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On the overlooked role of microstructure to explain post-punching fatigue performance of advanced high-strength steel
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Properties.ORCID iD: 0000-0001-6291-819X
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering.ORCID iD: 0000-0003-4798-4425
Luleå Univ Technol, Dept Engn Sci & Math, Div Solid Mech, S-97187 Luleå, Sweden..
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Structures.ORCID iD: 0000-0002-7656-9733
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2025 (English)In: Materials Science & Engineering: A, ISSN 0921-5093, E-ISSN 1873-4936, Vol. 927, article id 147946Article in journal (Refereed) Published
Abstract [en]

This study compares the role of microstructure on post-punching fatigue properties in three advanced high- strength steels (AHSSs) with a high-strength low-alloy (HSLA) steel commonly used in heavy-duty truck chassis. Microstructure characterization, tensile testing, high cycle fatigue (HCF) testing, fatigue crack growth rate (FCGR) testing, and neutron residual stress measurements are conducted. Punching significantly alters the microstructure, causing microstructure refinement, sub-grain formation, defect creation, tensile residual stresses, and a work-hardened shear-affected zone (SAZ) around, and a rough fracture zone, inside the punched hole. At 105 cycles, the HCF performance is primarily governed by the fatigue crack growth resistance of the as-rolled microstructure, with minimal sensitivity to punching. However, near the fatigue limit, post-punching fatigue failure is strongly related to strain localization when significant strength difference exists between micro- constituents (e.g., martensite and ferrite). Strain localization also promotes sub-grain formation, reducing the local threshold stress intensity factor range (Delta Kth), thus facilitating fatigue crack initiation. In microstructures with smaller strength differences (e.g., ferrite and bainite), sub-grains, together with surface roughness and residual stress, contribute significantly to the post-punching fatigue limit reduction. These findings provide insights into mechanisms of punching-induced fatigue performance degradation, offering potential strategies to optimize fatigue performance of AHSS for new applications.

Place, publisher, year, edition, pages
Elsevier BV , 2025. Vol. 927, article id 147946
Keywords [en]
Advanced high-strength steel (AHSS), Hole punching, Fatigue, Crack initiation, Multiphase microstructure, Microscopy
National Category
Applied Mechanics
Identifiers
URN: urn:nbn:se:kth:diva-361074DOI: 10.1016/j.msea.2025.147946ISI: 001427709500001Scopus ID: 2-s2.0-85217677191OAI: oai:DiVA.org:kth-361074DiVA, id: diva2:1943684
Note

QC 20250311

Available from: 2025-03-11 Created: 2025-03-11 Last updated: 2025-03-11Bibliographically approved

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Heshmati, NaderHoseini-Athar, Mohammad MehdiBorgenstam, AnnikaHedström, Peter

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