The paper is dedicated to forming and properties of passenger car’s B-pillar reinforcement drawn from simple blank and alternatively tailor-welded blank (TWB). Drawn part is characterised by a place with a large strain, while forming process simulation did not confirm the creation of crack using the TWB consisting of dual phase HCT980X instead of previous HCT600 steel. It is because HCT980X steel has higher strength and lower ductile properties. The analysis of properties of drawn parts is focused on the simulated crash test in Dynaform software. Obtained sizes of drawn forces in simulated frame of the drawn parts and their comparison proved the possibility of the replacement the 1.2 mm thick simple blank from HCT600 steel with the 1 mm thick TWB consisting of HCT600 and HCT980X steel. The changed thickness of the simple blank caused 20% weight saving while containing the same properties of the drawn part.

The high-strength steels and tailor welded blanks (TWB) are applied in construction of cars parts to reduction of cars weight [1, 2]. The application of these materials brings possible complicatons during the forming when it proves the considerable influence of stress-strain characteristics differences of of the individual parts of TWB what result in non-constant material flow and consequently a negative movement of the weld interface [3, 4]. One of the ways of elimination of this negative effect is to choose a suitable blankholder system with optimal distribution of blankholder forces by using elastic blankholder with adjustable distribution of blankholder forces. Within the bounds of study the experimental blankholder system with elastic blankholder with adjustable distribution of blankholder forces was used [5, 6]. Finite element methods (FEM) simulation has unsubstitutable role n the study of formability of TWB whereby it is possible to determine the values and points of application of the blankholder forces [7, 8]. The FEM simulations results carried out in simulative LS-Dyna software are presented in this article which is focused on achieving weld interface movement minimalization of tailor welded blanks from DP600 and BH220 materials by optimization of blankholder forces [9, 10].

This article is focused on an analysis of factors negatively affecting the tube production process of tubes made from austenitic stainless steel with a very small diameter of ϕ 0.34 mm. The analysis was concentrated on factors that affect the drawing process stability of the seam tubes where the desired final dimensions—a diameter of ϕ 0.34 mm and a wall thickness of 0.057 mm—are limiting factors. Seam tubes made from steel 1.4306 and 1.4301, from producers KT and EW with a longitudinal weld line made by tungsten inert gas (TIG) welding, were used as blanks for constituent drawing operations. It is desirable to provide sufficient inert gas flow and cooling during the formation of a weld joint in a protective atmosphere chamber. A significant temperature gradient prevents the formation of undesirable Cr₂₃C₆ carbides in the heat-affected zone (HAZ) which negatively affects the plasticity and formability of the steel and is the cause of technological fractures.

This work presents a new technology for joining dissimilar materials, Resistance Element Soldering (RES). This technology is fundamentally based on Resistance Element Welding (REW) technology; the difference is that the presented RES uses a bimetallic element composed of a hard Cu shell and a core made of Sn60Pb40 solder. The RES technology using the Cu/Sn60Pb40 bimetallic element was tested when joining a galvanized steel sheet (HX220BD-100MBO) to a thermoplastic (PMMA). The effect of the process parameters on the volume of the melted solder, the deformation of the element, and the structure of the soldered joint was investigated on the joints made. The final criterion for assessing the influence of the process parameters was the joint strength. Due to the low strength of PPMA, the maximum joint strength was determined on RES joints of galvanized steel sheet and aluminum. The results showed that, to ensure the joint strength at the level of the strength of the Sn60Pb40 solder used, a heat input of 952 J and a clamping force of 623 N are required. The mentioned parameters ensure the necessary conditions for the creation of a soldered joint with a galvanized steel sheet as well as the deformation of the bimetallic element to create a form-fit effect in the opening of the PMMA to create a mechanical connection.

The joining of sheet metal parts produced in the material combination of Fe-Fe, Fe-Al as well as Fe-thermoplastic and Al-thermoplastic can be realized by the Resistance Element Soldering (RES). Extruded bimetallic elements were used to form the overlap joint. The semi-finished product for extrusions was a Cu 99.9 tube with dimensions φ6 × 0.5 mm and length 9 mm, filled with Sn60Pb40 solder. “T” shaped overprints were produced in two ways. Simulation in the ANSYS software environment was chosen to optimize, select the appropriate forming process, and design the geometry of the functional parts of the forming tool, allowing to use only one extrusion forming operation. The results of the simulations are the magnitudes of stresses and strains, and different head shape geometries of the bimetallic element extrusions of the three proposed forming methods. The task was to achieve extrusions without defects of the Cu tube shell, such as corrugations and wrinkles. The geometry was observed and compared by macroanalysis of extrusion sections made on a laboratory forming tool.