CN116536485A - Wear resistant high strength roll formed parts - Google Patents

Wear resistant high strength roll formed parts Download PDF

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Publication number
CN116536485A
CN116536485A CN202210084483.2A CN202210084483A CN116536485A CN 116536485 A CN116536485 A CN 116536485A CN 202210084483 A CN202210084483 A CN 202210084483A CN 116536485 A CN116536485 A CN 116536485A
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Prior art keywords
workpiece blank
forming
component
chromium
range
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CN202210084483.2A
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Inventor
卢琦
王舟
王建锋
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GM Global Technology Operations LLC
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GM Global Technology Operations LLC
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Priority to CN202210084483.2A priority Critical patent/CN116536485A/en
Priority to DE102022119262.8A priority patent/DE102022119262A1/en
Priority to US17/889,812 priority patent/US20230235424A1/en
Publication of CN116536485A publication Critical patent/CN116536485A/en
Pending legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/18—Hardening; Quenching with or without subsequent tempering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
    • B21D5/14—Bending sheet metal along straight lines, e.g. to form simple curves by passing between rollers
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/06—Surface hardening
    • C21D1/09—Surface hardening by direct application of electrical or wave energy; by particle radiation
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/34—Methods of heating
    • C21D1/42—Induction heating
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/62—Quenching devices
    • C21D1/673—Quenching devices for die quenching
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D6/00—Heat treatment of ferrous alloys
    • C21D6/002—Heat treatment of ferrous alloys containing Cr
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D6/00—Heat treatment of ferrous alloys
    • C21D6/005—Heat treatment of ferrous alloys containing Mn
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D6/00—Heat treatment of ferrous alloys
    • C21D6/008—Heat treatment of ferrous alloys containing Si
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/13—Modifying the physical properties of iron or steel by deformation by hot working
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/005—Modifying the physical properties by deformation combined with, or followed by, heat treatment of ferrous alloys
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/02—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
    • C21D8/0205—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips of ferrous alloys
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/02—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
    • C21D8/0221—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips characterised by the working steps
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/02—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
    • C21D8/0247—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips characterised by the heat treatment
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D9/46—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for sheet metals
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/28—Ferrous alloys, e.g. steel alloys containing chromium with titanium or zirconium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/32—Ferrous alloys, e.g. steel alloys containing chromium with boron
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/34—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/38—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of manganese
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
    • B21D5/06—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles
    • B21D5/08—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D2211/00—Microstructure comprising significant phases
    • C21D2211/004—Dispersions; Precipitations
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D2211/00—Microstructure comprising significant phases
    • C21D2211/008—Martensite
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • 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
    • C21D2221/00—Treating localised areas of an article

Abstract

A method of forming a component having a cross section with a bend radius includes providing a workpiece blank from a Pressure Hardened Steel (PHS). The method further includes austenitizing the workpiece blank in the furnace via heating the sheet metal strip to achieve an austenitic microstructure therein, including soaking the workpiece blank for a predetermined amount of time. The method additionally includes quenching the austenitized workpiece blank to achieve a martensitic matrix microstructure having dispersed chromium-rich carbides therein. The method further includes roll forming the austenitized and quenched workpiece blank to produce a cross-section and a bend radius. The method may further include locally heating the region of the bend radius during roll forming of the cross-section to reduce an amount of chromium-rich carbide in the microstructure inside the bend relative to the microstructure outside the bend and thereby produce a component having high strength, ductility, and wear resistance.

Description

Wear resistant high strength roll formed parts
Technical Field
The present disclosure relates to systems and methods for producing wear resistant high strength roll formed components.
Background
Metal forming is a metal working process that produces metal parts and objects by mechanical deformation, wherein a workpiece is reformed without the addition or removal of material. Metal forming operates on the material science principle of plastic deformation, in which the physical shape of a metal workpiece is permanently deformed. Roll forming or rolling is a metal forming process in which a metal feedstock is passed through one or more pairs of rolls to shape a workpiece and impart desired mechanical properties to the finished part without reducing the metal thickness.
Roll forming involves continuously bending a long strip of sheet metal (typically coiled steel) into a desired cross section. The metal strip is typically passed through sets of rollers mounted on successive frames, each set of rollers performing an incremental portion of the curve until the desired cross section (profile) is obtained. Roll forming is well suited for producing long length and large batches of constant profile parts. The roll stands holding the roll pairs are typically combined together into a rolling mill capable of rapid processing of metal, typically steel, into products such as structural steel beams, bars and rails.
Disclosure of Invention
A method of forming a component having a cross-section with a bend characterized by a bend radius includes providing a workpiece blank from a Pressure Hardened Steel (PHS). The method further includes austenitizing the workpiece blank in the furnace via heating the sheet metal strip to achieve an austenitic microstructure therein, including soaking the workpiece blank for a predetermined amount of time. The method additionally includes quenching the austenitized workpiece blank to achieve a martensitic matrix microstructure having dispersed carbides therein. The method further includes roll forming the austenitized and quenched workpiece blank via at least one set of rolls to produce a cross section having a bend radius.
The method may additionally include locally heating the region of the bend radius during roll forming of the cross-section to reduce an amount of chromium-rich carbide in the martensitic matrix microstructure inside the bend radius relative to the martensitic matrix microstructure outside the bend radius. The austenitized and quenched regions of the locally heated bend radius are intended to promote roll formability of the cross section and maintain the material strength outside the bend radius, resulting in a component with high strength, ductility and wear resistance.
The cross-section may have a ratio of material thickness to bend radius of 1:1, i.e., the bend radius may be equal to the thickness of the workpiece blank without cracking or tearing.
According to the method, during roll forming, localized heating may be performed on the austenitized and quenched workpiece blank via laser, microwave or infrared means.
Depending on the method, the predetermined amount of time may be in the range of 1-1000 seconds, and may further be in the range of 200-500 seconds.
According to the method, quenching may be performed at a rate of greater than 10 ℃/sec.
PHS of the workpiece blank may include carbon (C) in the range of 0.05-0.45 wt%, manganese (Mn) in the range of 0-4.5 wt%, chromium (Cr) in the range of 0.5-6 wt% and silicon (Si) in the range of 0.5-2.5 wt%.
The amount of chromium in the chromium-rich carbide may be greater than 2 wt.%.
The chromium-rich carbide particles may have a diameter in the range of 5 nm-1.5 μm.
The martensite matrix microstructure with dispersed carbides may comprise more than 85 volume% martensite (with optionally less than 10 volume% austenite/ferrite martensite and optionally less than 5 volume% ferrite) and chromium-rich carbides in the range of 0.2-10 volume%.
The austenitized and quenched strips of PHS may have a tensile strength in the range of 1000-2000 MPa.
Also disclosed are high strength and wear resistant components roll formed from austenitized and quenched Pressure Hardened Steel (PHS) workpiece blanks.
The invention provides the following technical scheme:
1. a method of forming a component having a cross-section with a bend characterized by a bend radius, the method comprising:
providing a workpiece blank from a Pressure Hardened Steel (PHS);
austenitizing the workpiece blank in a furnace via heating the workpiece blank to achieve an austenitic microstructure therein, including soaking the workpiece blank for a predetermined amount of time;
quenching the austenitized workpiece blank to achieve a martensitic matrix microstructure therein having dispersed chromium-rich carbides; and
the austenitized and quenched workpiece blank is roll formed via at least one set of rolls to produce the cross-section having the bend radius.
2. The method of forming a component of claim 1, wherein the region of the bend radius is locally heated during roll forming of the cross-section to reduce an amount of chromium-rich carbide in the martensitic matrix microstructure inside the bend radius relative to the martensitic matrix microstructure outside the bend radius, thereby promoting roll formability of the cross-section and maintaining material strength outside the bend radius and thereby producing a component having high strength, ductility, and wear resistance.
3. The method of forming a component of claim 2, wherein the cross-section has a material thickness to bend radius ratio of 1:1 without cracking or tearing.
4. The method of forming a component of claim 2, wherein during said roll forming, localized heating is performed on said austenitized and quenched workpiece blank via one of laser, microwave, and infrared means.
5. The method of forming a component of claim 1, wherein the predetermined amount of time is in the range of 1-1000 seconds.
6. The method of forming a component of claim 1, wherein the quenching is performed at a rate of greater than 10 ℃/sec.
7. The method of forming a component of claim 1, wherein PHS of the workpiece blank comprises carbon (C) in the range of 0.05-0.45 wt%, manganese (Mn) in the range of 0-4.5 wt%, chromium (Cr) in the range of 0.5-6 wt%, and silicon (Si) in the range of 0.5-2.5 wt%.
8. The method of forming a component of claim 1, wherein the amount of chromium in the chromium-rich carbide is greater than 2 wt% and the particles of chromium-rich carbide have a diameter in the range of 5 nm-1.5 μm.
9. The method of forming a component of claim 1, wherein the martensitic matrix microstructure having dispersed chromium-rich carbides comprises:
more than 85% by volume of martensite (with optionally less than 10% by volume of austenite and optionally less than 5% by volume of ferrite); and
chromium-rich carbides in the range of 0.2-10 vol%.
10. The method of forming a component of claim 1, wherein the austenitized and quenched workpiece blank has a tensile strength in the range of 1000-2000 MPa.
11. A roll formed high strength and wear resistant component comprising:
a cross section having a bend characterized by a bend radius, the cross section being roll formed from an austenitized and quenched workpiece blank from a Pressure Hardened Steel (PHS) having a martensitic matrix microstructure with dispersed chromium-rich carbides.
12. The component of claim 11, wherein the martensitic matrix microstructure in the bend radius has a reduced amount of chromium-rich carbide relative to the martensitic matrix microstructure outside the bend radius.
13. The component of claim 11, wherein the cross section has a ratio of material thickness to the bend radius of 1:1 without cracking or tearing.
14. The component of claim 11, wherein the PHS of the workpiece blank comprises carbon (C) in the range of 0.05-0.45 wt%, manganese (Mn) in the range of 0-4.5 wt%, chromium (Cr) in the range of 0.5-6 wt%, and silicon (Si) in the range of 0.5-2.5 wt%.
15. The component of claim 11, characterized in that the amount of chromium in the chromium-rich carbide is greater than 2 wt% and the particles of chromium-rich carbide have a diameter in the range of 5 nm-1.5 μm.
16. The component of claim 11, wherein the martensitic microstructure having dispersed carbides comprises:
more than 85% by volume of martensite (with optionally less than 10% by volume of austenite and optionally less than 5% by volume of ferrite); and
chromium-rich carbides in the range of 0.2-10 vol%.
17. The component of claim 11 wherein the austenitized and quenched workpiece blank has a tensile strength in the range of 1000-2000 MPa.
18. A method of forming a structural component comprising a cross-section having a bend characterized by a bend radius, the method comprising:
providing a workpiece blank from a Press Hardened Steel (PHS) having carbides enriched in chromium greater than 2 wt%;
austenitizing the workpiece blank in a furnace via heating a sheet metal strip to achieve an austenitic microstructure therein, including soaking the workpiece blank for 200-500 seconds;
quenching the austenitized workpiece blank at a rate of greater than 10 ℃/sec to achieve a martensitic matrix microstructure therein having dispersed chromium-rich carbides to achieve a final tensile strength thereof in the range of 1000-2000 MPa;
roll forming the austenitized and quenched workpiece blank via at least one set of rolls to produce a cross section including a bend radius; and
the region of the bend radius is locally heated during roll forming of the cross-section to reduce an amount of chromium-rich carbide in the martensitic matrix microstructure inside the bend radius relative to the martensitic matrix microstructure outside the bend radius, thereby promoting roll formability of the cross-section and maintaining material strength outside the bend radius and thereby producing a component having high strength, ductility and wear resistance.
19. The method of forming a structural member of claim 18, wherein PHS of the workpiece blank comprises carbon (C) in the range of 0.05-0.45 wt%, manganese (Mn) in the range of 0-4.5 wt%, chromium (Cr) in the range of 0.5-6 wt%, and silicon (Si) in the range of 0.5-2.5 wt%.
20. The method of forming a structural member of claim 18 wherein the martensitic matrix microstructure having dispersed chromium-rich carbides comprises:
more than 85% by volume of martensite (with optionally less than 10% by volume of austenite and optionally less than 5% by volume of ferrite); and
chromium-rich carbides in the range of 0.2-10 vol%.
The above features and advantages and other features and advantages of the present disclosure will be readily apparent from the following detailed description of the embodiments and best modes for carrying out the described disclosure when taken in connection with the accompanying drawings and appended claims.
Drawings
Fig. 1 is a schematic perspective view of a roll formed and locally heated Pressure Hardened Steel (PHS) workpiece blank to create a structural component with a small radius bend in accordance with the present disclosure.
Fig. 2 is a schematic close-up view of a cross-section of a structural component roll formed from the workpiece blank shown in fig. 1 in accordance with the present disclosure.
FIG. 3 is a graphical representation of a dispersed chromium carbide rich martensitic matrix microstructure of a structural member roll formed from a PHS workpiece blank.
Fig. 4A is a data graph depicting a stress-strain comparison of PHS without carbide and PHS enriched in carbide.
Fig. 4B is a data graph depicting a comparison of wear resistance of PHS without carbide and PHS enriched in carbide.
Fig. 4C is a data graph depicting a comparison of impact toughness of PHS without carbide and PHS enriched in carbide.
Fig. 5 is a flow chart illustrating a method of roll forming a structural member from the PHS workpiece blank shown in fig. 1-4.
Fig. 6 is a data graph depicting austenitizing temperature versus time for a structural member formed from a PHS workpiece blank having a martensitic matrix microstructure with dispersed chromium-rich carbides as shown in fig. 3 in accordance with the present disclosure.
Detailed Description
Referring to the drawings, wherein like elements are designated with like numerals throughout, fig. 1 illustrates in detail the processing and forming of a workpiece blank 10. Such workpiece blanks 10 are often used in manufacturing processes such as metal stamping or roll forming to produce high strength components of specific shapes. Typically, such components are formed from a workpiece blank 10. Each workpiece blank 10 is typically a pre-cut piece of formable material, for example a sheet metal, such as cold rolled steel.
Specifically, the formable material may be a Pressure Hardened Steel (PHS) selected for the subject workpiece blank 10 used to fabricate the structural component 12. The component 12 is a high strength and wear resistant part having high ductility or fracture toughness. For example, the structural component 12 may be an automotive body frame rail or cross member (not shown) as shown in fig. 1. PHS is a high strength steel, typically delivered in rolls or rolls of various sizes, for blanking, austenitizing, and additional processing. Typically austenitization and quenching are hardening processes used on ferrous metals to promote better mechanical properties of the material. The purpose of austenitizing and quenching steel and other ferrous alloys is to provide strength and resistance to the material.
The temperature at which steel and other iron alloys are heated above their critical temperature is referred to as the austenitizing temperature. The austenitizing temperature range varies with different grades of carbon, alloys and tool steels. After the metal is heated to the austenitic region, it is then quenched in a heat extraction medium. In general, pressure hardening, also known as hot stamping or hot press forming, allows the PHS steel to be formed into complex shapes, which is often not possible in conventional cold stamping operations. However, austenitized and quenched PHS is typically not used for roll formed parts due to the possibility of material cracking and tearing, especially within the tight radius of the part cross-section created by the forming rolls.
The workpiece blank 10 is typically cut from a strip or roll 14 of the PHS described above and then austenitized, quenched, and roll formed to produce the structural component 12. The unformed workpiece blank 10 may be initially austenitized in the oven 16 (shown in fig. 1). To achieve the martensite matrix microstructure, which will be described in detail below, austenitizing of the workpiece blank 10 may be performed at a predetermined temperature above an austenitizing temperature Ac3 (shown in fig. 6), with the workpiece blank 10 being immersed at a particular temperature for a predetermined amount of time. The final tensile strength of the austenitized and quenched workpiece blank 10 may be in the range of 1000-2000 MPa (shown in fig. 4A).
After austenitization, the workpiece blank 10 may be quenched at a rate of greater than 10 ℃/sec and transferred to a roller system 18 (shown in fig. 1) having at least one set of rollers 18A. As shown, the roller system 18 may include multiple sets of rollers mounted on successive frames, with each set of rollers creating an incremental portion of the component 12. The austenitized and quenched workpiece blank 10 may be locally heated during roll forming via a heating device 20, such as a laser, microwave or infrared source, in the region where the rollers 18A contact the blank. In a system 18 employing multiple rollers, each respective roller 18A may be paired with a corresponding heating device 20 to locally heat the region of the workpiece blank 10 that is undergoing deformation. The localized heating is intended to promote and improve the ductility and rollformability of the workpiece blank 10, particularly when produced from high strength steels, such as austenitized and quenched PHS. Thus, localized heating enables the PHS workpiece blank 10 to be formed into a part 12 having a desired shape as well as high strength, ductility and wear resistance.
When used to make component 12, PHS includes carbon (C) in the range of 0.05-0.45 wt%, manganese (Mn) in the range of 0-4.5 wt%, chromium (Cr) in the range of 0.5-6 wt%, and silicon (Si) in the range of 0.5-2.5 wt%. The structural component 12 has a desired final shape or profile 12A (shown in fig. 1) and a cross-section or profile 12B (shown in fig. 2) having one or more bends 22 characterized by a radius R. As shown in FIG. 3, the component 12 material has a martensitic matrix microstructure 24 with dispersed chromium-rich carbides 26. Although a carbide-free PHS has similar tensile properties to a carbide-and in particular chromium-rich PHS (the stress-strain comparison shown in fig. 4A), a carbide-rich PHS will provide relatively higher strength and wear resistance (the wear resistance comparison shown in fig. 4B and the impact toughness comparison shown in fig. 4C).
The martensite matrix microstructure 24 with dispersed chromium-rich carbides 26 may specifically comprise greater than 85 volume% martensite (with optionally less than 10 volume% austenite and optionally less than 5 volume% ferrite), and further greater than 90 volume% martensite. The martensite base microstructure 24 with dispersed chromium-rich carbides 26 may additionally include chromium-rich carbides in the range of 0.2-10 vol%, less than 10 vol% austenite, and less than 5 vol% ferrite. The martensite in the martensite matrix microstructure 24 can also optionally include austenite/ferrite martensite. The amount of chromium in the chromium-rich carbide 26 may be greater than 2 wt.%. The particles of chromium-rich carbide 26 may have a diameter in the range of 5 nm-1.5 μm.
The area of the cross section or profile 12B that is adjacent to and surrounds the bend radius R is labeled as area A1 in fig. 2, with the area outside of area A1 being labeled as area A2 in fig. 2. The localized heating of region A1 during roll forming of cross section 12B is configured to digest and reduce the amount of chromium-rich carbide 26 in the martensitic matrix microstructure 24 inside the bend radius R relative to the martensitic matrix microstructure outside the bend radius. Specifically, before localized heating is applied to region A1 around bend 22, chromium-rich carbide 26 is present in regions A1 and A2 at substantially equal concentrations, but subsequent localized heating digests at least some of the carbide in region A1. Thus, the chromium-rich carbide 26 more concentrated in the region A2 outside the bent portion 22 maintains the strength and wear resistance of the austenitized and quenched PHS relative to the adjacent region A1.
As further shown in fig. 2, localized heating of the PHS material in region A1 during roll forming allows radius R to be of relatively small magnitude, i.e., cross section 12B may haveSmall material thicknesstRatio to the bending radius R without cracking or tearing in the bend 22. Specifically, the material thicknesstThe ratio to the bending radius R may be 1:1. Typically, the ratio of PHS material thickness to bend radius in the formed part exceeds 1:1.5 to reduce the likelihood of cracking and tearing. Material thickness in PHS roll formed cross section 12BtThe advantageous ratio to the bending radius R of the present subject matter is achieved in particular by the enhanced formability of the material at higher temperatures, i.e. by the above-mentioned localized heating to achieve a higher plasticity of the martensite.
Fig. 5 depicts a method 100 of forming a part 12 from the workpiece blank 10 shown and described above with reference to fig. 1-4. The forming of the part 12 begins in block 102 to provide a Pressure Hardened Steel (PHS) strip. As described above, the workpiece blank 10 may be cut or blanked from a roll or log of PHS. After block 102, the method proceeds to block 104. In block 104, the method includes austenitizing the workpiece blank 10 by heating the workpiece blank in the furnace 16 above a temperature Ac3 at a predetermined austenitizing temperature 28, as shown in fig. 6.
In block 104, the method further includes immersing the workpiece blank at the predetermined temperature 28 of the present subject matter for a predetermined amount of time 30 (shown in fig. 6) to achieve an austenitic microstructure in the cross-section 12B. The predetermined temperature 28 may be in the range of 880-950 ℃. The predetermined amount of soak time 30 may be in the range of 1-1000 seconds and may be further limited to the range of 200-500 seconds. After austenitizing the workpiece blank 10, the method proceeds to block 106. In block 106, the method includes quenching the austenitized workpiece blank 10 to achieve a martensitic matrix microstructure 24 having dispersed chromium-rich carbides 26 therein. As described with reference to fig. 1-4, quenching may be performed at a rate greater than 10 ℃/sec. In particular, the quenching of the workpiece blank 10 may be performed in a salt bath, mixed liquid and air quench or via water cooled die quench. The PHS workpiece blank 10 intended for austenitizing and quenching has a tensile strength in the range of 1000-2000 MPa.
After frame 106, the method moves to frame 108, where the method includes roll forming the austenitized and quenched workpiece blank 10 via the roller system 18 to produce a cross section 12B having a bend radius R. After block 108, the method may proceed to block 110. In block 110, the method includes locally heating a region A1 of a bend radius R during roll forming of the cross section 12B. By digesting at least some of the chromium-rich carbides 26 in the region A1, the localized heating of the region A1 serves to reduce the amount of chromium-rich carbides in and around the bend radius R relative to the martensitic matrix microstructure 24 outside the bend 22. As a result, the cross section 12B in the region A2 will have increased material strength and wear resistance relative to the material strength and wear resistance in the region A1 having the bend R. As described with reference to fig. 1-4, the austenitized and quenched workpiece blank 10 may be locally heated via a heating device 20, such as a laser, microwave, or infrared source.
After block 110, the method may proceed to block 112. In block 112, the method includes cooling the roll-formed component 12, such as by allowing the component to equilibrate with ambient temperature. After either block 108 or block 112, the method may proceed to block 114 and end therein, trimming excess material, cleaning, and/or packaging the final part 12. In general, the above disclosed method applied to the PHS workpiece blank 10, particularly using localized heating of the austenitized and quenched workpiece blank 10 in the region A1 of the bend radius R, is directed to producing a roll formed component 12 having high strength, ductility (fracture toughness) and wear resistance in the desired region.
The detailed description and drawings or figures support and describe the present disclosure, but the scope of the present disclosure is limited only by the claims. While the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims. Furthermore, the features of the embodiments shown in the drawings or of the various embodiments mentioned in this description are not necessarily to be understood as separate embodiments from each other. Rather, each of the features described in one of the examples of embodiments can be combined with one or more other desired features from other embodiments to produce other embodiments that are not described with text or with reference to the drawings. Accordingly, such other embodiments are within the scope of the following claims.

Claims (10)

1. A method of forming a component having a cross-section with a bend characterized by a bend radius, the method comprising:
providing a workpiece blank from a Pressure Hardened Steel (PHS);
austenitizing the workpiece blank in a furnace via heating the workpiece blank to achieve an austenitic microstructure therein, including soaking the workpiece blank for a predetermined amount of time;
quenching the austenitized workpiece blank to achieve a martensitic matrix microstructure therein having dispersed chromium-rich carbides; and
the austenitized and quenched workpiece blank is roll formed via at least one set of rolls to produce the cross-section having the bend radius.
2. The method of forming a component of claim 1, wherein the region of the bend radius is locally heated during roll forming of the cross-section to reduce an amount of chromium-rich carbide in the martensitic matrix microstructure inside the bend radius relative to the martensitic matrix microstructure outside the bend radius, thereby promoting roll formability of the cross-section and maintaining material strength outside the bend radius and thereby producing a component having high strength, ductility, and wear resistance.
3. A method of forming a component as claimed in claim 2, wherein the cross section has a material thickness to bend radius ratio of 1:1 without cracking or tearing.
4. The method of forming a component of claim 2, wherein during the roll forming, localized heating is performed on the austenitized and quenched workpiece blank via one of a laser, microwave, and infrared device.
5. The method of forming a component of claim 1, wherein the predetermined amount of time is in the range of 1-1000 seconds.
6. The method of forming a component of claim 1, wherein the quenching is performed at a rate of greater than 10 ℃/sec.
7. The method of forming a component of claim 1, wherein PHS of the workpiece blank comprises carbon (C) in the range of 0.05-0.45 wt%, manganese (Mn) in the range of 0-4.5 wt%, chromium (Cr) in the range of 0.5-6 wt%, and silicon (Si) in the range of 0.5-2.5 wt%.
8. A method of forming a component according to claim 1, characterized in that the amount of chromium in the chromium-rich carbide is more than 2 wt% and the particles of chromium-rich carbide have a diameter in the range of 5 nm-1.5 μm.
9. The method of forming a component of claim 1, wherein the martensitic matrix microstructure having dispersed chromium-rich carbides comprises:
more than 85% by volume of martensite (with optionally less than 10% by volume of austenite and optionally less than 5% by volume of ferrite); and
chromium-rich carbides in the range of 0.2-10 vol%.
10. The method of forming a component of claim 1, wherein the austenitized and quenched workpiece blank has a tensile strength in the range of 1000-2000 MPa.
CN202210084483.2A 2022-01-25 2022-01-25 Wear resistant high strength roll formed parts Pending CN116536485A (en)

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