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1 Great Designs in Steel is Sponsored by: AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation, Severstal North America and United States Steel Corporation

2 Investigation of Tooling Durability for Advanced High-Strength Steels Tareena Mulholland-General Motors LLC Darryl Young-Ford Motor Company Mike Klein-Chrysler LLC

3 Team Members and Contributors

4 Investigation Criteria Identify the tribological factors that contribute to the successful production of AHSS stampings Die Design Die Materials Surface Treatment Cost Effectiveness Progressive Die with a two phase approach Phase I: Form, Flange, Trim, Pierce Phase II: Trim, Pierce

5 Phase I Lower Shoe Upper Shoe

6 Phase I Description Trim Pierce Pierce Pierce Flange

7 Phase I Pierce Station Location Material % Backup 1 M2/A2 5% 15% 2 M2/A2 10% 3 M2/A2 15% 4 M2/A2 20% 5 M2/A2 25% 15% 6 M2/A2 30% 15% 7 M4/A2 5% 15% 8 M4/A2 10% 9 M4/A2 15% 10 M4/A2 20% 11 M4/A2 25% 15% 12 M4/A2 30% 15% 13 A2/A2 20% 15%

8 Phase I Pierce Results

9 Phase I Trim Station Material: 1. CALDIE + Ion Nitride +PVD TiCN 2. CC 1 (bar stock) 3. CPM 10V 4. AISI D2 5. AISI M4 6. AISI S7 7. VANADIS 4E

10 Phase I Trim Results Incomplete Test NAAMS G25HP (2) Caldie (2), CC 1, HWS AISI D2, S7, M4

11 Phase I Trim Results Hardness may have direct effect on die material performance

12 Phase I Flange Station Material: 1. AISI D2 2. AISI D2 +CVD TIC 3. CARMO +Nitride +PVD CrN 4. AISI M2 5. AISI M4 6. AISI M4 + CVD TIC 7. VANADIS 4E Maximum Strain

13 Phase I Flange Results Materials D2, M2, M4, Vanadis 4E Coatings PVD CrN, PVD TiAlN, Hard Chrome, MicroPlasma D2 + CVD TiC, M4 + CVD TiC, Carmo + Nitride + PVD CrN

14 Pierce Ideal clearance between 5-15% Trim Phase I Conclusions AISI D2 material performed the best Coating did not seem to improve performance (only tested for one instance) Flange Coatings are necessary PVD CrN performed better when applied over Ion Nitride

15 Phase I Lessons Learned From Phase I: Scope too broad Qualitative Wear Inconsistent trim clearance Improvements for Phase II: Narrowed scope Quantitative Wear Analysis Smaller inserts

16 Phase II Description Trim Long Pierce Long Pierce Pierce Pierce Pierce Pierce

17 Phase II 1 st & 2 nd Pierce Stations Tested Punch Clearances 8% 10% 12% 15% Tested Punch Materials AISI D2 AISI M2 Vanadis 4 Extra

18 Surface Wear Measured Area 1.5 mm x 0.63 mm 8 measurements μm Pre-Test μm Post DP μm Post DP980

19 Pierce Clearance* Break % Original Surface Material Original Surface Post DP780 Δ Roughness Phase II Pierce Surface Wear Post DP980 Δ Roughness Post DP780 % wear Pierce Material Post DP980 % wear AISI D μm μm μm 26.5% 123.0% AISI M μm μm μm 1.4% 22.6% Vanadis 4 Extra Post DP780 Δ Roughness Post DP980 Δ Roughness Post DP780 % wear Post DP980 % wear 8% μm μm μm 75.3% 711.4% 10% μm μm μm 27.7% 452.7% 12% μm μm μm 22.5% 436.8% 15% μm μm μm 3.0% 271.4% * Values are averaged μm μm μm -8.9% 45.0%

20 Phase II Trim Station Trim tests Trim angles from -30 to 30 in 5 increments Materials: Caldie, Vanadis 4 Extra, AISI D2, ASP 2015, and ASP Everlast (patent pending process)

21 Phase II Trim Results All 30 trim angles began chipping at 19,000 hits or less 3 Hits 7,065 Hits 18,000 Hits 211 Hits 8,530 Hits Everlast extended the life of the ASP 2015 by at least 99.2%

22 Phase II 3 rd Pierce Station Small round pierce AISI M2 Pierce angles from - 30 to 30 in 5 increments Tools with controlled edge profile vs. a standard edge

23 Phase II 3 rd Pierce Results Pierce angle was most accurate indication of punch life; -15 < angle <15 Investigating quantifiable wear data from edge condition

24 Pierce Ideal pierce clearance 15% AISI M2 Material performed the best Ideal pierce angles are between -15 and 15 Phase II Conclusions Trim Ideal trim angles are between -20 and 20 Everlast extended the life cycle of ASP 2015

25 Future Work Moving Forward Complete burr height analysis Complete metallurgical analysis Investigate optimal designs, materials, and coatings for forming Investigate significant differences between DP780 and DP980 Continue to narrow the large selection of die materials & surface treatments

26 Questions?

27 Great Designs in Steel is Sponsored by: AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation, Severstal North America and United States Steel Corporation