The present application relates to an improvement in press hardened steels, hot press forming steels, hot stamping steels, or any other steel that is heated to an austenitization temperature and formed and quenched in a stamping die to achieve desired mechanical properties in the final part. These types of steels are also sometimes referred to as “heat treatable boron-containing steels.” In this application, they will all be referred to as “press hardened steels.”
Press hardened steels are primarily used as structural members in automobiles where high strength, low weight, and improved intrusion resistance are desired by automobile manufacturers. A common structural member where press hardened steels are employed in the automobile structure is the B-pillar.
Current industrial processing of press hardened steel involves heating a blank (piece of steel sheet) to a temperature greater than the A3 temperature (the austenitization temperature), typically in the range 900-950° C., holding the material at that temperature for a certain duration, placing the austenitized blank into a hot stamping die, forming the blank to the desired shape, and quenching the material in the die to a low temperature such that martensite is formed. The end result is a material with a high ultimate tensile strength and a fully martensitic microstructure.
The as-quenched microstructure of prior art press hardened steel is fully martensitic. Conventional press hardened steels have ultimate tensile strengths of approximately 1500 MPa and total elongations on the order of 6%.
The steels and methods of the present application improve upon currently available press hardened steel alloys by using chemistry and processing to achieve higher residual toughness in the press hardened condition. Residual toughness refers to the toughness the material has in the press hardened condition.
The strength-ductility property of embodiments of the present steel alloys include ultimate tensile strengths greater than or equal to 1100 MPa and elongations of approximately 8%.
Press hardened steels are generally desirable for their high strength characteristics. In practice, this permits manufacturers to produce components having greater strength and less weight relative to components produced of non-press hardened steels. These high strength characteristics are generally achieved through formation of a predominately martensitic microstructure. In particular, during a hot stamping process associated with a press hardened steel blank, the blank is first subjected to an austenitization heat treatment. During this heat treatment, the temperature of the blank is raised to greater than the A3 temperature for the particular composition of the blank to thereby transform the microstructure of the blank into predominately austenite.
Once the austenitization heat treatment is complete, the blank is stamped into a predetermined shape using an internally cooled die set. In addition to shaping the blank, the stamping process also has the effect of rapidly cooling the blank below the martensite start temperature (Ms). As a consequence, the predominately austenitic microstructure of the blank is transformed to a microstructure of predominantly martensite. Because martensite is generally characterized as a strong and hard microstructure, the stamping process generally results in a final part having high strength and high hardness.
Although a high strength of the final hot stamped part is generally desirable for a wide variety of applications, in some circumstances additional toughness may be desirable. For instance, as described above, hot stamping generally results in a final part with high strength and high hardness. With high levels of hardness, the final part generally has relatively low ductility and thus relatively low toughness. Thus, in some circumstances it may be desirable to have a press hardened steel having the high strength characteristics of a conventional press hardened steel, but with improved residual toughness characteristics.
Prior to the hot stamping process described above, press hardened steels are subjected to a variety of pre-processing steps.
Once the slab is elevated to the re-heat temperature via the re-heat furnace (20), the slab is subjected to rough rolling (30) and then finishing rolling (40). These rolling steps progressively reduce the thickness of the slab to a final sheet thickness. During the rolling process, the temperature of the slab continuously decreases from the initial 2300° F. (1260° C.) re-heat temperature to a roughing temperature associated with rough rolling (30). In some examples the roughing temperature is approximately 2000° F. (1093° C.). During finishing rolling (40), the slab is subject to a finishing temperature of approximately 1600° F. (871° C.). As the temperature decreases, the slab is subjected to rolling operations that progressively reduce the thickness of the slab by relatively large amounts during rough rolling (30) to relatively small amounts during finishing rolling (40).
From the initial re-heat temperature associated with the re-heat furnace (20) to the temperature associated with finishing rolling (40), the temperature of the slab decreases at a relatively constant rolling cooling rate (12).
After completion of rolling, the press hardened steel material is in a steel sheet form. In the steel sheet form, the steel sheet is subject to coiling (50). Coiling (50) can be performed at a coiling temperature of approximately 1200° F. (649° C.). In some examples, coiling (50) can begin immediately after finishing (40). Thus, in some examples coiling (50) may begin at temperatures above 1600° F. (871° C.) and decrease to the coiling temperature of approximately 1200° F. (649° C.).
Prior to coiling (50), the steel sheet can be cooled to the coiling temperature at one or more different cooling rates (14, 16) as shown in
At the conclusion of coiling (50), the coiled steel sheet is permitted to cool to ambient or room temperature. The coiled steel sheet is then subsequently formed into blanks of steel material for press hardening. The blanks can then be subjected to the hot stamping process described above.
As described above, in some circumstances it may be desirable to increase the toughness of press hardened steel parts. In some circumstances, toughness can be improved by refining the grain size of the press hardened steel material by modifying certain parameters of the pre-processing steps described above.
Once the slab is elevated to the re-heat temperature of re-heat furnace (120), the slab is subjected to rough rolling (130) and then finishing rolling (140). This progressively reduces the thickness of the slab to a final sheet thickness. As an example, during the rolling process, the temperature of the slab continuously decreases from the initial 2300° F. (1260° C.) re-heat temperature of the re-heat furnace (120) to a roughing temperature of approximately 2000° F. (1093° C.) associated with rough rolling (130). Next, the slab is further reduced to a finishing temperature of approximately 1600° F. (871° C.) associated with finishing rolling (140). Unlike finishing rolling (40) in the conventional pre-processing method (10) described above, finishing rolling (140) in the present example is performed at a relatively lower temperature. As will be described in greater detail below, this relatively lower temperature can lead to increased grain refinement when performed in connection with a modified coiling temperature. As the temperature decreases, the slab is subjected to rolling operations that reduce the thickness of the slab by relatively large amounts during rough rolling (130) to relatively small amounts during finishing rolling (140).
From the initial re-heat temperature associated with the re-heat furnace (120) to the temperature associated with finishing rolling (140), the temperature of the slab decreases at a relatively constant rolling cooling rate (112). This cooling rate is similar to the rolling cooling rate (12) of the prior process.
After completion of rolling, the press hardened steel material is in a steel sheet form. In the steel sheet form, the steel sheet is subject to coiling (150). Coiling (150) can be performed at a coiling temperature of approximately 1050° F. (566° C.). In some examples, coiling (150) can begin immediately after finishing (140). Thus, in some examples coiling (150) may begin at approximately 1600° F. (871° C.) and decrease to the coiling temperature of approximately 1050° F. (566° C.). Alternatively, in some examples coiling (150) can be delayed until the steel sheet reaches the coiling temperature of approximately 1050° F. (566° C.). Once the coiling temperature is reached (150), the steel sheet may be held isothermally for the entirety of coiling (150). Preferably, the finishing (140) is performed at the finishing temperature of about 1600° F. (871° C.), the steel sheet is lowered to the coiling temperature of 1050° F. (566° C.), and coiling (150) is performed while the steel sheet is held at the coiling temperature.
Regardless of how the coiling temperature is reached, it should be understood that the coiling temperature of approximately 1050° F. (566° C.) is generally low relative to the coiling temperatures described above with respect to conventional pre-processing method (10). As will be understood, this reduced coiling temperature can generally result in improved grain refinement of the steel sheet that can lead to increased residual toughness in a final work product after hot stamping.
Prior to coiling (150), the steel sheet can be cooled to the coiling temperature at a cooling rate (114) as shown in
Unlike cooling rates (14, 16) described above, cooling rate (114) in the present example is generally relatively fast. This relatively fast cooling rate can be achieved using a run-out-table accelerated cooling method. As will be understood, this relatively fast cooling rate (114) can generally lead to increased grain refinement and associated improved residual toughness in a final work product after hot stamping.
At the conclusion of coiling (150), the coiled steel sheet is permitted to cool to ambient or room temperature. The coiled steel sheet is then subsequently formed into blanks of steel material for press hardening. The blanks can then be subjected to the hot stamping process described above.
As described above, the pre-processing methods (10, 100) can be performed using an as-cast slab comprising a predetermined composition. It should be understood that the particular composition of the slab can be varied such that a variety of compositions can be used with the methods (10, 100) described above. As will be described in greater detail below, various elements can be added to the slab to influence numerous metallurgical properties of the final work product.
Carbon is added to reduce the martensite start temperature, provide solid solution strengthening, and to increase the hardenability of the steel. Carbon is an austenite stabilizer. In certain embodiments, carbon can be present in concentrations of 0.1-0.5 mass %; in other embodiments, carbon can be present in concentrations of 0.2-0.30 mass %.
Manganese is added to reduce the martensite start temperature, provide solid solution strengthening, and to increase the hardenability of the steel. Manganese is an austenite stabilizer. In certain embodiments, manganese can be present in concentrations of 0.75-3.0 mass %; in other embodiments, manganese can be present in concentrations of 1.15-1.25 mass %.
Silicon is added to provide solid solution strengthening. Silicon is a ferrite stabilizer. In certain embodiments, silicon can be present in concentrations of 0.02-1.5 mass %; in other embodiments, silicon can be present in concentrations of 0.15-0.30 mass %.
Aluminum is added for deoxidation during steelmaking and to provide solid solution strengthening. Aluminum is a ferrite stabilizer. In certain embodiments, aluminum can be present in concentrations of 0.0-0.8 mass %; in other embodiments, aluminum can be present in concentrations of 0.02-0.15 mass %. In other embodiments, aluminum is entirely optional and can be therefore omitted or limited to an impurity element in some embodiments.
Titanium is added to getter nitrogen. In certain embodiments, titanium can be present in concentrations of 0.0-0.060 mass %; in other embodiments, titanium can be present in concentrations of a maximum of 0.045 mass %. In other embodiments, titanium is entirely optional and can be therefore omitted or limited to an impurity element in some embodiments.
Molybdenum is added to provide solid solution strengthening and to increase the hardenability of the steel. In certain embodiments, molybdenum can be present in concentrations of 0-0.5 mass %; in other embodiments, molybdenum can be present in concentrations of 0-0.3 mass %. In other embodiments, molybdenum is entirely optional and can be therefore omitted or limited to an impurity element in some embodiments.
Chromium is added to reduce the martensite start temperature, provide solid solution strengthening, and increase the hardenability of the steel. Chromium is a ferrite stabilizer. In certain embodiments, chromium can be present in concentrations of 0-0.5 mass %; in other embodiments, chromium can be present in concentrations of 0.15-0.25 mass %.
Boron is added to increase the hardenability of the steel. In certain embodiments, boron can be present in concentrations of 0-0.005 mass %; in other embodiments, boron can be present in concentrations of 0.003-0.005 mass %.
Nickel is added to provide solid solution strengthening and reduce the martensite start temperature. Nickel is an austenite stabilizer. In certain embodiments, nickel can be present in concentrations of 0.0-0.6 mass %; in other embodiments, nickel can be present in concentrations of 0.02-0.3 mass %. In still other embodiments, nickel is entirely optional and can be therefore omitted or limited to an impurity element in some embodiments.
Niobium is added to provide improved grain refinement. Niobium can also increase hardness and strength. In certain embodiments, niobium can be present in concentrations of 0-0.090 mass %.
A plurality of alloy compositions shown in Table 1 were prepared using standard steel making processes, except as noted below.
Composition 4310 of Table 1 in Example 1 was subjected to both pre-processing methods (10, 100) described above. The steel underwent simulated hot stamping. The steel was heated to approximately 930° C. for 5 min and then quenched in water-cooled copper dies. Samples subjected to each pre-processing method (10, 100) plus simulated hot stamping were then subjected to tensile testing to generate stress-strain curves. The resulting stress-strain curves are shown in
As can be seen in
Composition 4311 of Table 1 in Example 1 was subjected to both pre-processing methods (10, 100) described above. The steel underwent simulated hot stamping. The steel was heated to approximately 930° C. for 5 min and then quenched in water-cooled copper dies. Samples subjected to each pre-processing method (10, 100) plus simulated hot stamping were then subjected to tensile testing to generate stress-strain curves. The resulting stress-strain curves are shown in
As can be seen in
Composition 4312 of Table 1 in Example 1 was subjected to both pre-processing methods (10, 100) described above. The steel underwent simulated hot stamping. The steel was heated to approximately 930° C. for 5 min and then quenched in water-cooled copper dies. Samples subjected to each pre-processing method (10, 100) plus simulated hot stamping were then subjected to tensile testing to generate stress-strain curves. The resulting stress-strain curves are shown in
As can be seen in
Composition 4313 of Table 1 in Example 1 was subjected to both pre-processing methods (10, 100) described above. The steel underwent simulated hot stamping. The steel was heated to approximately 930° C. for 5 min and then quenched in water-cooled copper dies. Samples subjected to each pre-processing method (10, 100) plus simulated hot stamping were then subjected to tensile testing to generate stress-strain curves. The resulting stress-strain curves are shown in
As can be seen in
Toughness for samples having each composition identified in Table 1 of Example 1, above, was evaluated further using double-edge-notch tensile tests. A sample for each composition (e.g., 4310, 4311, 4312, 4313) was subject to each pre-processing method (10, 100) described above. Steels then underwent a simulated press hardening procedure in which they were austenitized at approximately 930° C. for 300 s and then quenched in flat, water-cooled dies. Double-edge notched tensile tests were then performed. Plots were then prepared of the resulting data for each composition as shown in
As can be seen in
The data discussed above with respect to Example 6 was analyzed further. In particular, integration of the area under the force-displacement curves shown in
The resulting strain energy for each sample was then plotted as a function of niobium concentration in the corresponding composition for each sample. The resulting plot is shown in
As can be seen in
A press hardenable steel comprising by total mass percentage of the steel:
wherein said steel is subject to the following processing:
A press hardenable steel of Example 8 or any one of the following Examples, comprising by total mass percentage of the steel:
0.10 to 0.50% Carbon;
0.00 to 0.005% Boron;
0.0 to 0.50% Chromium;
0.75 to 3.0% Manganese;
0.090% or less Niobium;
0.02 to 1.50% Silicon;
0.0 to 0.8% Aluminum;
0.0 to 0.060% Titanium;
0.0 to 0.50% Molybdenum;
0.0 to 0.6% Nickel; and
A press hardenable steel of Example 8 or 9 or any one of the following Examples, comprising 0.2-0.3 mass % carbon.
A press hardenable steel of any one of Examples 8 through 10 or any one of the following Examples, comprising 1.15-1.25 mass % manganese.
A press hardenable steel of any one of Examples 8 through 11 or any one of the following Examples, comprising 0.15-0.30 mass % silicon.
A press hardenable steel of any one of Examples 8 through 12 or any one of the following Examples, comprising 0.02-0.15 mass % aluminum.
A press hardenable steel of any one of Examples 8 through 13 or any one of the following Examples, comprising a maximum of 0.045 mass % titanium.
A press hardenable steel of any one of Examples 8 through 14 or any one of the following Examples, comprising 0-0.30 mass % molybdenum.
A press hardenable steel of any one of Examples 8 through 15 or any one of the following Examples, comprising 0.15-0.25 mass % chromium.
A press hardenable steel of any one of Examples 8 through 16 or any one of the following Examples, comprising 0.003-0.005 mass % boron.
A press hardenable steel of any one of Examples 8 through 17 or any one of the following Examples, comprising 0.02-0.3 mass % nickel.
A press hardenable steel of any one of Examples 8 through 18 or any one of the following Examples, comprising 0-1.0 mass % molybdenum.
A press hardenable steel of any one of Examples 8 through 19 or any one of the following Examples, wherein the rolling step includes a rough rolling operation and a finish rolling operation.
A press hardenable steel of any one of Examples 8 through 20 or any one of the following Examples, wherein the temperature of the slab during the rough rolling operation is greater than or equal to 2000° F.
A press hardenable steel of any one of Examples 8 through 21 or any one of the following Examples, wherein the temperature of the slab during the finish rolling operation is greater than or equal to about 1600° F. (871° C.).
A press hardenable steel of any one of Examples 8 through 22 or any one of the following Examples, further comprising the step of hot stamping at least a portion of the steel sheet after coiling the steel sheet.
A press hardenable steel of any one of Examples 8 through 23 or any one of the following Examples, further comprising the step of cooling the press hardenable steel from the re-heat furnace temperature to the rolling temperature at a first cooling rate, and cooling the press hardenable steel from the rolling temperature to the coiling temperature at a second cooling rate, wherein the second cooling rate is greater than the first cooling rate.
A press hardenable steel of any one of Examples 8 through 24 or any of the following Examples, wherein the step of cooling the press hardenable steel from the rolling temperature to the coiling temperature is performed using a run-out table accelerated cooling method.
A press hardenable steel of any one of Examples 8 through 25 or the following Example, wherein the temperature of the slab during the rough rolling operation is approximately 2000° F.
A press hardenable steel of any one of Examples 8 through 26, wherein the temperature of the slab during the finish rolling operation is approximately 1600° F. to 1700° F.
This application claims priority to U.S. Provisional application Ser. No. 62/426,788 filed Nov. 28, 2016, entitled “Press Hardened Steel with Increased Toughness and Method for Production;” the disclosure of which is incorporated by reference herein.
Number | Date | Country | |
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62426788 | Nov 2016 | US |