P 1133 - Development of pre-hole-free hybrid joining processes for mixed structures with novel steels with tensile strengths greater than 1,800 MPa

P 1132 - Extension of the fatigue design of K-nodes with gap made of RHP and KHP to high-strength steels and thick-walled sections Fatigue-stressed structures are increasingly being manufactured from high-strength steels in order to realise lightweight construction. In truss construction, the K-node with gap is the favoured node configuration. To facilitate the application and design of such nodes made of high-strength steel grades and with greater wall thicknesses, the existing design rules must be adapted and extended. The test programme carried out for this purpose comprises a total of 55 fatigue tests on K-nodes made of rectangular hollow sections (RHP) and circular hollow sections (KHP) of different dimensions made of S355, S500 and S700. K-knots of smaller dimensions are tested at TNO in Delft, Netherlands, on a test rig with individual cylinders. K-knots with large dimensions are tested at KIT in Karlsruhe on a specially manufactured test frame. The experimental tests are analysed according to the nominal stress concept of EN 1993-1-9 (2010) by creating Wöhler curves. In particular, the tests on small KHP K nodes with a welded gap show that the fatigue strength depends not only on the node dimensions and geometric parameters but also on the weld design and geometry. This is not taken into account in the design rules, but can be used for the design of fatigue-compliant structures. For example, the fatigue strength of KHP K nodes with a welded gap can be increased by two notch classes from 71 to 90. In contrast, the small RHP K-nodes investigated are manufactured with weld start and end points in the corners of the strut profiles, which means that the weak point of the weld seam coincides with the hot spot of the geometry. The test results of these test specimens therefore represent a lower limit for the fatigue strength. The fatigue strength of K-nodes depends heavily on the wall thickness of the components and their ratio value <span class="fontstyle3">t</span>. The classification for the nominal stress approach is therefore rightly based on the inverse wall thickness ratio 1/<span class="fontstyle3">Τ = t0 / Τi. The results of the fatigue tests on large RHP and KHP K-nodes made of S355 and S700 with 20 mm wall thickness fit well into the existing notch classes and can be categorised according to CIDECT Design Guide 8 or EN 1993-1-9 (2010) without wall thickness reduction. In parallel, numerical calculations are carried out to extend the scope of validity. The finite element models are calibrated using strain measurements in verification tests. Volume elements are used for this purpose and the weld seams are also modelled in order to enable an exact representation of the local stresses in the weld seam. A parameter study is carried out to extend the parameter range under consideration and to identify the influence of individual geometric parameters such as chord slenderness 2<span class="fontstyle3">y, wall thickness ratio <span class="fontstyle3">t, width or diameter ratio ß or strut inclination angle O<span class="fontstyle3">. For RHP K-nodes, 72 different node configurations are calculated, each with 4 separate load cases. KHP K-nodes are calculated in 16 different dimensions with 3 load cases each, so that a total of 336 FE models are created, calculated and analysed within the parameter study. In addition, stress concentration factors are determined on the basis of the strain measurements in the test. These are then used together with the results of numerical parameter studies to validate or adapt existing SCF formulae. For RHP K-nodes, a re-evaluation of previous and new data for the load case "Axial loading of the strut (AX)" is carried out and suitable formulas with a slight modification of existing CIDECT formulas are provided. For RHP K-nodes with gap under in-plane strut bending (IPB), no formulae are given in CIDECT. A new set of equations has been developed for this purpose. The evaluation of the structural stresses of KHP K-nodes under axial loading of the struts shows that the SCFs according to CIDECT formulas often provide very conservative values compared to the SCFs according to DNV GL-PR-C203 (2016) and from FEA. Since DNV GL-PR-C203 (2016) has a wider range of application and provides SCF formulas for the IPB and out-of-plane bending (OPB) load cases, it makes sense to use these formulas. Only the formula for SCFs for the belt under IPB is modified so that the SCFs are on the safe side. As the fatigue strength of hollow section connections is heavily dependent on the non-dimensional parameters, this should be taken into account at the planning stage by selecting suitable parameters. Through careful planning and execution, fatigue-resistant hollow section structures can be realised, even when using high-strength steels. Publication: March 2020 Authors: Dr.-Ing. S. Herion, Dr.-Ing. Hrabowski, Prof. Dr.-Ing. T. Ummenhofer, Dipl.-Ing. P. Ladendorf, Dr. ir. R. Pijpers

P 1131 - Alloying concepts and process strategies for press-hardening steels with increased residual formability One effective way of reducing emissions from passenger cars is to reduce the weight of the vehicle. The greatest savings potential lies in the area of car body construction, where, for example, high-strength steels are now replacing conventional thin sheet materials. However, the use of high-strength steels to increase vehicle safety in the event of a crash is particularly challenging. One of the most efficient processes for manufacturing crash-relevant components, such as the B-pillar, is press hardening, in which forming and hardening are combined in a single process step. The material 22MnB5 (1.5528) is currently used in the industrial series production of press-hardened components, but its ductility in the hardened state is limited due to the alloy concept. An improved property profile consisting of strength and residual formability is being sought for increased vehicle occupant safety in the event of a crash. This project is therefore concerned with the development of new alloy concepts and process strategies to improve the residual formability of press-hardened steels. Three different alloying concepts were investigated: the dual-phase concept (DP), the grain refinement concept (KF) and the retained austenite concept (RA). Depending on their chemical composition, different heat treatment cycles were combined with press hardening for a total of 6 steels. The investigations focussed on the microstructure development and the resulting characteristic properties in the tensile and bending test. In addition, the coatability and further processability by welding were investigated. It was demonstrated that an improvement in the ductility of press-hardened materials in the RA concept can be achieved by complex Q&amp;P structures (quench&amp;partitioning). In contrast, the DP and KF concepts, which were also investigated, showed only a marginal improvement in the property profile. The best properties in the RA concept result for a material with 0.3 wt% C and 2.5 wt% Mn with tensile strength values of 1400-1500 MPa and elongation at break values of 14-19 % depending on the respective heat treatment. Further tests on this alloy show that the material is temper resistant and therefore suitable for stove enamelling in vehicle production. Joining can be carried out by both laser beam and spot welding. Hot-dip coating with both AlSi and zinc coatings is possible in principle. This project has thus succeeded in demonstrating possibilities for improving the material properties of press-hardened steels using a Q&amp;P heat treatment strategy. The crash absorption potential of the materials produced was doubled compared to the reference material 22MnB5. Publication: 2021 Authors: Prof. Dr.-Ing. W. Bleck, Dipl.-Ing. A. Rüskamp, M.Sc. Y. Sparrer

P 1135 - Hot moulding process integrated surface structuring for hybrid components Due to increasing requirements in the areas of safety, comfort and lightweight construction, the demand for structural parts made of ultra-high-strength steels is growing in the automotive body-in-white. By using these steels, the sheet thickness of the components can be reduced and thus the weight lowered. However, the production of complex geometries proves to be problematic due to the high mechanical strength, as large loads act on the forming tools and the process accuracy is impaired by the springback behaviour. The press hardening process provides a solution to this problem. Press hardening is a non-isothermal process that combines the forming of the component and the hardening of the material. In this process, martensitic hardening of the sheet metal component can be achieved. However, stability problems with reduced sheet thicknesses limit the lightweight construction potential of press-hardened components. In other branches of industry, such as the aerospace industry, structural components are often made from fibre-reinforced plastic composites (FRP) or, in more recent approaches, in a hybrid composite of metal and FRP, while high-strength steels continue to dominate the automotive mass market. A targeted combination of metal and FRP leads to stress-adapted and cost-effective hybrid lightweight structures. In the load application area of such hybrid components, concentrated, three-dimensionally effective load collectives often occur, which are preferably absorbed by isotropically acting metallic components. The transition area or the interface from the metallic component to the fibre composite structure, where the forces have to be transferred, is critical. New surface pre-treatment processes can help to improve component performance by creating targeted interlocking effects. The aim of this project is to develop a process that introduces surface structuring into the hot forming process of high-strength steels in order to subsequently achieve improved bonding of fibre-reinforced plastics. The structuring is applied using the corresponding hot forming tool, which eliminates an additional work step compared to other structuring processes. For this purpose, a tool for structuring at sample body level is first developed, with which the samples are simultaneously structured and hardened. The mechanical properties of the hybrid structures made of FRP and 22MnB5 are then determined experimentally. Based on the knowledge gained, the method is then applied to an automotive body structure and validated. Publication: 2020 Authors: T. Tröster, K. Dröder

P 1136 - Use of friction stir welding for joining steels of different grades in conjunction with the simultaneous development of corresponding new types of ceramic tools The most important and first development objective of the project was the economic expansion of friction stir welding (FSW) for joining steel materials, including those with high strengths. A great deal of previous experience available at SLV Berlin-Brandenburg and experimental applications were incorporated into the project. Based on enquiries, mainly from the areas of shipbuilding, offshore, vehicle construction and special applications and requirements from the Project Advisory Committee (PA), steel joints of various grades were welded and analysed. These include, among others: S235, S355, S690, CrNi18-10 and H800. Blind seams, butt joints and lap joints were welded. For two steel grades, the butt joint was also welded on both sides to record greater thicknesses. In addition, it was examined whether the use of shielding gas was necessary and how this could be optimised (simple gas nozzle above the stirring tool, drag nozzle, etc.). This was dispensed with in the further course of the project. No significant advantages could be identified. Material tests such as tensile tests, bending tests, X-rays etc. confirm this tendency. The tested samples consistently showed quality values in the range of the base material. The second important aspect of the project was tool development. This is also the main reason why FSW on steels is not very common (except for university or institutional research applications). During the friction stir welding process on steels, the friction stir tools are exposed to extremely high temperatures ~1200°C (e.g. only ~500°C for aluminium), corrosive and abrasive wear. Tungsten-rhenium alloys are mainly used for FSW steel welding (WRe05, WRe25), but other special metallic materials such as tantalum-based materials and solid carbides are also used. Another variant is tools made of polycrystalline cubic boron nitride (pcBN). Conventional ceramic material systems offer a further, promising and much more economical option. These systems in particular were investigated in the research project by SLV Berlin-Brandenburg and FGK GmbH from Höhr- Grenzhausen. It was important to understand the interactions between the material to be welded and the ceramic tool. Derived from the tests and the subsequent laboratory investigations, a material system crystallised, silicon nitride. This material, chemical formula Si3N4, a non-oxide ceramic, has proven itself in all the steels tested. Oxide ceramics, on the other hand, although easier to produce, were not convincing. Only in the course of the project, and only towards the end, were improvements achieved in some oxide ceramics through special geometric and chemical adjustments. However, this is also an important result of the research project: Understanding the failure mechanisms and their effects on the various ceramic material systems. Ultimately, however, it can be said that the Si3N4 material is essentially ready for use. This was clearly demonstrated and confirmed by the results of the reference tests. This means that at least one material system has been verified for friction stir welding on steel. Publication: May 2021 Authors: R. Boywitt, Dr.-Ing. M. Emmel