Materials Science & Engineering A 680 (2017) 197202

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Materials Science & Engineering A

journal homepage: www.elsevier.com/locate/msea

A novel and simple technique for development of dual phase steels with
excellent ductility
crossmark

H. Ashra , M. Shamanian, R. Emadi, N. Saeidi
Department of Materials Engineering, Isfahan University of Technology, Isfahan 84156-83111, Iran

A R T I C L E I N F O A BS T RAC T

Keywords: A new and simple approach was introduced to produce dual phase (DP) steels with excellent ductility. This
Dual phase steel technique included intercritical annealing of a cold-rolled ferrite-pearlite structure followed by water quenching
Mechanical characterization to produce a ferrite-martensite duplex structure, and a subsequent short intercritical annealing at a lower
Ductility, work hardening temperature followed by water quenching to produce the nal DP steel. It was found that the microstructure of
the newly developed DP steel consisted of chain-like networked martensite in the ferrite matrix with both
ultrane and coarse grain structure. Despite the same value of ultimate tensile strength (736 MPa), the
uniform elongation and total elongation of the newly developed DP steel were 52% and 54% higher than those
for a DP steel with the same composition and martensite volume fraction produced by conventional intercritical
annealing. This new DP steel also exhibited a superior strength-elongation balance (UTSTE > 30,000 MPa%)
in comparison with commercial and thermomechanically processed DP steels. The newly developed DP steel
showed two stages of work hardening based on the Kocks-Mecking approach corresponding to an initial rapid
decrease of work hardening rate (= d/d) with stress followed by stage III hardening. This steel also exhibited
larger values of work hardening exponent in the Hollomon and Ludwik equations compared with the
intercritically annealed DP steel.

1. Introduction properties of DP steels. Das et al. [6] studied the inuence of

Dual phase (DP) steels which consisted of martensite islands in
ferrite matrix are part of the family of advanced high strength steels
(AHSS) that oer improved mechanical properties such as high
strength, continuous yielding, low yield ratio and high initial work
hardening rate, making them suitable for automotive applications
[1,2]. However, the moderate fracture strain is one of the, is not the
main, limitation for extending the range of applications for DP steels,
especially when the components undergo substantial deformation
during forming [3]. Present day industrial applications of sheet metal
forming require materials with high plastic deformation potential and
high strength. This goal is not easy to achieve, because usually an
increase in the strength of the sheet involves a reduction in its
formability. The requirements of specic application determines the
trade-o between strength and ductility which leads to microstructure
engineering challenges [4].
Mechanical properties of DP steels primarily depends on the
volume fraction, morphology, size, distribution and properties of the
constituent phases [5]. So far, some researches has been performed
regarding the inuence of microstructural features on the mechanical
martensite morphology on tensile properties of DP steels. They found
that ne and brous martensite obtained by intercritical annealing of
an initial martensitic structure possess the best combination of the
strength and ductility. Saeidi et al. [7] reported that by renement of
martensite particles in a DP steel, uniform elongation (UE) as well as
total elongation (TE) were improved by 25% and 34%, respectively,
while tensile strength was nearly the same. Papa Rao et al. [8]
produced ultrane grained DP steel with bimodal grain structure.
They observed that bimodal ferrite grain structure promoted work
hardening rate and UE, while ultimate tensile strength (UTS) slightly
decreased. These studies demonstrated that mechanical properties of
DP steels can be improved by controlling the microstructural features
like martensite morphology and size and ferrite grain structure.
DP steels are conventionally fabricated through intercritical anneal-
ing of a low carbon steel with suitable chemical composition [9]. In the
last decade many attempts have been made to design new processing
methods for the development of DP steels with improved mechanical
properties. However, these studies only focused on the improvement of
strength and production of ultra-high strength DP steels [1014].
In the present study, a novel and simple technique is introduced to

Corresponding author.
E-mail address: h.ashra@ma.iut.ac.ir (H. Ashra).

http://dx.doi.org/10.1016/j.msea.2016.10.098
Received 30 August 2016; Received in revised form 16 October 2016; Accepted 26 October 2016
Available online 28 October 2016
0921-5093/ 2016 Elsevier B.V. All rights reserved.
H. Ashra et al.
Fig. 1. Processing routes used in this study to produce DP steels, (a) one-step annealing,
(b) double-step annealing. A1 and A3: austenite formations start and nish temperature
during heating, respectively; WQ: water quenching; CR: cold rolling.
produce a DP steel with new microstructure and improved ductility
without the loss of strength. In this technique, rst a ferrite-martensite
duplex structure with equal volume fraction of each phase was
produced by intercritical annealing of a cold-rolled ferrite-pearlite
structure followed by water quenching. Then, this duplex structure
underwent a short intercritical annealing at a lower temperature and
subsequent water quenching to produce the nal DP steel. The tensile
properties of the newly developed DP steel were examined and
compared to those for a DP steel with the same amount of martensite
volume fraction prepared by conventional intercritical annealing and
subsequent water quenching.
2. Materials and methods
The steel used in this investigation was a hot rolled plate of low
carbon-manganese steel (0.18% C, 1.25% Mn, 0.2% Si) with a thickness
of 5 mm. The processing methods used in this study to produce DP
steels are schematically illustrated in Fig. 1. Two routes, a one-step
annealing and a double-step annealing, were employed to produce DP
steels with dierent microstructures. In the one-step annealing route or
conventional intercritical annealing process (Fig. 1a), rst the initial
ferrite-pearlite structure was cold-rolled up to 60% of thickness
reduction. The cold-rolled steel was then isothermally annealed at
the intercritical temperature of 720 C for 60 min and water-quenched
(cooling rate 300 C/s) to obtain the DP structure. In the double-step
annealing (Fig. 1b), the cold-rolled steel was rst annealed at the
intercritical temperature of 780 C for 60 min and quenched in water
to produce a ferrite-martensite duplex structure. The resulting duplex
structure was subsequently underwent a short intercritical annealing at
720 C for 15 min followed by water quenching to produce the nal DP
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Materials Science & Engineering A 680 (2017) 197202
steel. The critical temperatures of A1 and A3 were calculated to be
715 C and 833 C, respectively, using the following equations [15]:
A1 = 723 10.7Mn + 29.1Si 16.9Ni + 16.9Cr + 290As + 6.38W (1)
A3 = 910 203 C + 44.7Si 15.2Ni + 104V + 31.5Mo + 13.1W (2)
The microstructure of samples were investigated using optical
microscopy (OM) and scanning electron microscopy (SEM). After
grinding to 4000 grit nish and polishing with 0.3 m alumina
suspension, the specimens were etched in 2% Nital solution to reveal
the microstructure. Grain size and volume fraction measurements were
respectively conducted by mean intercept (ASTM E112-96 [16]) and
point counting (ASTM E562-83 standard [17]) methods, using the
image J software. Tensile specimens (12.6 mm gauge length, 5 mm
width, 2 mm thickness) were machined out from the processed steels
through electro discharge machining. For each kind of steel, three
specimens were prepared and tensile tested at a constant cross head
speed of 1 mm/min using a Hounseld H50KS machine. The fractured
surfaces of tensile tested specimens were examined by SEM to reveal
the nature of the fracture mode.
3. Results and discussions
3.1. Microstructures
Fig. 2a shows the microstructure of the initial steel consisted of
85 vol% of ferrite with a grain size of 6 m and 15 vol% of pearlite.
The microstructure of cold-rolled steel (Fig. 2b) consisted of elongated
pearlite and ferrite grains parallel to the rolling direction. After
intercritical annealing at 780 C for 60 min followed by water quench-
ing (Fig. 2c), a duplex microstructure composed of 50 vol% of
martensite islands (dark phase) in the ferrite matrix (bright phase)
was obtained. The average grain size of ferrite was 3.7 m and
martensite islands had an average diameter of 4.6 m.
Fig. 3 shows the SEM images of DP microstructures obtained by
dierent routes. For the DP steel produced by one-step annealing
(Fig. 3a), equiaxed and mostly isolated martensite islands were
observed in the ferrite matrix. For the newly developed DP micro-
structure obtained by the double-step annealing (Fig. 3b), chain-like
networked martensite islands along the ferrite grain boundaries were
observed. Both steels consisted of a similar martensite volume fraction
of 28%. However, the martensite islands were smaller in the double-
step annealed sample. The grain size of ferrite in the one-step and
double-step annealed samples were 5 0.18 and 4 0.3 m, respec-
tively. The ferrite grains in the DP microstructure produced by one-step
annealing were predominantly larger than 2 m, but the microstruc-
ture of the double-step annealed DP steel consisted of both ultrane
ferrite grains with sizes smaller than 2 m and coarse ferrite grains
with sizes larger than 5 m. All the ultrane ferrite grains were located
within the martensite islands, implying that they were nucleated in the
second intercritical annealing step. A small number of UFG ferrite
grains was also observed in the one-step processed sample. These UFG
ferrite grains were located in areas with the higher number density of
martensite islands, where the presence of austenite islands at the
intercritical temperature prevented the growth of ferrite grains. Park
et al. [18] also obtained chain-like networked martensite in DP steels
by intercritical annealing and subsequent water quenching of a cold
rolled martensitic microstructure. However, in the present study the
chain-like networked martensite islands in ferrite matrix were pro-
duced by intercritical annealing of un-deformed duplex microstructure
followed by water quenching.
3.2. Tensile properties
The engineering and true stress-strain curves of DP steels are
illustrated in Fig. 4. Table 1 presents a summary of tensile properties of
H. Ashra et al.
Fig. 2. OM micrograph of (a) initial steel, (b) initial steel after 60% of cold rolling, (c) duplex microstructure obtained by intercritical annealing of cold-rolled sample at 780 C followed
by water quenching.
studied DP steels. Both DP steels showed continuous yielding and low
yield ratio which are typical characteristics of DP steels [2]. Although
both steels had almost the same value of UTS, but the double-step
annealed DP steel showed a yield strength (YS) of 9% lower than that
for the one-step annealed sample. However, the double-step annealed
sample exhibited excellent UE and TE values of 31.33% and 42.51%,
respectively, which were about 52% and 54% higher than those for the
one-step annealed DP steel. The excellent elongation of DP steel
produced by double-step annealing route can be attributed to three
factors:
chain like networked morphology of martensite phase;
small size of martensite islands;
presence of UFG ferrite grains besides the coarse grained ferrite.
It has been demonstrated that chain-like networked martensite
surrounding ferrite grains improves the work hardenability of DP steels
and reduce the degree of strain partitioning between the ferrite and
Fig. 3. SEM micrographs of DP steels obtained by (a) one-step annealing, and (b) double-step annealing. CG F: Coarse grained ferrite; UFG F: Ultrane grained ferrite.
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Materials Science & Engineering A 680 (2017) 197202
martensite, leading to a DP steel with adequate elongation along with
high strength levels [18,19]. It was also demonstrated that the
plasticity of martensite increases with decreasing its particle size.
Reducing the martensite particle size also cause more eective load
transfer to them [14]. Therefore a DP steel with ne martensite particle
size is expected to have a low yield strength with high ductility. The
simultaneous presence of UFG and coarse ferrite grains also leads to a
DP steel with good combination of strength and ductility, as UFG
ferrite provides strength while CG ferrite provides ductility for the
material. This is in agreement with the previous results on bimodal
grain-sized steels [8,20,21].
Energy absorption capability (UTSTE) is an important parameter
representing the crashworthiness in the automotive industry [22].
Fig. 5 compares the data of UTS vs. TE for the DP steels produced in
the present study with those reported in the literature for DP and TRIP
steels [14,2327]. As can be seen, the new DP steel developed by
double-step annealing had superior strength-elongation balance
(UTSTE > 30,000 MPa%) compared with commercial and thermo-
H. Ashra et al. Materials Science & Engineering A 680 (2017) 197202

Fig. 6. Variations of work hardening rate (=d/d) versus true stress for DP steels
produced in this study. TS: Transient stage.

mechanically processed DP steels. This steel also exhibited a higher

strength-elongation balance compared with commercial TRIP590 and
TRIP780 steels. This was owing to the excellent elongation of the newly
developed DP steel, which along with its sucient level of strength,
make it very suitable for components that undergo substantial defor-
mation during forming processes.

3.3. Work hardening behavior

Fig. 4. (a) Engineering and (b) true stress-strain curves of the DP steels produced in the
The work hardening behavior of DP steels were analyzed based on
present study. the Kocks-Mecking approach [28]. Fig. 6 illustrates the variations of
work hardening rate (=d/d) as a function of true stress. The DP
Table 1 steel obtained by one-step annealing exhibited one stage of hardening
Summary of the tensile properties of studied DP steels. behavior corresponding to stage III in which the work hardening rate
decreased almost linearly with the true stress [28]. However, the
Sample YS (MPa) UTS (MPa) UE (%) TE (%) Yield ratio double-step annealed DP steel exhibited a two stage behavior corre-
One-step 441 7 736 5 20.58 0.26 27.56 0.31 0.6
sponding to an initial rapid decrease in work hardening rate with stress
annealed or transient stage followed by the stage III hardening at higher stresses.
DP steel The transient stage which was previously observed in Kocks-Mecking
Double-step 401 9 734 6 31.33 0.38 42.51 0.62 0.55 plots of ferritic steels [29], is dierent from stage I in single crystals,
annealed
and occurs only at low initial plastic strains, the value of which depends
DP steel
on stacking fault energy [30]. There are contradicting reports in the
literature regarding the work hardening behavior of DP steels. Farabi
et al. [31] observed two stages of work hardening in a DP600 steel
corresponding to stage III and stage IV, and three stages of work
hardening in a DP980 steel corresponding to stage II, stage III and
stage IV. In contrast, Delince et al. [32] only observed one stage of work
hardening corresponding to stage III for their DP steels with dierent
grain sizes and VM values. Other studies that used empirical analysis
methods like Hollomon [33], CrussardJaoul [6] and modied
CrussardJaoul [34] for analyzing the work hardening behavior of
DP steels also reported two or three stages of work hardening for DP
steels, which at each stage dierent deformation mechanisms are
involved.
According to Fig. 6, at low and medium stress levels the DP steel
produced by double-step annealing method had a lower work hard-
ening rate than the DP steel produced using one-step annealing,
whereas at high stresses the trend was reversed. This can be attributed
to the presence of UFG ferrite grains and small size of martensite
islands in the double-step annealed DP steel. It has been demonstrated
that UFG and nanocrystalline materials have a low work hardening rate
because the density of dislocations in a nanocrystalline sample
Fig. 5. Comparison of strength-elongation balance (UTSTE) for the new DP steel saturates due to dynamic recovery or due to the annihilation of
developed in this study with those reported for various DP and TRIP steels in the dislocations into the grain boundaries [35]. The presence of UFG
literature [14,2327].
ferrite grains in the DP steel produced by the double-step annealing
decreases its work hardening rate. It was also mentioned that the
plasticity of martensite increases with decreasing its particle size.
Therefore, the higher plasticity of ne martensite islands in the

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H. Ashra et al.
Table 2
Magnitude of work hardening and work hardening exponents of Hollomon (n) and
Ludwik (m) equation of studied DP steels.
Sample Work hardening magnitude (MPa) n m
One step annealed DP steel 295 0.23
Double-step annealed DP steel 333 0.28
double-step annealed sample also lowers its work hardening rate [36].
At high stress values, the DP steel produced by double-step annealing
method exhibited a higher work hardening rate than the one-step
annealed steel.
After yielding, the stress-strain curve in the uniform deformation
stage can be expressed by the following relations:
(1) Hollomon equation [37]:
= k n
(2) Ludwik equation [38]:
= 0 + k m
where and are true stress and true strain, 0 is the elastic limit, k is
the strength coecient and n and m are work hardening exponents.
Work hardening exponent (n) is a good indicator for the work
hardenability of a material. A material with a high value of n has a
high work hardening rate and is preferred for processes involving
plastic deformation. Furthermore, a material with a larger work
hardening exponent value can deform more before necking starts
[39]. The values of work hardening exponents of Hollomon and
Ludwik equations and magnitude of work hardening for studied DP
steels are presented in Table 2. The values of work hardening
exponents were evaluated by tting the true stress-strain curves to
the Eqs. (3) and (4). As can be seen in Table 2, the DP steel produced
by double-step annealing had larger values of work hardening exponent
than the DP steel produced by one-step annealing, which is consistent
with its higher values of UE and magnitude of work hardening. This
indicates that the new DP steel developed by double-step annealing has
a strong deformation ability and is more suitable for the parts requiring
intensive plastic deformation during their fabrication.
3.4. Fractography analysis
Representative fractographs of tensile tested specimens are pre-
sented in Fig. 7. The fracture surface of both DP steels consisted of
dimples, implying ductile fracture behavior for them. The ductile
fracture in DP steels occurs in three stages: voids nucleation, voids
growth and voids coalescence [33]. Three modes of void nucleation was
reported in DP steels, namely martensite cracking, ferrite-martensite
Fig. 7. SEM image on the fracture surfaces of DP steels produced by (a) one-step annealing, and (b) double-step annealing.
Materials Science & Engineering A 680 (2017) 197202
interface decohesion and decohesion at ferrite-ferrite interfaces [40].
The double-step annealed DP steel showed larger and deeper dimples
compared with the one-step annealed sample. It was shown by Park
et al. [18] that when the martensite grains form a chain-like networked
structure, their joint part acts as the preferential sites for micro-void
0.56 formation. On the other hand, when the martensite grains are isolated
0.58
in ferrite matrix, micro-voids predominantly form at the ferrite-
martensite interfaces. The number of dimples per unit area on the
fracture surface depends mainly on the number of nucleation sites [7].
Since the area of the joint part of martensite grains is less than the
ferrite-martensite interfaces, lower density of voids is created in the
new DP steel developed by double-annealing and the distance between
them would be higher than that for the one-step annealed DP steel.
Therefore, the dimples in the former can grow to a higher degree and
will coalescence with each other at larger strains. This is consistent
with the higher UE and TE of the double-step annealed DP steel.
Mazaheri et al. [41] also observed that in their thermomechanically
(3) processed DP steels, TE had a direct relation with the dimple size so
that TE increased with increasing the dimple areal density.
(4) 4. Conclusions
In this study, a new and simple method was developed to produce a
DP steel with excellent ductility. This method, named double-step
annealing, included intercritical annealing of a cold-rolled ferrite-
pearlite structure followed by water quenching to produce duplex
structure containing equal volume fraction of ferrite and martensite,
and a subsequent short intercritical annealing at a lower temperature
followed by water quenching to produce the nal DP steel. The
microstructure and mechanical properties of the new DP steel pro-
cessed by this double-step annealing method was compared to those
for a DP steel with the same composition and martensite volume
fraction produced by one-step annealing or conventional intercritical
annealing route. Examination of microstructure and tensile deforma-
tion behavior of both DP steels showed that:
1. The microstructure of the newly developed DP steel consisted of
chain-like networked martensite within the ferrite matrix, while the
martensite islands in the one-step annealed DP steels were isolated.
The former also contained both UFG and coarse ferrite grains.
2. The YS of the double-step annealed DP steel was 9% lower than
that for the one-step processed sample. However, despite the same
value of UTS, the former exhibited UE and TE values of 52% and
54% higher than those for the one-step annealed sample. The
double-step annealed DP steel also exhibited superior strength-
elongation balance (UTSTE > 30,000 MPa%) in comparison with
commercial AHSS and thermomechanically processed DP steels.
3. The newly developed DP steel showed two stages of work hardening
behavior based on the Kocks-Mecking approach corresponding to an
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initial rapid decrease of work hardening rate with stress followed by
stage III hardening in which the work hardening rate linearly
decreased with increasing the true stress. However, only onestage
of work hardening (stage III) was observed for the one-step annealed
sample. The newly developed DP steel also exhibited larger values of
work hardening exponent in comparison with the DP steel produced
by one-step annealing, implying that this steel is more suitable for
processes involving plastic deformation.
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