Influence of Punch Shape on Joint Strength in Forge Joining of Al-Si-Coated 22MnB5 Steel During Hot Stamping and Application to Hat Bending

Ultra-high-strength steel sheets were joined by forge joining during hot stamping. This study investigated the influence of punch cross-sectional shape and punch tip inclination shape on joint strength through experiments and finite element simulation, with applications in hat bending. The experiments systematically evaluated various punch geometries by varying the punch’s cross-sectional shape and the aspect ratio of rectangular punches. A second set of experiments focused on the influence of punch tip inclination shape. These experiments examined a rectangular punch with a slope. Joint strength is primarily assessed by measuring the tensile shear load. Finite element simulation was used to analyze joining mechanisms, investigating contact pressure and surface expansion rate distribution. The results from the experiments consistently indicated that, for a constant cross-sectional area, punch shapes with a larger punch perimeter on the upper sheet yielded a higher tensile shear load, though the changing inclination shape of the rectangular punch tip did not lead to an observed improvement in joint strength. Finite element simulation analysis revealed that punch shapes promoting a uniform distribution of contact pressure and surface expansion rate across the joint area tended to exhibit higher joint strength compared with the same punch cross-sectional area but less uniform distribution, a tendency that was more pronounced for the distribution of contact pressure than for the surface expansion rate.