This article details the ESAFORM Benchmark 2021. The deep drawing cup of a 1 mm thick, AA 6016-T4 sheet with a strong cube texture was simulated by 11 teams relying on phenomenological or crystal plasticity approaches, using commercial or self-developed Finite Element (FE) codes, with solid, continuum or classical shell elements and different contact models. The material characterization (tensile tests, biaxial tensile tests, monotonic and reverse shear tests, EBSD measurements) and the cup forming steps were performed with care (redundancy of measurements). The Benchmark organizers identified some constitutive laws but each team could perform its own identification. The methodology to reach material data is systematically described as well as the final data set. The ability of the constitutive law and of the FE model to predict Lankford and yield stress in different directions is verified. Then, the simulation results such as the earing (number and average height and amplitude), the punch force evolution and thickness in the cup wall are evaluated and analysed. The CPU time, the manpower for each step as well as the required tests versus the final prediction accuracy of more than 20 FE simulations are commented. The article aims to guide students and engineers in their choice of a constitutive law (yield locus, hardening law or plasticity approach) and data set used in the identification, without neglecting the other FE features, such as software, explicit or implicit strategy, element type and contact model.

The influence of the heating rates from 10 to 1000 °C/s and annealing temperatures on the microstructure and mechanical properties of two 0.2%C, 1.9%Mn, 1.4%Si cold-rolled steels with and without the addition of carbide-forming elements (Mo, Nb, and Ti) have been investigated. Results show that the increase of the heating rate above 100 °C/s refines the parent austenitic grains in both alloys. The increment of the heating rate led to carbon heterogeneities in the austenite, which after subsequent cooling promoted the formation of a complex mixture of fine-grained constituents. As expected, at the lower heating rates the presence of Nb and Ti-rich carbides and carbonitrides controls the austenite grain growth during the annealing treatment. The tensile test results reveal that high heating rates do not have a significant influence on the tensile strength of the alloy with carbide-forming elements. On the other hand, both the ultimate tensile strength (UTS) and total elongation of the alloy without carbide-forming elements decrease, due to the formation of bands of ferrite and high carbon martensite. However, samples treated at heating rates above 100 °C/s show a combination of UTS in the range of 1400–1600 MPa, and 12–18% of total elongation. The results suggest that the microstructure heterogeneity obtained after high heating rates, especially the ferrite content, has the major effect on the mechanical behavior of the studied steels.

This study focuses on the effect of non-conventional annealing strategies on the micro-structure and related mechanical properties of austempered steels. Multistep thermo-cycling (TC) and ultrafast heating (UFH) annealing were carried out and compared with the outcome obtained from a conventionally annealed (CA) 0.3C-2Mn-1.5Si steel. After the annealing path, steel samples were fast cooled and isothermally treated at 400 °C employing the same parameters. It was found that TC and UFH strategies produce an equivalent level of microstructural refinement. Neverthe-less, the obtained microstructure via TC has not led to an improvement in the mechanical properties in comparison with the CA steel. On the other hand, the steel grade produced via a combination of ultrafast heating annealing and austempering exhibits enhanced ductility without decreasing the strength level with respect to TC and CA, giving the best strength–ductility balance among the studied steels. The outstanding mechanical response exhibited by the UFH steel is related to the formation of heterogeneous distribution of ferrite, bainite and retained austenite in proportions 0.09–0.78–0.14. The microstructural formation after UFH is discussed in terms of chemical hetero-geneities in the parent austenite.