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Fracture split forged steel connecting rods are utilized in many new high performance automotive engines to increase durability. Higher strength levels are needed as the power density increases. Fracture splitting without plastic deformation is necessary for manufacturability. Metallurgical design is a key for achieving the required performance levels. Several medium carbon steels containing 0.07 wt pct P, 0.06 wt pct S and various amounts of Mn, Si, V, and N were produced by vacuum induction melting laboratory heats and hot working the cast ingots into plates. The plates were cooled at varying rates to simulate typical cooling methods after forging. Microstructures were generally ferrite and pearlite as evaluated by light optical and scanning electron microscopy. Mechanical properties were determined by standard tensile tests, high strain rate notched tensile tests, and Charpy V-notch impact tests to assess “splittability”.

Quenching and partitioning (Q&P) is a novel heat treatment to produce third generation advanced high-strength steels (AHSS). The influence of carbon on mechanical properties of Q&P treated CMnSi-steels was studied using 0.3C-1.5Mn-1.5Si and 0.4C-1.5Mn-1.5Si alloys. Full austenitization followed by two-step Q&P treatments were conducted using varying partitioning times and a fixed partitioning temperature of 400 °C. The results were compared to literature data for 0.2C-1.6Mn-1.6Si, 0.2-3Mn-1.6Si and 0.3-3Mn-1.6Si Q&P treated steels. The comparison showed that increasing the carbon content from 0.2 to 0.4 wt pct increased the ultimate tensile strength by 140 MPa per 0.1 wt pct C up to 1611 MPa without significantly decreasing ductility for the partitioning conditions used. Increased alloy carbon content did not substantially increase the retained austenite fractions. The best combinations of ultimate tensile strength and total elongation were obtained using short partitioning times.

Knowledge of high strain-rate deformation behavior of automotive body structural materials is of importance for design of new vehicles with improved crash-energy management characteristics. Since a large range of plastic strains is encountered during the forming process prior to assembly, the mechanical behavior of sheet steels under high strain rate deformation conditions must be understood after pre-straining, in addition to the as-produced condition. This paper presents the compression testing methodology employed to examine these properties, and focuses on the effects of quasi-static pre-strains (from 0 to 20%) on the subsequent behavior of a low carbon interstitial free steel tested over a broad range of strain rates (from 10−2 to 103s−1). The results suggest that the increase in yield stress associated with increasing strain rate is not substantially influenced by prior cold work.

The effects of deep rolling were evaluated by reviewing the fatigue performance of three medium-carbon (0.4 C) bar steels representing microstructural classes characteristic of forging steels used for crankshaft and other automotive applications. Deep rolling is a surface deformation process whereby a radially symmetric work piece undergoes a surface deformation operation. The steel grades included a quenched and tempered alloy steel (4140) that demonstrated a high yield stress and low strain hardening rate, a non-traditional bainitic experimental grade (1.2 Mn, 0.72 Si) containing high amounts of retained austenite with low yield stress and high strain hardening rate, and a ferritic/pearlitic grade (1.3 Mn, 0.56 Si) with a low yield stress and medium strain rate hardening rate. A reproducible test methodology to assess fatigue behavior was developed, based on flex-beam, fully reversed, S-N type laboratory fatigue testing.

Bake-hardening steels used for exposed auto-body panels provide low yield strengths before forming, and increased strength and dent resistance after the forming and paint-baking processes. Room temperature aging can alter the sheet properties before forming, after forming, or after baking. Knowledge of the evolution of mechanical properties is important, and the effects of room temperature and simulated room temperature aging (at 50°C and 100°C) on the yielding behavior and the bake hardening response of two different bake-hardening steel grades were studied. The steels included a low strength ultra-low carbon steel and a dual-phase steel with higher strength and greater bake-hardening index. Neither steel exhibited a substantial response to aging prior to tensile pre-straining, although both steels exhibited strength increases after either aging or baking following straining.

Dynamic mechanical properties of TRIP steels with the same volume fraction but different stabilities of retained austenite were evaluated over a wide range of strain rates using a high-velocity hydraulic tensile testing machine. Tensile tests were performed at strain rates ranging from 10-2 to 6×102s-1 and ultimate tensile strength, strain hardening behavior, and absorbed energy were evaluated. Strain control during high speed tensile testing was accomplished using a “stopper” attachment designed to limit strain within the gage section to an amount preset before testing. Strain was controlled successfully up to the highest strain rate examined, 200 s-1. The methodology allowed, for the first time, the extent of austenite transformation to be monitored at incremental strains during a high-rate test. At all strain rates, the extent of martensite transformation was considerable after only a few strain percent, and was essentially complete well before the onset of necking.