Dual Phase Steel Roll Forming Material Guide: Properties, Coil Sizes & Applications
Dual Phase Steel Roll Forming Material
1. Overview of Dual Phase Steel in Roll Forming
Dual Phase (DP) steel is an advanced high strength steel (AHSS) designed with a unique microstructure that combines high strength and good formability. It is widely used in applications requiring energy absorption, durability, and lightweight performance.
In roll forming, dual phase steel is used for automotive components, structural reinforcements, safety parts, and high-performance profiles.
Compared to conventional steels, DP steel offers significantly higher strength while maintaining reasonable ductility.
2. Material Composition & Structure
Dual Phase steel consists of:
- Iron base metal
- Low carbon content
- Manganese
- Micro-alloying elements
Microstructure (VERY IMPORTANT)
- Soft ferrite matrix → provides ductility
- Hard martensite phase → provides strength
👉 This dual structure is what gives DP steel its name and performance.
Common Grades
- DP600
- DP800
- DP1000
3. Available Coil Specifications
Thickness Range
- 0.5mm – 3.0mm
Coil Width
- 600mm – 1500mm
Coil Weight
- 3 tons – 10 tons
Coil ID / OD
- ID: 508mm / 610mm
- OD: up to 1600mm
Tolerance
- High precision coils
- Tight thickness control
4. Mechanical Properties
Typical values depending on grade:
- Yield Strength: 300 – 700 MPa
- Tensile Strength: 600 – 1000+ MPa
- Elongation: 10% – 25%
- Hardness: 150 – 300 HB
5. Coating Types
Dual phase steel may be supplied as:
- Uncoated
- Galvanized (GI)
- Galvalume (AZ)
- Electro-galvanized
- Painted (less common)
6. Surface Finishes
- Mill finish
- Galvanized
- Smooth surface
- Automotive-grade surface quality
7. Common Roll Forming Applications
- Automotive structural components
- Reinforcement profiles
- Crash structures
- Safety components
- High-strength framing
- Industrial applications
8. Advantages of Dual Phase Steel
- Very high strength
- Good formability for its strength
- Excellent energy absorption
- Lightweight potential
- Improved crash performance
- Suitable for advanced engineering applications
9. Disadvantages / Limitations
- Higher cost
- Increased springback
- Difficult forming compared to mild steel
- Requires advanced tooling
- Higher wear on rollers
10. Roll Forming Machine Considerations
Roll Tooling
- Precision hardened rollers required
- Multi-stage forming required
Speed
- 5–25 m/min
Lubrication
- Recommended
Cutting
- High-strength shear blades
- Flying shear preferred
Common Issues
- Springback
- Edge cracking
- Tool wear
11. Common Problems in Production
- High springback affecting profile accuracy
- Cracking at tight bends
- Tool wear due to hardness
- Surface defects if mishandled
- Forming instability if not optimized
12. Pricing Guide
Typical global pricing:
- Low: $900–$1200 per ton
- Medium: $1200–$1800 per ton
- High: $1800–$2500+ per ton
Factors affecting price:
- Grade (DP600 vs DP1000)
- Coating
- Supplier
- Volume
13. Comparison with Other Materials
Dual Phase vs HSLA
- DP = higher strength
- HSLA = easier to form
Dual Phase vs Mild Steel
- DP = much stronger
- Mild steel = cheaper
Dual Phase vs AHSS (General)
- DP = one type of AHSS
- Others include TRIP, martensitic steels
14. Best Industries Using Dual Phase Steel
- Automotive manufacturing
- Transport equipment
- Heavy engineering
- Industrial fabrication
- Safety-critical structures
15. How to Choose Dual Phase Steel
Choose Dual Phase Steel When:
- High strength required
- Weight reduction needed
- Safety performance critical
- Advanced engineering applications
Avoid When:
- Simple forming required
- Budget is limited
- Standard structural steel is sufficient
16. FAQ Section
What is dual phase steel?
A high-strength steel with ferrite and martensite structure.
What are DP grades?
DP600, DP800, DP1000.
Is dual phase steel good for roll forming?
Yes, but requires advanced setup.
Why is it strong?
Due to martensite phase in the structure.
Is it expensive?
More expensive than standard steels.
17. Machine Matcher Section
We supply roll forming machines for all material types including dual phase steel.
- Custom-built machines to your profile
- New machines built to specification
- Global delivery available
- UK and USA technical support
Contact:
Machine Matcher
Sales & Technical Team
Quick Specs
Thickness
0.5–3.0mm
Yield Strength
300–700 MPa
Coil Width
600–1500mm
Coil ID
508 / 610mm