US20140134450A1 - Method for Manufacturing a Product from a Flexibly Rolled Strip Material - Google Patents

Method for Manufacturing a Product from a Flexibly Rolled Strip Material Download PDF

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Publication number
US20140134450A1
US20140134450A1 US14/078,025 US201314078025A US2014134450A1 US 20140134450 A1 US20140134450 A1 US 20140134450A1 US 201314078025 A US201314078025 A US 201314078025A US 2014134450 A1 US2014134450 A1 US 2014134450A1
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Prior art keywords
coating
strip material
iron
zinc
blank
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US14/078,025
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English (en)
Inventor
Wolfgang Eberlein
Jorg Dieter Brecht
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Muhr und Bender KG
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Muhr und Bender KG
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Assigned to MUHR UND BENDER KG reassignment MUHR UND BENDER KG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EBERLEIN, WOLFGANG, BRECHT, JORG DIETER, DR.
Publication of US20140134450A1 publication Critical patent/US20140134450A1/en
Priority to US15/670,041 priority Critical patent/US20170335481A1/en
Priority to US16/047,581 priority patent/US20180340266A1/en
Abandoned legal-status Critical Current

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    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/34Pretreatment of metallic surfaces to be electroplated
    • C25D5/36Pretreatment of metallic surfaces to be electroplated of iron or steel
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21BROLLING OF METAL
    • B21B37/00Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
    • B21B37/16Control of thickness, width, diameter or other transverse dimensions
    • B21B37/24Automatic variation of thickness according to a predetermined programme
    • B21B37/26Automatic variation of thickness according to a predetermined programme for obtaining one strip having successive lengths of different constant thickness
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/02Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING 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
    • C21D1/00General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/62Quenching devices
    • C21D1/673Quenching devices for die quenching
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING 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
    • C21D8/00Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/02Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
    • C21D8/0205Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips of ferrous alloys
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING 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
    • C21D8/00Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/02Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
    • C21D8/04Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips to produce plates or strips for deep-drawing
    • C21D8/0405Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips to produce plates or strips for deep-drawing of ferrous alloys
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING 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
    • C21D8/00Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/02Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
    • C21D8/04Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips to produce plates or strips for deep-drawing
    • C21D8/0421Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips to produce plates or strips for deep-drawing characterised by the working steps
    • C21D8/0442Flattening; Dressing; Flexing
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING 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
    • C21D9/00Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/46Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for sheet metals
    • C21D9/48Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for sheet metals deep-drawing sheets
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/48After-treatment of electroplated surfaces
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/48After-treatment of electroplated surfaces
    • C25D5/50After-treatment of electroplated surfaces by heat-treatment
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D7/00Electroplating characterised by the article coated
    • C25D7/06Wires; Strips; Foils
    • C25D7/0614Strips or foils
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21BROLLING OF METAL
    • B21B2205/00Particular shaped rolled products
    • B21B2205/02Tailored blanks
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21BROLLING OF METAL
    • B21B2261/00Product parameters
    • B21B2261/02Transverse dimensions
    • B21B2261/04Thickness, gauge
    • B21B2261/05Different constant thicknesses in one rolled product
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING 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
    • C21D2221/00Treating localised areas of an article
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/4998Combined manufacture including applying or shaping of fluent material
    • Y10T29/49982Coating
    • Y10T29/49986Subsequent to metal working
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12389All metal or with adjacent metals having variation in thickness

Definitions

  • the invention relates to a method for manufacturing coated steel sheets made from a flexibly rolled strip material.
  • the steel sheet should be protected against corrosion by means of the coating.
  • Hot galvanization means plating of steel parts with a solid metallic zinc coating by means of dipping of the pretreated steel parts into a melt of liquid zinc.
  • Galvanic galvanization is carried out by dipping the workpieces into a zinc electrolyte. Electrodes of zinc serve, because of their less precious metal, as a “sacrificial anode”.
  • the workpiece to be galvanized serves as a cathode, because of which the coating is also characterized as a cathodic corrosion protection.
  • a hot or cold strip is electrolytically coated and subsequently flexibly rolled, wherein the coated steel strips receive different sheet thicknesses along the length.
  • the coating is adjusted to the sheet thickness after flexible rolling or to the rolling pressure during the flexible rolling. For this, the coating is formed varyingly thick.
  • a method for producing flexibly rolled strip material with a cathodic corrosion layer comprises the steps: providing a rolled strip as a hot or cold strip with a cathodic corrosion layer, and flexible cold rolling of the coated rolled strip with a rolling gap adjustable during the rolling process.
  • a method for achieving a workpiece with very high mechanical properties which starting from a steel sheet strip is formed by means of deep-drawing.
  • the workpiece is hot rolled and coated with a metallic alloy made from zinc.
  • the sheet is cut to size, heated up to a temperature of 800° C. to 1200° C. and subsequently a hot deep drawing process is carried out. Then, the sheet excesses, necessary for the deep drawing process, are removed by means of cutting.
  • the present invention is based on the object to provide a method for manufacturing coated steel sheets from a flexibly rolled strip material, which offers an especially good corrosion protection.
  • a first solution consists of a method for manufacturing a product from a flexibly rolled strip material comprising the steps: providing a strip material made from sheet steel, flexible rolling of the strip material, wherein a variable thickness is produced along the length of the strip material, electrolytic coating with a metallic coating material, which contains at least 93% by mass of zinc, wherein the electrolytic coating is carried out after the flexible rolling, heat treatment at temperatures above 350° C. and below a solidus line of the coating material, wherein the heat treatment is carried out after the electrolytic coating, working a blank from the flexibly rolled strip material, and cold or hot forming of the blank.
  • a second solution is a method for manufacturing a product from a flexibly rolled strip material comprising the steps: providing a strip material from sheet steel, flexible rolling of the strip material, wherein a variable thickness is produced along the length of the strip material, electrolytic coating with a metallic coating material, which at least contains zinc and iron, working a blank from the flexibly rolled strip material and cold or hot forming of the blank.
  • a flexibly rolled product is, in connection with the present invention, understood to be a steel strip with varying thickness as well as a rectangular blank or a form-cut (profile cut), respectively, which is produced from a flexibly rolled steel strip by means of mechanical cutting or laser cutting.
  • strip material for the flexible rolling a hot strip or cold strip can be used, wherein these terms should be understood in the sense of the technical terminology.
  • a hot strip is here seen to be a rolling steel finished product (steel strip), which is produced by means of rolling after preliminary heating.
  • a cold strip is here meant to be a cold rolled steel strip (flat steel), at which the last thickness reduction is carried out by means of rolling without a preceding heating.
  • the strip material which is provided for being rolled can also be referred to as band material.
  • a strip straightening can be provided after the flexible rolling.
  • the working of the blanks from the strip material can be carried out before or after the electrolytic coating.
  • “working a blank from a strip” is supposed to include, that the sheet blank can be stamped from the strip material, which means an edge remains at the strip, which is not further used, as well as, that a simple cutting of the strip material into partial pieces can be carried out, especially by means of a cutting process.
  • Working a blank from a strip can also be referred to as producing a blank from a strip.
  • a coating consisting at least of 93 mass percent of zinc is deposited on the strip material, wherein the proportion of zinc may especially be larger than 95, 97 or 99 mass percent and can even be 100% (pure zinc coating).
  • anodes made from pure zinc or from zinc and other alloy elements are used, which during feeding of current deposit metal ions on the electrolyte.
  • the zinc ions and possible ions of further alloy elements are deposited as atoms on the strip material, which is connected as a cathode, and form a coating.
  • the following heat treatment leads in an advantageous manner to an alloy formation between the deposited zinc and the iron contained in the strip material, so that altogether a zinc-iron coating is produced.
  • a zinc-iron-alloy layer is produced by means of electrolytic deposition.
  • the proportions of zinc and iron are preferably selected such, that at least one of the following conditions is valid: the alloy layer contains at least 5 mass percent of iron, the alloy layer contains at a maximum 80 mass percent of iron, the alloy layer contains at a minimum 20 mass percent of zinc and/or the alloy layer contains at a maximum 95 mass percent of zinc. It is especially advantageous, when the proportions of zinc and iron are selected such, that in the deposited state, at least partially ⁇ 1-phase, especially ⁇ 1-phase and ⁇ -phase, or only intermetallic ⁇ -phase is present.
  • the method according to the second solution can be carried out according to a first possibility without heat treatment after the electrolytic coating and before forming.
  • a heat treatment at a temperature range above 350° C. and below the melting temperature of the coating material can be provided as a further step after the electrolytic coating.
  • the solidus line marks in the finite state diagram for the coating material that line, below which only solid phase is present. Above the solidus line the coating material is at least present partially as melt.
  • the iron proportion in the coating increases, as iron atoms diffuse from the base material into the coating material. Because of the increasing iron proportion in the coating, the heat treatment temperature can then be increased, without reaching the solidus line or exceeding it. This is possible with suitable process control up to a temperature of 781° C. The possibility of the temperature increase during the heat treatment is obviously also valid for the first solution.
  • the temperature can be step-wise or continuously increased with increasing iron proportion.
  • the liquidus line marks in the finite state diagram for the coating material that line, below which a two-phase or multi-phase range, solid-liquid, is present. Above the liquidus line, the coating material is in the liquid form. The lower limit of the two-phase range is characterized as the solidus line.
  • the temperature of the solidus line depends on the proportional composition of the alloy. For pure zinc, the solidus line lies at 419.5° C., for a zinc-iron alloy it is maximal 782° C., insofar as still parts of ⁇ -phase are present.
  • a heat treatment in a temperature range of 500° C. up to 782° C. is, furthermore, suitable to carry out a re-crystallization annealing, so that the produced material is especially suited for an indirect hot forming.
  • An otherwise necessary re-crystallization annealing can, thus, be omitted after the flexible rolling and before the coating.
  • the heat treatment process can be started at an annealing temperature of 380° C. and, with increasing iron proportions due to diffusion processes, can then be step-wise increased up to a temperature of maximal 781° C.
  • the coating material can also contain further alloy elements, like for example manganese, chromium, silicon or molybdenum.
  • further alloy elements like for example manganese, chromium, silicon or molybdenum.
  • a feature of the invention is the temperature control for the purpose of forming the zinc-iron alloy layer.
  • the respective alloy temperature is selected such, that the solidus line of the coating material in the composition, currently present during the process, is reached or exceeded at no point of time of the alloy formation of the binary zinc-iron phase diagram or of a layer structure, containing more than two alloy elements, respectively.
  • the alloy is thus formed by solid phase diffusion.
  • the phase conversion can be achieved, as mentioned above, according to a first possibility by means of inductive heating.
  • This process method is especially suitable in an electrolytic deposition of zinc and iron, as here short diffusion paths are present, so that a short heat treatment can lead already to the required phase conversion.
  • the heat treatment can be carried out by annealing in a bell-type annealing furnace.
  • This annealing is especially suitable for the electrolytic deposition of pure zinc.
  • a holding time of 10 to 80 hours, preferably 30 to 60 hours, is provided, so that sufficient time is available, so that by means of diffusion a zinc-iron alloy is produced.
  • the holding time characterizes preferably the whole time, in which the blanks or the strip material is heat treated, and can also comprise a heating-, holding, and cooling phase.
  • a further possibility is the conductive heating, but other technically possible heat treatment methods are obviously not excluded.
  • the strip material is coated with an intermediate layer.
  • intermediate layer especially a nickel or aluminum containing layer can be used. These are layers, which contain at least partially nickel or aluminum, which also includes a pure nickel layer or a pure aluminum layer.
  • the nickel layer forms an additional protection of the surface and improves the adhesion of the coating, subsequently deposited and containing zinc.
  • the nickel coating can be formed, for example, by electrolytic deposition or deposition without a current from an external source. It is obvious, that other materials are not excluded for the intermediate layer.
  • a coating containing manganese or chromium can be used. Manganese and chromium have both a cubic lattice and have a good solubility in iron, which has advantageous effects on the alloy behavior.
  • the strip material can be provided with a scaling protection after the electrolytic coating.
  • a scaling protection after the electrolytic coating.
  • Scaling are mainly oxidic corrosion products, produced during the reaction of metallic materials in air or other oxygen containing gases at a high temperature.
  • the deposition of the scaling protection layer can be carried out by spraying or rolling, respectively coating.
  • a further advantage of the scaling protection layer is, that the surface has a high quality.
  • no cleaning treatment like shot-blasting is necessary.
  • the friction value is positively influenced during the hot forming as well as the heat absorption behavior.
  • a further advantage of the scaling protection is, that the adhesion of the cathodic corrosion protection layer arranged below is improved. Furthermore, a widening of the temperature-time window in the frame of the austenitization is possible, for example by means of alloy formation of the scaling protection material with the below arranged layer.
  • the scaling protection can be deposited before or after the heat treatment carried out below the solidus line.
  • blanks or form cuts are produced from the flexibly rolled strip material, which can be carried out by means of mechanically cutting or by means of laser cutting.
  • Blanks are understood to be especially rectangular sheet plates, which are cut from the strip material.
  • Form cuts means in particular sheet elements, cut from the strip material, which outer contour is already adapted to the form of the final product.
  • the term blanks is used uniformly for rectangular blanks as well as for form cuts.
  • the manufacture of blanks can be carried out before or after the electrolytic coating and if necessary before or after the deposition of a scaling protection.
  • Hot forming means forming processes in which the workpieces are heated up to a temperature in the range of the hot forming, before being formed.
  • the heating is carried out in a suitable heating device, for example in a furnace.
  • the hot forming can be carried out according to a first possibility as an indirect process, which comprises the partial steps cold pre-forming of the blanks to a pre-formed component, subsequent heating at least of partial areas of the cold pre-formed component up to an austenitization temperature, as well as subsequent hot forming for producing the final contour of the product.
  • Austenitization temperature is understood to be a temperature range, in which at least a partial austenitization (structural conditions in the two-phase area of ferrite and austenite) is present. Furthermore, it is also possible, to austenitize only partial areas of the blank, to enable for example a partial hardening.
  • the hot forming can be carried out according to a second possibility also as a direct process, which is characterized in that at least partial areas of the blank are directly heated to austenitization temperature and are subsequently hot formed to the required final contour in one step. An earlier (cold) pre-forming does not take place here. Also during the direct process, a partial hardening can be achieved by means of austenitization of partial areas.
  • the coating material at the point of time of initiating the hot forming is preferably in the solid state, i.e. the temperature has cooled down to an area below the solidus line of the coating material.
  • the iron content in the boundary layer is below 80%, preferably below 60%, especially preferred below 30%.
  • the sheet blanks can also be cold formed.
  • Cold forming are forming processes, in which the blank is not specifically heated before forming. The forming thus takes place at room temperature, the blanks are heated by the dissipation of the fed energy. Cold forming is especially used as a process for forming soft car body steels.
  • the solution of the above named object is further a sheet blank made from flexibly rolled sheet steel, which is electrolytically coated after the flexible rolling with a metallic coating and is hot formed after the coating.
  • a sheet blank made from flexibly rolled sheet steel, which is electrolytically coated after the flexible rolling with a metallic coating and is hot formed after the coating.
  • FIG. 1 a method according to the invention as a flow chart schematically in a first embodiment
  • FIG. 2 a method according to the invention as a flow chart schematically in a second embodiment
  • FIG. 3 a method according to the invention as a flow chart schematically in a third embodiment
  • FIG. 4 a zinc-iron-phase diagram.
  • FIG. 1 shows a method according to the invention for manufacturing a product from a flexibly rolled strip material 2 according to a first processing embodiment.
  • the strip material 2 which is wound onto a coil 3 in the starting condition, is worked by rolling, more particularly by means of flexible rolling.
  • the strip material 2 which before the flexible rolling has a more substantially constant sheet thickness along the length, is rolled by rolls 4 , 5 such, that a variable sheet thickness is produced in longitudinal direction of the rolling direction.
  • the process is monitored and controlled, wherein the data, determined from a sheet thickness measurement 6 , are used as input signals for adjusting the rolls 4 , 5 .
  • the strip material 2 has varying thicknesses in rolling direction.
  • the strip material 2 is wound again to a coil 3 after the flexible rolling, so that it can be transferred to the next method step.
  • the strip material 2 is smoothed in the method step V 2 , which is carried out in a strip straightening device 7 .
  • the method step of smoothing is optional and can be omitted.
  • the strip material 2 is provided with an anticorrosive coating in the method step V 3 .
  • the strip material 2 passes through an electrolytic strip coating device 8 . It is visible, that the strip coating is produced in through-feed method, this means, that the strip material 2 is wound from the coil 3 , passes through the coating device 8 and after the coating process is again wound to a coil 3 .
  • This method process is especially advantageous, as the handling expenditure is small for depositing the anticorrosive coating onto the strip material 2 and the process velocity is high.
  • the strip coating device 8 comprises an immersion tank 9 , which is filled with an electrolytic liquid 10 , through which the strip material 2 runs. Guiding of the strip material 2 is achieved by means of sets of rolls 11 , 12 .
  • the electrolytic coating is achieved in the present method embodiment with a metallic coating material, which contains at least 93% zinc. Because of the high zinc content, an especially good resistance to corrosion is achieved. It is understandable, that the zinc proportion could also be higher, for example larger than 95%, especially larger than 97% and can even be 100% (pure zinc).
  • anodes made from zinc can be used, which release during a current feed zinc ions to the electrolyte.
  • the zinc ions are deposited as zinc atoms and form a zinc layer on the strip material 2 , which is connected as a cathode.
  • inert anodes and a zinc electrolyte can be used.
  • the coating can still contain further alloying elements, as for example aluminum, chromium, manganese, molybdenum, silicon.
  • the proportion of the added alloying elements, if necessary, are less than 7%.
  • Manganese has a good solubility in iron, which has an advantageous effect on the alloy formation during heating.
  • the strip material 2 wound to a coil 3 , is heat treated in method step V 4 .
  • the heat treatment can be carried out in principle in any technically suitable manner, for example in an annealing furnace such as a bell-type annealing furnace or also by means of inductive heating, to only name two methods for example. In the present case the heat treatment is shown in a furnace 13 .
  • the heat treatment is carried out at temperatures larger than 350° C. and below the solidus line of the coating material.
  • the temperature profile of the solidus line depends on the proportional composition of the alloy. At the temperature within the stated range, a diffusion of iron is triggered into the zinc layer, so that with progressing holding time of the heat source a diffusion layer is produced.
  • the holding time for the heat treatment in an annealing furnace is preferably 10 to 80 hours, preferably 30 to 60 hours, so that sufficient time is available, so that a zinc-iron alloy is formed by diffusion.
  • a further effect of the heat treatment is, that hardenings of the material, produced during the rolling, are reduced or disappear, so that the rolled strip material 2 takes up again a higher ductility and elasticity.
  • the strip material can be easier further processed in the following method steps, wherein furthermore the material properties of the to be manufactured finished product can be positively influenced.
  • the individual sheet blanks 20 are worked from the strip material 2 in the next method step V 5 .
  • the working of the sheet blanks 20 from the strip material 2 takes place preferably by means of stamping or cutting. Depending on the shape of the to be manufactured sheet blanks 20 , these can be stamped from the strip material 2 as a shape cut, wherein a strip of the strip material remains, which is not further used, or the strip material 2 can simply be cut to length into partial pieces.
  • a sheet blank 20 worked from the strip material 2 , which also could be characterized as three-dimensional sheet blanks (3D-TRB), is shown schematically.
  • a forming of the blanks 20 to the required finished product takes place in method step V 5 .
  • the blanks 20 are hot formed or according to a second possibility cold formed.
  • the hot forming can be carried out as a direct or indirect process.
  • the blanks 20 are heated to the austenitization temperature before the forming, which heating can for example be done by means of induction or in a furnace.
  • Austenitization temperature is, in this case, a temperature range, in which at least a partial austenitization (structure in the binary phase region ferrite and austenite) are present. However, also partial areas of the blanks can be austenitized, to enable for example a partial hardening.
  • the heated blank is formed in a shape-giving tool 14 (forming tool) and at the same time is cooled with a high cooling velocity, wherein the component 20 receives its final profile and is hardened at the same time.
  • the blanks 20 are pre-formed before the austenitization.
  • the pre-forming takes place in the cold condition of the blank, i.e. without prior heating.
  • the component receives its profile, which however still does not correspond to the final shape, however this is approximated.
  • an austenitization and hot forming takes place, like during the direct process, wherein the component receives its final shape and is hardened.
  • the steel material should, insofar as a hot forming (direct or indirect) is provided, contain a proportion of carbon of at least 0.1 mass percent up to 0.35 mass percent.
  • the blanks can also be cold formed.
  • the cold forming is especially suitable for soft body steels or components, which do not have special requirements in view of strength. During the cold forming, the blanks are formed at room temperature.
  • a special feature of the method according to the invention is, that the electrolytic coating (V 3 ) is carried out after the flexible rolling (V 1 ).
  • the coating deposited on the strip material 2 has a constant thickness along the length, i.e. independent of the respective thickness of the strip material 2 .
  • the areas, which have been rolled more intensely to a smaller thickness have a sufficient thick coating, which protects reliably against corrosion.
  • a further special feature is the step of heat treatment after the electrolytic coating at a temperature range between 350° C. and below the solidus line of the coating material. Because of the heat treatment, zinc diffuses from the coating into the base material and iron from the base material into the coating.
  • a zinc-iron alloy is produced as coating, which withstands also higher temperatures of a subsequent hot forming process if needed and offers a reliable corrosion protection.
  • the strip material can be provided with an intermediate layer, especially a nickel, aluminum, or manganese layer, before the electrolytic coating.
  • This intermediate layer forms an additional protection of the surface and improves the adhesion capability of the subsequently deposited coating containing zinc.
  • the strip material or the blanks manufactured therefrom are provided with a scale protection after the electrolytic coating (V 3 ) and before or after the heat treatment (V 4 ). This is especially advisable, when the austenitization for a later heat forming does not take place in an inert atmosphere.
  • the deposition of the scale protection can be carried out by means of spraying or calendar coating.
  • a further advantage of the scale protection layer is, that the surface has a high quality. Furthermore, the friction coefficient during the hot forming as well as the heat absorption behavior is positively influenced by the scale protection.
  • a further advantage of the scale protection is, that the adhesion of the cathodic anti-corrosion layer arranged below is improved. Furthermore, a widening of the temperature-time-window during the austenitization is possible, for example by means of alloy formation of the scale protection material with the layer arranged below. An example for this is aluminum fins in a scale protection lacquer.
  • processing according to the invention can also be modified concerning the sequence of the carried out steps.
  • the working of blanks can also be carried out at another point, for example before the electrolytic coating or if necessary before or after the deposition of a scale protection.
  • FIG. 2 shows a method according to the invention for manufacturing a sheet blank from a strip material 2 according to a second processing embodiment. This corresponds in wide parts to the method of FIG. 1 , so that in view of the similarities it is referred to the above description. At the same time, the same or modified components or steps are provided with the same reference numerals as in FIG. 1 . In the following particularly the differences of the present methods are described.
  • the method steps V 1 (rolling), V 2 (strip straightening), V 5 (stamping) and V 6 (forming) are identical to the corresponding method steps V 1 , V 2 , V 5 and V 6 of FIG. 1 .
  • a first difference of the present embodiment to the method of FIG. 1 is the method step V 3 of the electrolytic coating.
  • the strip material is coated with a metallic coating material, which contains at least zinc and iron.
  • the zinc-iron-alloy layer is produced by the electrolytic deposition of a zinc-iron-layer.
  • the proportions of zinc and iron are in this case selected according to an advantageous method processing such, that the alloy layer contains at least 5 mass percent and/or at a maximum 80 mass percent, or that the alloy layer contains at least 20 mass percent and/or at a maximum 95 mass percent of zinc.
  • the proportions of zinc and iron are selected such, that in the deposited state at least partially ⁇ 1, especially ⁇ 1-phase and ⁇ -phase, or only intermetallic ⁇ -phase is present.
  • a proportion of iron in the coating can be selected between 10 and 30 mass percent, or a proportion of zinc of 70 to 90 mass percent. With these proportions at least partially an intermetallic phase is formed in the deposited state.
  • a further feature of the present method sequence of FIG. 2 is, that between the step of coating (V 3 ) and the step of forming (V 6 ) no interconnected heat treatment is carried out below the solidus temperature.
  • the method of FIG. 2 is thus time-wise especially short.
  • the subsequently carried-out step of forming corresponds to that of FIG. 1 , so that concerning this it is referred to the above description.
  • the blank 20 can be cold or hot formed (directly or indirectly).
  • FIG. 3 shows a method according to the invention for manufacturing a sheet blank from a strip material 2 according to a third method processing embodiment. This corresponds essentially to a combination of the methods of FIGS. 1 and 2 , so that concerning the similarities it is referred to the above description. At the same time, the same or modified components or steps are provided with the same reference numerals.
  • Steps V 1 (rolling), V 2 (strip straightening), V 3 (electrolytic coating), V 5 (stamping) and V 6 (forming) are identical to the corresponding method steps of FIG. 2 .
  • the only difference to the method of FIG. 2 is, that after the electrolytic coating (V 3 ) a heat treatment is carried out in method step V 4 , as in the method of FIG. 1 .
  • the special feature is the temperature control for forming a zinc-iron-alloy layer.
  • the respective alloy temperature is selected during the heat treatment (V 4 ) such, that at no point of time of the formation of the alloy, the solidus line of the binary zinc-iron-phase diagram (compare with FIG. 4 ) or the solidus line of a layer structure, consisting of more than two alloy elements, is reached or exceeded.
  • An example for such a layer structure would be for example a ternary alloy from zinc, iron and manganese, wherein the manganese stems from the steel substrate and reaches by means of the diffusion during the above named heating into the electrolytically deposited zinc layer or zinc-iron-alloy layer and does not form part of an electrolytic deposition.
  • manganese it is also possible, that for example chromium or aluminum or silicon or molybdenum diffuses into the electrolytically deposited layer.
  • steel alloy elements can be provided, which have not been named up to now and which are suitable, to diffuse by the above named heating process into the electrolytic deposited layer.
  • FIG. 4 shows the phase diagram for zinc-iron.
  • the proportions of iron (Fe) and zinc (Zn) are shown, respectively.
  • a material with 100% iron and 0% zinc is present, while at the right edge inversely 0% iron and 100% zinc is present.
  • the percentaged composition is found.
  • S characterizes the molten mass, ⁇ and ⁇ are iron-zinc-mixed crystal systems (rich in iron), ⁇ and ⁇ or ⁇ 1 and ⁇ are intermetallic phases, and ⁇ is a zinc-iron mixed crystal (rich in zinc).
  • an alloying temperature above 350° C. and below the melting temperature (solidus line) of 419.5° C. is selected, for example 400° C.
  • a diffusion of iron into the zinc layer takes place, so that with continuing holding time during the heat treatment (V 4 ) a diffusion layer is formed, for example a 6-phase.
  • the further temperature processing is such, that the respective temperature is always below the solidus line of the binary zinc-iron-phase diagram.
  • the starting temperature can be selected above the melting temperature of pure zinc.
  • a starting temperature of 600° C. can be selected. This temperature lies in fact above the melting temperature of zinc, however below the solidus line of the two-phase-range ⁇ + ⁇ 1.
  • a starting temperature smaller than 782° C. is possible.
  • An increase above this temperature is only then possible, when the layer is enriched during a following heat treatment so far with iron, that only an austenitic iron mixed crystal would be present (for example 70 mass percent iron and 850° C.).
  • the type of heat treatment is, as above described, not prescribed.
  • it can be an inductive heating or a heating in an annealing furnace or a heating by means of contact with a hot body, for example a thick steel plate, which delivers its heat to the blank or the profile cut.
  • an electrolytic zinc-iron alloy with an iron proportion of 8 to 12% is provided.
  • it is a composition, as it is used for steels with a so-called “galvannealed” coating.
  • the advantage of this composition is, that the elements zinc and iron have a distance in the range of nanometers, so that a drawn-out diffusion treatment can be waived. Rather by means of a short heat treatment in the method step V 4 an intermetallic ⁇ 1-phase can be produced from an electrolytic deposited zinc-iron alloy with an iron proportion of 8 to 12%.
  • Such a composition can be used for the cold forming as well as for the hot forming.
  • an electrolytic zinc-iron alloy is deposited, which stoichiometric composition corresponds to the ⁇ -phase.
  • this composition can also be reached by a deposition of a zinc-iron layer with a low iron proportion and a subsequent heat treatment, at which end the ⁇ -phase is present.
  • This layer starts only to melt at a temperature of 782° C., so that this layer is especially suitable for the hot forming, as in this case the formation of a melting phase can be restricted or can be prevented by means of stabilizing the layer with elements from the steel substrate as manganese (ternary system iron-zinc-manganese).
  • a layer is electrolytically deposited, which itself is not present in a molten state even during the heating to the maximum austenitizing temperature for the hot forming (for example at 900° C.).
  • a coating would for example have a composition of 20 weight percent of zinc and 80 weight percent of iron. In this case, it is an iron based alloy of the binary iron-zinc system.

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US20160237585A1 (en) * 2015-02-13 2016-08-18 Muhr Und Bender Kg Producing a product from a rolled strip material
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US20170335481A1 (en) 2017-11-23
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