A Review of Current State and Prospects of the Bendability and Hydrogen Embrittlement Behavior of Press- Hardening Automobile Steels

doi:10.11900/0412.1961.2025.00272

Acta Metall Sin

2026, Vol. 62

Issue (5): 959-974 DOI: 10.11900/0412.1961.2025.00272

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A Review of Current State and Prospects of the Bendability and Hydrogen Embrittlement Behavior of Press- Hardening Automobile Steels

DU Dehao¹^,²^,³, GUAN Ming¹^,², CAO Zuoheng¹^,², WANG Ming¹^,²(

), HE Binbin³, HUANG Mingxin¹^,²(

)

1 Department of Mechanical Engineering, University of Hong Kong, Hong Kong 999077, China
2 Shenzhen Institute of Research and Innovation, University of Hong Kong, Shenzhen 518057, China
3 Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen 518055, China

Cite this article:

DU Dehao, GUAN Ming, CAO Zuoheng, WANG Ming, HE Binbin, HUANG Mingxin. A Review of Current State and Prospects of the Bendability and Hydrogen Embrittlement Behavior of Press- Hardening Automobile Steels. Acta Metall Sin, 2026, 62(5): 959-974.

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Abstract

Press-hardening steel offers numerous advantages, such as exceptional strength, excellent formability, and the ability to produce complex geometries, making it an essential material for lightweight, high-performance structures in new-energy vehicles. Press-hardening steel is widely used in manufacturing safety components for vehicles. With the escalating demand for lightweight components in the automotive industry, press-hardening steel is evolving toward enhanced strength, ductility, and fracture toughness. However, alongside technological advancements, the challenges faced by press-hardening steel in terms of low bending toughness and hydrogen embrittlement are becoming increasingly severe. This review summarizes the current state and future prospects of press-hardening steel from three key perspectives. Firstly, it describes the press-hardening process and the development of advanced materials with enhanced strength and toughness. Secondly, it reviews recent research on toughening commercial press-hardening steels, examining the interplay between surficial steel coatings and cold-bending-angle standards, addressing the structural limitations of current products, and highlighting future advancements in coatings. Lastly, the paper summarizes the latest research on hydrogen embrittlement in press-hardening steel, starting with the underlying mechanisms of hydrogen-induced damage, while considering factors such as the internal microstructure and surface coating conditions of the steel. The paper concludes by outlining research directions for developing higher-strength press-hardening steels with improved resistance to hydrogen embrittlement.

Key words: press-hardening steel coating bendability hydrogen embrittlement

Received: 14 September 2025

ZTFLH:

TG142

Fund: National Natural Science Foundation of China(52130102);National Natural Science Foundation of China(52425105);National Key Research and Development Program of China(2019YFA0209900);Research Grants Council of Hong Kong(C7045-19E);Research Grants Council of Hong Kong(R7066-18);Innovation and Technology Fund(MHP/064/20);New Cornerstone Science Foundation through the XPLORER PRIZE

Corresponding Authors: HUANG Mingxin, professor, Tel: (00852)39177906, E-mail: mxhuang@hku.hk; WANG Ming, research assistant professor, Tel: (00852)69931959, E-mail: mingwang@hku.hk

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Fig.1 Cross-sectional SEM images of the Al-Si coated boron steel before (a, b) and after (c) press hardening^[5]
(a) as-coated (b) detail of intermetallic layer (c) austenitized at 920 ^oC for 5 min

Table 1 Chemical compositions and tensile strengths of typical press-hardening steels^[11-14]

Fig.2 Coating structures and bending fracture toughnesses under different double austenitization (DA) conditions (The SA number indicates the austenitization temperature, and the DA numbers indicate the first austenitization temperatures)^[25]
(a) Al profile within the interdiffusion ferrite layer under different DA conditions
(b) resulting bending angles, compared with those of a traditional single austenitization (SA) sample
(c1, c2, d1, d2) electron backscatter diffraction (EBSD) inverse pole figures (IPFs) (c1, d1) and local misorientation maps (c2, d2) of major cracks in Al-Si coating structures on DA 930 sample bent at 46° (c1, c2) and DA 1100 sample bent at 58° (d1, d2)

Fig.3 Schematic of hot-dip galvanized Zn (GI) coating before and after press hardening (a), cross-sectional morphologies of liquid metal embrittlement (LME) cracks and EDS analysis illustrating the distribution of Zn elements on the coated surface of 22MnB5 steel (Yellow arrows indicate the presence of LME cracks) (b), the process of LME occurrence during press hardening of Zn-coated steels (c), and processing window of the press hardening process for Zn and Al-Si coatings (d)^[29]

Fig.4 Relationships between overall average hydrogen concentration and the local hydrogen concentration in prior-austenite grain boundary (PAGB), lath boundary (LB), and matrix within low (a) and high (b) hydrostatic stress regions^[44]

Fig.5 Fracture toughnesses and crack propagation behaviors of press hardening steel (PHS) with tensile strengths of 1500 and 2000 MPa^[47]
(a) J-integral-based resistance curves (J-R curves) measured from the side-grooved compact tension specimens at room temperature
(b) corresponding fracture toughness in terms of K (K is the mode I stress intensity factor, which characterizes the elastic stress field at the crack tip and reflects the fracture resistance of materials. K_JIc and K_Jss represent crack-initiation toughness and crack growth toughness in terms of K, respectively)
(c) complete stress-displacement curves of PHS notched samples under long charging durations
(d) magnified regions in Fig.5c after the respective peak stress

Fig.6 Influences of grain refinement on the microstructure and hydrogen embrittlement resistance of 1800 MPa PHS^[61] (a, b) SEM image (a) and EBSD IPF (b) of Nb free steel (c, d) SEM image (c) and EBSD IPF (d) of Nb steel (e) plots of fracture stress vs H concentrations of the Nb and Nb free steels acquired using the notch tensile samples (Error bars of the fracture stress represent the standard deviation of three pre-charge tensile tests for the same charging time)

Fig.7 Influences of NbC on hydrogen embrittlement resistance of high-strength martensitic steels^[63] (a-c) tensile stress-strain curves with and without hydrogen charging for martensitic steels as-quenched (900-Q') (a), tempered at 480 ^oC (Q&T-480) (b), and tempered at 560 ^oC (Q&T-560) (c) (HC—hydrogen pre-charged) (d) thermal desorption spectroscopy (TDS) curves (The TDS profiles corresponding to the temperature range from 300 ^oC to 500 ^oC are shown in the enlarged inset) (e) schematics showing how NbC nano-precipitates enhance hydrogen embrittlement resistance

Fig.8 Influences of inclusions on hydrogen embrittlement (a-c) high-resolution tritium autoradiographies of FeS (a), TiN (b), and MnS (c), respectively, as hydrogen traps^[71.74] (d) fisheye morphology on the fracture surface of PHS1900 after hydrogen charging^[71] (e) enlarged image of Fig.8d^[71] (e1-e5) EDS analyses of the inclusion in Fig.8e^[71]

Fig.9 Influences of Zn coating on the hydrogen embrittlement risk of PHS^[8,85] (a, b) tensile curves (a) and thermal desorption analysis (TDA) curves (b) of aluminized, uncoated, and galvanized PHS austenitized at 900  ^oC for an aus-tenitizing time (t_A) of 6 min^[8] (c) evolution of localized necking elongation (elon-gation from ultimate tensile strength up to fracture) with strain rate for a Zn-coated steel in 3%NaCl solution and air conditions^[85]

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