METHOD FOR PRODUCING A STEEL COMPONENT WHICH IS PROVIDED WITH A CORROSION-RESISTANT METAL COATING, AND STEEL COMPONENT

Abstract

A process for producing a steel component with a metallic, corrosion protection coating and very good mechanical properties may involve directly applying an iron-based alloy to a steel substrate. The iron-based alloy may contain 50-80% by weight of Fe, 0-30% by weight of Mg, 0-5% by weight of Al, 0-5% by weight of Ti, 0-10% by weight of Si, 0-10% by weight of Li, 0-10% by weight of Ca, 0-30% by weight of Mn, and a balance of Zn and unavoidable impurities. The steel substrate that has been coated with the iron-based alloy may then be subjected to hot forming in order to obtain the steel component. A metallic coating that protects against corrosion for steel components to be produced by the process of hot forming can be obtained.

Claims

1.-8. (canceled)

9. A process for producing a steel component having a metallic, corrosion protection coating, the process comprising: applying an iron-based alloy directly to a steel substrate, wherein the iron-based alloy comprises: 50-80% by weight Fe, 0-30% by weight Mg, 0-5% by weight Al, 0-5% by weight Ti, 0-10% by weight Si, 0-10% by weight Li, 0-10% by weight Ca, 0-30% by weight Mn, and a balance of Zn and unavoidable impurities; and subjecting the steel substrate thereafter to hot forming.

10. The process of claim 9 wherein the iron-based alloy is applied to the steel substrate in a way such that a coating formed by the iron-based alloy on the steel substrate has a layer thickness of more than 1 m.

11. The process of claim 9 wherein the iron-based alloy is applied to the steel substrate in a way such that a coating formed by the iron-based alloy on the steel substrate has a layer thickness of more than 2 m.

12. The process of claim 9 wherein the iron-based alloy is applied to the steel substrate by at least one of physical vapor deposition or electrolytic deposition.

13. The process of claim 9 further comprising heating the steel substrate so that the steel substrate has a temperature of 250-350 C. while the iron-based alloy is applied.

14. The process of claim 9 wherein the iron-based alloy comprises at least one of: 2-30% by weight Mg; 2-5% by weight Al; 2-5% by weight Ti; 2-10% by weight Si; 2-10% by weight Li; 2-10% by weight Ca; or 2-30% by weight Mn.

15. The process of claim 9 wherein the iron-based alloy contains 20-30% by weight Mg.

16. The process of claim 9 further comprising cooling a steel component obtained from the hot forming during or after the hot forming in such a way that the steel component receives quench hardening.

17. A steel component that has a metallic, corrosion protection coating and has been produced according to the process of claim 9.

18. A process for producing a steel component having a metallic, corrosion protection coating, the process comprising: applying an iron-based alloy directly to a steel substrate, wherein the iron-based alloy comprises: 50-80% by weight Fe, at least some but not more than 30% by weight Mg, at least some but not more than 5% by weight Al, at least some but not more than 5% by weight Ti, at least some but not more than 10% by weight Si, at least some but not more than 10% by weight Li, at least some but not more than 10% by weight Ca, at least some but not more than 30% by weight Mn, and a balance of Zn and unavoidable impurities; and subjecting the steel substrate thereafter to hot forming.

19. The process of claim 18 wherein the iron-based alloy is applied to the steel substrate in a way such that a coating formed by the iron-based alloy on the steel substrate has a layer thickness of more than 1 m.

20. The process of claim 18 wherein the iron-based alloy is applied to the steel substrate in a way such that a coating formed by the iron-based alloy on the steel substrate has a layer thickness of more than 2m.

21. The process of claim 18 wherein the iron-based alloy is applied to the steel substrate by at least one of physical vapor deposition or electrolytic deposition.

22. The process of claim 18 further comprising heating the steel substrate so that the steel substrate has a temperature of 250-350 C. while the iron-based alloy is applied.

23. The process of claim 18 wherein the iron-based alloy comprises at least one of: 2-30% by weight Mg; 2-5% by weight Al; 2-5% by weight Ti; 2-10% by weight Si; 2-10% by weight Li; 2-10% by weight Ca; or 2-30% by weight Mn.

24. The process of claim 18 wherein the iron-based alloy contains 20-30% by weight Mg.

25. The process of claim 18 further comprising cooling a steel component obtained from the hot forming during or after the hot forming in such a way that the steel component receives quench hardening.

26. A steel component with a metallic, corrosion-protection coating that comprises an iron-based alloy that includes 50-80% by weight Fe; at least some but not more than 30% by weight Mg; at least some but not more than 5% by weight Al; at least some but not more than 5% by weight Ti; at least some but not more than 10% by weight Si; at least some but not more than 10% by weight Li; at least some but not more than 10% by weight Ca; at least some but not more than 30% by weight Mn; and a balance of Zn and unavoidable impurities.

Description

[0027] The invention will be illustrated in more detail below with the aid of working examples. The figures show:

[0028] FIG. 1 a round cup produced from a galvannealed fine sheet by hot deep drawing in a perspective front view with cracks in the region of greatest deformation;

[0029] FIG. 2 a part of a round cup produced by hot deep drawing having the region of greatest deformation in a perpendicular or vertical polished section;

[0030] FIG. 3 the results of a macroscopic crack evaluation on round caps which have been produced from galvannealed fine sheet or from fine sheet coated with an iron-based alloy according to the invention, in each case by hot deep drawing at various temperatures and hold times (heating times); and

[0031] FIG. 4 a microcrack evaluation on round caps produced from galvannealed fine sheet (GA) or from fine sheet coated according to the invention with an iron-based alloy (Fe-Bas.), in each case by hot deep drawing at 880 C. and various hold times.

[0032] The results of a macroscopic crack evaluation presented in FIG. 3 and of the microcrack evaluation presented in FIG. 4 are based on round cups N which have in the one case been produced from galvannealed fine sheet having an alloyed ZnFe coating (GA) and in the other case according to the invention from fine sheet coated with an iron-based alloy (Fe-Bas.), in each case by hot deep drawing.

[0033] The base material of the fine sheet used consisted in each case of press-hardenable steel, e.g. steel of the type 22MnB5. The alloyed ZnFe coating of the galvannealed fine sheet contained about 11% by weight of Fe, about 0.3% by weight of Al with zinc as balance, while the Fe-based alloy (Fe-Bas.) applied directly by means of electron beam vaporization in the PVD process contained about 51% by weight of Fe, about 22% by weight of Mg and about 27% by weight of Zn.

[0034] The respective metal sheets which had been cut to size were heated to about 880 C., 900 C. or 920 C. before hot deep drawing and maintained at the respective stated temperature for a period of 3 min, 5 min or 10 min.

[0035] The cut-to-size metal sheets which had been heated in this way were formed to give round cups N by means of a press having a punch and a die.

[0036] The round cups N shaped from the galvannealed fine sheet which had been heated with a hold time of 3 minutes had visible cracks in each case in the region which had undergone the greatest deformation, i.e. in the transition region from the bottom to the circumferential cylindrical surface of the round cup (cf. FIG. 1 and FIG. 3). Furthermore, the round cups N shaped from the galvannealed fine sheet which had been heated for 5 minutes also showed no indication of cracks in said region (cf. FIG. 3). Finally, in the case of the round cups N shaped from the galvannealed fine sheet which had been heated for 10 minutes, neither visible cracks nor any evidence of cracks could be found. Accordingly, crack formation during hot forming of galvannealed fine sheet can be reduced only by means of relatively long hold times. In contrast, no cracks could be found in the region subjected to the greatest deformation on the round cups which had been shaped according to the invention from the fine sheet coated with the Fe-based alloy (Fe-Bas.), at the stated three temperatures and three hold times (cf. FIG. 3).

[0037] For the microcrack evaluation, round cups which had in one case been shaped from the galvannealed fine sheet and in the other case from the fine sheet coated with the Fe-based alloy (Fe-Bas.) which had in each case been heated to about 880 C. and maintained at this temperature for 3 min, 5 min or 10 min were cut vertically and ground so that a vertical polished section was obtained in the transition region from the bottom of the round cup to its circumferential cylindrical surface (cf. FIG. 2). The place of greatest deformation is denoted by B.sub.max in FIG. 2. The polished section was examined, starting from the place of greatest deformation, in both directions over an evaluation distance of in each case 4 mm. Here, no appreciable cracks could be found on the round cups shaped from the fine sheet coated with the Fe-based alloy (Fe-Bas.). In the case of the round cups shaped from the galvannealed fine sheet, on the other hand, significant crack depths were found. In the case of a round cup N made from the galvannealed fine sheet which had been maintained at a temperature of 880 C. for 3 minutes before hot deep drawing, a crack depth of about 120 m was found. The crack depth decreased with increasing hold time. Thus, the crack depth in the case of a round cup N made of the galvannealed fine sheet which had been maintained at a temperature of 880 C. for 5 minutes before hot deep drawing was only about 40 m. In the case of a round cup made of the galvannealed fine sheet which had been maintained at a temperature of 880 C. for 10 minutes before hot deep drawing, no appreciable cracks could be found.

[0038] The invention is further illustrated below with the aid of the results of three experiments:

[0039] Experiment 1:

[0040] A base material, e.g. fine steel sheet of the type 22MnB5, is coated with 50% by weight of Fe and 49% by weight of Zn and also 1% by weight of Ti by means of PVD in a continuous coating process. This is achieved by simultaneous deposition of Fe and Ti by means of an electron beam vaporizer and deposition of Zn in a separate coating step by means of jet PVD. Owing to the different melting and boiling points of Fe and Zn, simultaneous deposition of the two elements is difficult. A layer thickness of about 8 m resulted. This layer is subsequently after-densified thermally at 380 C. for a time of 25 seconds in a tunnel kiln. The thermal after-densification serves to improve adhesion of the layers and effect initial alloy formation by solid-state diffusion.

[0041] The material produced in this way in a continuous strip coating process was subsequently cut, in a manner similar to the processes of further-processing customers, to form plates and introduced into a press hardening process. During the heating phase shortened from 6 minutes to 3 minutes in the laboratory press hardening furnace, a coating comprising 55% by weight of Fe, 44% by weight of Zn and 1% by weight of Ti and having an only 1.5 m thick Ti oxide and zinc oxide layer was formed.

[0042] The steel components produced by press hardening had (in contrast to steel components produced from fine sheets of the type Z or ZF (10% by weight of Fe)) no cracks extending into the steel substrate even at degrees of deformation in the range from 20 to 30%. The residual content of metallic zinc in the coating is high enough to ensure active corrosion protection.

[0043] Experiment 2:

[0044] A base material, e.g. fine steel sheet of the type 22MnB5, is coated with 50% by weight of Fe and 45% by weight of Zn and also 5% by weight of Mg by means of PVD in a continuous coating process. This is achieved by deposition of Mg and Zn in each case by means of JET PVD and also application of Fe onto a substrate which has preferably been heated beforehand to about 300 C. by means of electron beam vaporization in a second coating step. The total layer thickness obtained in this way was about 8 m.

[0045] The material produced in this way in the continuous strip coating process was subsequently cut, in a manner similar to the processes of further-processing customers, to form plates and introduced into a press hardening process. During the heating phase shortened from 6 minutes to 3.5 minutes in the laboratory press hardening furnace, a coating comprising 65% by weight of Fe, 32% by weight of Zn and 3% by weight of Mg and having a 1-2 m thick magnesium oxide layer was formed.

[0046] The press-hardened steel component had no deep substrate cracks as occur after hot forming in the case of zinc coatings which are not thermally stable.

[0047] The coating could be cleaned, phosphated and KTL-coated without problems. Even suitability for resistance spot welding was ensured.

[0048] It was also surprisingly found that the corrosion protection was equal to that of a pure zinc coating having a thickness of 10 m in the starting state after indirect press hardening.

[0049] Experiment 3:

[0050] An about 5 m thick Zn layer was firstly applied electrolytically to a base material, e.g. fine steel sheet of the type 22MnB5. An about 5-6 m thick Fe layer was subsequently applied by means of electron beam vaporization in a PVD process. Al was simultaneously deposited by means of a further target.

[0051] The layer obtained in this way contained 50% by weight of Fe, 48% by weight of Zn and 2% by weight of Al. The layer was subsequently after-densified thermally at 450 C. for 2 minutes in a tunnel kiln. This treatment step serves to improve the adhesion of the layers and effects initial alloy formation by solid-state diffusion.

[0052] The material produced in this way in the continuous strip coating process was subsequently cut, in a manner similar to the processes of further-processing customers, to give plates and introduced into a press hardening process. During the heating phase shortened from 6 minutes to 3.5 minutes in the laboratory press hardening furnace, a coating comprising 65% by weight of Fe, 33% by weight of Zn and 2% by weight of Al and having an about 2 m thick Al oxide and zinc oxide layer was formed.

[0053] In addition, it was surprisingly found that the steel components produced in this way display electrochemically detectable, active corrosion protection of the steel substrate.