Fracture toughness of automotive-grade dual-phase steel (DP450) and interstitial free (IF) steel is determined using essential work of fracture (EWF) methodology. Geometrical constraints of standard fracture toughness tests made the EWF method an alternative for thin sheets. Double edge notched tension (DENT) specimens are used for the EWF tests. The two steels have different mechanical and microstructural properties, which helps test the applicability of the EWF methodology to different materials. The effect of notch-tip radius on the EWF test results is analyzed for both the steels. The sensitivity of fracture toughness to notch-tip radius is not the same for both steels. During the EWF test, the digital image correlation (DIC) technique is used to determine the local strain variation of DENT specimens. The hole expansion ratio is determined for the two steels to compare against the EWF test results. The IF steel, despite lower strength, has better fracture toughness and hole expansion capability against the DP450 steel.

Fracture toughness determination of dual-phase DP450 steel using the essential work of fracture (EWF) methodology is the major focus of this research work. The EWF method is used for the determination of fracture toughness of thin sheets in a plane stress dominant condition. The EWF method is discussed in detail with the help of DP450 steel experimental results. Double edge notched tension (DENT) specimens with fatigue pre-crack and without fatigue crack (notched) have been used for testing. Specific essential work of fracture (we), crack tip opening displacement (δce) and crack tip opening angle (ψe) parameters were used for the comparative analysis. High-intensity laser beam cutting technology was used for the preparation of notches. Fracture toughness values of fatigue pre-cracked and notched samples were compared. The effect of notch tip radius and fatigue crack on the fracture toughness values were analysed. Digital image correlation (DIC) technology was used for the identification of local strain distribution and validation of the methodology. Fractured surfaces were examined by a scanning electron microscope (SEM) to analyse the fracture morphology and stress state.

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In this work, strength and plastic deformation effect of the dual phase steel are analysed in the static and dynamic conditions. Since the dual phase steel is extensively used in the outer body parts of the automotive vehicles, their dynamic strength and plastic strain energy absorption during the crash are essential. Dynamic strength of the dual phase steel is examined using the pendulum impact hammer tester machine. Spread of the plastic strain during the crash is an important factor for the energy absorption to passive safety, which is examined using the local hardness measurement using the Vickers hardness and local indentation yield strength is calculated using the cylindrical indenter and obtained force-depth results are analysed using the Hencky theory for the plane strain indentation. Further, tested samples are observed using the scanning electron microscopy for the fracture response after the static and dynamic tests.