Quantification of forming-induced damage in case-hardening steel AISI 5115 by advanced SEM methods

Abstract As climate change and resource scarcity intensify, the need for energy efficiency, emissions reduction, and resource conservation grows. Forming technology offers significant potential for light weighting, cost and resource efficiency. However, current component design often neglects forming-related damage, such as voids, focusing primarily on mechanical properties and safety factors. Integrating knowledge of these voids into the design process can improve efficiency and increase light weighting potential. Advanced scanning electron methods, such as electron contrast channeling imaging, evaluated forming-induced damage and correlated it with fatigue properties. Crack initiation occurred mainly near manganese sulfide inclusions or near-surface voids, influencing crack propagation. Analyzing void distribution using advanced secondary electron methods enabled the development of a 3D volume model.