US10385415B2 - Zinc-coated hot formed high strength steel part with through-thickness gradient microstructure - Google Patents

Zinc-coated hot formed high strength steel part with through-thickness gradient microstructure Download PDF

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US10385415B2
US10385415B2 US15/141,272 US201615141272A US10385415B2 US 10385415 B2 US10385415 B2 US 10385415B2 US 201615141272 A US201615141272 A US 201615141272A US 10385415 B2 US10385415 B2 US 10385415B2
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US20170314089A1 (en
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Jianfeng Wang
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GM Global Technology Operations LLC
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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
    • C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/10—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for compacting surfaces, e.g. shot-peening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/013—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium
    • 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
    • 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
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold 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
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
    • 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
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
    • C21D7/06—Modifying the physical properties of iron or steel by deformation by cold working of the surface by shot-peening or the like
    • 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
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • 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
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • 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
    • C22C38/14—Ferrous alloys, e.g. steel alloys containing 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
    • C22C38/28—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
    • C22C38/38—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of 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
    • C22C38/60—Ferrous alloys, e.g. steel alloys containing lead, selenium, tellurium, or antimony, or more than 0.04% by weight of sulfur
    • C—CHEMISTRY; METALLURGY
    • 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
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
    • C23C2/06—Zinc or cadmium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • 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
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/34—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the shape of the material to be treated
    • 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
    • C21D2211/001—Austenite
    • 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

Definitions

  • the present disclosure relates to a hot-formed press-hardened high-strength steel part with a through-thickness gradient microstructure and methods for making selective surface hardening to form a hot-formed press-hardened high-strength steel part.
  • Press-hardened steel is also referred to as “hot-stamped steel” or “boron-steel” (e.g., 22 MnB5 alloy) is one of the strongest steels used for automotive body structural applications, typically having tensile strength properties on the order of about 1,400 megapascals (MPa) or higher.
  • boron-steel e.g., 22 MnB5 alloy
  • Such a steel alloy has low manganese levels and no aluminum and exhibits desirable properties, including high strength-to-weight ratios.
  • Components formed from PHS have become prevalent in various industries and applications, including general manufacturing, construction equipment, automotive or other transportation industries, home or industrial structures, and the like.
  • PHS components are often used for forming load-bearing components, like structural pillars and door beams, which typically require high strength materials.
  • the finished state of these steels are designed to have high strength and enough ductility to resist external forces, for example, to resist intrusion of external objects into the passenger compartment without fracturing, so
  • the PHS steel blank is then austenitized in a furnace. Austenitization is typically conducted in the range of about 880° C. to 950° C.
  • the steel blank may then be hot stamped by being pressed and quenched in dies.
  • hot stamping of PHS forming and hardening are combined into a single operation, which may be one of two main types of processes: indirect and direct.
  • the direct method the PHS component is formed and pressed simultaneously between dies, which quenches the steel.
  • the dies may be water-cooled, for example.
  • the PHS component is cold formed to an intermediate partial shape before austenitization and the subsequent pressing and quenching steps are then conducted.
  • the quenching of the PHS component hardens the component by transforming the microstructure from austenite to martensite.
  • the PHS high-strength steel microstructure is predominantly (e.g., greater than 98%) martensite.
  • PHS components may require cathodic protection.
  • the PHS component may be coated prior to applicable pre-cold forming (if the indirect process is used) or austenitization. Coating the PHS component provides a protective layer to the underlying steel component.
  • Such coatings typically include an aluminum-silicon alloy and/or zinc.
  • Zinc coatings offer cathodic protection; the coating acts as a sacrificial layer and corrodes instead of the steel component, even where the steel is exposed.
  • liquid metal embrittlement LME
  • LME liquid metal embrittlement
  • Alternative high-strength steel alloy materials to PHS alloy may be used to form press-hardened steel components, such as select high-strength transformation induced plasticity (TRIP) steel like delta-TRIP steel and medium manganese content TRIP steel.
  • TRIP transformation induced plasticity
  • alternative hot-formed press-hardened structures formed from such select TRIP steels often have microstructures with retained austenite and thus may not have comparable high-strength or hardness levels to comparative PHS structures having fully martensitic microstructures.
  • select alternative high-strength TRIP steel alloy materials are galvanized or galvannealed and then press-hardened, they likewise may suffer from LME.
  • the present disclosure provides a method of strengthening surface regions of a high-strength steel.
  • the method may comprise shot peening at least one region of an exposed surface of a hot-formed press-hardened component comprising a high-strength transformation induced plasticity (TRIP) steel.
  • TRIP steel may be selected from the group consisting of:
  • the present disclosure provides a method of strengthening regions of zinc-coated high-strength steel.
  • the method may comprise shot peening at least one region of an exposed surface of a zinc-coated hot-formed press-hardened component comprising a high-strength transformation induced plasticity (TRIP) steel having a surface coating comprising zinc.
  • TRIP steel may be selected from the group consisting of:
  • the present disclosure provides a zinc-coated hot-formed press-hardened component.
  • the component comprises at least one hardened surface region comprising less than or equal to about 1% by volume austenite and a center region comprising greater than or equal to about 5% by volume retained austenite in a matrix of martensite.
  • the component comprises a high-strength transformation induced plasticity (TRIP) steel having a surface coating comprising zinc.
  • TRIP steel may be selected from the group consisting of:
  • FIG. 1 shows an exemplary schematic of a high-strength high manganese transformation induced plasticity (TRIP) steel alloy microstructure having a matrix of martensite with a distributed phase of retained austenite after hot forming and press hardening.
  • TRIP transformation induced plasticity
  • FIG. 2 shows a simplified cross-sectional schematic of a zinc-coated sheet blank having a corrosion coating applied to two sides prior to hot forming and press hardening.
  • FIG. 3 shows an exemplary schematic of a hot-formed press-hardened high-strength high manganese transformation induced plasticity (TRIP) steel alloy microstructure having a matrix of martensite with a distributed phase of retained austenite in a center region and a first surface that is selectively hardened in accordance with certain aspects of the present disclosure.
  • TRIP transformation induced plasticity
  • FIG. 4 shows an exemplary schematic of a hot-formed press-hardened high-strength high manganese transformation induced plasticity (TRIP) steel alloy microstructure having a matrix of martensite with a distributed phase of retained austenite in a center region and two distinct surfaces that are selectively hardened in accordance with yet other aspects of the present disclosure.
  • TRIP transformation induced plasticity
  • FIG. 5 shows an exemplary and simplified cross-sectional view of a shot peening device for shot peening a transformation induced plasticity (TRIP) steel alloy in accordance with other aspects of the present disclosure.
  • TRIP transformation induced plasticity
  • FIG. 6 shows a representative front view of a high-strength structural component in the form of a conventional B-pillar for an automobile.
  • FIG. 7 shows a detailed side perspective view of a lower portion of a high-strength structural component like that shown in FIG. 6 having two distinct surface hardened regions formed in accordance with certain aspects of the present disclosure.
  • Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific compositions, components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
  • compositions, materials, components, elements, features, integers, operations, and/or process steps are also specifically includes embodiments consisting of, or consisting essentially of, such recited compositions, materials, components, elements, features, integers, operations, and/or process steps.
  • the alternative embodiment excludes any additional compositions, materials, components, elements, features, integers, operations, and/or process steps, while in the case of “consisting essentially of,” any additional compositions, materials, components, elements, features, integers, operations, and/or process steps that materially affect the basic and novel characteristics are excluded from such an embodiment, but any compositions, materials, components, elements, features, integers, operations, and/or process steps that do not materially affect the basic and novel characteristics can be included in the embodiment.
  • first, second, third, etc. may be used herein to describe various steps, elements, components, regions, layers and/or sections, these steps, elements, components, regions, layers and/or sections should not be limited by these terms, unless otherwise indicated. These terms may be only used to distinguish one step, element, component, region, layer or section from another step, element, component, region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first step, element, component, region, layer or section discussed below could be termed a second step, element, component, region, layer or section without departing from the teachings of the example embodiments.
  • Spatially or temporally relative terms such as “before,” “after,” “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures.
  • Spatially or temporally relative terms may be intended to encompass different orientations of the device or system in use or operation in addition to the orientation depicted in the figures.
  • “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters.
  • “about” may comprise a variation of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in certain aspects, optionally less than or equal to 0.1%.
  • disclosure of ranges includes disclosure of all values and further divided ranges within the entire range, including endpoints and sub-ranges given for the ranges.
  • the word “substantially,” when applied to a characteristic of a composition or method of this disclosure, indicates that there may be variation in the characteristic without having a substantial effect on the chemical or physical attributes of the composition or method.
  • the present disclosure pertains to methods of forming high-strength components from high-strength steel alloys, such as transformation induced plasticity (TRIP) steels.
  • a high-strength steel is one that has an ultimate tensile strength of greater than or equal to about 1,000 megapascals (MPa), for example, greater than or equal to about 1,400 MPa to less than or equal to about 2,200 MPa.
  • the high-strength TRIP steel alloy comprises manganese at relatively high amounts, for example, at greater than or equal to about 4% by mass or weight of the total the high-strength TRIP steel alloy composition.
  • Such a high-strength TRIP steel alloy having manganese at a nominal amount of above 4% by weight may be considered to be a high-strength high manganese transformation induced plasticity (TRIP) steel alloy microstructure or Mn-TRIP steel.
  • the Mn-TRIP steel alloy may comprise manganese at greater than or equal to about 4% by weight to less than or equal to about 12% by weight of the total composition.
  • the high-strength Mn-TRIP steel alloy may further comprise carbon present at greater than or equal to about 0.1% by weight to less than or equal to about 0.4% by weight.
  • the high-strength Mn-TRIP steel alloy optionally comprises manganese at greater than or equal to about 4% by weight to less than or equal to about 12% by weight of the total composition; carbon present at greater than or equal to about 0.1% by weight to less than or equal to about 0.4% by weight; one of more of the following alloying ingredients: silicon greater than or equal to about 0.1% by weight to less than or equal to about 0.5% by weight; chromium at less than or equal to about 1% by weight; titanium present at less than or equal to about 0.2% by weight; aluminum present at less than or equal to about 0.1% by weight; phosphorus present less than or equal to about 0.2% by weight; sulfur present less than or equal to about 0.05% by weight; and one or more impurities cumulatively present at less than or equal to about 0.5% by weight, preferably at less than or equal to about 0.1% by weight, and a balance iron.
  • manganese at greater than or equal to about 4% by weight to less than or equal to about 12% by weight of the total composition
  • Suitable variations of a high-strength Mn-TRIP steel alloy may include a 7 Mn-TRIP steel, a 10-Mn-TRIP steel, and the like.
  • 7 Mn-TRIP steel has a nominal manganese content of approximately 7% by weight of the total alloy composition
  • 10 Mn-TRIP steel has a nominal manganese content of approximately 10% by weight of the overall alloy composition.
  • ⁇ -TRIP steel may have the following composition: aluminum present at greater than or equal to about 3% by weight to less than or equal to about 6% by weight of the total composition; manganese at greater than or equal to about 0.1% by weight to less than or equal to about 1% by weight of the total composition; carbon present at greater than or equal to about 0.3% by weight to less than or equal to about 0.5% by weight; one of more of the following alloying ingredients: silicon greater than or equal to about 0.1% by weight to less than or equal to about 0.5% by weight; chromium at less than or equal to about 1% by weight; titanium present at less than or equal to about 0.2% by weight; phosphorus present less than or equal to about 0.2% by weight; sulfur present less than or equal to about 0.05% by weight; and one or more impurities cumulatively present at less than or equal to about 3% by weight to less than or equal to about 6% by weight of the total composition; manganese at greater than or equal to about 0.1% by weight to less than or equal to about 1% by weight of the total composition
  • the methods of the present disclosure pertain to certain high-strength TRIP steels, such as a Mn-TRIP steel, a delta-TRIP steel, and the like.
  • such select high-strength TRIP steel alloys have a microstructure with a retained austenite embedded in a primary matrix of martensite after a hot stamping and/or press-hardening process.
  • a select high-strength Mn-TRIP steel alloy 20 includes a matrix of martensite 22 with a distributed phase of retained austenite 24 .
  • the phases as shown in the schematic are merely representative and may have distinct morphology/shapes, sizes, and distributions.
  • high-strength alloys such as press hardened steel (PHS)/boron steels
  • PHS press hardened steel
  • boron steels typically have about 100% martensite after press-hardening and hot stamping.
  • the high-strength Mn-TRIP steel alloy 20 has greater than or equal to about 5% by volume to less than or equal to about 30% by volume of retained austenite 24 , optionally greater than or equal to about 8% by volume to less than or equal to about 12% by volume, and in certain aspects, about 10% by volume of retained austenite.
  • hot forming of the select high-strength TRIP steels may be conducted as follows.
  • a sheet or blank of high-strength TRIP steel alloy may be formed into a three-dimensional component via hot forming.
  • Such a high-strength three-dimensional component may be incorporated into a device, such as a vehicle.
  • high-strength structures are particularly suitable for use in components of an automobile or other vehicles (e.g., motorcycles, boats, tractors, buses, motorcycles, mobile homes, campers, and tanks), they may also be used in a variety of other industries and applications, including aerospace components, consumer goods, office equipment and furniture, industrial equipment and machinery, farm equipment, or heavy machinery, by way of non-limiting example.
  • components and vehicles that can be manufactured by the current technology include automobiles, tractors, buses, motorcycles, boats, mobile homes, campers, and tanks.
  • Other exemplary structures that have frames that can be manufactured by the current technology include construction and buildings, such as houses, offices, bridges, sheds, warehouses, and devices.
  • the high-strength structural automotive component may be selected from the group consisting of: rocker rails, structural pillars, A-pillars, B-pillars, C-pillars, D-pillars, bumper, hinge pillars, cross-members, body panels, vehicle doors, roofs, hoods, trunk lids, engine rails, and combinations thereof in certain variations.
  • FIG. 2 shows a cross-sectional view of a sheet blank 50 that may be formed from a metal stock or coil in a blanking operation, for example, by cutting.
  • the sheet blank 50 includes a main base layer 52 formed of a high-strength TRIP steel like the compositions previously discussed above.
  • a first coating layer 54 may be formed on a first side 56 of the main base layer 52
  • a second coating layer 58 may be formed on a second opposite side 60 of the main base layer 52 . While shown on both the first and second sides 56 , 60 of the main base layer 52 , the first coating layer 54 and the second coating layer 58 may be optionally omitted from either or both sides.
  • the first coating layer 54 and the second coating layer 58 comprise zinc, for example, such coatings may be zinc or an alloy of zinc and thus predominantly comprise zinc at greater than about 90%. It should be appreciated, however, that the composition of the first coating layer 54 and the second coating layer 58 is not limited to comprising zinc, but may further include additional elements.
  • the sheet blank 50 thus undergoes the hot forming process to provide a three-dimensionally formed component.
  • the sheet blank may be introduced into a furnace or other heat source.
  • the amount of heat applied to the sheet blank heats and soaks the sheet blank to a temperature of at least the austenitization temperature of the select high-strength TRIP steel.
  • the high-strength TRIP steel has an austenitization temperature (T 1 ) of greater than or equal to about 750° C. to less than or equal to about 850° C., optionally less than or equal to about 782° C. in certain variations.
  • T 1 austenitization temperature
  • Such an austenitization temperature is far below that for typical PHS/boron steels, which are generally at least about 880° C. to 950° C.
  • the sheet blank may have a surface layer comprising zinc for corrosion protection.
  • Zinc has a melting temperature of 420° C. and, at 782° C., begins to react with iron via a eutectoid reaction and forms a brittle phase that results in liquid metal embrittlement (LME).
  • temperatures are favorable (e.g., above 782° C. in certain high-strength Mn-TRIP steel) and the zinc is a liquid metal
  • the zinc can wet freshly exposed grain boundaries (of the phase in the substrate) and cause de-cohesion/separation along the grain boundary.
  • the zinc thus attacks grain boundaries, especially where austenite is present, which can undesirably form cracks associated with LME.
  • the sheet blank is soaked for a period long enough to austenitize the high-strength TRIP steel to a desired level.
  • the stamping press may include a die having a cooling system or mechanism.
  • the die(s) may have a water-cooling system, which are well known in the art.
  • the die is designed to form a desired final three-dimensional shape of the component from the austenitized sheet blank.
  • the die may include a first forming die and a second forming die that are brought together to form the desired final shape of the three-dimensional component therebetween.
  • the cooled dies thus may quench the formed sheet blank in a controlled manner across surfaces of the formed component to cause a phase transformation from austenite to martensite. Therefore, the first and second die may cooperate to function as a heat sink to draw heat from, and otherwise quench, the formed component.
  • the high-strength TRIP steel has a critical cooling rate that is the slowest rate of cooling to produce a hardened martensitic condition of greater than about 70 volume % in the component.
  • the critical cooling rate for the high-strength TRIP steel is no greater than about 10 Kelvin/second (K/s).
  • K/s Kelvin/second
  • high-strength TRIP steel may have lower critical cooling rates, such as about 1 K/s.
  • the select high-strength TRIP steels of the present disclosure not only greatly reduce the austenitization temperature, but also significantly shift the ferritic and pearlitic transformation curves of the continuously cooling transformation (CCT) diagram to the right, allowing more time, so the critical cooling rate can be slower.
  • the lower critical cooling rate improves the hardenability of the TRIP steel and makes processing conditions less demanding.
  • the lower critical cooling rate has the following impact on die design: (i) less demand on complex cooling channels, (ii) less sensitivity to die re-tooling, and/or (iii) less demand on uniformity of cooling rate.
  • the die may still be cooled as quickly as possible to maintain processing through-put.
  • the temperature of the sheet blank is desirably kept below about 782° C. to avoid forming a zinc iron (ZnFe) phase/compound, which depletes zinc from the coating layers (the first coating layer 54 and the second coating layer 58 in the sheet blank 50 in FIG. 2 ).
  • ZnFe zinc iron
  • LME described above can be significantly reduced or eliminated.
  • an increased zinc concentration on the hot formed component results in improved corrosion protection.
  • the press-hardened component is substantially free of liquid metal embrittlement.
  • the zinc coating may be applied by conventional methods, such as hot dip galvanizing.
  • substantially free as referred to herein means that the LME microstructures and defects are absent to the extent that undesirable physical properties and limitations attendant with their presence are minimized or avoided (e.g., cracking, loss of ductility, and/or loss of strength).
  • a PHS component that is “substantially free” of LME defects comprises less than about 5% by weight of the LME species or defects, more preferably less than about 4% by weight, optionally less than about 3% by weight, optionally less than about 2% by weight, optionally less than about 1% by weight, optionally less than about 0.5% and in certain embodiments comprises 0% by weight of the LME species or defects.
  • a method of press-hardening a high-strength TRIP steel alloy comprises creating a blank having a zinc-coated high-strength TRIP steel alloy.
  • the blank is heated to a temperature of less than or equal to about 782° C. to partially austenitize the zinc-coated steel alloy.
  • the blank is then press hardened and quenched in a die to form a press-hardened component having a multi-phase microstructure, such as the exemplary microstructure 20 formed in FIG. 1 . While the retained austenite 26 in the martensite matrix 24 provides greater ductility and/or energy absorption, the retained austenite 26 in the martensite matrix 24 also diminishes hardness as compared with a fully martensitic microstructure.
  • a microstructure is formed that has a retained austenite present at greater than or equal to about 5% to less than or equal to about 30% by volume and a balance of martensite at greater than or equal to about 70% by volume to less than or equal to about 95% by volume.
  • the present disclosure provides methods for selectively increasing a surface hardness of the select high-strength TRIP steel alloys after these hot forming processes.
  • the surface hardness is increased via a surface hardening process, such as shot peening.
  • a surface hardening process such as shot peening.
  • Subjecting one or more surfaces of the hot formed component to shot peening or another surface hardening process serves to transform retained austenite near the surface of the part into martensite.
  • a gradient microstructure is formed through a thickness of the part, where the microstructure transitions from a high volume of martensite, for example, 98-100% martensite, into a bulk of the material where the microstructure has less martensite, for example, greater than or equal to about 70% by volume to less than or equal to about 95% by volume with the balance being retained austenite.
  • a hot-formed press-hardened select high-strength Mn-TRIP steel alloy 20 A has a microstructure that includes a matrix of martensite 22 with a distributed phase of retained austenite 24 .
  • the phases shown in the schematic are merely representative and may have distinct morphology/shapes, sizes, and distributions.
  • a first surface 26 of the alloy 20 A has been surface hardened by shot peening to form a hardened layer 30 comprising martensite.
  • the martensite in the hardened layer 30 is present at greater than or equal to about 98% by volume, optionally greater than or equal to about 99% by volume, optionally greater than or equal to about 99.5% by volume, optionally greater than or equal to about 99.7% by volume, and in certain variations, optionally greater than or equal to about 99.9% by volume martensite.
  • the retained austenite in the hardened layer 30 is less than or equal to about 2% by volume, optionally less than or equal to about 1% by volume, optionally less than or equal to about 0.5% by volume, optionally less than or equal to about 0.3% by volume, optionally less than or equal to about 0.1% by volume.
  • a thickness of the hardened layer 30 may have a thickness of greater than 0% of the total thickness of the high-strength Mn-TRIP steel alloy 20 A to less than or equal to about 20% of the total thickness of the high-strength Mn-TRIP steel alloy 20 A.
  • a thickness of the alloy 20 A is 2 mm
  • the hardened layer 30 may have a thickness ranging from 2% or about 0.04 mm (40 ⁇ m) to about 20% or about 0.4 mm (400 ⁇ m).
  • the hardened layer 30 may instead be selectively applied to certain regions of the surface, for example, by protecting areas from exposure to the shot during shot peening with a mask/protective barrier or only directing the shot peen towards select regions of the surface.
  • a central region 32 of the high-strength Mn-TRIP steel alloy 20 A remains intact having greater than or equal to about 5% by volume to less than or equal to about 30% by volume of retained austenite 24 , optionally greater than or equal to about 8% by volume to less than or equal to about 12% by volume, and in certain aspects, about 10% by volume of retained austenite in the matrix of martensite 22 .
  • retained austenite was present at the first surface of the alloy 20 A, it is at least partially transformed into martensite (partially transformed austenite 28 is shown in FIG. 3 ).
  • a transition region between the hardened layer 30 microstructure and the central region 32 may occur, depending on the nature and extent of the surface hardening process.
  • FIG. 4 shows a hot-formed press-hardened select high-strength Mn-TRIP steel alloy 20 B that like high-strength Mn-TRIP steel alloy 20 A has a first surface 26 that has been surface hardened by shot peening to form a first hardened layer 30 comprising martensite.
  • hot-formed press-hardened select high-strength Mn-TRIP steel alloys 20 A and 20 B in FIGS. 3 and 4 share common features, for brevity, such features will not be discussed again herein unless germane to the new aspects of the hot-formed press-hardened select high-strength Mn-TRIP steel alloy 20 B.
  • the high-strength Mn-TRIP steel alloy 20 B also has a second surface 34 that has been surface hardened by shot peening to form a second hardened layer 36 .
  • the martensite in the first hardened layer 30 or the second hardened layer 36 is present at greater than or equal to about 98% by volume, optionally greater than or equal to about 99% by volume, optionally greater than or equal to about 99.5% by volume, optionally greater than or equal to about 99.7% by volume, and in certain variations, optionally greater than or equal to about 99.9% by volume martensite.
  • the retained austenite in the first hardened layer 30 or second hardened layer 32 is less than or equal to about 2% by volume, optionally less than or equal to about 1% by volume, optionally less than or equal to about 0.5% by volume, optionally less than or equal to about 0.3% by volume, optionally less than or equal to about 0.1% by volume.
  • a thickness of the first hardened layer 30 may be like previously described above, where a thickness varies from greater than 0% to less than or equal to about 20% of the total thickness of the high-strength Mn-TRIP steel alloy 20 B.
  • a thickness of the second hardened layer 36 may have a thickness of greater than 0% of the total thickness of the high-strength Mn-TRIP steel alloy 20 B to less than or equal to about 20% of the total thickness of the high-strength Mn-TRIP steel alloy 20 B.
  • the thicknesses of the first hardened layer 30 and the second hardened layer 36 may be distinct from one another.
  • a total cumulative thickness for all the hardened layers may be a thickness of greater than 0% of the total thickness of the high-strength Mn-TRIP steel alloy 20 B to less than or equal to about 40% of the total thickness of the high-strength Mn-TRIP steel alloy 20 B.
  • the first hardened layer 30 and the second hardened layer 36 may be selectively applied to certain predetermined regions of either of the first surface 26 or second surface 34 rather than the entire surface. Other surfaces may also be shot peened as needed.
  • a shot peening process is used on a hot stamped part to transform the surface having retained austenite to martensite and thus forming a hardened surface layer, while the microstructure in the core remains the same.
  • the surface can exhibit greater hardness levels, while the core region exhibits greater ductility and/or energy absorption properties due to the presence of higher levels of retained austenite.
  • a through-thickness gradient microstructure is formed having more martensite on the surface and less martensite in the core.
  • the gradient microstructure can be formed on selected areas of a three-dimensional press-hardened part.
  • the shot peening device 80 has a first stream 82 that receives a pressurized gas, such as air.
  • the first stream 82 has a sufficient velocity to entrain a plurality of shot particles 84 and thus may be a jet stream.
  • the pressure, velocity, and volumetric flow rate of the first stream 82 may be adjusted as required to achieve the desired extent of shot peen hardening.
  • a second stream 86 receives the shot peen or shot particles 84 .
  • Shot particles 84 for a shot peening process are typically round or oval particles.
  • Exemplary shot particles 84 may have an average particle size diameter of greater than or equal to about 500 ⁇ m to less than or equal to about 5000 ⁇ m.
  • shot peen media may be selected from the group consisting of: solid carbon dioxide particles (rounded pellets of dry ice), steel shot (steel balls), and combinations thereof.
  • suitable ball media for shot peening include those formed from silicon carbide, tungsten carbide, and the like.
  • the shot peen media is cooled to help maintain desirably low temperatures during the shot peening process.
  • the first stream 82 and the second stream 86 may be combined so that the shot particles 84 are entrained in a shot peen stream 96 and carried towards a surface of a substrate 90 to be shot peened.
  • a range of suitable velocities for the shot peen second stream 96 may be greater than or equal to about 10 m/s to less than or equal to about 500 m/s.
  • a plurality of shot particles 84 are entrained and shot peened from a nozzle 92 at a selected region 96 of a surface of substrate 90 .
  • the shot peening causes transformation of the metastable retained austenite to martensite by applying mechanical energy via cold work and thus facilitating phase transformation and surface hardening.
  • the surface of the substrate is maintained at a temperature of less than or equal to about 150° C., optionally less than or equal to about 100° C. during the entire shot peening process.
  • An average statistical surface coverage during shot peening may range from greater than or equal to about 200% to less than or equal to about 1,000%.
  • a microstructure treated in accordance with the methods of the present disclosure can have a hot-formed press-hardened part with improved resistance against bending, by enhancing strength near the surface, with extra martensite generated by shot peening. Further, the shot peening process can mitigate the risks of micro-crack propagation in the zinc-coating in press-hardened component by introducing compressive residual stress at the surface after shot peening. Accordingly, shot peening a press hardened component can improve functional performance of a hot formed steel component (zinc-coated or bare), such as improving fatigue strength and impact under service load (especially bending loads).
  • a gradient microstructure through a thickness of a zinc-coated component is obtained by creating a surface layer that is stronger than a core of a made by hot forming process.
  • This can be achieved by a shot peening operation, where shot peen is directed against a surface of a formed part having a microstructure comprising martensite and retained austenite.
  • the retained austenite near the surface transforms to martensite, and hence increasing the strength of the material near the surface.
  • the mechanical performance of the hot stamped component is significantly improved, such as fatigue strength and static/dynamic load bearing capability after the shot peening process.
  • the hot formed components having a zinc coating formed in accordance with the present teachings have improved anti-corrosion performance as compared to conventional aluminum-silicon coated press hardened steel components.
  • the austenitization temperature is below the temperature at which undesirable compounds form between zinc and iron, thus helping to minimize LME.
  • the shot peening process further closes micro-cracks in a zinc-coating, thus minimizing or eliminating risk of crack propagation that can cause corrosion.
  • the present technology thus enables zinc-coated press hardened components formed of high-strength TRIP steel having improved corrosion performance formed at a lower cost (compared to conventional aluminum silicon coatings).
  • the present disclosure thus provides in certain aspects, a zinc-coated hot-formed press-hardened component.
  • the component comprises at least one hardened surface region comprising less than or equal to about 2% by volume austenite, optionally less than or equal to about 1% by volume austenite, and a center region comprising greater than or equal to about 5% by volume retained austenite in a matrix of martensite.
  • the component comprises a high-strength transformation induced plasticity (TRIP) steel having a surface coating comprising zinc.
  • the component is substantially free of liquid metal embrittlement (LME).
  • the TRIP steel may be selected from the group consisting of:
  • FIG. 6 shows a representative front view of a high-strength structural component in the form of a B-pillar 100 for an automobile. It should be noted that FIGS. 6 and 7 show representative simplified versions of the B-pillar 100 and may have many additional parts joined together to form the B-pillar 100 .
  • the B-pillar 100 should have extreme strength in its upper section 102 , but a balance of strength and ductility in its lower section 104 . The combination of these different properties promotes buckling at a desired location when a force or impact is applied to the B-pillar 100 , which may correspond to seat level within the interior of the vehicle to protect the occupant(s) after the force or impact is applied.
  • FIG. 7 shows a detailed side perspective view of a lower portion 104 of a high-strength structural component B-pillar 100 like that shown in FIG. 6 .
  • Two distinct surface hardened regions 110 are formed on a side 112 of the B-pillar 100 near where the B-pillar 100 is attached to a rail 114 .
  • the two distinct surface hardened regions 110 increase the surface hardness in these preselected regions and are formed in accordance with the methods of the present disclosure described above.
  • the increased surface hardness in the surface hardened regions 110 increases the strength and hardness at the surface where impact or force may be received; however, the center region of the component still has retained austenite and therefore greater ability to absorb impact energy.
  • high-strength structural automotive components can be made having select surface hardened regions where required.
  • the high-strength structural automotive components may be selected from the group consisting of: rocker rails, structural pillars, A-pillars, B-pillars, C-pillars, D-pillars, bumper, hinge pillars, cross-members, body panels, vehicle doors, roofs, hoods, trunk lids, engine rails, and combinations thereof in certain variations.

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US11613789B2 (en) 2018-05-24 2023-03-28 GM Global Technology Operations LLC Method for improving both strength and ductility of a press-hardening steel
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