CN112899599A - 一种镀锌板热压应力硬化管状零部件的制备方法 - Google Patents

一种镀锌板热压应力硬化管状零部件的制备方法 Download PDF

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CN112899599A
CN112899599A CN202110052884.5A CN202110052884A CN112899599A CN 112899599 A CN112899599 A CN 112899599A CN 202110052884 A CN202110052884 A CN 202110052884A CN 112899599 A CN112899599 A CN 112899599A
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刘培星
郝亮
侯晓英
陈钢
金光宇
殷继丽
曹光明
任东
展英姿
高兴昌
胡华东
孙卫华
汤化胜
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SD Steel Rizhao Co Ltd
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Abstract

本发明公开了一种镀锌板热压应力硬化管状零部件的制备方法,包括以下步骤:A:热成形钢带上下表面涂覆一层不等厚锌层;B:将镀锌热成形钢分条卷管获得初始管,初始管被加热至一定温度和时间用以保证初始管件完全奥氏体化;C:加热后的初始管转移至模具中,两端密封并充入一定压力P的压缩空气;D:在模具下行合模过程中,封闭管件两端在液压驱动装置或模具斜锲作用下保证合适的进料量L,保证管内侧涂层沿着管轴向始终处于压应力状态;E:成形后模具保持压力实现管状板料于模具之间热量的快速交换实现淬火。本发明解决了镀锌板管状零部件成形过程中LMIE开裂问题,提高管状热成形零部件在服役过程中的耐蚀性。

Description

一种镀锌板热压应力硬化管状零部件的制备方法
技术领域
本发明涉及金属材料领域,具体涉及一种镀锌板热压应力硬化管状零部件的制备方法。
背景技术
汽车轻量化有力的降低了汽车油耗,减少了尾气的排放。封闭截面的管状零部件因具有更好的刚性而被广泛应用。管件冷成形技术主要是内高压成形技术和低压镦胀成形技术;管件热成形技术主要有热气胀成形和热墩胀成形技术。而针对热成形钢的管件热成形技术所用的材料都是冷轧热成形钢(裸板),裸板在加热过程中会产生大量的氧化铁皮,成形后的管件内外表面都含有氧化铁皮,后续工艺中需要进行抛丸,然而封闭截面零部件内表面的抛丸非常麻烦,生产效率较低;且零部件没有涂层防护,服役过程中缺少阴极保护,服役性能差。
专利《CN 107127238 A》一种锌系镀覆钢板或钢带的热冲压成型方法:该方法中加热后的镀锌板在高温成形前进行“预冷”和“落料工序”,高温冲压成形(拉应力成形)的温度范围为:400~650摄氏度。然而该方法在传统热冲压过程中增加了高温落料工序,浪费原材料。且该方法无法解决封闭截面管状零部件高温成形过程中因涂层在高温状态下拉应力作用下产生的“液化金属诱导”开裂(LMIE开裂)问题。
专利《CN 111451351 A》一种管状成形成性一体化方法:该方法中初始管坯被加热至300-1400摄氏度范围;管内第一次充入内压P为变形提供驱动力,初始管坯发生胀形(涂层发生拉应力)而部分贴膜;在第二次充压后,零部件发生收缩变形达到零部件尺寸精度;长时间保压完成淬火。该方法在第一次胀形过程中会导致板料内外表面都发生拉应力,会导致镀锌涂层发生LMIE开裂问题。
发明内容
本发明的目的在于提供一种镀锌板热压应力硬化管状零部件的制备方法,解决了镀锌板管状零部件成形过程中LMIE开裂问题,提高管状热成形零部件在服役过程中的耐蚀性。
本发明解决其技术问题所采用的技术方案是:一种镀锌板热压应力硬化管状零部件的制备方法,包括以下步骤:
A:热成形钢带上下表面涂覆一层不等厚锌层;薄锌层一侧镀层厚度为:4.3-7.1um(30-50g/m2);厚锌层一侧镀层厚度为:8.6-21.4um(60-150g/m2);
B:将镀锌热成形钢分条卷管获得初始管,初始管内壁镀层厚,初始管外壁镀层薄,初始管周长为d;初始管被加热至一定温度和时间用以保证初始管件完全奥氏体化;
C:加热后的初始管转移至模具中,两端密封并充入一定压力P的压缩空气;
D:在模具下行合模过程中,封闭管件两端在液压驱动装置或模具斜锲作用下保证合适的进料量L,保证管内侧涂层沿着管轴向始终处于压应力状态;在合模过程中管坯每个圆环截面中,管坯内侧涂层沿着垂直直径方向始终处于压应力状态;
E:成形后模具保持压力实现管状板料于模具之间热量的快速交换实现淬火;保压时间为5-25s;其中合模保压力F_press和管内气压P_air的关系式为(F_press-P_air*A)/A>=5MPa,A表示法向投影面积。
进一步,所述步骤A中热成形钢带的基体成分为:C:0.05-0.35%,Si:0.01-1.5%,Mn:0.4-2.5%,B:0%-0.020%,Ti:0%-0.20%,Nb:0%-0.30%,V:0%-3.0%,Cr:0%-5.0%,Mo:0%-1.0%余量为Fe和杂质。
进一步,所述步骤A中薄锌层一侧镀层与厚锌层一侧镀层厚度比为:1/3-1/2
进一步,所述步骤B中初始管周长d大于等于目标零部件任何一个位置的周长。
进一步,步骤A中加热和保温过程中初始管坯外侧涂层充分扩散实现涂层凝固;加热温度范围:850℃-900℃;保温时间15s~(3min+2min*h/6);h为管坯外侧涂层厚度。
进一步,所述步骤A中加热和保温过程中管坯内侧涂层不凝固,合金化程度为涂层中Zn含量大于45%;用以保证较好的耐蚀性。
进一步,所述步骤E中气体压力P的设定原则:P<σs﹒h/r,其中σs为材料屈服应力,h为材料厚度,r为管状试样半径。
进一步,所述材料屈服应力σs随着温度的降低会增大,成形过程中P是变化的。
进一步,所述步骤D中进料量L的公式为DL>=L0-L;L为零部件中最短线长度;L0为初始管坯长度。
成形技术同样适用于GA涂层,ZnAlMg涂层等低熔点(加热后涂层凝固点低于850℃)耐腐蚀涂层。
本发明具有以下有益效果:本发明的一种镀锌板热压应力硬化管状零部件的制备方法,1、利用管内外涂层差异,采用合理的加热制度,有效避免镀层涂层在拉应力作用下的LMIE开裂问题(管外侧涂层薄,成形过程中部分区域受拉应力,加热后涂层与基体扩散充分,涂层凝固点提高,成形过程中不开裂,但管外侧耐蚀性差;管内测涂层厚,成形过程中始终受压应力避免LMIE开裂问题,加热后涂层与基体扩散有限,涂层凝固点低,管内侧耐蚀性强)。
2、镀锌管状零部件服役过程中具有阴极保护作用,耐蚀性强。
附图说明
图1镀锌板热压应力硬化管状零部件制备流程示意图。
具体实施方式
下面结合附图和具体实施案例对本发明作进一步说明,具体实施步骤如下:
一种镀锌板热压应力硬化管状零部件的制备方法将板厚1.5mm酸扎料(化学成分C:0.2%;Si:0.25%;Mn:1.2%;Cr:0.25;B:0.003%;Ti:0.015%)经过GI型热镀锌产线,通过气刀控制钢带上下表面镀锌含量,获得不等厚锌层热成形钢(薄锌层一侧:45g/m2;厚锌层一侧:90g/m2);
不等厚镀锌层热成形钢分条卷管获得初始管坯,保证管内壁涂层厚,管外壁涂层薄;初始管坯的周长d大于等于目标零部件最大截面周长;
初始管坯通过加热炉进行辐射加热,加热和保温过程中初始管坯外侧涂层充分扩散实现涂层凝固;加热温度范围890摄氏度,保温时间5min。
加热后管坯转移至模具上,模具两端进行快速密封并通入初始气体压力P,气体压力P的设定原则:P<σs﹒h/r,其中σs为材料屈服应力,h为材料厚度,r为管状试样半径。本次试制中r为20mm,890摄氏度的屈服应力为80MPa,初始气体压力P为5MPa。
压机下行模具合模的过程中,封闭管件两端在液压驱动装置作用下保证合适的进料量L,从而确保管内侧涂层沿着管轴向始终处于压应力状态;在合模过程中管坯每个圆环截面中,管坯内侧涂层沿着垂直直径方向始终处于压应力状态。
成形后模具保持压力F_press,管内气体压力升至P_air,保证管状板料与模具压紧实现热量快速交换;保压时间10s。合模保压力F_press和管内气压P_air的关系式为(F_press-P_air*A)/A=10MPa左右,A表示法向投影面积。
泄压后零部件取出,零部件力学性能:屈服强度为1080MPa,抗拉强度为1556MPa,断后延伸率7%(A50标距);管件内表面涂层无LMIE开裂,涂层中Zn含量为46~55%(wt);外表面涂层Zn含量为28~35%(wt)。

Claims (9)

1.一种镀锌板热压应力硬化管状零部件的制备方法,其特征在于,包括以下步骤:
A:热成形钢带上下表面涂覆一层不等厚锌层;薄锌层一侧镀层厚度为:4.3-7.1um(30-50g/m2);厚锌层一侧镀层厚度为:8.6-21.4um(60-150g/m2);
B:将镀锌热成形钢分条卷管获得初始管,初始管内壁镀层厚,初始管外壁镀层薄,初始管周长为d;初始管被加热至一定温度和时间用以保证初始管件完全奥氏体化;
C:加热后的初始管转移至模具中,两端密封并充入一定压力P的压缩空气;
D:在模具下行合模过程中,封闭管件两端在液压驱动装置或模具斜锲作用下保证合适的进料量L,保证管内侧涂层沿着管轴向始终处于压应力状态;在合模过程中管坯每个圆环截面中,管坯内侧涂层沿着垂直直径方向始终处于压应力状态;
E:成形后模具保持压力实现管状板料于模具之间热量的快速交换实现淬火;保压时间为5-25s;其中合模保压力F_press和管内气压P_air的关系式为(F_press-P_air*A)/A>=5MPa,A表示法向投影面积。
2.如权利要求1所述的一种镀锌板热压应力硬化管状零部件的制备方法,其特征在于,所述步骤A中热成形钢带的基体成分为:C:0.05-0.35%,Si:0.01-1.5%,Mn:0.4-2.5%,B:0%-0.020%,Ti:0%-0.20%,Nb:0%-0.30%,V:0%-3.0%,Cr:0%-5.0%,Mo:0%-1.0%余量为Fe和杂质。
3.如权利要求1所述的一种镀锌板热压应力硬化管状零部件的制备方法,其特征在于,所述步骤A中薄锌层一侧镀层与厚锌层一侧镀层厚度比为:1/3-1/2。
4.如权利要求1所述的一种镀锌板热压应力硬化管状零部件的制备方法,其特征在于,所述步骤B中初始管周长d大于等于目标零部件任何一个位置的周长。
5.如权利要求1所述的一种镀锌板热压应力硬化管状零部件的制备方法,其特征在于,步骤A中加热和保温过程中初始管坯外侧涂层充分扩散实现涂层凝固;加热温度范围:850℃-900℃;保温时间15s~(3min+2min*h/6);h为管坯外侧涂层厚度。
6.如权利要求1所述的一种镀锌板热压应力硬化管状零部件的制备方法,其特征在于,所述步骤A中加热和保温过程中管坯内侧涂层不凝固,合金化程度为涂层中Zn含量大于45%;用以保证较好的耐蚀性。
7.如权利要求1所述的一种镀锌板热压应力硬化管状零部件的制备方法,其特征在于,所述步骤E中气体压力P的设定原则:P<σs﹒h/r,其中σs为材料屈服应力,h为材料厚度,r为管状试样半径。
8.如权利要求7所述的一种镀锌板热压应力硬化管状零部件的制备方法,其特征在于,所述材料屈服应力σs随着温度的降低会增大,成形过程中P是变化的。
9.如权利要求1所述的一种镀锌板热压应力硬化管状零部件的制备方法,其特征在于,所述步骤D中进料量L的公式为DL>=L0-L;L为零部件中最短线长度;L0为初始管坯长度。
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