Ecole thématique Métallurgie Mécanique ArcelorMittal ... · Ecole thématique Métallurgie...

Ecole thématique Métallurgie Mécanique

ArcelorMittal : Transforming Tomorrow Through

Innovation

Thierry IUNG, with the contribution of

M. BABBIT, N. POTTORE, N. LOUKACHENKO, S. CORRE, A.

PERLADE, R. JACOLOT, B. DONNAY, P. BARGES, I. ZUAZO, D.

VERCHERE, C. ALLELY, J. PETITJEAN, J.C. HELL, S. ALLAIN, B.

WEBER, X. LEMOINE, P. DIETSCH, K. TIHAY, F. BONNET, D.

JACQUET, ….

October 26th, 2016

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Outline

• Fe-C phase diagram

(effect of alloying elements)

• Texture in steel sheet

• CCT and TTT : continuous cooling and

isothermal phase diagram

• Steel standards :

– Description of XC 50, XC55, XC60, XC65 …. XC 80

– From 22MnB5, 30MnB5, 36MnB5, …. to 54 SCV 6

– Adamantium

1

Austénite +

Carbon content

(wt.%)

Carbon content

(at.%)

fiber a : <110> // D.L. fiber g : <111> // D.N.

a and g fibers

DL

DT DN

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Outline

• Fe-C phase diagram

(effect of alloying elements)

• Texture in steel sheet

• CCT and TTT : continuous cooling and

isothermal phase diagram

• Steel standards :

– Description of XC 50, XC55, XC60, XC65 …. XC 80

– From 22MnB5, 30MnB5, 36MnB5, …. to 54 SCV 6

– Adamantium

2

Austénite +

Carbon content

(wt.%)

Carbon content

(at.%)

fiber a : <110> // D.L. fiber g : <111> // D.N.

a and g fibers

DL

DT DN

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Outline

• History and trends for steel, focus on ArcelorMittal, main markets

• Market request and steel answers, examples

Corrosion resistance and surface function

Energy and gas transport

Automotive

Long products application

• Microstructure engineering during elaboration processes to control final

performance

3

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Outline

• History and trends for steel, focus on

ArcelorMittal, main markets





Automotive


performance

4

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From the ‘iron age’ to the era of advanced,

sustainable, eco-efficient steels

5

–Steel has now to compete with other materials (weight, cost, design)

–Needs for constant new offer – Increase of steel properties (a third of the present steel grades did not exist 5 years ago).

• The end-user functions drive the new development – from steel grades to complex parts (steel solution design, Tailored blanks,

steel in association with other materials, …).

Now and tomorrow

800 BC

4000 BC

1700

1870

1950

1973

Iron was discovered in the middle-east area more than 6000 years ago • Mostly pure iron, very soft and ductile, used for decorative purposes

• Sometimes more expensive than gold, sometimes hated as a devil’s metal owing to its rusty

color

Discovery of carburization and quenching by the Celt people (800-600 b.c.) • Iron competed successfuly with bronze for sword manufacture

• Smith became a major craftsman

The modern era definitly started at the end of the XIXe with the invention of

the blast-furnace and the converter to make steel : Buildings, bridges,

railways, weapons, …

5

The use of the coke at the beginning of the XVIIIcentury allows to produce

large quantity of cast iron (iron with more than 2% carbon) for construction

and cannons

After the second world war, coal mines and steel industries were the major actors of the rebuilding : Customers had to adapt to the quality and the quantity provided by the steel makers (!)

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World steel production

Reference in 1973 : around 600Mt

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Still a lot of players in the steel industry

ArcelorMittal is the only non-asian in the top ten

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Geographical reach

* Latin America includes Mexico.

Industrial and commercial network focus on our franchise businesses

Market position by region

Leader in

North America

Leader in

Latin America*

Leader in

Europe Major producer

in the CIS

Leader in

Africa

9

JV’s in China and the Middle East

ArcelorMittal

Others

ArcelorMittal : The world’s leading steel

and mining company

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ArcelorMittal key figures

2015 2014 2013

Sales (US$ billion) 63.6 79.3 79.4

Ebitda (US$ billion) 5.2 7.2 6.9

Operating income / (loss) (US$

billion)

(4.2) 3.0 1.2

Net income / (loss) (US$ billion) (7.9) (1.1) (2.5)

Steel shipments (million tonnes) 84.6 85.1 82.6

Crude steel production (million

tonnes)

92.5 93.1 91.2

Own iron ore production (million

tonnes)*

62.8 63.9 58.4

Around 210,000 employees

in more than 60 countries

Allocation of employees in 2015

according to geographic location

(full-time equivalent)

*Own iron ore and coal production excluding strategic long-term contracts.

ArcelorMittal is the world’s leading steel and mining company

10

0%

39%

14%

14%

9% 16%

5%

EU28

Other European countries

North America

South America

Asia

Middle East and Africa

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Global R&D: Scope and Mission • 1,300 full time researchers

• Broad, comprehensive portfolio and programs addressing business needs

• Worldwide network of laboratories: 12 labs in Europe and Americas

• Budget spending by focus area and range of activities:

Exploratory

Process Product

R&D effort fully aligned with group strategy: geography, value chain, product differentiation 11

mill

support

application

support and

co-engineering

new process

and product

developments

customer

technical

assistance

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… across 12 research centres and at

customer locations on 3 continents…

Canada

Hamilton

USA

East

Chicago

France

Gandrange

Le Creusot

Maizières

Montataire

Forbach (*)

Spain

Asturias

Basque Country

Luxembourg

Esch-sur-

Alzette

Belgium

Gent

Liège (*)

Czech

Republic

Ostrava

(*) Strategic partner

- Forbach: CPM

- Liège: CRM

Brazil

Tubarão

On-site product-portfolio deployment: Product Development Engineers

Automotive Residents, Process Development & Deployment Specialists

Canada, USA Spain, France, Germany,

Italy

China, South Korea,

Japan

12

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Date R&D Lab/Dept – Title of the presentation 13

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Wide market applications , large spectrum of performances

• Automotive: compromise between weight reduction, comfort, safety & durability

• Packaging: cost effectiveness, easy processing, weight reduction, innovative look, food

compatibility, green products

• Appliances: cost reduction, antibacterial, aesthetics, environmental friendly…

• Construction: energy-efficiency, environmental issues, safe buildings, durability, fast

erection, health & comfort, aesthetics,…

• Metal Processing: weight and cost saving, corrosion resistance, safety, reduced total

cost of ownership, high temperature resistance

• Electrical Engineering: higher efficiency and power density machines through low loss,

high permeability, high strength electrical steels

• Energy pipes: heavy gauge, high strength, corrosion resistance, improved welding

14

Customers’ needs, examples

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Our steel – the fabric of life

Through innovation, steel remains the material of choice

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Superconducting Supercollider Magnets

• CERN needed 50,000 tons of magnets with strictly identical

properties for the most complex experimental facility ever built –

the Large Hadron Collider (LHC) – the particle accelerator that

fires trillions of protons around a 27km tunnel at 99.99 percent

of the speed of light …..built with ArcelorMittal’s Magnetil®

16

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Shipbuilding - Luxury Cruiseliner

17

• ArcelorMittal supplied 100 percent of the steel used in the

world’s largest cruise ship: Harmony of the Seas

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18

Skyscrapers

• Customer Broad Sustainable Building recently made headlines in the architecture

world when they completed the construction of a 57-storey high-rise in Changsha,

China, in a record 19 days – the equivalent of three storeys per day. ArcelorMittal

played a pivotal role in bringing this ambitious project to fruition, by providing over

10,000 tons of HISTAR® for the structure, as well as technical advices.

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Construction – Olympic Stadium

• ArcelorMittal Brazil supplied more than half the steel used for

infrastructure work related to the 2014 World Cup and 2016 Rio

Olympics in Brazil for a variety of buildings from stadiums, to

train stations to giant aquariums.

19

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Nuclear Containment – Chernobyl Sarcophagus

• ArcelorMittal has supplied over 100,000 m² of steel for a state of

the art containment structure for the Chernobyl nuclear power

plant in Ukraine – the Chernobyl sarcophagus.

20

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Coastal Protection - Floodgates

• ArcelorMittal supplied over 100,000 metric tons of sheet piling to

the Mose project in Venice, intended to build 78 floodgates to

protect the ancient city.

21

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Bridges

22

• Tailor-made plates for the construction of key bridge arch components for the new

bridge spanning the Moselle, linking Grevenmacher in Luxembourg and Wellen in

Germany. Strong and lightweight materials were used to achieve the refined,

streamlined design in a very tight four-and-a-half month construction schedule to

minimize traffic disruption

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Rails for High Speed Trains

• ArcelorMittal has supplied more than 1,5 million tons of rails that combine

excellent reliability, geometrical precision, strict flatness tolerance and the

highest quality for high speed railway networks in Spain, France, Germany,

Portugal, Turkey, Saudi Arabia and Morocco.

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Outline



Corrosion resistance and functions


Automotive



performance

24

SURFACES

CRYOGENIC APPLICATION

STEEL SOLUTIONS

SHORTEN PROCESS ROUTE

MACHINABILITY

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What is at stake in corrosion protection ?

• Corrosion protection represents 2% of world GDP !

• Among solutions: paints, surface treatments, … and metallic coatings

• One target: improve protection given by the metallic coating

• With two main approaches on the market:

- Increase protection while keeping production costs constant

Improve metallic coatings performances compared to existing solutions

- Keep protection constant while decreasing production costs

Reduce amount of raw materials required for corrosion protection

Very competitive field !

SURFACES

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What is the ArcelorMittal product offer ?

Hot-dip coating Electrodeposition

Zn (Z) Zn-Fe (ZF) Zn-Al (ZA)

Extragal

Galvannealed Galfan

Al-Zn (AZ)

Aluzinc

Al

Alupur

Al-Si (AS)

Alusi

Zn (ZE)

Electrogalvanized

Metallic coating

Zn-Al-Mg (ZM)

- Magnelis (Industry)

- ZnAlMg (Auto)

~ Pure zinc

Primary zinc

dendrite

Ternaire

Zn/Al/Mg

ZnAlMg

SURFACES

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How Aluminium and Magnesium improve

protection • Benefits of Aluminium and Magnesium added in Zinc

demonstrated for years (Galfan, NSC’s Superdyma, …)

• Understanding only recently possible :

Compact

corrosion

products

High

inhibition

ZHC / AlMg LDH

ZnAlMg coating

Porous

corrosion

products

Low

inhibition

ZnO

Zn coating

ZnAlMg

10µm

Zn

10µm

SURFACES

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14/11/2016 Didier Verchère 28

New surface functions for construction,

appliances or packaging market

SURFACES

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14/11/2016 Didier Verchère 29

Organic Coating solution on coil coating line

Metallic

coating Steel

Ste

el s

ub

str

ate

0,4

to

1m

m

Primer

Top-coat

Backcoat 5 to 12 µm

5 to 30 µm

20 to 200 µm

Surface

treatment

Surface treatment

SURFACES

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Oil & Gas Pipeline Design

30

Steel Solutions in Transport

Oil LNG

Tank car Oil tanker LNG liquefaction LNG tanker

Tank car and shipbuilding plate Crogenic plate, pipe, bar (Ni, CRA)

o

o

o

o

o

o

o


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Typical LNG chain

- Cryogenic structural Ni alloyed steel steel grade

- 9%Ni steel (Industeel) : widely used as a main material of inner

walls of LNG tanks and LNG transportation vessels due to the high

strength properties, excellent toughness level and crack arrest

properties exposed at very low temperature

9% Nickel

steel

Storage and transportation of LNG

7%Ni steel (CryElso™ 7) concept : a cost-effective lean high strength steel

with 9%Ni properties for cryogenic applications


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7%Ni versus 9%Ni : equivalent properties

Developed 7%Ni steel → level of strength and toughness properties

down to LNG service temperatures equivalent to

those of conventional 9% Ni quenched and tempered steel

0

50

100

150

200

250

300

500 525 550 575 600 625 650 675 700 725 750

Charp

y a

v. v

alu

es

at

-196

°C,

J

YS at T room, MPa

CryElso®9Q

CryElso®7

A553M

0.2

YS m

in v

alu

e

A553M type III Charpy min value (Transv. Dir.)

A553M type III Charpy min value (Long. Dir.)

625

650

675

700

725

750

775

800

825

500 525 550 575 600 625 650 675 700 725 750

TS a

t T

room

, M

Pa

YS at T room, MPa

CryElso®9Q

CryElso®7

A553M

0.2

YS m

in v

alu

e

A553M TS min value

• Satisfactory crack arrest properties (no break for all

specimens tested at -196C)

•Drop weight test according to ASTM Standard E 208

•Energy used for the test : ~400J


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ArcelorMittal Automotive Worldwide

33

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What’s a car made of?

34 34

Steel

57% (44% flat/13% long)

Plastic,

glass

and other

materials

22% Alu

min

ium

9%

Ir

on 8

%

Various m

eta

ls: copper,

zin

c,

…

4%

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• Global platforms: Carmakers

demand that the same products be

delivered to their production

facilities worldwide, to support

global platforms that are designed

centrally. The percentage of

vehicles built on global platforms

will increase from 46% in 2014 to

63% in 2020

• Regulation: Shift in product needs

to meet regulatory targets for fuel

economy as well as passenger

safety during crash events

• ArcelorMittal offers

the specific solutions

to address these

challenges

• ArcelorMittal

maintains both its

geographical and its

technological

leadership in the

automotive market

Key automotive industry requirements

ArcelorMittal well positioned to meet automotive industry requirements

35

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Drawing steels

High strength IF steels

Bake Hardening steels

HSLA steels

Dual Phase steels

Hot rolled ferrite-bainite steels

Complex Phase steels

TRIP steels

Steels for cold stamping - Fortiform®

Steels for Hot stamping - Usibor® Ductibor®

MartINsite® steels

The broadest product offer in the world

36

ArcelorMittal steels for automotive cover all metallurgical families of steels and

offer a full range of compromises between formability and weight reduction

STEEL SOLUTIONS

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The “body in white” weight reduction needed to achieve emission targets can be achieved

at attractive cost and without impacting vehicle performance

with existing steel grades and solutions, with further potential from new grades

From a steel provider, to a global solution provider

S-in motion®

C-Segment Vehicle

Achieved 20% BIW

weight reduction

from 2009 baseline

2010 2012

S-in motion® Battery

Electric Vehicle

Achieved 11% BIW

weight reduction

from 2011 baseline

2014

S-in motion® Pickup

Truck

Achieved 23% BIW

weight reduction

from 2013 baseline

S-in motion®

Electric &

Plug-in Hybrid

C-Segment

Vehicles

2013

S-in motion®

Light Commercial

Vehicles

Achieved 20%

underbody weight

reduction

2012

37

A long tradition of development of steel solutions, even before ArcelorMittal was

created

STEEL SOLUTIONS

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Baseline Representative of US Market. Midsize vehicle

Near term grades Solution

Component Total Mass

Vehicle curb weight 1478.2kg

BIW 324.4 kg

Front Doors 16.5 kg (x2)

Rear Doors 13.9 kg (x2)

Total BIW + doors 385.2 kg

~ 100kg weight savings

with near term steel grades

Component Total Mass Weight savings

Vehicle curb weight 1378.6kg 7%

BIW 235.0 kg 28%

Front Doors 14.1 kg (x2) 15%

Rear Doors 11.2 kg (x2) 19%

Total 285.6 kg 26%

Automotive Applications: S-in motion®

STEEL SOLUTIONS

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Automotive solutions in Long Products…examples

Product

segment Current Offer

Automotive

Applications

Innovations / Developments

Products Targets

Cold

Heading

Cold Heading from

5.5 to 52 mm in

Wire Rod (market full

range)

Fasteners

Ball joints

Extruded parts

High Strength (>1500

MPa) maintaining H2

resistance Freeform®

M1500 H2

Screws for con-rod

caps, crankshaft bearings

& engine flywheel

Screws for chassis

Class 12.9 with improved

H2 resistance

Spring

Super Clean

spring grades

Clutch spring

Valve springs

High Strength > 2000

MPa

Corrosion resistant

Spring Steel

reduce weight of

springs

Increase durability

Free-

Cutting

High Speed

Free-Cutting steels

Components for

camshafts

Injector pieces

High strength and

machinable steels

reduction of tool wear

Lead-free solutions

Avoid heat treatment

Forging

Hot forging micro-

alloyed steels

Full Bar / Billet

dimensional range

Steering knuckle s &

lever

Con-rods

Rocker arms

Crankshafts

High Strength steels

bainitic steel

SOLAM ® family

Also solutions adapted

to induction hardening

Reduction of

processing costs

(avoid heat treatment)

Reduce weight of part

STEEL SOLUTIONS

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Lighten & high mechanical & corrosion

resistance : suspension spring steel application

40

1500

1600

1700

1800

1900

2000

2100

2200

2300

500 600 700 800 900 1000 1100 1200 1300

Maximal shear stress on spring (MPa)

Ultim

ate

te

nsile

str

en

gth

(M

Pa

) Evolution of springs with high characteristics

STEEL SOLUTIONS

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41

Example of design (S-in motion)

Solution

1.9 kg

Comparison Weight: -21%

Base

2.4 kg

Key properties

• Decrease in the number of active rings and in the wire diameter

• Increase in the ultimate tensile strength

• Fatigue limit after corrosion: decrease < 30% & increase by 10% towards 54SiCr6

54SiCr6

UTS: 1900 MPa

Z: 38.8%

Agt: 12.1%

Fatigue ratio: 0.36

New spring grade

UTS: 2050 MPa

Z: 38.7%

Agt: 10.8%

Fatigue ratio: 0.42

STEEL SOLUTIONS

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42

Lighten & shorten the process route

Solam ® B 1100 for forging application

Range of properties

allowing weight

saving or higher

power

STEEL SOLUTIONS : weight reduction and short processing route

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SOLAM® B 1100:

an economical and environment friendly grade

43

• Low carbon grade C ≈ 0,16-0,2%

• Microalloyed with :

– Mn ≈ 1,6-1,9%, Cr ≈ 0,8-1,2%, Ni ≈ 0,2 -

0,5%

– Niobium, Vanadium, ...

• Formation of bainite for cooling rates compatible

with main hot forging process

• Reinforced ferritic matrix

Natural or Controlled*

Forging

Cooling

Quenching

Tempering

Austenitisation

Traditional Process

using 42CrMo4

Forging

Cooling

Advanced Process

using SOLAM® B 1100

Straightening

Process

Eliminated

=

Cost &

Energy

Savings

Light Straightening


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44

SOLAM® B1100: S-in motion project

Baseline comparison

Upright+bearing

Weight: -0.9 kg, -14%

5.5 kg

Cast iron baseline

Upright+bearing

6.4 kg

Highlights

•Cast iron baseline compared to two forging

solutions providing different bearing fixing

•Weight estimation including bearing and fixing

bolts

Bearing

Cast iron

YS=250MPa - UTS=400MPa

New

bearing

Baseline comparison

Upright+bearing

Weight: -1.2 kg, -19%

5,2 kg

Bainitic steel SOLAM B1100

YS=850MPa – UTS=1100MPa

Bainitic steel SOLAM B1100

YS=850MPa – UTS=1100MPa


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Optimisation of process route & costs at the customer : Machining

Targets

- Machining of new High Strength Steel for

weight reduction application

- Reduction of the machining costs

- Improvement of the chip breakage

- Improvement of surface quality

- Increase in tool life

STEEL SOLUTIONS : improved machinability

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46

- Resullfurization

- Ca treatment

- Controlled oxides

…to protect the tools

Creation of a Built Up Layer at the interface tool/material which acts as a :

-Lubricant

-Thermal shield

-Anti diffusion barrier

Chip

Work piece Built Up Layer

Tool

STEEL SOLUTIONS : improved machinability

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Outline






Automotive

• Microstructure engineering during elaboration

processes to control final performance

47

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The process-product relationship

Oct 2015 Steel for steel people 48

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14/11/2016 Author 49

49

Automotive needs for new performance : Design & Development of Next Generation Steels

Maximize Steel’s Advantages Address Steel’s Limitations

Stiffness-Limited

•C-Pillar Ring

•Closures

•Floor Pans

•Chassis

Strength-Limited

•Rockers

•Cross Members

•Rail Extensions

•A-, B-Pillars

Energy -Limited

•Rails

•Lower B-Pillar

•Windshield

Members

Push UTS

beyond 1500

MPa

Develop High

UTS plus High

Elongation

Develop Low

Density Steels

Develop High

Modulus Steels

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What defines a microstructure

• Large variety of constituents :

Austenite (CFC), Ferrite, Bainite, martensite (CC),

Cementite (iron carbide).

Pearlite (Lamellae ferrite/cementite)

• and for each constituent

– Size and shape (grain size, interlamellar spacing, …)

– Solute elements : Mn, Ni, C …

– Precipitates : AlN, TiN, Nb(C,N), ...

– Crystallographic texture

Ferrite (Drawing application) Ferrite – Martensite (DP for automotive) Pearlite (for rails) Oct 2015 Steel for steel people 52

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Microstructure engineering : Macro

Microstructure Nanostructure

Optical Microscopy (grains)

Electron Microscopy (atoms)

Optical Macroscopy (macro-deformations)

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Microstructure scales :

ATOM

10-10 m PRECIPITATE

from 10-9 to 10-6 m

GRAIN

from 10-6 to 10-3 m

CAN

Oct 2015 Steel for steel people 54

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Microstructure control all along steel elaboration process :

Quantification and observation, understanding and modeling

precipitation and dissolution of precipitates

work-hardening and

recrystallization

phase transformations

(texture formation)

work-hardening

Texture formation

precipitation and dissolution of precipitates

recrystallization

texture formation

phase

transformations

work-hardening

(texture formation)

precipitation

phase transformations

Slab

reheating

Hot rolling

Cooling

Coiling

Cold rolling

Heating

Soaking

Cooling

Overageing

Annealing Temper

rolling

HOT STRIP MILL COLD ROLLING PLANT STEELMAKING

PLANT

Steelmaking

Casting

Having unique elaboration processes to get long term

competitive advantage

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57

Microstrucure

control :

Deformation at

high temperature

Unit 1

Austenite flow behaviour

Possible dynamic + Post dynamic recrystallization

Recrystallised

Deformed

Recovered

Legend

Unit 2

Static recrystallisation

Unit 3

Recovery

Unit 4

Precipitation

Unit 5

Normal grain growth

Unit 6

Averaging

Microstructure

before pass n°i

Fe-70Ni alloy, 700°C, =0.8 [H. Réglé]

t=10s t=1000s

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58

Use of Nb to control microstructure during

deformation

Microstructure

before pass n°i Microstructure just

after pass n°i

Microstructure

just after pass n°i

Microstructure just

before pass n°i+1

Recrystallised

Deformed

Recovered

Legend


Unit 1


Unit 1

Dynamicrecrystallization

Unit 2


Unit 2

Post-dynamicrecrystallization

Unit 3


Unit 3

Staticrecrystallisation

Unit 4


Unit 4

Normal grain growth

Unit 7

Normal grain growth

Unit 7

Averaging

Unit 8

Averaging

Unit 8

Recovery

Unit 5

Recovery

Unit 5

Precipitation

Unit 6

Precipitation

Unit 6

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59

Static recrystallization: Main equations

extXexp1X

3t

0rexst dt)t(G)t(MNX

r2

F3b

2

1)t(G v2 g

Driving force for recrystallization

A stored energy of deformation term

A retarding zener term

1

epure M

1

M

1)(f)t(M

Grain boundary mobility

Mpure according to the Turnbull

estimation

Solute drag effect of various elements

(Mn, Si, Mo)

Effect of strain on fragmentation

(progressive misorientation between cells):

A

SvkNrex

Site density for recrystallization (m-3)

Sv= the grain surface area per unit volume

A is the area occupied by each nucleus= R2,

R is the mean radius of dislocation cells R=Kc/

k is a constant

Extended recrystallized fraction

Microstructure

before pass n°i Microstructure just

after pass n°i

Microstructure

just after pass n°i

Microstructure just

before pass n°i+1

Recrystallised

Deformed

Recovered

Legend


Unit 1


Unit 1


Unit 2


Unit 2


Unit 3


Unit 3


Unit 4


Unit 4

Normal grain growth

Unit 7

Normal grain growth

Unit 7

Averaging

Unit 8

Averaging

Unit 8

Recovery

Unit 5

Recovery

Unit 5

Precipitation

Unit 6

Precipitation

Unit 6

32

K

[E. Galindo et al.]

[E. Galindo et al.]

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60

Example of applications of process/microstructure

model for hot rolling

0

500

1000

1500

2000

2500

3000

3500

0 500 1000 1500 2000 2500 3000 3500

Measured load (T)C

alc

ula

ted load (

T)

Non microalloyed

Microalloyed

Prediction of rolling loads

2nd finishing stand - Fos

F0 F5 F6 F7 F8 F9 F10

E0 FSB

14,6 m 5,8 m 5,8 m5,8 m 5,8 m 5,8 m

F0 F5 F6 F7 F8 F9 F10F0 F5 F6 F7 F8 F9 F10

E0 FSB

14,6 m 5,8 m 5,8 m5,8 m 5,8 m 5,8 m

Flow stress in the roll bite

Forward slip

Rolling loads and friction coefficient

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61

The model enables the design of the rolling

schedules to obtain desired microstructure :

grain size, recrystallisation, …

• Objective: Replace the simplistic Tnr-parameter by “processing regime maps”

which combine temperature-time-deformation history with enhanced

knowledge of the operational metallurgical mechanisms

• The application has been tested in the frame of product development to

optimize new and improved hot rolling schedules and steel chemistries

2 3 4 5 6 800

850

900

Final tickness (mm)

FRT

(°C

)

X_rec

0-0,1 0,1-0,2 0,2-0,3 0,3-0,4 0,4-0,5 0,5-0,6

2 3 4 5 6 800

850

900

Final tickness (mm)

FRT

(°C

)

X_rec

0-0,2 0,2-0,4 0,4-0,6 0,6-0,8 0,8-1

0.1%C – 2%Mn 0.1%C – 2%Mn – 0.08%Nb

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Drawing steels

High strength IF steels

Bake Hardening steels

HSLA steels

Dual Phase steels

Hot rolled ferrite-bainite steels

Complex Phase steels

TRIP steels

Steels for cold stamping - Fortiform®

Steels for Hot stamping - Usibor® Ductibor®

MartINsite® steels

Next generation of steel for automotive

62

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63

• Microstructure engineering : define the appropriate combination

to reach properties and performances

Control of microstructure evolution:

3er generation steels - complex microstructures

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3er generation steels - complex microstructures

Phase identification of

complex phases

Martensite

Ferrite a

Ferrite a

Martensite a’

Martensite a’

Austénite g twins

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Nanostructured Carbide Free Bainitic Steels • Multiphase microstructure

– A ferritic matrix (αb) with a lath morphology

– Retained austenite (γ) (interlath and granular) stabilized at RT by carbon partitioning during the bainitic transformation (carbide precipitation delayed thanks to Si addition)

– Fresh martensite (α’) obtained during final cooling

Temperature

Time

α + Fe3C ferrite

martensite

Statis => Incomplete transformation

C diffusion in austenite

Caballero, FG; Allain, S; Cornide, J; Puerta Velásquez, JD; Garcia-Mateo, C; Miller, MK ;

Design of Cold Rolled and Continuous Annealed Carbide-Free Bainitic Steels for Automotive Application,

MATERIALS AND DESIGN 49 (2013) p667-680

Typical TTT diagram

Fully austenitic soaking

No carbide precipitation

Partial formation of fresh martensite


bainite

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o Complex hierarchical and intricate

microstructures

o Bainitic lath thickness about 300 nm

o Films of retained austenite 50 mm

αb

αb

γ

γ

MA = α’+ γ

αb+γ

prior γ grain

Hell, JC; Dehmas, M; Allain, S; Prado, JM; Hazotte, A; Chateau, JP;

Microstructure - Properties Relationships in Carbide-free Bainitic Steels,

ISIJ INTERNATIONAL 51 10 (2011) p1724-1732

FEG-SEM EBSD FEG-SEM SE

High mechanical performances

Nanostructured Carbide Free Bainitic Steels


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14/08/14 67

1

2

3

4

5 6

7

8

9

180 nm

Blocks (50-60°)

Laths (0,5-5°)

Laths (0,5-5°)

Laths (0,5-5°)

1µm

Sub-blocks of 2 variants

Laths


Laths


Laths


Laths


Laths


Laths

(47-67°)

(20-45°) (5-15°)

(<5°)

Structure of

lower bainite

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Undissolved

cementite

No cementite, finer

microstucture

Mn

7 à 20%Mn 6 à 10%Mn

Mn profile

Mn profile

0.8-1.4%C in austenite 0.3-0,6%C in austenite

Mn

Standard cycle New cycle


Local chemistry evolution during phase transformation

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Work hardening in multiphase steels

• Tensile behaviors depend strongly on the microstructure

– Fractions and strengths of the ferritic components

– Stability of the retained austenite (carbon content, size, local environment)

• Best formability reached when TRIP effect is efficient

– TRIP = dynamical strengthening mechanism

– Strain induced transformation of retained austenite into fresh and carbon saturated martensite

0 5 10 15 20

0

200

400

600

800

1000

1200

1400

1600

Ms-50°C

MS (330°C)

Ms+50°C

En

gin

ee

rin

g s

tre

ss

(M

Pa

)

Elongation (%)

0.00 0.05 0.10 0.150.0

0.1

0.2

0.3

0.4

0.5

n() =

n =

.d

/

.d

True strain

TRIP like behavior

Hell, JC; Dehmas, M; Allain, S; Prado, JM; Hazotte, A; Chateau, JP;

Microstructure - Properties Relationships in Carbide-free Bainitic Steels,

ISIJ INTERNATIONAL 51 10 (2011) p1724-1732

TRIP like behavior

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• We use ISO-W approach for multiphase steels.

• Excellent correlation with experimental data

– Work hardening well described

– CFB present a high YS above 900 Mpa Retained austenite appears to be the

softest phase

71

0

500

1000

1500

2000

2500

3000

3500

0 0.1 0.2 0.3

Tru

e s

tre

ss

(M

Pa

)

True strain

FM

TrM

RA

B

Model

Experiment

Ms+50 C

Work hardening in multiphase steels

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Precipitation hardening used as complementary

Strengthening mechanisms

Matrix

Precipitates

500 nm

Dislocations

Ex-situ OBSERVATION of

Interaction between dislocations and

carbides

Joël DOUIN CEMES-CNRS

X 200 000

SIMULATION of

Interaction between dislocations

and carbides

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50 nm

002

022

Zone axis [100]

002

Austenite

V(C,N)x

022

020

x

Characterization of precipitation morphology :

importance for hydrogen trapping

Orientation relationship

cube/cube between MX and

austenite matrix and shape

determination.

(111)g II (111)V(C,N)

Tomography

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Key issue on multiphase steels : damage

control Without coupling

With

coupling

Growth

of voids

FractureNucleation

Coalescence

N =number of cavities

studied volume

DP11

Decohesion criterion

DP11

Decohesion criterion

DP11T DP62

Fracture criterion

DP11T DP62

Fracture criterion

X-ray tomography

Local mechanical state, control of morphology/Size, hardness

difference

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Slide 75

Development of micro-macro metallurgical-

mechanical models

Understanding

microstructure by

experimental

analysis

Metallurgical -

Mechanical Model

Implementation in FE

Code

Comparison forming

prediction/experimenta

l measurement

Metallurgical – Mechanical

From microstructure to the

structure Optical Micrograph

X-ray

tomography

Holographic

Reconstructio

n

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Summer School Dortmund,

7. September 2012 Slide 76

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• Example : influence of a plastic pre-strain on the high cycle

fatigue properties of high strength steel sheets:

In-use performance of avanced steels

200

250

300

350

400

450

104

105

106

107

Dual Phase steel

R

Str

ess

Am

pli

tud

e,

0 (

MP

a)

Number of cycles to failure, N

Unbroken

Initial Grade Pre-strained grade, ||Eps

|| = 20 %

320 MPa

250 MPa

pspsps EEE :3

2

Eps = plastic strain tensor

Fatigue properties evolution

Fatigue tests are specimens and time consuming, development

of self heating experiments to predict fatigue limit

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Example : Fatigue behaviour of welds

Gap

1mm

Gap

1mm

In-use performance of avanced steels

No straightforward influence of stress concentration (Kt), we can explain this by the combined

effect of irregularities in the geometry of the weld, the presence of local defects, porosities,

distribution of residual stresses and so on product validation on prototypes

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• Test conditions and results: – Severe impact conditions to obtain failure

– Usibor®1500 1.8mm + closing plate Mild Steel 1mm

– Impact at 8m/s (Mass = 430 kg)

In use performance : Crash resistance on B-Pillar in Usibor®1500

Experimental test

After 16ms

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Strain at same displacement

= Failure strain

• Plane strain is the most critical strain state for crash application

– Thus, its characterization is mandatory to run any FE failure analysis

• Failure in plane strain is accurately measured through coupling of

experiment and FEA:

Failure strain characterization Highlight on plane strain failure characterization

Displacement at failure

FE simulation with

accurate material law

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Validation on B-Pillar in Usibor®1500 Simulations with LS-DYNA MAT224

(*MAT_TABULATED_JOHNSON_COOK)

1st deletion at 12ms 1st deletion at 12ms

1st deletion at 14ms

-2 -3

-4 -5 -3 -7

Plastic Strain

Accurate failure prediction

for all mesh size

5mm

2mm 3mm

More accurate model:

LS-DYNA MAT224 failure

modeling takes into account

deformation path

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14/11/2016 Author 82

82

Automotive needs for new performance : Design & Development of Next Generation Steels

Maximize Steel’s Advantages Address Steel’s

Limitations

Stiffness-Limited

•C-Pillar Ring

•Closures

•Floor Pans

•Chassis

Strength-Limited

•Rockers

•Cross Members

•Rail Extensions

•A-, B-Pillars

Energy -Limited

•Rails

•Lower B-Pillar

•Windshield

Members

Push UTS

beyond 1500

MPa

Develop High

UTS plus High

Elongation

Develop Low

Density Steels

Develop High

Modulus Steels

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rmation Grade designed for stiffness: 15% weight-saving can be achieved with 7% density

reduction and 8% weight saving via higher Young E-modulus.

Standard steels: E=200GPa, ρ=7.85 kg/dm3.

High Modulus FeTiB2 steel: E=240GPa, ρ=7.32 kg/dm3

Concept: In-situ precipitation of fine TiB2 particles in steel matrix during solidification.

Compact Strip Production process is required to achieve rapid cooling and control particles

size & distribution.

Precipitation of TiB2 in steel matrix

20 m

Cold stamping formability

is confirmed

Application: A large range of strength/ductility compromises

can be achieved through metallurgical designs to fulfill

automotive BIW & chassis applications.

500

600

700

800

900

1000

200 300 400 500 600 700 800 900

UT

S,

MP

a

YS, MPa

Lab casting

Industrial casting

Forming Limit Curve Ys-UTS accessible range

High Young Modulus TiB2 composite steel

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Reduced density : Al added steels

Three types of products can be achieved

• Fully ferritic steels (a): 10% density reduction,

Al~6-8%, Low Carbon

Typical Grades 500-600MPa

• Duplex steels (a+g): 10% density reduction,

Al~6-8%, Mn~4-8%, C~0.1-0.3%

Typical Grades 700-1000MPa

• Triplex steels g+few (a + 3rd phase): 14% dens. red.,

Al~6-10%, Mn~20-30%, C~0.9-1.3%

3rd phase is Kappa carbide

Typical grades 1000-1300MPa, 30-40% elongation

a

a

g

a

g

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Concluding Remarks

• ArcelorMittal, the world’s largest steel and mining company

and the leader in every major global steel market, including automotive,

construction, household appliances and packaging, with leading R&D

and technology and outstanding distribution networks, offers products

and steel solutions to serve most customer needs.

• Talented, Creative and Innovative Individuals…..

– with a Passion to Safely and Sustainably Lead the…

– Design, Development and Industrialization of…

– Products and Processing Technologies…

– to Boldly Resolve umpteen Challenges….

– with Steel Solutions that will Transform Tomorrow…

– should find plenty of Opportunities at ArcelorMittal

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Ecole thématique Métallurgie Mécanique ArcelorMittal ... · Ecole thématique Métallurgie...

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