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Metals
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Novel Insights into Hot Sheet Metal Forming of High-Performance Materials
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Novel Insights into Hot Sheet Metal Forming of High-Performance Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (25 April 2025) | Viewed by 3408

Special Issue Editors

Prof. Dr. Daniel Casellas

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Guest Editor
1. Eurecat, Centre Tecnològic de Catalunya, Manresa, Barcelona, Spain
2. Division of Mechanics of Solid Materials, Luleå University of Technology, Luleå, Sweden
Interests: fracture mechanics; fatigue; advanced high strength steels
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Jens Hardell

E-Mail Website
Guest Editor
Division of Machine Elements, Luleå University of Technology, Luleå, Sweden
Interests: high temperature tribology; friction and wear in dry contacts; tribomaterials; surface engineering for friction and wear control
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The biannual CHS2 conference series has, after eight very successful conferences since 2008, grown into the leading platform for scientific exchange in hot forming technologies.

The interest in thermo-mechanical forming processes of high-performance materials has grown significantly in recent years. The automotive sector has been the main driver of this development, pushed by the constant demands on passenger safety and environmental regulations. Press hardening of boron steels is now a mature technology, deployed all around the world. It has proven to be unbeatable for forming complex shape parts and easy forming of high strength materials with reduced spring-back. It also allows for producing parts with tailored properties under accurate process monitoring. While being the solution to many lightweight actions, the hot forming industry will also face its own challenges to meet the global sustainability goals. Improving efficiency in heating technology and minimizing scrap, as well as the introduction of green or fossil-free steels will help us to shift to a higher degree of circularity.

Research and Development both on the academic as well as on the industrial level is one of the most important prerequisites for continuous innovation in hot forming of high-performance materials and open new scenarios to exploit their lightweight potential. The 9th CHS2 conference will be held in Nashville (USA) and aims to keep pushing the innovation trends in press hardening and related thermo-mechanical processes and to boost their application to other markets (such as heavy duty and industrial vehicles, aerospace, etc.), new applications (new needs from e-mobility), and new materials (light alloys, CFRP, hybrid materials, etc.) while considering sustainability and circularity topics.

Prof. Dr. Daniel Casellas
Prof. Dr. Jens Hardell
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • press hardening
  • hot forming
  • process modelling
  • microstructure
  • surface engineering and coatings
  • process monitoring
  • fatigue and fracture
  • friction and wear

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Published Papers (3 papers)

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Research

23 pages, 9366 KiB  
Article
Material Characterisation, Modelling, and Validation of a UHSS Warm-Forming Process for a Heavy-Duty Vehicle Chassis Component
by Fredrik Larsson, Samuel Hammarberg, Simon Jonsson and Jörgen Kajberg
Metals 2025, 15(4), 424; https://doi.org/10.3390/met15040424 - 9 Apr 2025
Viewed by 286
Abstract
The lightweighting of heavy-duty vehicles (HDVs) is an effective strategy to reduce fuel consumption and lower CO2 emissions in the transport sector. The widespread application of ultra-high-strength steels (UHSSs) in HDV construction offers a viable solution, particularly for thick-walled chassis components. This [...] Read more.
The lightweighting of heavy-duty vehicles (HDVs) is an effective strategy to reduce fuel consumption and lower CO2 emissions in the transport sector. The widespread application of ultra-high-strength steels (UHSSs) in HDV construction offers a viable solution, particularly for thick-walled chassis components. This study aimed to support the lightweighting of heavy vehicles by developing a methodology capturing the entire warm-forming process in the range of 430–580 °C for thick-walled UHSSs—from material characterisation, including elastoplastic and fracture properties, to downstream forming process simulations. A novel 7 mm thick UHSS grade, WARMLIGHT-980 (ultimate tensile strength (UTS) of 980 MPa), intended for warm forming was investigated at 430, 505, and 580 °C using samples of reduced thickness. The results showed that thickness reduction had minimal influence on mechanical response at elevated temperatures, enabling flexible specimen design. The thermal uniformity improved in thinner samples, enhancing testing reliability. The calibrated hardening and fracture models demonstrated strong agreement with experimental data. Validated simulations of thick-walled components confirmed the accuracy of the modelling approach. The findings support the development of reliable, temperature-dependent models for warm-forming applications and contribute to the design of lighter, more sustainable HDV components without compromising structural integrity. Full article
(This article belongs to the Special Issue Novel Insights into Hot Sheet Metal Forming of High-Performance Materials)
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22 pages, 19071 KiB  
Article
Assessment of Rate-Dependency and Adiabatic Heating on the Essential Work of Fracture of Press-Hardening Steels
by Simon Jonsson, David Frómeta, Laura Grifé, Fredrik Larsson and Jörgen Kajberg
Metals 2025, 15(3), 316; https://doi.org/10.3390/met15030316 - 13 Mar 2025
Cited by 1 | Viewed by 517
Abstract
The automotive industry is currently in a paradigm shift transferring the fleet over from internal combustion vehicles to battery electric vehicles (BEV). This introduces new challenges when designing the body-in-white (BIW) due to the sensitive and energy-dense battery that needs to be protected [...] Read more.
The automotive industry is currently in a paradigm shift transferring the fleet over from internal combustion vehicles to battery electric vehicles (BEV). This introduces new challenges when designing the body-in-white (BIW) due to the sensitive and energy-dense battery that needs to be protected in a crash scenario. Press-hardening steels (PHS) have emerged as an excellent choice when designing crash safety parts due to their ability to be manufactured to complex parts with ultra-high strength. It is, however, crucial to evaluate the crash performance of the selected materials before producing parts. Component testing is cumbersome and expensive, often geometry dependent, and it is difficult to separate the bulk material behaviour from other influences such as spot welds. Fracture toughness measured using the essential work of fracture method is a material property which has shown to be able to rationalise crash resistance of advanced high-strength steel (AHSS) grades and is thereby an interesting parameter in classifying steel grades for automotive applications. However, most of the published studies have been performed at quasi-static loading rates, which are vastly different from the strain rates involved in a crash. These higher strain rates may also lead to adiabatic self-heating which might influence the fracture toughness of the material. In this work, two PHS grades, high strength and very high strength, intended for automotive applications were investigated at lower and higher strain rates to determine the rate-dependence on the conventional tensile properties as well as the fracture toughness. Both PHS grades showed a small increase in conventional mechanical properties with increasing strain rate, while only the high-strength PHS grade showed a significant increase in fracture toughness with increasing loading rate. The adiabatic heating in the fracture process zone was estimated with a high-speed thermal camera showing a significant temperature increase up to 300 °C. Full article
(This article belongs to the Special Issue Novel Insights into Hot Sheet Metal Forming of High-Performance Materials)
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19 pages, 7888 KiB  
Article
Novel Aging Warm-Forming Process of Al-Zn-Mg Aluminum Alloy Sheets and Influence of Precipitate Characteristics on Warm Formability
by Wan-Ling Chen and Rong-Shean Lee
Metals 2024, 14(8), 844; https://doi.org/10.3390/met14080844 - 24 Jul 2024
Viewed by 1654
Abstract
Concurrently improving the formability and post-formed strength of Al-Zn-Mg alloy sheets is crucial for producing high-strength parts with complex shapes. A novel process of aging warm-forming (AWF) to form solution heat-treated and water-quenched aluminum alloy sheets is proposed in this paper. The as-quenched [...] Read more.
Concurrently improving the formability and post-formed strength of Al-Zn-Mg alloy sheets is crucial for producing high-strength parts with complex shapes. A novel process of aging warm-forming (AWF) to form solution heat-treated and water-quenched aluminum alloy sheets is proposed in this paper. The as-quenched AA 7075 sheet was first pre-aged and then formed at the desired temperature. The automotive paint–bake process was then utilized as the second aging step to achieve the target strength of the formed part. Additionally, the post-formed strength and warm formability of specimens under the AWF process conditions, as well as the warm-forming of various heat-treated Al-Zn-Mg alloy sheets proposed in previous studies, were compared through tensile and limit dome height tests. Precipitate characteristics of specimens subjected to different warm-forming process conditions were examined to understand their impact on warm formability. The warm formability of Al-Zn-Mg alloy sheets was significantly enhanced, and the post-formed strength achieved was more than 90% of the strength of as-received AA 7075-T6 sheets under the AWF process condition. The results demonstrated the feasibility of this novel AWF process to manufacture Al-Zn-Mg alloy stamped parts for improved spring-back, formability, and good overall post-formed strength. The results also indicate that microstructural characteristics in Al-Zn-Mg alloy sheets under different warm-forming process conditions have a noticeable influence on warm formability and final mechanical properties. Full article
(This article belongs to the Special Issue Novel Insights into Hot Sheet Metal Forming of High-Performance Materials)
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