Processing Optimization of the New Steel Grade 45SiCrV9Ni for Modern Leaf Springs in Battery Electric Vehicles

The optimization of battery electric vehicles requires advanced high-strength steels that combine ductility and toughness, enabling lightweight leaf spring constructions with improved performance. This study investigates processing optimization by comparing the newly developed 45SiCrV9Ni, previously identified as promising for stress peening and fatigue, with the conventional 51CrV4 as a benchmark. Dilatometric, mechanical, and microstructural analyses were conducted in as-supplied and heat-treated conditions. Both steels show excellent high-temperature ductility, making them suitable for hot forming under similar conditions. However, 45SiCrV9Ni requires a higher temperature for homog-enized austenitization. After tempering, it consistently exhibits superior hardness and toughness compared to 51CrV4. Importantly, its ductility remains nearly constant over a wide tempering temperature range, allowing lower ones to be chosen without compromising strength or toughness, offering additional energy-saving possibilities. These results highlight the potential of 45SiCrV9Ni for leaf spring applications.