Hot forming die quenching (HFDQ) is used to transform ultrahigh strength steel blanks into martensitic body-in-white components that are lighter than parts made from traditional mild steels, without sacrificing crash performance. The part is sometimes locally reinforced by spot-welding patches to the blanks, but the increased thickness of the patched blanks sometimes results in incomplete austenitization, which can compromise the strength of as-formed parts. This paper presents an integrated thermo-metallurgical model of the austenitization of Al-Si coated 22MnB5 within a roller hearth furnace. While previous models account for the latent heat of austenitization by heuristically adjusting the specific heat, the present model explicitly simulates austenite formation using a first-order metallurgy submodel derived from dilatometry measurements. The model is validated by comparing predicted temperatures to measurements carried out on coupons heated within a lab-scale muffle furnace and full-sized blanks heated in an industrial-scale roller hearth furnace. Finally, the model is used to optimize roller speed based on zone temperatures.

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