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<p>The influence of the flash butt welding (FBW) process on 590CL high-strength low-alloying steel was studied using physical simulations on a Gleeble 3500 thermo-mechanical simulator. The FBW-ed samples exhibited distinct microstructural zones: coarse-grained heat-affected zone (CGHAZ), fine-grained heat-affected zone (FGHAZ), and inter-critical heat-affected zone (ICHAZ). The CGHAZ contained lamellar bainite (LB), acicular ferrite (AF), and granular bainite (GB), while the FGHAZ had reduced LB and AF. The ICHAZ primarily consisted of equiaxed polygonal ferrite with smaller amounts of AF and GB. The grain size followed the trend: CGHAZ &gt; FGHAZ &gt; base metal (BM) &gt; ICHAZ. Microhardness values varied across zones: CGHAZ (&gt; 220 HV<sub>0.5</sub>), FGHAZ (200 to 220 HV<sub>0.5</sub>), ICHAZ (190 to 200 HV<sub>0.5</sub>), and BM (180 to 190 HV<sub>0.5</sub>), influenced by phase structure, dislocation density, grain refinement, and local misorientation. A higher flash allowance led to grain coarsening and increased hardness while increasing flash speed reduced dislocation density and hardness in the HAZs. Increasing the upsetting allowance refined the CGHAZ grain structure and lowered hardness by extruding material. However, a small increase (e.g., 1.5 mm) in upsetting allowance raised hardness due to greater plastic deformation. The FBW process had no effect on the ultimate tensile strength of 590CL steel. These findings provide insights for optimising the FBW process of 590CL steel wheel rim production.</p>

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Physical Simulation of Flash Butt Welding of 590CL Steel for Automotive Wheel Using: Process, Microstructure and Mechanical Properties

  • 期刊论文

  • 发表日期：

    2025年9月12日

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  • Lisong Zhu,
  • Hongqiang Liu,
  • Zhiqiang Zhang,
  • Mengyuan Ren,
  • Hao Liu,
  • Li Sun,
  • Limin Wang,
  • Cheng Ma,
  • Jian Han,
  • Zhengyi Jiang

摘要

The influence of the flash butt welding (FBW) process on 590CL high-strength low-alloying steel was studied using physical simulations on a Gleeble 3500 thermo-mechanical simulator. The FBW-ed samples exhibited distinct microstructural zones: coarse-grained heat-affected zone (CGHAZ), fine-grained heat-affected zone (FGHAZ), and inter-critical heat-affected zone (ICHAZ). The CGHAZ contained lamellar bainite (LB), acicular ferrite (AF), and granular bainite (GB), while the FGHAZ had reduced LB and AF. The ICHAZ primarily consisted of equiaxed polygonal ferrite with smaller amounts of AF and GB. The grain size followed the trend: CGHAZ > FGHAZ > base metal (BM) > ICHAZ. Microhardness values varied across zones: CGHAZ (> 220 HV0.5), FGHAZ (200 to 220 HV0.5), ICHAZ (190 to 200 HV0.5), and BM (180 to 190 HV0.5), influenced by phase structure, dislocation density, grain refinement, and local misorientation. A higher flash allowance led to grain coarsening and increased hardness while increasing flash speed reduced dislocation density and hardness in the HAZs. Increasing the upsetting allowance refined the CGHAZ grain structure and lowered hardness by extruding material. However, a small increase (e.g., 1.5 mm) in upsetting allowance raised hardness due to greater plastic deformation. The FBW process had no effect on the ultimate tensile strength of 590CL steel. These findings provide insights for optimising the FBW process of 590CL steel wheel rim production.