CN106460126B - 由具有金属覆层的钢板制造钢构件的方法、钢板及钢构件 - Google Patents
由具有金属覆层的钢板制造钢构件的方法、钢板及钢构件 Download PDFInfo
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Abstract
本发明涉及一种用于由具有金属覆层的钢板来制造三维成型的钢构件的方法,该钢板加热并随后通过热成型成型为钢构件,其中所使用的钢板具有作为金属的覆层的Fe‑Al基合金。为了防止该钢板或该钢构件生成氧化皮,通过电镀过程和/或物理气相沉积将Fe‑Al基铝合金直接施加在钢板上并使其在为了热成型而实施的对覆层的钢板的加热之前就具有直到超出900℃的稳定的Fe‑Al相,其中这样制成的覆层含有30‑60重量%的Fe、剩余Al以及可选的0.1‑10重量%的Mg和/或0.1‑5重量%的Ti和/或0.1‑10重量%的Si和/或0.1‑10重量%的Li和/或0.1‑10重量%的Ca。此外,本发明还涉及一种用于制成一种或多种通过热成型产生的钢构件的、相应覆层的钢板。
Description
技术领域
本发明涉及一种用于由具有金属覆层的钢板来制造三维的成型钢构件的方法,该钢板加热并且随后通过热成型而成型为钢构件,其中所使用的钢板包括作为金属覆层的Fe-Al基合金。此外,本发明还涉及一种用于制造一种或多种通过热成型产生的钢构件的钢板,该钢板设有金属的覆层,该金属的覆层由Fe-Al基合金构成。此外,本发明还涉及一种成型的钢构件,该钢构件通过对这样的钢板进行热成型而制成。
背景技术
在将钢于含有氧气的气氛中加热至约500℃以上的情况下,在钢表面上形成了氧化层,即,所谓的氧化皮。氧化皮的形成通常是不期望的,因为氧化皮带来了严重的问题。由此在钢板的成型过程中氧化皮的压入可能造成表面印记或者不令人满意的或完全无法接受的表面质量。氧化皮由于其高硬度而增大了承载待成型的钢板的运输辊以及成型工具的磨损。而氧化皮的去除则导致额外的成本。
发明内容
因此,本发明的目的在于,给出一种前述类型的方法,其中尽可能地避免了氧化皮形成的问题。本发明的目的特别在于,提供一种钢板,该钢板具有特别为了待通过热成型制造的构件而设的防止氧化皮生成的金属覆层。
为了防止钢板或由该钢板通过热成型(加压淬火)制成的钢构件生成氧化皮,根据本发明通过电镀层过程和/或物理气相沉积将Fe-Al基合金直接地施加在钢板上,并使其在为了热成型而实施的对覆层的钢板的加热之前就已经具有直到超出900℃的稳定的Fe-Al相,其中这样制成的覆层含有30-60重量%的Fe、剩余铝以及可选的0.1-10重量%的Mg和/或0.1-5重量%的Ti和/或0.1-10重量%的Si和/或0.1-10重量%的Li和/或0.1-10重量%的Ca。
与以通过“预退火”制成的、具有金属间的合金层来覆层不同,根据本发明Fe-基或Fe-Al-基合金是直接施加的。为此特别适合的是电镀覆层方法以及物理气相沉积(所谓的PVD法)。这两种方法都实现了连续的覆层过程。这两种覆层方法的结合以及其与热浸镀法的结合都属于本发明用于获得Fe-Al基覆层的范围内。
根据本发明的覆层具有以下优点:
1.覆层与热成型设施的热炉构件、特别是陶瓷的运输辊之间的反应通过已经稳定化的Fe-Al相而得以避免。这具有对覆层的钢板的表面质量的正面作用并且减少了就加热炉而言的维护成本。
2.已经预合金化的覆层由于更好的发射率(吸收能力)而能够明显更快地加热,这实现了热成型过程的缩短。这引起了生产率的提高并且促使了减少所制成的加压淬火的钢构件的制造成本。
3.热成型工具的磨损通过避免由于还未完全合金化的(“糊状的”)覆层组成成分而造成的结块而降低。
可选的合金成分镁、钛、硅、锂和钙具有比铁更高的腐蚀可能性,由此有利于对于加压淬火的覆层的可能损坏的区域进行既定的阴极保护。由于具有铝的低熔点相的形成趋势并且由于由此带来的液相引起的裂纹的风险,在根据本发明的覆层中放弃使用锌作为合金元素。
本发明的一种优选的设计方案的特征在于,Fe-Al基合金含有至少28重量%的Al、特别优选至少38重量%的Al。由此,提高了防止氧化皮生成的保护作用,而不会对于基本材料产生任何负面影响。
根据本发明的另一种有利的设计方案,Fe-Al基合金具有0.1-10重量%的Mg和/或0.1-5重量%的Ti。合金成分镁和钛对于覆层的表面具有正面效果。试验证明,在宽的制程窗口的情况下调整出理想的粗糙度,该粗糙度一方面通过减少的基本粗糙度(Ra,Rz)而促成优化的腐蚀保护,并且另一方面提供了提高的峰值(RPc),通过该峰值而优化了在KTL过程中涂覆的漆层的漆附着。
有利的是,根据另一种优选的设计方案使Fe-Al基合金具有0.1-10重量%的Li和/或0.1-10重量%的Ca。试验证实,由此能够明显改善阴极腐蚀保护。这也特别在加入镁的情况下适用。
当Fe-Al基合金根据另一种优选的设计方案而含有最大20重量%、特别是最大15重量%并且优选最大12重量%的、由Mg、Ti、Si、Li和Ca组成的合金元素时,针对于氧化皮生成以及腐蚀的保护作用方面能够达到特别好的效果。
在此,在应用PVD法之前对于已经覆层的或者未覆层的钢基板进行调温或者事后调温至250-500℃促成了覆层附着力的改善。如果随后进行热浸镀,则不必要进行额外的加热。
为了制造具有非常高的机械性能的减重的钢构件,在根据本发明的方法的另一设计方案中钢板能够在热成型期间和/或紧接着热成型之后通过快速冷却而淬火。
具体实施方式
随后根据若干实施例(试验)来进一步说明本发明。
试验1:
将基本材料、例如种类为22MnB5的可加压淬火的钢借助于物理气相沉积(PVD)在连续的覆层过程中以约60重量%的Al和约39重量%的Fe以及约1重量%的Ti来覆层。这通过借助于电子束蒸发的铁和钛的同步沉积以及在单独的热学的PVD工艺步骤中铝的沉积而实现。这得到了约8μm的层厚度。该层随后在连续炉中热学地在约500℃的条件下以及约60秒的处理时间(保持时长)的情况下再致密。热学的再致密促使了层的附着力优化以及促使了通过固体材料扩散进行第一次合金形成。
这样在连续的带覆层工艺中制成的钢带随后取决于客户处的进一步加工工序而定裁切成扁坯并且引入到加压淬火过程。在实验室加压淬火炉中从6分钟缩短为3分钟的加热阶段的期间,调整出具有约55重量%的Fe和约45重量%的Al以及仅约150nm厚度的铝和钛氧化层的覆盖层(覆层)。该覆盖层具有对于进一步加工、特别是对于涂漆而言非常适合的基本粗糙度Ra=0.8-1μm以及RPC=150-200。
已经确定的是,在连续炉的陶瓷的运输辊以及在成型工具上都没有显示出有铝附着。
出乎意料地确定了,与具有铝-硅覆盖层的参照板材不同的、减少了的基本粗糙度促成了在以KTL法覆层的钢构件上的腐蚀保护的改善。
试验2:
将基本材料、例如种类为22MnB5的可加压淬火的钢借助于物理气相沉积在连续的覆层过程中以约50重量%的Al和约45重量%的Fe以及约5重量%的Mg进行覆层。这通过借助于来自分开的坩埚的Jet-PVD的铝和镁的同步沉积以及在单独的覆层步骤中借助于电子束蒸发的铁的沉积而实现。这样得到的层厚度约为8μm。该层随后在连续炉中热学地在约400℃的条件下以约60秒长地再致密。该热学的再致密促使层的附着力改善以及通过固体扩散引起第一次合金形成。
将这样在连续的带覆层工艺中制成的钢带随后根据客户处的进一步加工过程而定地裁切成扁坯以及引入加压淬火过程中。在实验室加压淬火炉中由6分钟缩短成3.5分钟的加热阶段期间内,调整出具有约55重量%的Fe、约42重量%的Al和约3重量%的镁以及约1μm的厚度的铝和镁的氧化层的金属覆盖层(覆层)。该覆盖层具有对于进一步加工、特别是对于涂漆而言的非常适合的基本粗糙度Ra=1-2.2μm并且RPC=100-120。
已经确定的是,在连续炉的陶瓷的运输辊上以及在成型工具上都没有显示出铝的附着。
此外,出乎意料地确定了,在KTL法中覆层的构件上钢板中的腐蚀深度由于镁的存在而比在具有铝-硅的标准覆层的钢板的情况下明显更低,该腐蚀深度是通过在刮痕处以及板边缘处进行的汽车典型的试验测定的。
试验3:
在基本材料上、例如品种为22MnB5的可加压淬火的钢上首先电镀约4μm厚的Fe层。随后,在将基板加热至350℃之后,借助于热学的PVD工艺施加约6μm厚的铝-镁层。从两个分开的坩埚同时沉积这两种合金成分(Al和Mg)。得到的Al层具有约10重量%的Mg含量。
这个层在钢基板上促成了在已经加压淬火的构件上也留下的通常为被动的腐蚀保护。
这样在连续的带覆层过程中制造的钢带随后取决于顾客处的进一步加工过程地裁切成扁坯并且引入到加压淬火过程。在实验室的加压淬火炉中从6分钟缩短为3.5分钟的加热阶段的期间,调整出具有约60重量%的Fe、约37重量%的Al和约3重量%的镁的以及约1μm的厚的铝和镁氧化层的金属覆盖层(覆层)。该覆盖层具有对于进一步加工、特别是对于涂漆而言非常适合的基本粗糙度Ra=1-2.2μm并且RPC=100-120。
已经证实的是,在连续炉的陶瓷运输辊以及在成型工具上都没有显示出铝的附着。
此外,出乎意料地确定了,在KTL法中覆层的构件上钢基板中的腐蚀深度由于镁的存在而比在具有铝-硅的标准覆层的钢板的情况下明显更低,该腐蚀深度是通过在刮痕处以及板边缘处进行的汽车典型的试验测定的。
Claims (14)
1.一种用于由具有金属覆层的钢板制造三维成型的钢构件的方法,所述钢板加热并随后通过热成型而成型为钢构件,其中所使用的钢板具有作为金属覆层的Fe-Al基合金,其特征在于,所述Fe-Al基合金通过电镀过程和/或通过物理气相沉积而直接施加在钢板上,其中这样制成的覆层含有:
30-60重量%的Fe,
剩余铝以及
0.1-10重量%的Mg和/或
0.1-5重量%的Ti和/或
0.1-10重量%的Si和/或
0.1-10重量%的Li和/或
0.1-10重量%的Ca,
并且使所述覆层在为了热成型而对覆层的钢板实施的加热之前就已经具有直至超出900℃的稳定的Fe-Al相;
其中,所述Fe-Al基合金包含至少28重量%的Al;以及
所述Fe-Al基合金含有最大20重量%的由Mg、Ti、Si、Li和Ca组成的合金元素。
2.根据权利要求1所述的方法,其特征在于,所述Fe-Al基合金含有最大15重量%的由Mg、Ti、Si、Li和Ca组成的合金元素。
3.根据权利要求1所述的方法,其特征在于,所述Fe-Al基合金包含至少38重量%的Al。
4.根据权利要求1-3中任意一项所述的方法,其特征在于,所述Fe-Al基合金包含0.1-10重量%的Mg和/或0.1-5重量%的Ti。
5.根据权利要求1至3中任意一项所述的方法,其特征在于,所述Fe-Al基合金包含0.1-10重量%的Li和/或0.1-10重量%的Ca。
6.根据权利要求1至3中任意一项所述的方法,其特征在于,所述Fe-Al基合金含有最大12重量%的由Mg、Ti、Si、Li和Ca组成的合金元素。
7.根据权利要求1至3中任意一项所述的方法,其特征在于,所述钢板在热成型期间和/或紧接着热成型之后通过快速冷却而淬火。
8.一种用于制造一种或多种通过热成型产生的钢构件的钢板,所述钢板具有金属的覆层,所述金属的覆层由Fe-Al基合金构成,其特征在于,所述Fe-Al基合金通过电镀过程和/或通过物理气相沉积直接施加在钢板上并且这样制成的覆层含有:
30-60重量%的Fe,
剩余铝以及
0.1-10重量%的Mg和/或
0.1-5重量%的Ti和/或
0.1-10重量%的Si和/或
0.1-10重量%的Li和/或
0.1-10重量%的Ca,
其中这样得到所述覆层,即,使所述覆层在为了热成型而对已覆层的钢板实施加热之前就已经具有直至超出900℃的稳定的Fe-Al相;
其中,所述Fe-Al基合金包含至少28重量%的Al;以及
所述Fe-Al基合金含有最大20重量%的由Mg、Ti、Si、Li和Ca组成的合金元素。
9.根据权利要求8所述的钢板,其特征在于,所述Fe-Al基合金含有最大15重量%的由Mg、Ti、Si、Li和Ca组成的合金元素。
10.根据权利要求8所述的钢板,其特征在于,所述Fe-Al基合金含有至少38重量%的Al。
11.根据权利要求8或9所述的钢板,其特征在于,所述Fe-Al基合金含有0.1-10重量%的Mg和/或0.1-5重量%的Ti。
12.根据权利要求8至10中任意一项所述的钢板,其特征在于,所述Fe-Al基合金含有0.1-10重量%的Li和/或0.1-10重量%的Ca。
13.根据权利要求8至10中任意一项所述的钢板,其特征在于,所述Fe-Al基合金含有最大12重量%的由Mg、Ti、Si、Li和Ca组成的合金元素。
14.一种三维成型的钢构件,所述钢构件通过对根据权利要求8至13中任意一项所述钢板的热成型而制成。
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