Paper Titles
Hybrid Hot Forming of High-Strength Aluminum Alloys: Influence of Local Deformation on Post-Aging Mechanical Properties
p.171
Mitigation of Geometric Inaccuracy in Closed-Contour Incremental Sheet Forming via Curvilinear Toolpath
p.181
Multi-Stage Roller Embossing of Bipolar Plate Microchannels Using 3D-Printed Tooling
p.191
Experimental and Numerical Investigation of AA6061 Tube Flowformability
p.207
Resistance Heating in an Atmosphere Suitable for XHV with Thin Aluminium Film Coating
p.217
Rubber Forming as a Novel Manufacturing Approach for Bipolar Plates in Fuel Cell Systems
p.227
Single Point Incremental Forming (SPIF) of Stainless Steel 304 Quilted, Laser Welded Blanks
p.243
Reducing the Uncertainty in Flow Forming of Metastable Austenites
p.253
Agile Tube Roll Forming, a New Process Architecture for Manufacturing of Longitudinally Welded Tubes
p.267

Resistance Heating in an Atmosphere Suitable for XHV with Thin Aluminium Film Coating

Article Preview
View Pdf By email

Abstract:

Hot stamping of manganese–boron steels is widely used in automotive manufacturing to produce ultra-high-strength components with tensile strengths exceeding 1500 MPa . Conventional industrial heating relies on gas-fired roller hearth furnaces, which require 5 – 10 min to reach austenitization and exhibit low energy efficiency . Resistance heating offers a compact and energy-efficient alternative, enabling heating rates above 100 K/s and full austenitization within seconds. However, rapid heating of uncoated steels leads to severe oxidation, and established coating systems such as AlSi are not designed for diffusion-controlled bonding within such short times . This study demonstrates that resistance heating in an XHV-adequate atmosphere – consisting of nitrogen and monosilane – suppresses oxidation while simultaneously enabling adhesion of a pre-laminated aluminum foil to the steel substrate. For coating preparation, 22MnB5 sheets were roughened by corundum blasting, cleaned, and laminated with an aluminum foil using a flat-die pressing tool. The pre-coated blanks were heated in a self-developed resistance-heating chamber, in which the oxygen concentration was reduced to an XHV-adequate level. Several heating profiles were investigated to determine suitable process windows for coating formation. The results show that resistance heating achieves austenitization within a few seconds, reducing heating times by more than an order of magnitude compared to furnace heating. The XHV-adequate atmosphere reliably prevents scale formation, enabling completely oxidation-free surfaces during rapid heating. Under these conditions, the laminated aluminum foil bonds uniformly to the substrate, forming a continuous coating layer. Metallographic cross-sections and SEM analyses confirm the formation of Al–Fe intermetallic phases at the interface, demonstrating robust metallurgical bonding suitable for subsequent hot stamping operations. Overall, the combination of resistance rapid heating and an XHV-adequate atmosphere provides a highly energy-efficient process route for hot stamping while offering an opportunity to integrate aluminum-based protective coatings directly into the heating step. This approach addresses the limitations of current furnace-based heating and coating technologies and opens a promising pathway toward more flexible, sustainable, and functionally integrated hot-stamping process chains.

You have full access to the following eBook
Incremental and Sheet Metal Forming Read eBook

Info:

Periodical:

Solid State Phenomena (Volume 389)

Pages:

217-225

DOI:

https://doi.org/10.4028/p-cl9cUk

Citation:

Cite this paper

Online since:

April 2026

Authors:

Bernd Arno Behrens, Sven Hübner, Ulrich Holländer, André Langohr, Alexander Schnettger, Henrik Depke, Lorenz Albracht*

Keywords:

Coating, Hot Stamping, Resistance Heating

Funder:

The publication of this article was funded by the Leibniz Universität Hannover (LUH) / Technische Informationsbibliothek (TIB)

Export:

RIS, BibTeX

Permissions:

Creative Commons CC BY 4.0

Share:

Citation:

* - Corresponding Author

References

[1] Karbasian H, Tekkaya AE. A review on hot stamping. Journal of Materials Processing Technology 2010; 210 (15): 2103-18.

DOI: 10.1016/j.jmatprotec.2010.07.019

Google Scholar

[2] Pfeifer F, Knorr L, Schlosser F, Marten T, Tröster T. Ecological and Economic Feasibility of Inductive Heating for Sustainable Press Hardening Processes. J. sustain. dev. energy water environ. syst. 2023; 11(3): 1–20.

DOI: 10.13044/j.sdewes.d11.0450

Google Scholar

[3] Wieland Michael. Entwicklung einer Methode zur Prognose adhäsiven Verschleißes an Werkzeugen für das direkte Presshärten 2015.

Google Scholar

[4] Tobias Opitz. Vermeidungsstrategien fluiddynamischer Effekte beim Einsatz von Schnellerwärmungstechnologien in der Warmumformung 2018.

Google Scholar

[5] Gerhardt KW. Untersuchungen zur konduktiven Erwärmung für Warmzugversuche an Blechen. DissertationShaker Verlag.

Google Scholar

[6] Christian Gebel. Bewertung von martensitischen Chromstählen für die Warmumformung der automobilen Großserienfertigung 2021.

DOI: 10.51202/9783959005708

Google Scholar

[7] Philipp Olle. Numerische und experimentelle Untersuchungen zum Presshärten 2010.

Google Scholar

[8] Yilkiran D. Abschlussbericht Konduktive Erwärmung von Formplatinen für das Presshärten 2014.

Google Scholar

[9] Mori K, Maeno T, Yamada H, Matsumoto H. 1-Shot hot stamping of ultra-high strength steel parts consisting of resistance heating, forming, shearing and die quenching. International Journal of Machine Tools and Manufacture 2015; 89: 124–31.

DOI: 10.1016/j.ijmachtools.2014.10.008

Google Scholar

[10] Behrens B-A, Langohr A, Farahmand E, et al. Resistance Heating in XHV-Adequate Atmosphere: An Energy-Efficient Heating Process for Hot Stamping. In: Resistance Heating in XHV-Adequate Atmosphere: An Energy-Efficient Heating Process for Hot Stamping; 2024. AIST; 126-32.

DOI: 10.33313/512/a0603

Google Scholar

[11] Behrens B-A, Hübner S, Holländer U, Langohr A, Pfeffer C, Albracht L. Increasing the energy absorption of monolithic manganese boron steels in oxygen-free environment. IOP Conf. Ser.: Mater. Sci. Eng. 2021; 1157 (1): 12021.

DOI: 10.1088/1757-899x/1157/1/012021

Google Scholar

[12] Holländer, U.; Wulff, D.; Langohr, A.; Möhwald, K.; Maier, H. J. (2019): Brazing in SiH4-Doped Inert Gases - A New Approach to an Environment Friendly Production Process, Int. J. of Precis. Eng. and Manuf.-Green Tech. 495, 2019 (1), 187.

DOI: 10.1007/s40684-019-00109-1

Google Scholar

[13] Szafarska, M.; Olszok, V.; Holländer, U.; Gustus, R.; Weber, A. P.; Maus-Friedrich, W. (2023): Gas Phase Reaction of Silane with Water at Different Temperatures and Supported by Plasma, ACS Omega, 2023, 8, 9, 8388-8396.

DOI: 10.1021/acsomega.2c07209

Google Scholar

[14] Behrens B-A, Hübner S, Holländer U, et al. Oxygen-free resistance heating with nitrogen and silane as an energy-efficient heating process for hot stamping. IOP Conf. Ser.: Mater. Sci. Eng. 2023; 1284 (1): 12007.

DOI: 10.1088/1757-899x/1284/1/012007

Google Scholar