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Cost-Effective One-Shot Stamping of Steel-Based High-Performance Lightweight Multi-Material Structures

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Abstract:

To address the challenges met in the manufacturing of state-of-the-art multi-material structures, this work employs a novel one-shot stamping process with single-stamp forming of advanced high-strength steels (AHSS)-based multi-material structures consisting of dual-phase steel (DP780) and low-cost glass fibre-reinforced polyamide 6 (GF/PA6). The effects of DP780 surface treatment and forming temperature on interfacial bonding with GF/PA6 were first assessed using double cantilever beam (DCB) tests, alongside tensile tests of DP780 to assess post-stamping performance. Sandblasting on DP780 significantly improved bonding strength compared to non-treated surface, while the interfacial fracture energy (GC) increased with forming temperature up to 350 °C before decreasing at higher temperatures, which is attributed to PA6 squeeze-out and DP780 surface oxidation. Although the tensile strength for DP780 decreased with increasing temperature, the yield strength peaked at 350 °C, identifying sandblasting and a forming temperature of 350 °C as the optimal processing conditions for DP780. Based on the optimal conditions determined, high-quality U-shaped demonstrator components were successfully produced with good surface finish, minimal polymer squeeze-out, and no observable defects, via further optimisation of the forming conditions.

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Periodical:

Solid State Phenomena (Volume 387)

Pages:

95-101

DOI:

https://doi.org/10.4028/p-B5pfph

Citation:

Cite this paper

Online since:

April 2026

Authors:

Hao Wu*, Mohamed Mohamed, Chunyi Gao, Zerong Ding, Manikandan Ganapathy, Pinaki Biswas, Rahul K. Verma, Ambrose Taylor, Nan Li

Keywords:

Advanced High-Strength Steel, DP780, Glass Fibre, Multi-Material Structures, PA6, Sheet Forming

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Creative Commons CC BY 4.0

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* - Corresponding Author

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