As climate change and resource scarcity gain increasing significance, the demand for energy efficiency, emission reduction, and resource conservation continues to grow. In this context, forming technology presents considerable potential for lightweight design, cost efficiency, and resource optimization. However, forming-induced ductile damage, such as void formation and growth, is not yet accounted for in component design. Conventional designs typically rely on mechanical properties and the use of safety factors. Incorporating insights into forming-induced voids enables more efficient designs and maximizes the exploitation of lightweight potential.
Since both MnS inclusions and forming-induced voids significantly impact mechanical performance, the void distribution was analyzed using a focused ion beam scanning electron microscope (FIB-SEM). The resulting data was utilized to develop a 3D volume modeling approach based on AI-based image segmentation. By employing these advanced SEM techniques, more precise assessments of forming-induced damage can be achieved. To examine the distribution of voids in relation to their interaction with MnS inclusions, an intersection approach was applied in Fiji. The in-lens images of the MnS inclusions were combined with the secondary electron images of the voids, enabling the conversion of these intersections into a volumetric representation.