Patent Application
20150064052
This disclosure relates to a warm press forming method that can suppress defects in dimensional accuracy due to geometric changes such as springback that occur in a high strength steel sheet being press-formed.
The disclosure also relates to an automobile frame component produced by the warm press forming method.
To achieve a reduction in the weight of automobile bodies to improve fuel efficiency and crash safety of automobiles to protect occupants, high strength steel sheets have been increasingly applied to automotive parts. It is generally known, however, that high strength steel sheets exhibit poor press formability, undergo considerable geometric changes (springback) caused by elastic recovery after being removed from the die, and are prone to defects in dimensional accuracy. Thus, there are currently a limited number of parts that can be obtained by applying press forming to high strength steel sheets.
Therefore, to improve press formability and shape fixability (to reduce springback), JP 2005-205416 A discloses an example of hot press forming applied to a high strength steel sheet in which a steel sheet is press-formed after being heated to a predetermined temperature.
The aforementioned hot press forming involves forming of a steel sheet at temperatures higher than those at which cold press forming is performed to reduce the deformation resistance of the steel sheet for press forming, in other words, to increase the deformation capacity thereof, aiming to improve the shape fixability and at the same time prevent the occurrence of press cracking.
With the hot press forming disclosed in JP 2005-205416 A, press forming is based on draw forming. In draw forming, edges of the heated steel sheet (which will be also called a “blank”) are compressed between a die and a blank holder during the formation process and, accordingly, the edges of the blank and other portions thereof contact with, e.g., the die for different times. In addition, a drop in the temperature of the contact zone of the blank during the press forming process leads to a non-uniform temperature distribution in the press-formed part immediately after the formation (hereinafter also called “panel”) due to the difference in the contact time with the aforementioned die, and so on.
This results in a problem that panels, in particular, automobile frame components to which high strength steel sheets are applied, undergo geometric changes during the air cooling process after the hot press forming, which prevents the provision of panels with sufficiently satisfactory dimensional accuracy.
In addition, general hot press forming involves heating of a steel sheet to the austenite region as well as cooling of the steel sheet accompanying quenching and phase transformation and, consequently, the microstructure of the steel sheet tends to change after formation, causing the problem of large variations in the tensile properties such as strength and ductility, of the press-formed part.
It could therefore be helpful to provide a warm press forming method that can suppress geometric changes such as springback that occur in panels, thereby improving the dimensional accuracy of the panels and obtaining the desired mechanical properties in the resulting press-formed parts.
It could also be helpful to provide an automobile frame component produced by the warm press forming method.
When a high strength steel sheet is applied, we tried to limit the heating temperature of the high strength steel sheet, which would otherwise need to be heated to the austenite region with conventional hot press forming, below the austenite transformation temperature.
We also studied forming methods and forming conditions to determine the conditions under which geometric changes caused by springback can be suppressed.
As a result, we discovered that when forming a high strength steel sheet into a press-formed part including flange portions and other portions by press forming, the intended results can be achieved advantageously by
(1) heating a steel sheet to a so-called warm-forming temperature range; and
(2) then press-forming the heated steel sheet using draw forming to obtain a press-formed part, with the steel sheet being held at a press bottom dead point over a certain period of time.
We thus provide:
[1] A warm press forming method for forming a steel sheet having a tensile strength of 440 MPa or more into a press-formed part including flange portions and other portions by press forming, the method comprising:
heating the steel sheet to a temperature range of 400° C. to 700° C.; and
then press-forming the heated steel sheet using draw forming to obtain a press-formed part, with the steel sheet being held at a press bottom dead point in the die for one second to five seconds.
[2] The warm press forming method according to the aspect [1], wherein a difference in average temperature among flange portions and other portions of the press-formed part immediately after the draw forming is kept within 150° C.
[3] The warm press forming method according to the aspect [1] or [2], wherein the press-formed part has a tensile strength of 80% to 110% of a tensile strength of the steel sheet.
[4] The warm press forming method according to any one of the aspects [1] to [3], wherein the steel sheet has a chemical composition containing, by mass %,
C: 0.015% to 0.16%,
Si: 0.2% or less,
Mn: 1.8% or less,
P: 0.035% or less,
S: 0.01% or less,
Al: 0.1% or less,
N: 0.01% or less, and
Ti: 0.13% to 0.25%,
provided that a relation defined by Expression (1) below is satisfied, and
the balance including Fe and incidental impurities, and
wherein the steel sheet has a microstructure containing a ferrite phase by 95% or more on an area ratio basis with respect to the entire microstructure, ferrite crystal grains constituting the ferrite phase have an average grain size of 1 μM or more, and carbides having an average particle size of 10 nm or less are dispersed and precipitated in the ferrite crystal grains
2.00≧([% C]/12)/([% Ti]/48)≧1.05 (1)
where [% M] indicates the content by mass % of element M.
[5] The warm press forming method according to the aspect [4], wherein the chemical composition further contains, by mass %, at least one selected from
V: 1.0% or less,
Mo: 0.5% or less,
W: 1.0% or less,
Nb: 0.1% or less,
Zr: 0.1% or less, and
Hf: 0.1% or less,
provided that a relation defined by Expression (1)′ is satisfied:
2.00≧([% C]/12)/([% Ti]/48+[% V]/51+[% W]/184+[% Mo]/96+[% Nb]/93+[% Zr]/91+[% Hf]/179)≧1.05 (1)′
where [% M] indicates the content by mass % of element M.
[6] The warm press forming method according to the aspect [4] or [5], wherein the chemical composition further contains, by mass %, B: 0.003% or less.
[7] The warm press forming method according to any one of the aspects [4] to [6], wherein the chemical composition further contains, by mass %, at least one selected from Mg: 0.2% or less, Ca: 0.2% or less, Y: 0.2% or less, and REM: 0.2% or less.
[8] The warm press forming method according to any one of the aspects [4] to [7], wherein the chemical composition further contains, by mass %, at least one selected from Sb: 0.1% or less, Cu: 0.5% or less, and Sn: 0.1% or less.
[9] The warm press forming method according to any one of the aspects [4] to [8], wherein the chemical composition further contains, by mass %, at least one selected from Ni: 0.5% or less and Cr: 0.5% or less.
[10] The warm press forming method according to any one of the aspects [4] to [9], wherein the chemical composition further contains, by mass %, at least one selected from O, Se, Te, Po, As, Bi, Ge, Pb, Ga, In, Tl, Zn, Cd, Hg, Ag, Au, Pd, Pt, Co, Rh, Ir, Ru, Os, Tc, Re, Ta, Be and Sr, in a total amount of 2.0% or less.
[11] The warm press forming method according to any one of the aspects [1] to [10], wherein the steel sheet comprises a coating or plating layer on a surface thereof.
[12] An automobile frame component produced by the warm press forming method according to any one of the aspects [1] to [11].
It is possible to suppress geometric changes made to a panel being air-cooled after the press forming process, allowing manufacture of automobile frame components having good dimensional accuracy. Consequently, high strength steel sheets, which could not conventionally be applied to automobile frame components due to defects in dimensional accuracy, can be applied thereto to allow a reduction in weight of automotive body, which may greatly contribute to solving environmental issues.
In addition, the warm press forming does not involve quenching and/or phase transformation before and after the forming process and can directly make use of the mechanical properties of steel sheets as blank material, thereby allowing for stable production of press-formed parts with desired properties.
Our methods and components will be further described below with reference to the accompanying drawings, wherein:
a-1c illustrate a press forming process using draw forming, where (a) shows a state when the forming process starts, (b) shows a state during the forming process, and (c) shows a state at the press bottom dead point (a state when the forming process ends).
a) illustrates an exemplary automobile frame component produced from a panel obtained by press forming.
b) illustrates flange portions of a panel obtained by press forming using draw forming.
a) is a graph showing the relationship between the difference in average temperature among flange portions and other portions of a panel obtained by warm press forming using draw forming and the amount of geometric changes made to the panel from the time immediately after press forming (the time when the panel was removed from the die) until the end of air cooling.
b) is a diagram explaining the amount of geometric changes made to the panel from the time immediately after press forming (the time when the panel was removed from the die) until the end of air cooling.
a) is a graph showing the relationship between the difference in average temperature among flange portions and other portions of panels, each being obtained by warm press forming using draw forming, and the holding time at press bottom dead point.
b) is a graph showing the relationship between the amount of geometric changes made to the panels from the time immediately after warm press forming using draw forming (the time when the panels were removed from the die) until the end of air cooling and the holding time at press bottom dead point.
a) schematically illustrates a center pillar upper press panel.
b) is a diagram explaining the amount of geometric changes made to the panel from the time immediately after press forming (the time when the panel was removed from the die) until the end of air cooling.
Our methods and components will be described in detail below.
First, the reasons for heating a steel sheet to temperatures of 400° C. to 700° C. prior to press forming will be described below.
When a steel sheet is heated to temperatures of 400° C. or higher, the strength is reduced and the ductility increases. This may facilitate deformation of the steel sheet in conformity with the die during press forming, thereby preventing the occurrence of press cracking and suppressing the formation of wrinkles. If the heating temperature of the steel sheet exceeds 700° C., however, the material strength is reduced so much as to incur the risk of cracking, fracture, and the like. Therefore, the heating temperature of the steel sheet is 400° C. to 700° C. In particular, when the heating temperature of the steel sheet is 400° C. or higher and lower than 650° C., it is possible to suppress oxidation of surfaces of the steel sheet and/or formation of cracks and, furthermore, to prevent an excessive increase in press load, which is still more advantageous.
Next, the reasons for holding a steel sheet at a press bottom dead point in the die for one second to five seconds prior to a press forming process using draw forming will be described below.
For a panel requiring high sidewall portions, press forming is usually performed using draw forming. In performing the draw forming, even a warm (or hot) press forming process is generally carried out by a blank holder arranged as shown in
In
As shown in
In the case of the aforementioned draw forming, the edges of the blank are continuously compressed between the blank holder and the upper die from the early stage of the forming process until the completion of the process. Consequently, the heated steel sheet (blank) is subject to a heat transfer from edges of the blank to the die during the press forming process, with the result that the edges of the blank are susceptible to a temperature drop, leading to a large difference in temperature among flange portions and other portions of the panel immediately after the formation.
Such a difference in temperature in the panel results in different rates of thermal contraction at different points in the panel in the course of cooling to room temperature and, consequently, causes residual stress in the panel, which in turn is subject to geometric changes to release the stress. We have identified this mechanism as the major cause of geometric changes that would occur during the cooling process.
Then, we focused on and investigated the relationship, in the case of a press forming process using draw forming, between the difference in average temperature among flange portions and other portions of a panel and the amount of geometric changes made to the panel from the time immediately after press forming until the end of air cooling.
As used herein, the term “difference in average temperature” means a difference in average temperature immediately after press forming, unless otherwise specified. As used herein, the phrase “immediately after press forming” refers to a point in time that represents the end of a holding process at a press bottom dead point and the start of air cooling of a panel after being removed from the die. In addition, the term “the amount of geometric changes” means a difference (variation) between the geometry of a panel after removal from the die immediately after warm press forming and the geometry of the panel after air cooling.
Further,
It can be seen from
From the results of the aforementioned investigation, we found that the difference in average temperature among flange portions and other portions of a panel closely correlates to the amount of geometric changes made to the panel from the time it is removed from the die immediately after press forming until the end of air cooling. Based on this finding, we studied how to suppress the aforementioned difference in average temperature during draw forming. As a result, we held a steel sheet at the press bottom dead point as shown in
The mechanism by which the aforementioned difference in average temperature can be suppressed by holding a steel sheet at the press bottom dead point will be described below.
That is, when a panel formed from a blank is held at the press bottom dead point, not only the flange portions constrained by the die and the blank holder, but also other portions than the flange portions such as sidewall portions, are cooled by contact with the die and the punch die. This facilitates soaking in the panel and, therefore, suppresses the difference in average temperature among the flange portions and the other portions.
a) shows the relationship between the difference in average temperature among flange portions and other portions of those panels having a substantially hat-shaped cross section that were obtained warm press forming using draw forming and the holding time at the press bottom dead point; and
It can be seen from
It can also be understood that even for the heating temperatures of 650° C. and 700° C., the difference in average temperature among flange portions and other portions of each panel may be kept within 150° C. and the amount of geometric changes made to each panel may be suppressed to 1.0 mm or less, by setting the holding time at press bottom dead point to three seconds or more.
However, a holding time at press bottom dead point exceeding five seconds is disadvantageous in terms of production efficiency, although the amount of geometric changes is kept substantially constant for any of the heating temperatures.
In view of the above, a steel sheet is held at the press bottom dead point for one second to five seconds, and preferably three to five seconds, at the time of press forming using draw forming.
As described above, to suppress the difference in average temperature in steel sheets of any tensile strength grade within 150° C., it suffices to set the heating temperature of the steel sheet to 400° C. to 700° C. and the holding time at press bottom dead point to three seconds or more. In this case, while no particular limitation is placed on the draw forming conditions, the pressing speed is preferably 10 spm to 15 spm (strokes per minute, which represents the number of parts that can be formed in one minute plus any additional time, if applicable, taken to hold parts at the press bottom dead point).
In addition, with draw forming, flange portions are continuously compressed during formation, which provides the benefit of making the flange portions less prone to wrinkle formation. Further, we hold the steel sheet at the press bottom dead point as described above, which makes it possible to suppress wrinkle formation in flange portions in a more effective manner.
It is assumed that heating the steel sheet has the same effect irrespective of the heating method used such as heating in an electric furnace, electrical heating, and rapid heating using far infrared heating.
In addition, as mentioned earlier, the warm press forming method is applied to a steel sheet having a tensile strength of 440 MPa or more. Further, the warm press forming method may preferably be applied to a steel sheet having a tensile strength of 780 MPa or more, and even 980 MPa or more.
Additionally, as mentioned earlier, the warm press forming method makes it possible to directly make use of the mechanical properties of steel sheets as blanks, thereby allowing a press-formed part obtained by press forming of a steel sheet to have a tensile strength which is not greatly different from, or 80% to 110% of, that of the steel sheet before press forming.
Furthermore, it is possible to obtain a press-formed part that retains, even after the press forming process, a tensile strength which is almost as high as that of the steel sheet before press forming (or, that has a tensile strength of 95% to 100% of the tensile strength of the steel sheet prior to the press forming process), depending on the forming conditions and the properties of the steel sheet.
Therefore, depending on the properties required for press-formed parts, the use of steel sheets having the corresponding properties as blanks allows for stable production of press-formed parts with desired properties.
The chemical composition range of a steel sheet that can preferably be used as a blank will be described below. Note that the unit “%” of each component is “mass %” unless otherwise specified.
Carbon (C) is an important element in that it forms carbides with other elements such as Ti, V, Mo, W, Nb, Zr, and Hf, which exhibit fine particle distribution in the matrix to thereby increase the strength of a steel sheet. In this case, to achieve a tensile strength as high as 440 MPa or more, the content of C in steel is preferably 0.015 or more. However, if the content of C exceeds 0.16%, the ductility and toughness are significantly reduced, which makes it impossible to ensure good impact absorption ability (such as expressed by “tensile strength TS×total elongation El”). Therefore, the content of C is preferably 0.015% to 0.16%, more preferably 0.03% to 0.16%, and still more preferably 0.04% to 0.14%.
Silicon (Si) is a solid-solution-strengthening element that suppresses the reduction of strength in a high temperature range and, consequently, adversely affects formability in a warm-forming temperature range (warm formability). Therefore, the content of Si in steel is preferably kept as low as possible in the present invention, but a Si content of up to 0.2% is tolerable. In view of this, the content of Si is preferably 0.2% or less, more preferably 0.1% or less, and still more preferably 0.06% or less. Note that the content of Si may be reduced to impurity level.
Manganese (Mn) is also a solid-solution-strengthening element, like Si, that suppresses the reduction of strength in a high temperature range and, consequently, adversely affects the formability in a warm-forming temperature range (warm formability). Therefore, the content of Mn in steel is preferably kept as low as possible in the present invention, but a Mn content of up to 1.8% is tolerable. In view of this, the content of Mn is preferably 1.8% or less, more preferably 1.3% or less, and still more preferably 1.1% or less. Note that if the content of Mn is too low, the austenite (γ) to ferrite (α) transformation temperature may rise excessively, which could lead to coarsening of carbides. Therefore, the content of Mn is preferably 0.5% or more.
Phosphorus (P) is an element that has a very high, solid-solution-strengthening ability, suppresses the reduction of strength in a high temperature range, and consequently adversely affects formability in a warm-forming temperature range (warm formability). Additionally, P exists in a segregated manner at grain boundaries, thereby lowering the ductility during and after warm forming. In view of this, the content of P in steel is preferably kept as low as possible, but a P content of up to 0.035% is tolerable. Accordingly, the content of P is preferably 0.035% or less, more preferably 0.03% or less, and still more preferably 0.02% or less.
Sulfur (S) is an element that exists as inclusion in steel. S reduces the strength of the steel sheet when bonded to Ti, while forming sulfides when bonded to Mn, leading to a reduction of the ductility of the steel sheet at room temperature, under warm condition, and the like. Therefore, the content of S is preferably kept as low as possible, but a S content of up to 0.01% is tolerable. Accordingly, the content of S is preferably 0.01% or less, more preferably 0.005% or less, and still more preferably 0.004% or less.
Aluminum (Al) is an element that acts as a deoxidizer. To obtain this effect, it is desirable that Al is contained in steel by 0.02% or more. However, if the content of Al exceeds 0.1%, more oxide-based inclusions form, significantly reducing the ductility under warm condition. Therefore, the content of Al is preferably 0.1% or less, and more preferably 0.07% or less.
Nitrogen (N) is an element that forms coarse nitrides when bonded to Ti, Nb, and the like at the steelmaking stage. Accordingly, the strength of the steel sheet significantly decreases if it contains a large amount of N. In view of this, the content of N is preferably kept as low as possible, but a N content of up to 0.01% is tolerable. Therefore, the content of N is preferably 0.01% or less, and more preferably 0.007% or less.
Titanium (Ti) is an element that forms carbides when bonded to C and thereby contributes to increased strength of the steel sheet. To ensure that the steel sheet has a tensile strength as high as 440 MPa or more at room temperature, as targeted by the present invention, the content of Ti is preferably 0.13% or more. On the other hand, if the content of Ti exceeds 0.25%, coarse TiC particles remain and micro voids form during heating of the steel material. Therefore, the content of Ti is preferably 0.25% or less, more preferably 0.14% to 0.22%, and still more preferably 0.15% to 0.22%.
In the foregoing, the preferred composition ranges of the components have been described. However, it does not suffice for the components to only satisfy the aforementioned ranges, and it is also important for C and Ti, in particular, to satisfy Expression (1):
2.00≧([% C]/12)/([% Ti]/48)≧1.05 (1)
where [% M] indicates the content by mass % of element M.
That is, Expression (1) is a requirement to enable the strengthening by precipitation with carbides, which will be described later, and to ensure a high strength as desired after warm forming. When the contents of C and Ti satisfy Expression (1), it is possible to allow precipitation of a desired amount of carbides, thereby ensuring a high strength as desired.
In addition, if the result of ([% C]/12)/([% Ti]/48) is less than 1.05, not only does the grain boundary strength decrease, but also the carbides exhibit lower thermal stability upon heating. Accordingly, the carbides are more prone to coarsening, which makes it impossible to achieve a high strength as desired. On the other hand, if the result of ([% C]/12)/([% Ti]/48) exceeds 2.00, cementite precipitates excessively. This results in formation of micro voids, and consequently cause cracks during warm forming. Note that the result of ([% C]/12)/([% Ti]/48) is more preferably 1.05 to 1.85.
In addition to the aforementioned basic components, the steel sheet that can preferably be used in the warm press forming method may optionally contain the following elements as appropriate.
At Least One Selected from V: 1.0% or Less, Mo: 0.5% or Less, W: 1.0% or Less, Nb: 0.1% or Less, Zr: 0.1% or Less, and Hf: 0.1% or Less
Vanadium (V), molybdenum (Mo), tungsten (W), niobium (Nb), zirconium (Zr), and hafnium (Hf) are elements, like Ti, that form carbides to contribute to increasing the strength of the steel sheet. Therefore, the steel sheet may contain at least one element in addition to Ti, selected from V, Mo, W, Nb, Zr, and Hf, if a further enhancement of its strength is required. To obtain this effect, it is preferred that the content of V is 0.01% or more, the content of Mo is 0.01% or more, the content of W is 0.01% or more, the content of Nb is 0.01% or more, the content of Zr is 0.01% or more, and the content of Hf is 0.01% or more.
On the other hand, if the content of V exceeds 1.0%, carbides are more prone to coarsening; in particular, coarsening of carbides in a warm-forming temperature range makes it difficult to control the average particle size of the carbides after being cooled to room temperature to be 10 nm or less. Accordingly, the content of V is preferably 1.0% or less, more preferably 0.5% or less, and still more preferably 0.2% or less.
In addition, if the contents of Mo and W are more than 0.5% and 1.0%, respectively, the γ-to-α transformation is exceedingly delayed. As a result, bainite phase and martensite phase exist in a mixed manner in the microstructure of the steel sheet, which makes it difficult to obtain ferrite single phase, which will be described later. In view of this, the contents of Mo and W are preferably 0.5% or less and 1.0% or less, respectively.
Additionally, if Nb, Zr, and Hf are contained in steel by more than 0.1%, respectively, coarse carbides are not completely dissolved and remain in slab being reheated. Consequently, micro voids form more easily during warm forming. In view of this, the contents of Nb, Zr, and Hf are preferably 0.1% or less, respectively.
Note that if the above elements are also contained in steel, the following Expression (1)′, instead of Expression (1), needs to be satisfied. The reason for this requirement is the same as stated in conjunction with Expression (1).
2.00≧([% C]/12)/([% Ti]/48+[% V]/51+[% W]/184+[% Mo]/96+[% Nb]/93+[% Zr]/91+[% Hf]/179)≧1.05 (1)′
where [% M] indicates the content by mass % of element M.
Furthermore, the steel sheet that can preferably be used in the warm press forming method may optionally contain the following elements as appropriate. B: 0.003% or less
Boron (B) is an element that acts to inhibit nucleation of the γ-to-α transformation to lower the γ-to-α transformation point, thereby contributing to the refinement of carbides. To obtain this effect, it is desirable that the content of B is 0.0002% or more. However, containing over 0.003% of B does not increase this effect, but is rather economically disadvantageous. Therefore, the content of B is preferably 0.003% or less, and more preferably 0.002% or less.
At Least One Selected from Mg: 0.2% or Less, Ca: 0.2% or Less, Y: 0.2% or Less, and REM: 0.2% or Less
Magnesium (Mg), calcium (Ca), yttrium (Y), and REM all act as refining inclusions, which action provides an effect of suppressing stress concentration in the vicinity of inclusions and the base material during warm forming, and thereby improving the ductility. Therefore, these elements may optionally be contained in steel. Note that the REM, which is an abbreviation for Rare Earth Metal, represents lanthanoid elements.
However, if Mg, Ca, Y, and REM are contained in steel in an excessive amount over 0.2%, respectively, these elements compromise castability (which is the ability of a molten steel to flow through a mold before solidification; higher castability represents better flowability of a molten steel), rather leading to lower ductility. It is thus preferred that the content of Mg is 0.2% or less, the content of Ca is 0.2% or less, the content of Y is 0.2% or less, and the content of REM is 0.2% or less. More preferably, the content of Mg is 0.001% to 0.1%, the content of Ca is 0.001% to 0.1%, the content of Y is 0.001% to 0.1%, and the content of REM is 0.001% to 0.1%.
It is also desirable that the total amount of these elements is adjusted to be 0.2% or less, and more preferably 0.1% or less.
At Least One Selected from Sb: 0.1% or Less, Cu: 0.5% or Less, and Sn: 0.1% or Less
Antimony (Sb), copper (Cu), and tin (Sn) are elements that concentrate near surfaces of a steel sheet and has an effect of suppressing softening of the steel sheet that would be caused by nitriding of the surfaces of the steel sheet during warm forming. Therefore, at least one of these elements may optionally be contained in steel. Note that Cu is also effective to improve anti-corrosion property. To obtain this effect, it is desirable that Sb, Cu, and Sn are contained in steel by 0.005% or more, respectively. However, if Sb, Cu, and Sn are contained in steel in excessive amounts over 0.1%, 0.5%, and 0.1%, respectively, the resulting steel sheet has a poor surface texture. Therefore, it is preferred that the content of Sb is 0.1% or less, the content of Cu is 0.5% or less, and the content of Sn is 0.1% or less.
At Least One Selected from Ni: 0.5% or Less and Cr: 0.5% or Less
Both Ni and Cr are elements that contribute to increased strength of steel. At least one of these elements may optionally be contained in steel. Ni is an austenite-stabilizing element that suppresses formation of ferrite at high temperature and contributes to increased strength of the steel sheet. In addition, Cr is a quench-hardenability-improving element that suppresses, as is the case with Ni, formation of ferrite at high temperature and contributes to increased strength of the steel sheet.
To obtain this effect, it is preferred that Ni and Cr are contained in steel by 0.01% or more. However, if Ni and Cr are contained in steel in an excessive amount over 0.5%, respectively, formation of a low temperature transformation phase, such as martensite phase and bainite phase, is induced. A low temperature transformation phase, such as martensite phase and bainite phase, shows recovery during heating, thereby causing a reduction in the strength after warm forming. To obtain this effect, it is preferred that Ni and Cr are contained in steel by 0.5% or less, and more preferably by 0.3% or less, respectively.
At Least One Selected from O, Se, Te, Po, as, Bi, Ge, Pb, Ga, in, TI, Zn, Cd, Hg, Ag, Au, Pd, Pt, Co, Rh, Ir, Ru, Os, Tc, Re, Ta, be and Sr in a Total Amount of 2.0% or Less
A total amount of 2.0% or less of the above elements is tolerable since it does not affect the strength or warm formability of the steel sheet. The total amount is more preferably 1.0% or less.
The balance other than the aforementioned components includes Fe and incidental impurities.
Next, a preferred microstructure of the aforementioned steel sheet will be described.
Area Ratio of Ferrite Phase with Respect to the Entire Microstructure: 95% or More
The steel sheet has a metal structure of ferrite single phase. As used herein, the term “ferrite single phase” is not only intended to represent a situation where the area ratio of ferrite phase is 100%, but also to encompass a substantially ferrite single phase where the area ratio of ferrite phase is 95% or more.
For the steel sheet having a ferrite single phase as its metal structure, it is possible to retain excellent ductility and even suppress changes to the material properties caused by heating. The coexistence of hard phases such as bainite phase and martensite phase in the microstructure causes recovery of dislocations introduced to the hard phases by heating and, consequently, the hard phases soften, which makes it impossible to maintain the strength of the steel sheet even after warm forming. Accordingly, the absence of pearlite, bainite phase, and martensite phase delivers better results, although the coexistence of such hard phases and even a retained austenite phase is tolerable as long as the area ratio of these phases with respect to the entire microstructure is 5% or less.
In this case, if a steel sheet has a metal structure of substantially ferrite single phase, the metal structure remains as substantially ferrite single phase even when the steel sheet is heated to a temperature range of 400° C. to 700° C. (warm-forming temperature range). Additionally, the aforementioned steel sheet may show an increase in ductility as it is heated, achieving good total elongation in the warm-forming temperature range.
Moreover, in the case where the steel sheet is subjected to a forming process in the warm-forming temperature range, the forming process is conducted in connection with recovery of dislocation and, consequently, with little reduction in ductility during warm forming. Furthermore, since the steel sheet does not show any microstructural changes even when cooled to room temperature after warm forming, it maintains the metal structure of substantially ferrite single phase and exhibits excellent ductility.
For ferrite having an average grain size of less than 1 μM, crystal grains tend to grow during warm forming, with the result that the material properties of a press-formed part after warm forming considerably differ from those observed before warm forming, reducing the stability of the steel sheet as a material. Therefore, ferrite preferably has an average grain size of 1 μm or more.
On the other hand, if ferrite has an excessively large, average grain size over 15 μm, it is not possible to achieve strengthening through grain refinement of the microstructure, which makes it difficult to ensure a desired strength of the steel sheet. Therefore, ferrite preferably has an average grain size of 15 μm or less, and more preferably 12 μm or less.
To obtain a microstructure with ferrite having an average grain size of 1 μM or more, it is effective to prevent nucleation sites for ferrite from excessively increasing in number. The number of nucleation sites is closely related to the amount of strain energy to be stored in the steel sheet during the rolling process. Consequently, to prevent refinement of ferrite grains, it is necessary to prevent excessive storage of strain energy. To this end, the finisher delivery temperature is preferably at 840° C. or higher.
With the aforementioned ferrite single phase structure, it is difficult to obtain a steel sheet having a sufficiently high tensile strength and/or yield ratio. In this regard, the strength of the steel sheet may be increased by allowing fine carbides having an average particle size of 10 nm or less to be precipitated in the ferrite crystal grains. In this case, if the average particle size of the carbides is more than 10 nm, it is difficult to obtain the aforementioned high tensile strength and/or yield ratio. Note that the average particle size of the carbides is more preferably 7 nm or less.
Examples of the fine carbides include Ti carbides, and furthermore, V carbides, Mo carbides, W carbides, Nb carbides, Zr carbides, and Hf carbides. These carbides do not undergo coarsening and the average particle size thereof remains 10 nm or less, as long as the heating temperature of the steel sheet is held at 700° C. or lower. The coarsening of the carbides is thus suppressed even when the steel sheet is heated to a warm-forming temperature of 400° C. to 700° C. for warm forming, with the result that the steel sheet will not show a considerable reduction in its strength after cooled to room temperature following the warm forming process. Thus, by providing a steel sheet with a microstructure that contains the aforementioned carbides having an average particle size of 10 nm or less in a matrix of substantially ferrite single phase, it is possible to effectively suppress the reduction of yield strength of a press-formed part obtained by warm forming of the steel sheet while heating it to the warm-forming temperature of 400° C. to 700° C.
Note that the aforementioned steel sheet may comprise a coating or plating layer such as a hot dip galvanized layer. Examples of such a coating or plating layer include an electroplated layer, an electroless-plated layer, a hot-dipped layer, and so on. Further, a galvannealed layer may also be used.
Next, a method of manufacturing a steel sheet that can preferably be used in the warm press forming method will be described.
The steel sheet that can preferably used in the warm press forming method is obtained by heating a steel material, then subjecting the steel material to hot rolling including rough rolling and finish rolling and, subsequently, coiling the steel material to obtain a hot rolled steel sheet.
In this case, the method of manufacturing a steel raw material preferably includes, without any particular limitation: preparing a molten steel having the aforementioned composition by a well-known steelmaking method such as a converter and an electric furnace; subjecting the molten steel to optional secondary refining in a vacuum degassing furnace; and casting the molten steel to obtain a steel raw material, such as slab, by a well-known casting method such as a continuous casting. Note that the continuous casting is preferred in terms of productivity and quality.
Preferred manufacturing conditions will now be described.
Coarse carbides fail to be dissolved if the heating temperature of the steel raw material is below 1100° C. and, consequently, fewer fine carbides are dispersed and precipitated in the resulting steel sheet, which makes it difficult to ensure a high strength as desired. On the other hand, if the heating temperature of the steel raw material is above 1350° C., oxidation progresses so much as to form oxide scales during hot rolling and to deteriorate the surface texture of the steel sheet, thereby lowering the warm formability of the steel sheet. Therefore, the heating temperature of the steel raw material is preferably 1100° C. to 1350° C. A more preferable range is 1150° C. to 1300° C.
If the finisher delivery temperature is below 840° C., the microstructure contains extended ferrite grains and ends up with a mixed-grain-size microstructure in which individual ferrite grains are greatly different in grain size, with the result that the strength of the steel sheet significantly decreases. In addition, a finisher delivery temperature below 840° C. results in excessive strain energy being stored in the steel sheet during the rolling process, which makes it difficult to obtain a microstructure containing ferrite grains having an average grain size of 1 μm or more. Therefore, the finisher delivery temperature is preferably 840° C. or higher, and more preferably 860° C. or higher.
Time to Initiate Forced Cooling after Completion of Hot Rolling: Within Three Seconds
After completion of the aforementioned hot rolling, the resulting hot rolled steel sheet is subjected to forced cooling. If more than three seconds elapse before the forced cooling is initiated after completion of the hot rolling, a large amount of carbides are subject to strain-induced precipitation, which makes it difficult to ensure desired precipitation of fine carbides. Therefore, the forced cooling is preferably initiated within three seconds after completion of the hot rolling, and more preferably within two seconds.
Average Cooling Rate from the Start to the End of Cooling: 30° C./s or Higher
If the average cooling rate from the start to the end of cooling is lower than 30° C./s, the steel sheet is maintained at a high temperature for a longer period of time, which accelerates coarsening of carbides caused by strain-induced precipitation. Therefore, the aforementioned forced cooling after the hot rolling is preferably performed at an average cooling rate of 30° C./s or higher to rapidly cool the steel sheet to a predetermined temperature. The average cooling rate is more preferably 50° C./s or higher.
Note that a cooling stop temperature is set such that a coiling temperature eventually falls within a target temperature range, taking into account the temperature drop that would occur in the steel sheet during a period from the end of cooling to the start of coiling. That is, since the steel sheet experiences a drop in temperature as it is air cooled after the end of cooling, the cooling stop temperature is normally set to be approximately equal to the temperature of coiling temperature+5° C. to +10° C.
A coiling temperature below 500° C. results in an insufficient amount of carbides being precipitated in the steel sheet for providing the steel sheet with as high strength as desired. On the other hand, a coiling temperature above 700° C. induces coarsening of precipitated carbides, which also makes it difficult to provide the steel sheet with as high strength as desired. Therefore, the coiling temperature is preferably 500° C. to 700° C., and more preferably 550° C. to 680° C.
In addition, the resulting hot rolled steel sheet may be subjected to a coating or plating process using a well-known method to form a coating or plating layer on its surface. The coating or plating layer is preferably a hot-dip galvanized layer, a galvannealed layer, an electroplated layer, or the like.
Next, the mechanical properties of the steel sheet that may be obtained by the aforementioned manufacturing method and preferably be used in the warm press forming method will be described.
Specifically, the preferred steel sheet has the following mechanical properties:
(a) tensile strength at room temperature: 780 MPa or more, and yield ratio at room temperature: 0.85 or more;
(b) yield strength YS2 in a warm-forming temperature range of 400° C. to 700° C.: 80% or less of yield strength YS1 at room temperature; and (c) total elongation El1 in a warm-forming temperature range of 400° C. to 700° C.: 1.1 times or more total elongation El1 at room temperature
The aforementioned properties will be described below.
While the warm press forming method is applied to a steel sheet having a tensile strength at room temperature of 440 MPa or more, the aforementioned manufacturing method may be used to obtain a steel sheet having TS1 of 780 MPa or more and a yield ratio at room temperature of 0.85 or more.
As used herein, “TS1” represents a tensile strength at room temperature and “room temperature” refers to a temperature of (22±5)° C.
For a steel sheet having a yield strength YS2 in a warm-forming temperature range of 400° C. to 700° C. which is more than 80% of a yield strength YS1 at room temperature, the deformation resistance of the steel sheet is not sufficiently reduced at the time of warm forming and accordingly increased load (press load) is required for warm forming, leading to a shortened die life. Additionally, the body size of the processing machine (press machine) must be necessarily increased for applying a large load (press load). As the body size of the processing machine (press machine) increases, it takes a longer time to transfer a steel sheet heated to a warm forming temperature to a processing machine, which causes a temperature drop in the blank and accordingly makes it difficult to perform warm forming at a desired temperature range. Moreover, shape fixability is not improved sufficiently and, consequently, the effect to be obtained by warm forming is reduced.
Therefore, the yield strength YS2 in the warm-forming temperature of 400° C. to 700° C. is preferably 80% or less, and more preferably 70% or less of the yield strength YS1 at room temperature.
For a steel sheet having a total elongation El2 at the warm-forming temperature of 400° C. to 700° C. which is 1.1 times or more the total elongation El1 at room temperature, formability for warm forming is improved sufficiently to allow the steel sheet to be formed more easily into a member having a complicated shape, without causing any defects such as cracking.
Therefore, the total elongation El2 in the warm-forming temperature of 400° C. to 700° C. is preferably 1.1 times or more, and more preferably 1.2 times or more the total elongation El1 at room temperature.
Further, a steel sheet, which exhibits the following mechanical properties in addition to the above after being formed into a press-formed part, may more preferably be used in the warm press forming method.
Yield Strength YS3 at Room Temperature and Total Elongation El3 at Room Temperature of a Press-Formed Part: 80% or More of the Yield Strength YS1 at Room Temperature and the Total Elongation El1 at Room Temperature of the Material Steel Sheet Prior to Press Forming
For a press-formed part having a yield strength YS3 at room temperature and a total elongation El3 at room temperature that are less than 80% of the yield strength YS1 at room temperature and the total elongation El1 at room temperature of the material steel sheet prior to press forming, respectively, the strength and total elongation of the resulting member after warm forming are insufficient. If such a steel sheet is subjected to warm press forming to produce an automobile component of desired shape, the resulting component offers insufficient crash worthiness upon crash of the automobile, resulting in reduced reliability as an automobile component.
In view of this, it is preferred that a press-formed part has a yield strength YS3 at room temperature and a total elongation El3 at room temperature that are 80% or more, and more preferably 90% or more of the yield strength YS1 at room temperature and the total elongation El1 at room temperature of the material steel sheet prior to press forming.
Steel sheets, each having a sheet thickness of 1.6 mm and a tensile strength of 440 MPa grade to 1180 MPa grade, were heated under the conditions shown in Table 1 and subjected to draw forming to obtain center pillar upper press panels as shown in
In this case, the steel sheets were heated in an electric furnace. The in-furnace time was set to be 300 seconds so that each blank can be heated in the furnace, resulting in a uniform temperature distribution throughout the blank. The heated blanks were then removed from the furnace and fed into a press machine after a transfer time of 10 seconds, respectively, where the blanks were subjected to forming processes with different holding times at the press bottom dead point as shown in Table 1.
Immediately thereafter, the temperature difference between flange portions and other portions of each of the formed panels was measured. That is, the temperature was measured in each panel at six points (indicated by “X” in
In addition, a servo press was used as a press machine, where the pressing speed was set to be 15 spm (strokes per minute, which represents the number of parts that can be formed in one minute plus any additional time, if applicable, taken to hold the parts at the press bottom dead point).
The formed panels were air cooled for a sufficiently long period of time, after which, regarding the cross sectional shape of each center pillar upper press panel as shown in
10
15
—
258
2.5
—
263
2.6
—
260
2.5
—
168
1.2
—
183
1.3
—
203
1.4
—
231
1.8
As Table 1 shows, each of steel Nos. 1, 2, 5 to 9 of our examples, in which steel sheets were held at the press bottom dead point for one second or more, yielded good dimensional accuracy such that the difference in average temperature among flange portions and other portions of each press-formed part was kept within 150° C. and the amount of geometric changes a was 1.0 mm or less.
In contrast, none of steel Nos. 10 to 16 of the comparative examples, in which steel sheets were held at the press bottom dead point for less than one second, yielded sufficient dimensional accuracy, because the difference in average temperature among flange portions and other portions of each press-formed part was greater than 150° C. and the amount of geometric changes a was 1.2 mm to 2.6 mm.
It is clearly understood from the above results that the warm press forming method may suppress the difference in average temperature among flange portions and other portions of a panel, and thereby reduce the amount of geometric changes made to the panel from the time immediately after press forming until the end of air cooling, thereby providing the press-formed part with significantly improved dimensional accuracy.
Molten steels having the chemical compositions shown in Table 2 were prepared by steelmaking in a converter, and subjected to continuous casting to obtain slabs (steel raw materials). The slabs (steel raw materials) were heated to the heating temperatures shown in Table 3, then subjected to soaking, rough rolling, finish rolling under the hot rolling conditions shown in Table 3, cooling, and subsequent coiling to obtain hot rolled steel sheets (sheet thickness: 1.6 mm). Note that each of the steel sheets a, i, k, m was heated to 700° C. in a continuous galvanizing line and immersed in a hot-dip galvanizing bath at a liquid temperature of 460° C. to form a hot-dip galvanized layer on the surfaces of the steel sheet, and the hot-dip galvanized layer thus obtained was subjected to alloying treatment at 530° C. to form a galvannealed layer. The coating weight was set to be 45 g/m2 for each steel sheet.
Then, test pieces were collected from the hot rolled steel sheets thus obtained and analyzed by microstructure observation, precipitation observation, and tensile tests. The analysis was carried out as follows.
(1) Microstructure Observation
Test pieces were collected from the obtained hot rolled steel sheets for microstructure observation. Each test piece was polished and etched (etching solution: 5% nital solution) at its cross section parallel to the rolling direction (L-section), and then its center part in the sheet thickness direction was observed and imaged in ten fields of view under a scanning electron microscope (at magnification of ×400). The micrographs thus obtained were analyzed using an image processing technique to identify the microstructure and to measure the microstructure proportion and the average grain size of each phase.
That is, the obtained micrographs were used to distinguish ferrite phase from other phases so as to measure the area of the ferrite phase, thereby determining an area ratio of the ferrite phase to the entire fields of view being observed. While the ferrite phase is observed with smoothly curved grain boundaries with no corrosion marks appeared in the grains, any grain boundaries appeared in linear form were construed as part of the ferrite phase. The obtained micrographs were also used to determine the average grain size of ferrite by a cutting method in conformity with ASTM E 112-10.
(2) Precipitate Observation
In addition, test pieces were collected from the center portions in the sheet thickness direction of the obtained hot rolled steel sheets, and subjected to mechanical and chemical polish to obtain thin films for observation under a transmission electron microscope (TEM). The thin films thus obtained were observed under a TEM (at magnification of ×120,000) for precipitates (carbides). Measurements were made of the particle size of 100 or more carbides to determine an arithmetic mean value thereof, which was defined as the average particle size of carbides in each steel sheet. Note that coarse cementite and nitride particles greater than 1 μm in diameter were excluded from the measurements.
(3) Tensile Test
JIS No. 13B tensile test pieces were collected from the obtained hot rolled steel sheets with a direction orthogonal to the rolling direction being the tensile direction, in accordance with JIS Z 2201 (1998). The collected test pieces were subjected to tensile tests in accordance with JIS G 0567 (1998) to measure mechanical properties (yield strength YS1, tensile strength TS1, total elongation El1) at room temperature (22±5° C.) and high-temperature mechanical properties (yield strength YS2, tensile strength TS2, total elongation El2) at temperatures shown in Table 4. Note that all of the tensile tests were conducted with a cross-head speed of 10 mm/min. In addition, in the case of measuring high-temperature mechanical properties, tensile tests were carried out in such a way that test pieces were heated in an electric furnace and retained for 15 minutes after they had reached a condition where they were stably maintained at temperatures of ±3° C. of the test temperature.
Tables 3 and 4 list the test results (1) to (3).
Then, the steel sheets thus obtained were heated under the conditions shown in Table 5, and then subjected to warm draw forming to obtain center pillar upper press panels as shown in
Additionally, under the same conditions as those in Example 1, measurements were made of the temperature difference between flange portions and other portions of each panel immediately after the formation, and of the amount of geometric changes a made to the edges of each panel until the end of the air cooling process, in relation to the reference panel shape (which is the shape the panel took when it was removed from the die immediately after press forming).
Moreover, JIS No. 13B tensile test pieces were collected from the formed panels and subjected to tensile tests at room temperature under the same conditions as described above, to measure their mechanical properties (yield stress (YS3), tensile strength (TS3), and total elongation (El3)).
The obtained results are shown in Table 5.
As Table 5 shows, each of steel Nos. 17 to 42 of our examples yielded good dimensional accuracy such that the difference in average temperature between flange portions and other portions was kept within 150° C. and the amount of geometric changes a was 1.0 mm or less.
In particular, steel Nos. 17 to 22, 29 to 36, 40, and 41 of our examples using steel sheets having preferred chemical compositions and microstructures yielded good dimensional accuracy in the press-formed parts after the formation, despite the use of high strength steel sheets having a tensile strength of 780 MPa or more, and furthermore, the press-formed parts exhibited extremely good mechanical properties such that, for example, the tensile strength TS3 of these press-formed parts was 99% to 104% of the tensile strength TS1 of the respective material steel sheets before press forming.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-048725 | Mar 2012 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2013/001316 | 3/4/2013 | WO | 00 |
