Towards Strength–Ductility Synergy through the Synthesis and Processing of a Hybrid Sustainable AHSS, XHSS, and UHSS | ||||
| The International Conference on Applied Mechanics and Mechanical Engineering | ||||
| Volume 22, Issue 22, October 2025, Page 1-15 PDF (1.4 MB) | ||||
| Document Type: Original Article | ||||
| DOI: 10.1088/1757-899X/973/1/amme.2025.449036 | ||||
 View on SCiNiTO | ||||
| Authors | ||||
Mahmoud M Abu Elkhier  1; Bakr M Rabeeh2; S kaitbay3; Amir A Abdelsalam3
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| 1Ph.D. Postgraduate, Benha College of Engineering, Benha University, Egypt. | ||||
| 2Professor of Engineering, German University in Cairo (GUC). | ||||
| 3Staff members, Benha College of Engineering, Benha University, Egypt. | ||||
| Abstract | ||||
| Steel can be processed to reach ultra-high strength through a complicated, energy consuming time, heat treatment but usually at a drastic loss of ductility. By purposely deploying, a thermomechanical processing for heterogeneous nanostructures in an otherwise single or dual -phase steels. A ceramization, powder pack processing is being used with eutectic Boron mixture along with ammonium bicarbonate. A non-traditional hybrid structure is being introduced as a recent advance in overcoming this trade-off. Several structural designs are being explored, however a sandwich, and hierarchical, functionally gradient, domain-dispersed nanostructures is being introduced. A distinct comparison is being achieved in low alloy steel (A333 grade 6) and high alloy austenitic Mn-steel (S-52) normalized achieving either advanced high strength steel (AHSS), advanced extra-high strength steel (A-XHSS), or advanced ultra-high strength steel (A-UHSS).Ultra-fast ceramization is conducted at low energy input at 220°C, with time domain (10 and 30 minute). Low melting depressant temperature, LMD, coating (Boron-Mixture, and Ammonium Bicarbonate (ABC)), stress mismatch and thermal gradient are being considered. All previous factors induce intentional structural heterogeneities with alloy segregation, twinning, recrystallization, localized micro-plasticity, along with dominant ductility, and/or precipitated hardened phase. Moreover, these heterogeneous nanostructures in steels at ultra-fast low temperature ceramization (220°C /10 minute) play a significant role similar to multiple phases in complex alloys, for functionally graded hybrid (ceramic/metal) composite structure. A compromising is being achieved via these future innovations (Ceramization) towards a synergetic effect between high strength and high ductility, highlighting several recent steel classes (AHSS, XHSS, and UHSS). The key takeaway for this advanced low temperature processing is not only, a thermomechanical behaviour, but also a thermochemical fusion reaction along with techno economic energy and time saving of the corresponding fabricated part. A good balance of strength and ductility is achieved for either advanced high strength steel with energy balance (X~ 20,000 MPa %), advanced extra high strength steel with energy balance (X~ 40,000 MPa %) or advance ultra-high strength steel with energy balance (X ~ 60,000 MPa %) for either aerospace or automotive engineering, identifying outstanding energy challenges and sustainable opportunities. | ||||
| Keywords | ||||
| advanced high strength; extra high strength; high ductility; fusion; high strength; hybrid; heterogeneous; thermomechanical; thermochemical; synergy; and ultra-high strength | ||||
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