CN104379775B - 由涂覆有非金属涂层的金属板形成的机动车部件 - Google Patents
由涂覆有非金属涂层的金属板形成的机动车部件 Download PDFInfo
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- 239000011248 coating agent Substances 0.000 title claims abstract description 96
- 238000000576 coating method Methods 0.000 title claims abstract description 96
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 75
- 239000010959 steel Substances 0.000 claims abstract description 75
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 16
- 238000005240 physical vapour deposition Methods 0.000 claims abstract description 16
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 15
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 14
- 239000010703 silicon Substances 0.000 claims abstract description 14
- 239000002184 metal Substances 0.000 claims abstract description 13
- 229910052751 metal Inorganic materials 0.000 claims abstract description 13
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical class N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims abstract description 12
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical class [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 6
- 229910052757 nitrogen Inorganic materials 0.000 claims abstract description 6
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 6
- 239000001301 oxygen Substances 0.000 claims abstract description 6
- 238000003856 thermoforming Methods 0.000 claims description 34
- 238000000034 method Methods 0.000 claims description 27
- 239000000463 material Substances 0.000 claims description 23
- 239000000203 mixture Substances 0.000 claims description 5
- 230000008569 process Effects 0.000 claims description 5
- 239000002828 fuel tank Substances 0.000 claims description 3
- 229910052755 nonmetal Inorganic materials 0.000 claims description 2
- 230000002787 reinforcement Effects 0.000 claims description 2
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- 239000000919 ceramic Chemical class 0.000 abstract description 4
- 239000007789 gas Substances 0.000 description 6
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- 238000005097 cold rolling Methods 0.000 description 4
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- 230000007613 environmental effect Effects 0.000 description 2
- 238000005098 hot rolling Methods 0.000 description 2
- 229910052756 noble gas Inorganic materials 0.000 description 2
- 150000002835 noble gases Chemical class 0.000 description 2
- 238000010791 quenching Methods 0.000 description 2
- 230000000171 quenching effect Effects 0.000 description 2
- 238000001953 recrystallisation Methods 0.000 description 2
- 238000005480 shot peening Methods 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- 239000011701 zinc Substances 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 229910000712 Boron steel Inorganic materials 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910004012 SiCx Inorganic materials 0.000 description 1
- 229910020286 SiOxNy Inorganic materials 0.000 description 1
- 229910000635 Spelter Inorganic materials 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229910001566 austenite Inorganic materials 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
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- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
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- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titanium dioxide Inorganic materials O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
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- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/02—Pretreatment of the material to be coated
- C23C14/024—Deposition of sublayers, e.g. to promote adhesion of the coating
- C23C14/025—Metallic sublayers
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- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
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- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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Abstract
机动车部件(20)通过在热冲压钢坯(26)之前将非金属涂层(24)沉积在钢坯(26)的表面上制造而成。非金属涂层(24)通常通过物理气相沉积施加。非金属涂层(24)由均具有不同组成的一至三个层(32)形成。非金属涂层(24)包括硅和碳中至少之一,并且还可以包括氧、氮、陶瓷复合物和碳化物。非金属涂层(24)的总厚度小于300nm。可以在非金属涂层(24)之前向钢坯施加金属涂层(30)。非金属涂层(24)提供了许多优点,包括在热冲压过程中减少起氧化皮。
Description
相关申请的交叉引用
该PCT专利申请要求2012年5月3日提交的题为“由涂覆有非金属涂层的金属板形成的机动车部件(Automotive Component Formed Of Sheet Metal Coated With A Non-Metallic Coating)”的美国临时专利申请序列第61/642113号的权益,认为该申请的全部公开内容是本申请的公开内容的一部分,并且在此通过引用并入本文。
技术领域
本发明涉及包含热成型钢的机动车部件及其制造方法。
背景技术
机动车辆部件经常由热成型钢坯,例如冷轧或热轧钢板制成。这样的机动车部件的实例包括A柱、B柱、D柱、门梁、保险杠梁、底框梁(sill)、摇杆、油箱护板、防滑板、前纵梁、中纵梁、后纵梁、门框、门内侧加强部件、前管道以及如沿机动车辆底板的零件的湿区部件(wet area component)。热成型过程在温度大于700℃下进行,并且时常包括热冲压钢板。热成型工艺增加钢板的机械强度并且可以提高钢板的其他物理性能。然而,由于在热成型过程期间所采用的高温,在钢板的表面经常发生形成白色氧化物、起氧化皮(scaling)、腐蚀结垢或脱碳,这降低了机械强度并且磨损了在热成型过程期间所使用的制造工具。表面的形成白色氧化物、起氧化皮、腐蚀结垢和脱碳还导致粘附力差并且使得难以给零件的表面涂涂料。尽管热成型钢零件可以进行喷丸处理以除去白色氧化物、氧化皮和其他表面缺陷,但是喷丸过程需要大量的能量,并且可以使钢零件变形以及增加成本。
发明内容
本发明的一个方面提供了一种机动车部件,该机动车部件包括热成型钢零件,以及布置在热成型钢零件的表面上的非金属涂层。该非金属涂层包含硅和碳中至少之一并且具有不大于300nm的厚度。
本发明的另一方面提供了一种形成机动车部件的方法。该方法包括:提供由钢材料形成的坯;以及对坯进行热成型来提供热成型零件。该方法还包括在热成型步骤之前在坯的表面上布置非金属涂层。该非金属涂层包含硅和碳中至少之一并且具有不大于300nm的厚度。
在热成型过程期间,非金属涂层防止或减少钢坯表面的起氧化皮、结垢、氧化和脱碳。非金属涂层还润滑该表面并且从而提高可成形性。与未涂覆的钢零件或具有不同涂层的零件相比,非金属涂层还可以具有使得能够更快速加热钢坯的颜色和反射系数。非金属涂层还可以提高热成型零件与施加到零件的涂料或另一材料之间的粘附力。
附图说明
因为结合附图考虑时,通过参照以下具体实施方式,本发明变得更好理解,所以可容易地理解本发明的其他优势,附图中:
图1示出了根据一个示例性实施方案的形成机动车辆部件的方法;
图2是根据另一示例性实施方案的机动车辆部件的一部分的截面图;以及
图3是通过本发明的方法形成的其他示例性机动车部件的透视图。
具体实施方式
在图1中一般性地示出了形成包括涂覆有非金属涂层24的钢零件22的机动车辆部件20的方法。经涂覆机动车部件20是在热成型钢坯26之前,优选地通过物理气相沉积(PVD)或反应溅射向由钢材料形成的坯26施加非金属涂层24而形成。在热成型过程期间,非金属涂层24防止钢坯26起氧化皮、结垢、腐蚀、氧化和脱碳。非金属涂层24还可以润滑,并且从而提高钢坯26的可成形性;调节表面颜色和反射系数以提供钢坯26的更快速加热;以及提高涂料和粘合剂的粘附力。此外,向钢坯26施加非金属涂层24的过程是环保的并且需要很少的能量。
形成机动车部件20的方法首先包括提供由钢材料形成的未涂覆坯26。用于形成坯26的钢材料可以是纯钢或任何类型的钢合金。坯26优选地是通过热轧、冷轧或本领域中已知的另外工艺形成的如图1中所示的钢材料的板。热轧可以包括在高于钢的再结晶温度的温度下使如板坯、大方坯或小方坯的钢原料通过成对的辊来形成钢的板。冷轧包括在低于钢原料的再结晶温度的温度下使钢原材料通过成对的辊来形成钢板。在一个优选的实施方案中,钢坯26是冷轧硼钢,被称为22MnB5,并且具有包括铁素体和珠光体的显微组织。
在非金属涂层24之前也可以将金属涂层30,或另一类型的涂层,布置在坯26上以提高可成形性并且使得能够更快速地加热。例如,在施加非金属涂层24之前可以向钢坯26施加包含锌的金属涂层30。图2是根据不同于图1的实施方案的另一示例性实施方案的机动车辆部件20的一部分的截面图。在图2的实施方案中,金属涂层30布置在钢零件22与非金属涂层24之间。另外,可以向坯26施加防腐蚀层来防止腐蚀和生锈。
在提供钢坯26之后,该方法包括:在钢坯26的表面上或在金属涂层30上直接施加非金属涂层24。在施加涂层之前钢坯26经清洗和干燥或以其他方式制备。通常使用物理气相沉积(PVD)或反应溅射来施加非金属涂层24。在一个实施方案中,向钢坯26施加锌形成的金属涂层30,接着是PVD表面涂层,其中PVD表面涂层是非金属涂层24。锌涂层和PVD表面涂层在热成型步骤期间防止白色氧化物的形成。因此,能够取消为了去除白色氧化物的喷丸处理。
非金属涂层24包含硅和碳中至少之一。优选地,非金属涂层24包含硅或碳两者之一,但是非金属涂层24可以同时包含硅和碳。基于非金属涂层24的总重量,硅通常以40重量百分数至70重量百分数(wt%)的量存在,碳以最高达15wt%的量存在。非金属涂层24也可以包含氧和氮中至少之一,并且通常同时包含氧和氮。基于非金属涂层24的总重量,氧和氮的总含量不大于50wt%。此外,非金属涂层24可以包含陶瓷复合物和碳化物中至少之一以提高抗高温起氧化皮和抗腐蚀性。陶瓷复合物可以是SiOxNy,碳化物可以是CNx,其中x,y和z为正整数或正分数。非金属涂层24还可以包含SiCxOyNz。非金属涂层24不含金属和包含如Al2O3、TiO2和CrNx的组成的金属。
非金属涂层24包括多个独立的层32,优选一至三个独立的层32,并且更优选如图2中所示出的两个独立的层32。层32共同具有不大于300nm的总厚度,并且优选不大于100nm的总厚度。在一个示例性实施方案中,层32共同具有不大于50nm的总厚度。在另一实施方案中,层32共同具有不大于30nm的总厚度。小厚度的非金属涂层24在每一个层32上提供较小的内应力与低的生产成本。厚度小的非金属涂层24也有助于卓越的行为(exceptionalbehavior)、可成形性、以及在热成型过程期间改善性能。
非金属涂层24的各个层32包含硅和碳中至少之一。各个层32也可以包含氧和氮中至少之一,以及包含陶瓷复合物和碳化物中至少之一。然而,非金属涂层24的各个层32优选具有不同于其他层32的组成或化学计量。形成具有不同组成或化学计量的层32降低任何针孔的长度,增加层32的叠层的密度,并且有助于提高抗腐蚀性。此外,各个层32可以包括梯度,其中随着层32的厚度增加,一种或更多种组分的量增加或减少以提供更密集的柱状生长(denser columnar growth)。
直接布置在钢坯26的表面上或在金属涂层30上的第一层32可以具有小于,大于,或等于其他层32厚度的厚度。优选地,第一层32的厚度不大于3纳米,这在钢表面与非金属涂层24的其他层32之间提供卓越的粘附力。第二层32直接布置在第一层32上并且通常具有比第一层32更大的厚度,例如大于3纳米。然而,第二层32也可以具有小于或等于第一层32的厚度。
可以根据本领域已知的多种方法来提供或者制备非金属涂层24。通过能够提供非常薄的层32的工艺,例如物理气相沉积(PVD)或反应溅射向钢坯26施加非金属涂层24。向钢坯26施加非金属涂层24的工艺也是环保的,需要很少的能量,并且不使用氢。
可以使用多种不同的PVD过程来向钢坯26施加非金属涂层24。如图1中所示,PVD过程通常包括:将钢坯26连同由非金属材料组成的用于形成非金属涂层24的源材料44一起放置在真空室42中。该方法接下来包括利用如电子束或离子束的高能源轰击源材料44来使源材料44汽化。源材料的所蒸发的原子46移动通过真空室42并且在钢坯26上沉积以形成非金属涂层24。
反应溅射包括将源材料44和钢坯26放置在真空室42中并将气体引入到真空室42中,该气体通常是反应性气体和惰性气体。源材料44与反应性气体之间发生化学反应,这使得源材料44在钢坯26上沉积并形成非金属涂层24。非金属涂层24的组成、化学计量或性质可以通过改变惰性气体与反应性气体的相对压力来控制。
可单独涂覆钢坯26以使得坯的所有表面和边缘都被涂覆。根据另一实施方案,非金属涂层24以卷的形式施加到钢材料的板,并且在施加非金属涂层24之后,冲压经涂覆的板来提供经涂覆的钢坯26。在该实施方案中,非金属涂层24将仅布置在钢坯26的顶部和底部,而不是沿着钢坯26的边缘布置。
一旦将非金属涂层24施用到钢坯26的表面,形成机动车部件20的方法包括制备用于热成型过程的经涂覆的钢坯26。热成型过程采用高温并且通常为至少700℃的温度。
用于形成机动车部件20的热成型过程通常包括热冲压经涂覆的钢坯26。如图1中所示,热冲压可以包括将经涂覆的钢坯26布置在炉或烘箱34中,并且将该经涂覆的钢坯26加热至足以在钢材料中形成奥氏体相的温度。在一个实施方案中,将经涂覆的钢坯26加热到至少700℃,并且优选为700℃至950℃的温度。在另一实施方案中,将经涂覆的钢坯26加热到900℃的温度。与未涂覆的钢坯或具有不同类型的涂层的钢坯相比,非金属涂层24可以具有使得能够更快速加热炉中的钢坯26的颜色和反射系数。
其次,如图1所示,将经加热坯26迅速转移到压制机(press)并布置在成对的冲模36之间。该方法通常包括,在坯26仍是热的同时在冲模36之间冲压坯26以使坯26形成为具有预定的形状与尺寸的零件22。然后将热冲压零件22进行淬火或在冲模36之间进行冷却。冲模36通常包括用于淬火步骤的冷却通道38。热冲压零件22的钢材料通常具有在淬火步骤之后的马氏体显微组织。
在热成型过程中,非金属涂层24防止或减少零件22表面的起氧化皮、结垢、腐蚀、氧化和脱碳。非金属涂层24还润滑该表面并且从而提高可成形性。
一旦具有非金属涂层24的热成型零件22冷却下来,经涂覆零件22可以被用作机动车辆部件20。在图1的实施方案中,可以向经涂覆钢零件22施加例如粘合剂或涂料48的另一种材料。与未涂覆零件或具有其他类型的涂层的零件相比,非金属涂层24提供了涂料48或粘合剂对钢零件22的提高的粘附力。另外,非金属涂层24可以提供改善的钎焊。因此,如图1所示,可将热成型零件22钎焊到另一零件40以提供最终的机动车辆部件20。
包括布置在热成型零件22上的非金属涂层24的机动车辆部件20可以是A柱、B柱、D柱、门梁、保险杠梁、底框梁、摇杆、油箱护板、防滑板、前纵梁、中纵梁、后纵梁、门框、门内侧加强件、前管道或湿区部件。图3中示出了根据本发明形成的机动车辆部件20的实例。在图3中示出的其他部件是未涂覆的,但是也可以利用非金属涂层24涂覆。
显然,鉴于上述教导,除了如所具体描述的之外,本发明的许多修改方案和变化方案是可能的并且可以被实施,同时包括在所附权利要求的范围之内。
Claims (14)
1.一种机动车部件,包括:
由钢材料形成的热成型零件,以及
在热成型之前直接布置在所述零件的所述钢材料的表面上的非金属涂层,其中所述非金属涂层包含硅和碳中至少之一并且具有不大于100nm的厚度。
2.根据权利要求1所述的机动车部件,其中所述非金属涂层不含金属并且包含:40重量百分数至70重量百分数wt%的量的硅;最高达15wt%的量的碳;以及总量低于50wt%的氧与氮中至少之一。
3.根据权利要求1所述的机动车部件,其中所述非金属涂层包含陶瓷和碳化物中至少之一。
4.根据权利要求1所述的机动车部件,其中所述非金属涂层调节所述零件的所述表面的反射系数。
5.根据权利要求1所述的机动车部件,其中所述非金属涂层包括一至三个独立层,所述层中的每一个均包含硅和碳中至少之一,并且所述层中的每一个均包含不同于其他层的组成。
6.根据权利要求1所述的机动车部件,其中所述零件的所述钢材料是22MnB5。
7.根据权利要求1所述的机动车部件,其中所述部件是A柱、B柱、D柱、门梁、保险杠梁、底框梁、摇杆、油箱护板、防滑板、前纵梁、中纵梁、后纵梁、门框、门内侧加强件、前管道或湿区部件。
8.根据权利要求1所述的机动车部件,其中所述热成型零件通过对钢坯进行热成型而形成,并且在所述热成型的步骤之前将所述非金属涂层施用到所述钢坯。
9.一种形成机动车部件的方法,包括以下步骤:
提供由钢材料形成的坯;
对所述坯进行热成型以提供零件;以及
在所述热成型之前在所述坯的所述钢材料的表面上直接布置非金属涂层,其中使用物理气相沉积(PVD)过程施加所述非金属涂层,所述非金属涂层包含硅和碳中至少之一并且具有不大于100nm的厚度。
10.根据权利要求9所述的方法,其中所述非金属涂层不含金属并且包含:40重量百分数至70重量百分数wt%的量的硅;最高达15wt%的量的碳;以及任选的陶瓷和碳化物中至少之一。
11.根据权利要求9所述的方法,其中在所述坯上布置所述非金属涂层的步骤包括在所述坯上布置一至三个层,其中所述层中的每一个均包含硅和碳中至少之一,并且所述层的每一个均具有不同于其他层的组成。
12.根据权利要求9所述的方法,其中所述热成型的步骤包括将所述坯加热到至少700℃的温度。
13.根据权利要求9所述的方法,其中所述热成型的步骤包括热冲压。
14.根据权利要求13所述的方法,其中所述热冲压的步骤包括:对经涂覆的坯进行加热;对经加热坯进行成型以提供具有预定尺寸的所述零件;以及对所述零件进行冷却。
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