In this work, the mechanism of void and microcrack formation along the adiabatic shear bands (ASB) was studied for processing dual phase steel by cold heading. Experimental investigation along with finite element simulation has confirmed that this mechanism depends on two types of instabilities, namely geometrical and thermal instabilities. The geometric instability occurs in the presence of second phase particles (inclusions) and in relation to the material flow orientation, whilst the thermal softening arises due to the localized plastic deformation inside the ASB. Progressive deformation was observed to cause the elongation of voids in the direction of shearing that formed microcracks in the ASB of the cold headed specimen. In addition, transformed bands were observed in the highly deformed zones as a result of the temperature in the ASB exceeding the Ac 3 transformation temperature 847°C. The superposition of the location of the ASB region containing the voids and micro-cracks with the phase transformation zone indicates that the development of optimized processing conditions is particularly critical for preventing fracture during cold heading of dual phase steels.KEY WORDS: dual phase steel; cold heading; adiabatic shear bands; voids; cracks; inclusions.rials. However, most of the plastic work (90-95 %) is converted into heat causing a local temperature increase and a flow stress decrease. Thus, a competing mechanism between the work hardening and the thermal softening commences and continues in the deformation zone. As the work hardening mechanism dominates over the thermal softening at the beginning, an increase in the flow stress occurs and with continuing deformation, the thermal softening mechanism can progressively dominate over work hardening increases, which then triggers unstable deformation. This instability condition will force the deformation to localize into a narrower band that through further localization can lead to final failure.
4)There are two types of ASBs, namely the deformed adiabatic shear bands (DASBs) and the transformed adiabatic shear bands (TASBs). DASBs occur in materials that do not undergo phase transformation, or when the local increased temperature in the band is not high enough to cause phase transformation. The damage and fracture process in DASBs involves a number of metallurgical events involving different steps between void nucleation and crack propagation. The initial phase of damage coincides with void nucleation at inclusion edges or at grain boundaries due to the interaction of local stresses and dislocations phenomena. The damage in the material is then driven by the accumulated plastic strain and affected by the stress triaxiality. 5) Moreover, deformation under compressive loads shows that when there is compressive (negative) stress triaxiality, the formability is greater than in the tensile loading state, i.e. positive stress triaxiality.6) It is therefore a competition between the stress triaxiality levels reached in the specimen and the high plastic strains, w...