequentlyremoved from the
"hard"
St. St. st. drilled specimens.No significant burr was observed at
HVlO
Grade phase dev. phase dev. dev. punched and wire cut specimens. Specimens were
fHV0.21 loAl fHV0.2t lo/"1 Io/"1 positioned according to the mentioned standardinto the
DP8OO 336 l5 592 i6 268 < l testing device with the so-calledrollover zone being in
CP8OO 384 ll 449 4 299 < 1 contact with the penetrating punching tool. The hole
expansion testing is conducted by expanding the hole
using a conicalpunch with a 60" top angle.The motion of
Table 5. Mechanicalpropertiesof the HDGtreatedindustrially the punch into the hole is stoppedwhen a crack at the edge
cold rolled DPB00and CP800 steels.The quantitiesFpo,z and Fm of the expandinghole is observed.The final hole diameter
standfor the yieldand the ultlmatetensilestrength,whileÄs and A
after testing is measuredby averagingtwo readingstaken
denotethe uniformand total elongation,respectively.
perpendicularlyto each other.The hole expansionratio,),
p is then calculatedaccordinsto
Rpo.z Ae A
Grade Rpo.:/R. A,,IA
lMPal IMPa] t%l l%l
DPSOO 843 531 12.6 17.8 0.71 0.1r l l " l " ] : 0 ,, o o x l o o % , (1)
d,,
CP8OO 857 687 7.5 13.l 0.80 0.55

72 steelresearchint.B0 (2009)No. 1
 "hard" phaseis in this case composedof a
10 where dr [mm] is the averagehole diameterafter testing, distinct. The
t\ and de [mm] is the initial diameterof the hole' mixture of bainite, marlensite and possibly tempered
ne martensite.Due to this fact the measuredhardnessof the
"hard" phase of the CP grade appears lower when
NS
:d. Results and Discussion comparedto the hard mafiensiteof the DP grade. On the
"soft" phaseof the CP grade is harder than
is contrary,the
"soft"
ng Microstructure: qualitative and quantitative analysis. ferrite of the DP grade. Increasedhardnessof the
phaserefersin this casemainly to the strengthened bainitic
nd Microstructuresof the as receivedmaterialsare shown in
ls. Figures 1 and 2. Grade DP800 exhibits a typical fine- ferrite. No safe conclusions can be however drawn,
)re grained dual-phase microstructure,consisting of a soft because of the very fine-grained microstructure. The
ltS ferritic matrix and embeddedmartensiteislands,a higher indentationsare relatively closeto the grain boundaries,or
amount of retained austenite and a small amount of even indenting more than one grain, therefore the
ite pearlite, Figure la. On the contrary,the microstructureof measurementcould include the hardening effect of the
ed grade CP800 is more complex.The matrix is composedof grain boundaries or of the neighbouring grains. lt is,
ric ferrite and/or strengthened(bainitic) ferrite and a higher however,possibleto concludethat the hardnessdifference
)nt amount of bainite and martensite,Figure lb. SEM micro- between the microstructuralconstituentsof dual phase-
he graphs taken at a magnificationof 5000x are shown in steelgrade(256HV) is significantlyhigher than that of the
'he Figure 2, where the presenceof the bainitic phasein the complex-phase steel grade (65HV). Increased overall
SE, microstructureof CP800 is clearly evidenced,Figure 2b. hardnessof CP800 grade can be explained by a higher
"hard" phase(- 660Ä)as comparedto 28Vo
on LePera's etching techniqueis applicablefor the charac- fraction of the
terization of the DP800 microstructure,however it is not of hard marlensitein the DP800 grade.
sufficient to distinguishclearly enoughthe phasesfor the
the quantitative descriptionof the complex microstructureof Tensile properties. The tensile properlies of the
lus CP800. The application of this etchant enabled to investigateddual-phaseand complex-phasesteel grades
distinguish ferrite from mafiensitebut did not allow the are presentedin Table 5. CP800 exhibits a markedly
ing identification of temperedmartensite,bainite and retained higher yield strength, while its tensile strength is
austenite. To identify all existing phases, consecutive comparableto that of DP800. Despite the similar tensile
rial etchings were applied on the CP steelgrade' Micrographs strength,the uniform as well as the total elongation of
red of the samespecimenpositionafterapplicationof different grade DP800 are higher than that of the CP800 grade.
propertiesare present
ha etchants,such as BerahaI, Kalling, and Nital + Na2S2O5 Since the differencesin mechanical
despite of similar chemical composition, they depend on
lof were taken and compared.All three etchings color ferrite
3an white and martensite black or dark
reSS brown. Beraha I is additionallY
)nts coloring bainite and temPered
SO mafiensite light brown. BY a
combination of Nital and Na2S2O5,
and both tempered martensite and bainite
Jlic appear brown structured and pearlite
3ets becomes black (though only present
rens in a negligible amount).After phase
vith identification, a quantitative phase
the analysis on specimensetched with
Iole Nital + NazSzOswas perfonned.This
Ias etching provides a high contrast of
the grain boundariesbecauseof the of (a) DPB00(Le Pera' setched)and (b) cPB00 (Nital
Figure1. Lightopticalmicrographs
the combination of a grain boundary + NazSzOs etched).
AT etching with an anodic surface layer
re etching. Resultsof the qualitativeand
the quantitative microstructural analyses
in as well as of the retained austenite
le volumetric measurementsare listed in
le Table 3.
of Microhardness measurements
fHV0.2) on individual constituentsof
the microstructure as well as the
overall material hardness(HV10) are
,), summarized in Table 4. Designation
"soft" phase refers in case of the
DP800 grade to the ferritic matrix (b)
"hard" phase rePresents
(a)
r) and
mafiensite. In case of the CP800 Figure 2. scanningelectronmicrographsof (a) DPB00and (b) cP800, Nital etched
grade this description is not that (Flferrite.M- martensite, TM- temperedmartensite).
B- bainite,RA- retainedaustenite,

steel researchint.80 (2009)No. 1

/ J
Materials Technology

the processinghistory determining the final microstructure
of the material.
Hole expansion testing: Surface and edge damage
characteristics of the holes. Already before the hole
expansion test, the edge of the hole is severely deformed
by the hole preparation procedure. To characterize the
damage introduced by hole preparation procedure,a set of
specimens was investigated before the hole expansion
testing via light optical microscopy (LOM) as well as via
scanningelectron microscopy (SEM). The specimenswere
cut into smaller segmentsin the vicinity of the introduced
hole, as illustrated by the sketch in Figure 3-a. Cross
sectionsparallel to the rolling direction were analyzedand
compared.
Figures 3 and 4 show cross sectionsof punched (a),
drilled (b) and wire cut (c) holes of DP800 and CP800,
where the damage of the hole edge and hole surface
inhoduced by the applied hole preparation method can be
clearly identified and compared. It is obvious, that wire
cutting causesonly minor deviations from the desiredhole
geometry Figures 3co 4c. However, despite the precise
hole geometry the sharp edges created by wire cutting
may have a detrimental effect, as they are the possible
stressconcentratorsduring hole expansion. Shearededges
and hole surface roughness deviations, depending on the
sharpnessof the drilling tool as well as on the load applied
during the hole creating, are observed in specimenswith
drilled holes,Figures 3b, 4b.
The macroscopic plastic deformation in the vicinity of
the hole induced by hole-punching is much more severe
than in the case of drilling or wire cutting. This trend is
more pronounced in the dual-phasesteel grade, where the
influenced zone characterized by the distortion of the
microstructure in the vicinity of the hole surface appears
larger. Many voids are formed in this location, as observed
by SEM analysis, mainly at the matrix/coarse second
phaseinterfaces,seethe arrows in Figure 5.
In specimenswith drilled holes, cracks parallel to the
sheet surface corresponding to the drilling steps were
frequently observed (Figure 6a). These circumferential
cracks are however less critical, since during the hole
expansion, they will have the tendency to close, rather
than to propagate.Hole surfacesof wire cut specimensare

(a) (b) (c)

Figure 3. Light opticalmicrographsof cross sectionalareas showingthe materialdeformationand the differencesin surfacequalityin the
(a) punched,(b) drilledand (c) wire cut hole of DP800,etchedwith LePera.

(a) (b) (c)

Figure 4. Lightopticalmicrographsof cross seitional areas showingthe materialdeformationand the differencesin surfacequalityin the
(a) punched,(b) drilledand (c) wire cut hole of CP800,etchedwith LePera.

74 steel researchint. 80 (2009)No. 1


rg the most uniform ones from the point of roughness and
rle edge accuracy, however axial cracks propagating at the
CS hole edge are observed(Figure 6b). This type of cracks
he has the tendency to open during hole expansion, having
ed therefore a detrimental effect on the results of the hole
rth expansion test. This can explain that despite the
outstanding quality of wire cutting method, values of hole
iof expansion ratios measuredon specimenswith wire cut
holes are not significantly higher comparedto the drilled
specimens,as would be expected(cf. Figure 7).
Results of hole expansion testing. The results of hole
expansion testing of DP800 and CP800 are shown in
Figure 7. Inespective of the edge condition the trend
2cpsoo ) ,tpp3ssis observed, i.e. grade CP800 exhibits
consistently higher hole expansion ratios than grade
DP800, even though the elongationproperties(Ar, A) of
grade CP800 are lower than that of DP800 (cf. Table 5).
This is consistentwith the observation,that steelswith a
higher ratio of yield strength to ultimate tensile strength
generally show betterhole expansion[5- 15]. Variationsin
2 betweenDP800 and CP800can be also explainedby the
differences in microstructureand dependon the nature and
properties of the microstructural constituents. The
importance of the hardness ratio between micro-
constituentshas been already emphasizedas a possible
explanation for the different hole expansion values. The
strength (hardness) differences between the harder and
softer phase (martensite and fenite) of dual-phase steels
are much higher than in the caseof complex-phasesteels
(a)
Figure 5. SEM micrographsof crosssectionalarea in the surfacelayerof a punchedhole
of (a) DPB00and (b) CP800,Nitaletched.Void appearanceis shown by arrows.
(a)
Figure 6. SEM micrographsof (a) circumferential crack in drilled hole surface, (b)
axial crack in wire cut hole surfaceof DP800,Nitaletched.
steel research int. 80 (2009) No. 1
MaterialsTechnology
t40
t20
:i 100
, ö u
:'
i" ao
3 4 0
z0
CPSOO DPSOO
Figure7. Influence of theholeedgecondition
on holeexpansion
(expressedby.i- ratio)of DPB00andCPB00steelgrades.
consisting of bainite, ferrite and marlensite, where the
contrastin hardnessof the phasesis lower (cf. Table 4).
Due to this fact the CP microstructure is "mechanically"
more homogenous and the local stresses at phase
boundariesare much lower than in the DP microstructure.
A high contrast in strength results in a high density of
geometrically necessary dislocations surrounding the
martensite island, where it is then easy to initiate
microcrackspropagatingduring hole expansion,leadingto
through-thicknesscracks of the specimen. The higher
volume fraction of marlensitein grade DP800 has also a
significant impact on the stress distribution in the
microstructure. Even though the
overall material hardnessis lower as
comparedto the CP grade, the local
stressesat the phase boundariesare
responsible for ar easier crack
propagation.
Fracture analysis of expanded
holes. Fractureanalysisof specimens
after testing comprisesmacroscopic
a s w e l l a s m i c r o s c o p iicn v e s t i g a t i o n s .
Figure 8 shows images of tested
specimens,focusing on the hole area.
(b) The same trend of crack appearance
is observed in both steel grades.
Specimenswith drilled and wire cut
holes exhibit at most two main
cracks, diagonal or parallel to the
rolling direction (RD), indicatingthat
planar anisotropy of the steel sheet
(due to the production) govems the
locationof lailure.On the contrary.in
specimens with punched holes,
multiple cracksdistributedall around
the hole rim without any preferential
orientation are noticed. In this case
the deformation and damage
initiation induced by the hole
preparation method lead to a more
uniformly distributed material stress
(b)
state around the circumference. This
disparity in crack orientation
indicates that plastic deformation and
75
MaterialsTechnology

the residual stress state as well as damage of the hole
surface induced by the hole preparation method together
with anisotropy effects are the main factors determining
the crack initiation during hole expansion.
Fracture surfaces formed during the hole expansion of
sampleswith drilled holes were investigatedvia scanning
electronmicroscopy(Figures 9 and l0). Macroscopically,
both steel grades exhibit ductile fracture, evidencedby the
formation of dimples at locations of high local plastic
deformation. Oval dimples with a complete rim are
observed in the DP grade, located in areas where a large
void intersectssmaller subsurfacevoids, Figure 9b. Also
specific serpentine interwoven pattems in the form of
smoothed ripples are observed locally on the fracture
surface of grade DP800, resembling glide plane
decohesionsteps,Figure 9a. On the contrary the fracture
surface of CP800 is characterized by the presence of
stretchedfeaturelessflat areasobserved at locations away
from the hole lip in the centreof the fracture area116,l7l.
The rims of the dimples located near these areas are not
complete and appear elongated into the loading direction,
being characteristicfor a shearingmode,seeFigure 10b.
Even though this qualitativeanalysisis not suflcient to
explain all the influences and characteristics of the

(a) (b) (c)

Figure L Appearanceof cracks on the rim of an expandedhole, grade CPB00.(a) Punchedhole; cracksare evenly distributedover the
circumference.(b) Drilledhole;two majorcrackson a diameterof the hole orientedparallelto the rollingdirection(RD) of the sheet.(c)
Wirecut hole;onlyone crackappears.

(a) (b)

Figure 9. Fracture surfaces produced during the hole expansion test in DP800, SEM.

(a) (b)

Figure 10. Fracturesurfacesproducedduringthe hole expansiontest in CP800,SEM.

76 steel researchint. 80 (2009)No. 1


complex multiaxial loading state as present in hole
expansion, it neverthelessprovides detailed information on
the deformation mechanisms and fracture characteristics of
the investigated high strengthsteelgrades.
Summary
Two industrially produced high-strength steel grades,
DP800 (dual-phase) and CP800 (complex-phase), were
investigated by means of optical and scanning electron
microscopy. Different etching techniqueswere applied in
order to describethe complex and very fine microstructure
of the steel grades. Qualitative and quantitative micro-
structural analyses were employed to correlate micro-
structural characteristics and mechanical properties of the
steelswith their formability describedby hole expansion.
It was found that for identical hole edge conditions
higher hole expansion ratios are measured for the
complex-phase grade (CP800) than for the dual-phase
grade (DP800), even though the elongation properties
determined in uniaxial tensile tests show the opposite
tendency.
Imperfections and damage introduced into the material
in the vicinity of the hole mainly during hole-punching or
hole-drilling, have a dehimental influence on the hole
expansion ratio and decreasematerial formability in both
investigated steel grades.
Hole expansion was found to be strongly related to the
steel's microstructure and to the properties of the
microstructural constituents,especially the strength of the
matrix and the contrast in hardness between softer and
harder phases.
Besides that, induced plastic deformation and surface
quality obtained by the hole preparation method sig-
nificantly affect the hole expansionbehaviour.Analysis of
steelresearchint.80 (2009)No.1
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Materials Technology
fracture surfacesrevealed a ductile fracture mode in both
steel grades, however, locations with features charac-
teristic for shear-modefracture were observed.
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