Steel Processing Properties and Their Effect on Impact Deformation of Lightweight Structures

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Objective

The Partnership for New Generation Vehicles (PNGV) goal of 40% vehicle weight reduction has resulted in numerous research projects aimed at replacing steel as the main vehicle structural material. Viewed solely from a weight-to-strength perspective, steel, as employed in current vehicle designs, is clearly inferior to alternative materials. However, as soon as other important issues are brought into consideration (cost, structural performance, uniformity in properties, manufacturability, ease of application, to name just a few), there are substantial obstacles which will have to be overcome in order for other materials to became a viable alternative to steel.

An alternative weight reduction methodology, demonstrated in the studies of the Ultra Light Steel Auto Body (ULSAB) Consortium, has shown that significant weight reduction is possible by holistic design improvements. The objective of this research is to further pursue the ULSAB approach and to investigate and document the effects of advanced material processing, forming and joining techniques on ULSAB structural performance in high strain rate deformation conditions. By using computational modeling and optimization coupled with state-of-the-art equipment, we will be able to consider the variety of effects resulting from material processing and manufacturing of ULSAB structure.

Project Schedule

Phase I

• Develop a partnership between AISI member companies, ULSAB design teams, and Oak Ridge National Laboratory, and
• Select candidate lightweight steel vehicle designs for analysis.

Phase II

• Develop finite element models for computational study of new lightweight steel design
• Incorporate material processing and manufacturing effects into structural finite element model of the vehicle.
• Develop parametric computer models that will allow for:
  • modifications of material structural properties based on processing and manufacturing conditions.
  • modifications of vehicle geometry
• Investigate the effects of material processing and manufacturing on vehicle structural performance

Acknowledgment

Research sponsored by the American Iron and Steel Institute under Project Number ERD-97-XM001 with the U.S. Department of Energy. Work was performed at the Oak Ridge National Laboratory, which is managed by UT-Battelle, LLC for the U.S. Department of Energy under contract DE-AC05-00OR22725.