U.S. patent application number 14/003324 was filed with the patent office on 2014-02-20 for flat steel product and method for producing a flat steel product.
This patent application is currently assigned to THYSSENKRUPP STEEL EUROPE AG. The applicant listed for this patent is Janko Banik, Marc Blumenau, Maria Koeyer, Tobias Lewe, Axel Schrooten. Invention is credited to Janko Banik, Marc Blumenau, Maria Koeyer, Tobias Lewe, Axel Schrooten.
Application Number | 20140048181 14/003324 |
Document ID | / |
Family ID | 45808921 |
Filed Date | 2014-02-20 |
United States Patent
Application |
20140048181 |
Kind Code |
A1 |
Banik; Janko ; et
al. |
February 20, 2014 |
Flat Steel Product and Method for Producing a Flat Steel
Product
Abstract
A flat steel product, intended to be formed into a component by
hot press forming and having a base made of steel, onto which a
metal anti-corrosion coating of a Zn or a Zn alloy is applied. A
separate finishing coat is applied to at least one of the free
surfaces of the flat steel product. The finishing coat includes at
least one base metal compound (oxide, nitride, sulphide, sulphate,
carbide, carbonate, fluoride, hydrate, hydroxide, or phosphate).
Also, a method enabling the production of a flat steel product of
this kind.
Inventors: |
Banik; Janko; (Altena,
DE) ; Blumenau; Marc; (Hagen, DE) ; Koeyer;
Maria; (Dortmund, DE) ; Lewe; Tobias;
(Munster, DE) ; Schrooten; Axel; (Dortmund,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Banik; Janko
Blumenau; Marc
Koeyer; Maria
Lewe; Tobias
Schrooten; Axel |
Altena
Hagen
Dortmund
Munster
Dortmund |
|
DE
DE
DE
DE
DE |
|
|
Assignee: |
THYSSENKRUPP STEEL EUROPE
AG
Duisburg
DE
|
Family ID: |
45808921 |
Appl. No.: |
14/003324 |
Filed: |
March 8, 2012 |
PCT Filed: |
March 8, 2012 |
PCT NO: |
PCT/EP2012/054013 |
371 Date: |
November 4, 2013 |
Current U.S.
Class: |
148/230 ;
148/225; 148/243; 148/252; 148/270; 148/318; 148/319; 427/372.2;
428/328; 428/336; 428/341; 428/469; 428/471; 428/472.3;
428/684 |
Current CPC
Class: |
B32B 15/013 20130101;
C23C 2/26 20130101; C25D 5/48 20130101; C23C 8/46 20130101; Y10T
428/12576 20150115; B32B 15/16 20130101; Y10T 428/12972 20150115;
Y10T 428/1259 20150115; C23C 8/42 20130101; B32B 15/18 20130101;
C23C 2/28 20130101; C25D 5/50 20130101; C23F 17/00 20130101; C23C
2/06 20130101; C23C 28/345 20130101; B32B 15/043 20130101; Y10T
428/12583 20150115; C22C 38/04 20130101; Y10T 428/273 20150115;
C21D 7/13 20130101; C10M 111/00 20130101; Y10T 428/256 20150115;
C21D 1/673 20130101; C25D 5/36 20130101; Y10T 428/12611 20150115;
C21D 8/0278 20130101; C25D 3/565 20130101; Y10T 428/12535 20150115;
C21D 9/48 20130101; C23C 8/50 20130101; C23C 28/321 20130101; Y10T
428/265 20150115; C21D 9/46 20130101 |
Class at
Publication: |
148/230 ;
148/318; 148/319; 148/225; 148/243; 148/270; 148/252; 427/372.2;
428/469; 428/472.3; 428/341; 428/336; 428/684; 428/471;
428/328 |
International
Class: |
C23C 8/42 20060101
C23C008/42; C23C 8/46 20060101 C23C008/46; C23C 8/50 20060101
C23C008/50 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 8, 2011 |
DE |
102011001140.4 |
Claims
1. A flat steel product intended for heat treatment, comprising a
separate finishing coat is-applied to at least one of the free
surfaces of the flat steel product, said finishing coat comprising
at least one oxide-, nitride-, sulphide-, sulphate-, carbide-,
carbonate-, fluoride-, hydrate-, hydroxide- or phosphate-compound
of a base metal.
2. The flat steel product according to claim 1, Wherein the surface
density of the finishing coat is between 0.01 and 15 g/m.sup.2.
3. The flat steel product according to claim 1, wherein the
finishing coat thickness is between 0.01 and 5 .mu.m.
4. The flat steel product according to claim 1, further comprising
a steel base layer and a metal protective coating for corrosion
protection applied to the base layer, wherein the finishing coat is
applied to the protective coating.
5. The flat steel product according to claim 1, wherein the metal
of the compound contained in the finishing coat belongs to the
group of alkaline earth metals.
6. The flat steel product according to claim 1, wherein the metal
of the compound belongs to the group of alkaline metals.
7. The flat steel product according to claim 1, wherein the metal
of the compound belongs to the group of semi-metals.
8. The flat steel product according to claim 1, wherein the metal
belongs to the group of transition metals.
9. The flat steel product according to claim 1, wherein the metal
of the compound belongs to the group consisting of Na, K, Mg, Ca,
B, Al, Si, Sn, Ti, Cr, Mn, and Zn.
10. The flat steel product according to claim 1, wherein the
compound present in the finishing coat is particulate.
11. The flat steel product according to claim 10, wherein the
average diameter of the particles in the compound is between 0.01
and 5 .mu.m.
12. The flat steel product according to claim 1, wherein the
finishing coat further comprises up to 15% wt. of carbon black or
graphite.
13. A method for producing a flat steel product, comprising the
following steps: a) provision of a flat steel product, b)
application of a finishing coat to the flat steel product by b.1)
applying a coating liquid to the flat steel product, wherein the
coating liquid comprises between (in % wt.) 5 and 50% of an oxide,
nitride-, sulphate-, sulphide-, carbide-, carbonate-, fluoride-,
hydrate-, hydroxide- or phosphate-compound of a base metal, between
1 and 20% of a binder and the remainder water, and optionally up to
15% wt. of carbon black or graphite, b.2) setting the thickness of
the finishing coat to a thickness of between 0.1 and 5 .mu.m and c)
drying the finishing coat.
14. The method according to claim 13, wherein the coating liquid
contains between 5 and 35% wt. of the base metal compound.
15. The method according to claim 13, wherein the coating liquid
contains between 2 and 10% wt. of the binder.
16. The method according to claim 13, wherein the coating liquid
contains between 30 and 94% wt. water as a solvent.
17. The method according to claim 13, wherein the method steps are
performed in continuous succession without interruption.
18. The method according to claim 13, wherein the flat steel
product provided in step a) is a blank cut from a strip or sheet,
and the method further comprises heating the flat steel product
after drying the finishing coat based on the drying temperature to
a deformation temperature required for hot forming and hot forming
the heated flat steel product into a component.
19. The method according to claim 18, wherein the formed component
is rapidly cooled from the deformation temperature in order to
produce a martensitic structure in the component.
Description
[0001] The invention relates to a flat steel product which is
intended for heat treatment. Heat treatment involves, for example,
heating to a deformation temperature at which the flat steel
product is thermoformed into a component. Hot working can be
carried out as hot press forming where the flat steel product heats
up to a sufficiently high temperature to form a martensitic
structure, is then deformed and cooled rapidly to form the
strength-enhancing martensitic structure.
[0002] Furthermore, the invention relates to a method for producing
a flat steel product of this type.
[0003] `Flat steel products` in this context mean steel strips,
sheet steel or blanks derived therefrom.
[0004] The mechanical properties of flat steel products can be
influenced by the most varied heat treatments. Depending on their
strength, deformation behaviour and their thickness, flat steel
products can also only be formed into components when hot. Heat
treatment or heat deformation generally requires heating the flat
steel product to be treated or deformed from a low initial
temperature to a significantly higher temperature required for heat
treatment or heat deformation. From the perspective of optimum
energy use, minimum processing time and optimum process control
options, there is a requirement for an effective as possible
transfer of the heat energy generally introduced as heat radiation
to the flat steel product.
[0005] An example of a method dependent on a high level of
effectiveness of the heat input into the flat steel product to be
heated is hot press forming.
[0006] In order to meet the current demand in modern vehicle body
construction for a combination of light weight, maximum strength
and protective effect, hot press-formed components made of high
tensile steel are used today in those areas of the vehicle body,
which can be subjected to particularly heavy stresses in the event
of a crash.
[0007] In hot press hardening, steel blanks, which are separated
from a cold-rolled or hot-rolled steel strip, are heated to a
deformation temperature, which is usually above the austenitisation
temperature of the respective steel, and placed in the heated state
into the die of a forming press. In the course of the forming
subsequently carried out, the sheet blank or the component formed
from it undergoes rapid cooling through contact with the cool die.
The cooling rates are set in such a way that a martensitic
structure develops in the component.
[0008] A typical example of steel suitable for hot press hardening
is known under the designation `22MnB5` and can be found in the Key
to Steel 2004 under the material number 1.5528.
[0009] The advantages of known MnB steels, particularly suited to
hot press hardening are, however, in practice confronted with the
disadvantage that steels with a high manganese content are too
unstable against wet corrosion and can only be passivated with
difficulty.
[0010] In order to improve the corrosion resistance of steels
containing manganese of the type under discussion, EP 1 143 029 B1
suggests providing a steel blank designated for hot press forming
firstly with a zinc coating and then heating it prior to heat
deformation such that an intermetallic compound is produced upon
heating the flat steel product through a transformation of the
coating on the steel sheet. Said compound is intended to protect
the steel sheet against corrosion and decarburisation and to assume
a lubricating function during hot working in the pressing die.
[0011] In addition to anti-corrosion coatings made of zinc (`Z
coating`) or a zinc alloy (for example, zinc aluminium (`ZA
coatings`) with up to 5% wt. Al, zinc ferrite (`ZF coatings`) with
up to 15% wt. Fe, more particularly Fe content of at least 8% wt.,
zinc nickel (`ZN coatings`) with up to 12% wt. Ni, more
particularly Ni content of least 8% wt., or zinc magnesium coatings
(`ZM coatings`) with up to 5% wt. Mg, more particularly Mg content
of at least 0.5% wt. as well as up to 3% wt. Al, more particularly
Al content of at least 0.2% wt., corrosion-sensitive flat steel
products intended for hot press hardening are also provided in
practice with an AlSi layer (`AS coatings`) with up to 12% wt. Si,
more particularly Si content of at least 8% wt., or an AlZn layer
(`AZ coatings`) with up to 49% wt. Zn and optionally up to 2% wt.
Si, more particularly [Zn] content up to 43.4% wt. and up to 1.6%
wt. Si. Zinc aluminium layers (`ZA coatings`) with up to 5% wt. Al
are also used as metallic anti-corrosion coatings. AS coatings of
the above-mentioned type typically have Si content of up to 10% wt.
here. The above-mentioned coatings can be applied to the respective
steel substrate in a particularly economical manner by hot dip
coating (DE 10 2006 053 819 A1).
[0012] For hot cress form hardening, flat steel products coated in
this manner must be brought to a desired temperature at a certain
speed at which temperature they are subsequently hot press formed.
In practice, this results in the problem that the radiant heat is
reflected onto the smooth and reflective surfaces of the metallic
anti-corrosion coating applied to the flat steel product. This
leads to a significant delay in the heating process with the result
that more time and energy is required for heating. Moreover,
particularly in protective coatings with a higher Al content,
deposits build up on the furnace rollers as a result of the
reaction between the coating and the ceramic furnace rollers. The
diffusion of metallic Al creates the risk that furnace rollers will
break due to thermal dilation of the penetrated metal. Finally,
abrasion, deposits and build-up of the protective coating material
can occur on the surface of the forming die used. This risk is also
present particularly if the anti-corrosion coating on the flat
steel product has a high Al content.
[0013] A method for producing a hardened steel component with areas
of different ductility is known from DE 10 2008 027 460 A1. In said
method, the behaviour of the steel sheet is changed during heating
such that the heat absorption capacity of the steel sheet is
influenced during heating to harden depending on the desired degree
of hardness. Good heat absorption behaviour is realised for this
purpose for high degrees of hardness and reduced heat absorption
behaviour for less hard areas. It should be possible in this manner
to vary the configuration of the structure over the surface of the
component or over the surface of the blank respectively, wherein
adjustment of the structure and the heat absorption behaviour can
be controlled by the surface emissivity. Thus the aim of the known
method is to set locally different degrees of hardness during
quench hardening from the austenite phase and stipulates `surface
emissivity` for this purpose, i.e. to modify the capacity of the
surface or the degree of absorption in locally restricted areas.
This change is intended to be achieved in metallic coatings with
zinc or on the basis of zinc by adjusting the thickness of the
coating in accordance with the respective surface emissivity
required. Consequently, a thinner coating is applied in the areas
intended to be subjected to greater heat in order, as a result of
an increased alloyed coating with the steel substrate of the flat
steel product, to obtain a darker colour that absorbs the heat
radiation better thereby creating higher surface emissivity of the
coating. Greater zinc coating thicknesses on the other hand should
lead to fewer discolourations and at the same time to lower surface
emissivity and correspondingly less intense heating.
[0014] Against the background of the prior art explained above, the
object of the invention is to create a flat steel product that can
be brought to the initial temperature required for the respective
heat treatment within shorter heating times. Moreover, a method,
which allows the production of such a flat steel product, shall
also be indicated.
[0015] With regard to the flat steel product, this problem is
solved as per the invention in that it has the features indicated
in claim 1.
[0016] A method for producing a flat steel product as per the
invention includes, as per the invention, the features indicated in
claim 13.
[0017] Advantageous embodiments and variations of the invention are
indicated in the dependent claims and are explained in detail below
as is the general inventive concept.
[0018] According to the invention, a flat steel product intended
for heat treatment is additionally coated on at least one of its
free surfaces with a separate finishing coat which contains an
oxide-, nitride-, sulphide-, sulphate-, carbide-, carbonate-,
fluoride-, hydrate-, hydroxide- or phosphate-compound of a base
metal.
[0019] Practical tests have shown that the advantages of the
invention explained in detail below already appear in flat steel
products where the finishing coat is applied directly onto the
surface of the steel substrate and where therefore no further
coatings are present on the flat steel product.
[0020] The application of a finishing coat as per the invention has
proven particularly advantageous in flat steel products, however,
which comprise a base consisting of steel and a metallic
anti-corrosion coating applied to the base. In this case, the
finishing coat as per the invention is applied to the protective
coating and consequently the finishing coat seals the layer
structure formed on the base on the outer side thereof.
[0021] Also in the case of flat steel products in which the base is
coated with a non-metallic coating, the application of a finishing
coat as per the invention significantly improves the heating
behaviour. Such non-metallic coatings applied to the base include,
for example, temperature-stable, abreacted organic compounds, such
as carbon black, sodium or calcium-based salts, nitrates and
phosphates, such as NaCl, Na.sub.2O, KNO.sub.3, K.sub.3PO.sub.4,
K.sub.2SO.sub.4, K.sub.2S, K.sub.2CO.sub.3, CaCO.sub.3, each of
which have a high melting or boiling point.
[0022] According to the invention, a finishing coat is applied
accordingly in a separate step and irrespective of the other
coatings optionally present on the flat steel product as per the
invention. Firstly, this finishing coat reduces the reflection
capacity of the flat steel product, more particularly of the
coating optionally present on the flat steel product. The surface
of a flat steel product coated in a manner as per the invention is
generally duller and is characterised by an increased ability to
absorb infrared radiation.
[0023] Consequently, absorption levels (the terms `absorption
level` and `absorption coefficient` are used synonymously here)
between 0.3 and 0.99% are achieved using a finishing coat as per
the invention.
[0024] Accordingly, flat steel products coated with a finishing
coat as per the invention absorb between 30% and 99% of the heat
radiation striking them.
[0025] It has been demonstrated in the process that the metallic
compound derived from the oxide, nitride, sulphide, sulphate,
carbide, carbonate, fluoride, hydrate, hydroxide or phosphate group
present in the finishing coat as per the invention, is
temperature-stable in the typical temperature range for the heat
treatment of steel of between 300 and 1200.degree. C. and
consequently also enables extremely effective heating even at high
temperatures corresponding to at least the Ar3 temperature, as
generally required for hot press forming, for example.
[0026] Secondly, the finishing coat provided as per the invention
on a flat steel product of the type described above acts like a
lubricant and thus improves the suitability of flat steel products
for forming into components by hot press forming.
[0027] At the same time, the finishing coat acts like a barrier and
prevents direct contact between the flat steel product and the
rollers or other parts of the furnace used to heat the flat steel
product. This proves particularly advantageous if the flat steel
product as per the invention is covered with an anti-corrosion
coating, which may melt as a result of heating. In flat steel
products coated in this manner, the finishing coat applied as per
the invention can prevent deposits from building up in the heating
furnace in forming dies used in optional hot forming. Consequently,
in a flat steel product as per the invention, not only is the time
required to heat to the respective initial hot forming temperature
significantly reduced, but also the risk of damage to parts of the
heating furnace or the forming die used for optional hot forming is
also significantly reduced.
[0028] The requirement as per the invention that one metallic
compound derived from the oxide, nitride, sulphide, sulphate,
carbide, carbonate, fluoride, hydrate, hydroxide or phosphate group
should be present in the finishing coat applied as per the
invention naturally implies that the finishing coat also contains a
plurality of such compounds. However, it was clear from the
practical testing of the invention that the presence of just one of
the cited compounds in the finishing coat achieves the desired
effects as per the invention.
[0029] The positive effects of the finishing coat as per the
invention occur independently from the alloying of its base
material in all flat steel products.
[0030] This applies, as mentioned, particularly if the flat steel
product is coated with a metallic anti-corrosion coating onto the
outer side of which the finishing coat is applied in turn.
Practical tests have shown here that heating times can be
significantly reduced, both in the case of flat steel products
provided with a zinc-based anti-corrosion coating and in the case
of such flat steel products where the anti-corrosion coating is
aluminium-based.
[0031] Table 1 shows the proportion in `%` for various
anti-corrosion coatings by which the heating times are reduced in a
flat steel product coated as per the invention compared with a flat
steel product without a finishing coat which is heated to the
respective initial temperature required for hot press forming. The
thickness of the dried finishing coat is in the optimum range
between 0.1 and 0.3 .mu.m.
[0032] However, in the case of flat steel products coated in this
manner, not only a reduction of the required heating times is
achieved by the invention, but also a significant reduction in the
build-up of deposits and improved deformation behaviour in the
forming die.
[0033] The substances present in a finishing coat provided as per
the invention are temperature resistant and at temperatures of up
to 1200.degree. C. have only very slight or even non-existent
reactivity, but are characterised by high absorption capacity in
the thermal radiation wavelength range of interest here.
Specifically considered are inorganic salts formed from base metals
(in the form of oxides, sulphides, sulphates, fluorides and
phosphates) or salt-like substances such as ionic carbides,
carbonates or nitrides. The typical particle size of said
substances contributes to the desired increase in surface roughness
of the coating which increases the absorption capacity.
[0034] The base metals from which the oxide, nitride, sulphate,
sulphide, carbide, carbonate, fluoride, hydrate, hydroxide or
phosphate compounds of the finishing coat applied to a flat steel
product covered optionally with an anti-corrosion coating as per
the invention are formed, are according to the understanding of the
invention all metals which react under normal conditions with the
oxygen in the atmosphere. Moreover, the base metals here also
include alkaline earth metals, alkaline metals and semi-metals,
also called metalloids, as well as transition metals. Examples of
metals from which the compounds present in the finishing coat as
per the invention are formed are Na, K, Mg, Ca, B, Al, Si, Sn, Ti,
Cr, Mn, Zn.
[0035] The base of a flat steel product provided as per the
invention consists, for example, of steels alloyed with Mn, as have
already been provided in various embodiments in the prior art for
hot press forming and explained, as mentioned at the start using
the example of the known steel, 22MnB5. Such steels typically have
Mn content of between 0.1 and 3% wt. and content of B in order to
achieve the required level of strength. Flat steel products, which
are produced from such steels, are generally extremely
corrosion-sensitive and are therefore coated with a Zn or Al-based
protective metal coating which is designed to protect it against
corrosion. Even in the hot press forming of such flat steel
products where an anti-corrosion coating is applied to the steel
base of the flat steel product on which the finishing coat lies,
the finishing coat as per the invention proves especially
effective.
[0036] It was also possible to demonstrate that during hot press
forming of flat steel products, which are provided with a Zn or
Al-based protective metal coating and in a manner as per the
invention with a finishing coat on the top thereof, approx. 80%
fewer cracks appeared than in the case of comparative products,
which although they had the same protective coating, had been hot
press formed without a finishing coat as per the invention.
[0037] The compounds in a finishing coat provided as per the
invention include, for example, alkaline earth metal compounds such
as Mg.sub.3Si.sub.4O.sub.10(OH).sub.2, MgO or CaCO.sub.3, alkaline
metal compounds, K.sub.2CO.sub.3 or Na.sub.2Ca.sub.3, NaOH,
Na.sub.2CO.sub.3 semi-metal compounds, such as BN, Al.sub.2O.sub.3
(cubic), SiO.sub.2, SnS, SnS2 and transition metal compounds, such
as TiO.sub.2, Cr.sub.2O.sub.3, Fe.sub.2O.sub.3, Mn.sub.2O.sub.3,
ZnS.
[0038] A finishing coat as per the invention leads to a significant
improvement in heat absorption capacity and to a significant
reduction of friction during the forming of a flat steel product as
per the invention in the respective forming die. This is the case
in particular if the metal compounds provided in the finishing coat
as per the invention are applied in particle form, wherein this
implies the possibility that together the particles form a thick,
compact finishing coat. If the average diameter of the particles of
the at least one compound present in the finishing coat as per the
invention is larger than the average thickness of the finishing
coat, a roughness that is particularly advantageous for the effects
desired here is obtained. Good results are achieved in the forming
of a flat steel product as per the invention if the average
diameter of the particles of the compound present in the finishing
coat as per the invention is between 0.01 and 5 .mu.m, more
particularly between 0.01 and 3 .mu.m. Optimum results are achieved
if the average diameter of the particles of the compound is between
0.01 and 0.3 .mu.m.
[0039] Alternatively, the finishing coat as per the invention can
also be applied as a solution, from which metallic salts develop
whilst said coat is drying, which form a crystalline coating on the
flat steel product.
[0040] The specific advantage of the composition of the finishing
coat indicated as per the invention consists in this respect in
that its effect is assured even at the high temperatures at which
the heat treatment or hot forming of a flat steel product coated as
per the invention takes place. The finishing coat adheres so firmly
to the respective steel substrate without requiring additional
measures resulting in minimal abrasion and slight deposit build-up
both in the furnace used to heat the blanks and in the forming die
used for optional hot forming.
[0041] The latter also proves advantageous in particular if a flat
steel product coated as per the invention is heated to the
deformation temperature in a continuous furnace and is conveyed in
the process on rotating furnace rollers. The finishing coat
composed as per the invention of a flat steel product as per the
invention remains attached to the furnace rollers at most in small
quantities and consequently the wear and tear of the rollers and
the cost of their maintenance are kept to a minimum.
[0042] Practical tests have shown in this context that the
finishing coat composed as per the invention also maintains all its
required properties over a sufficiently long period, even after
direct temperature exposure in a temperature range typical for hot
press forming between 300 and 1200.degree. C., more particularly
between 700 and 1000.degree. C., and preferably between 800 and
950.degree. C., and in particular also remains stable at high
temperatures until the forming of the respective flat steel product
coated as per the invention finished.
[0043] The finishing coat as per the invention also has no adverse
influence on the desired oxide layer formation of a protective
metal coating optionally present on the flat steel product during
the heating phase for hot working. The presence of the finishing
coat as per the invention also presents no disadvantages for
further processing. In particular, the finishing coat as per the
invention does not hamper suitability for welding, bonding,
painting or the application of other coatings. Accordingly, there
is no need to remove the finishing coat as per the invention
between hot press forming and the steps taken subsequently in
respect of the component obtained.
[0044] The finishing coat applied as per the invention bridges the
considerable basic roughness which develops on the respective
surface of the flat steel product during heating for subsequent hot
press working. Practical tests have shown in this respect that the
finishing coat applied as per the invention should be as thin as
possible, more particularly between 0.01 and 5 .mu.m thick. Tests
revealed that a relatively thin coating of between just 0.1 and 1
.mu.m, more particularly less than 0.5 .mu.m, ideally between 0.1
and 0.3 .mu.m, is sufficient to bring about a complete heat
transfer from the finishing coat to the base material of the flat
steel product. It was demonstrated in the process that the increase
in the heating rate that was achievable and the associated
reduction in heating time for a given finishing coat material is
largely independent of the respective coating thickness. A
particularly thin finishing coat has the advantage here, however,
that the chemical/mechanical influence of the finishing coat on the
base material and the optional anti-corrosion coating between the
finishing coat and the base material is minimal.
[0045] In particular, the surface weight at which the finishing
coat as per the invention is applied to the flat steel product
should be between 0.01 and 15 g/m.sup.2 on the finished product,
more particularly up to 5 g/m.sup.2, wherein the increase in heat
absorption occurs at surface weights of less than 1 g/m.sup.2.
Optimum effects of the finishing coat as per the invention are to
be expected here if the surface weight is between 0.02 and 1
g/m.sup.2. Firstly, with minimal surface coverage of this kind, the
friction-reducing effect of the finishing coat is also useful in
the forming die. Secondly, with a thin finishing coat as per the
invention, negative influences on the results of the steps taken
during further processing of a flat steel product as per the
invention can be safely ruled out.
[0046] Consequently, the invention provides a flat steel product
that can not just be heated to a target temperature rapidly and in
an energy-saving manner, but is also characterised by optimum
deformability.
[0047] Carbon black or graphite contents of up to 15% wt. in the
finishing coat can further increase the heat absorption capacity of
a flat steel product coated as per the invention without adversely
affecting the other positive characteristics of the finishing coat
and the optional anti-corrosion coating.
[0048] From a production perspective, the key advantage of a
finishing coat as per the invention consists in that it can be
easily applied to the flat steel product, more particularly to the
protective metal coating on the steel base present on the flat
steel product, in a continuous production process.
[0049] The method as per the invention for producing a flat steel
product procured in accordance with any of the preceding claims
thus includes the following steps:
[0050] a) provision of a flat steel product,
[0051] b) application of a finishing coat to the flat steel product
by [0052] b.1) applying a coating liquid to the flat steel product,
wherein between 5 and 50% (as % wt.) of the coating liquid consists
of an oxide-, nitride-, sulphate-, sulphide-, carbide-, carbonate-,
fluoride-, hydrate-, hydroxide- or phosphate-compound of a base
metal and between 1 and 20% of a binder and the rest water, wherein
the coating fluid can also contain up to 15% carbon black or
graphite, [0053] b.2) setting the thickness of the finishing coat
to a thickness of between 0.01 and 5 .mu.m and
[0054] c) drying of the finishing coat at a drying temperature, for
example between 100 and 300.degree. C.
[0055] There is a version of the invention that is particularly
important in practice that leads to a significant reduction in
processing times and enables optimum exploitation of the available
resources where the application of the finishing coat takes place
immediately prior to the heating process, in which the flat steel
product is heated to the respective temperature required for heat
treatment.
[0056] The steps provided for the coating of a flat steel product
as per the invention can be taken, for example, in a hot dip
coating line, electrolytic coating line or coil coating line after
the process steps required for application of a protective metal
coating in a coating device, which is in a line with the work
stations required for application of the protective metal coating
and in which the flat steel product exiting the last of said work
stations enters a continuous, uninterrupted course of movement.
Naturally the finishing coat can also be applied in a separate,
continuous line, which is an integral part of a production line,
through which the respective flat steel product passes
continuously.
[0057] Depending on the quantity of other components of the coating
liquid applied to the flat steel product, more particularly the
optional protective coating on the flat steel product, a finishing
coat is provided with an approach as per the invention, which
consists of between 20 and 98% wt. of the respective base metal
compounds (oxide, nitride, sulphate, sulphide, carbide, carbonate,
fluoride, hydrate, hydroxide or phosphate) and the rest consists of
the respective other components.
[0058] Whilst the respective base metal compounds contained in a
coating liquid applied as per the invention make an essential
contribution to minimising the friction in the die during hot press
forming, the binders also present in the coating liquid ensure a
sufficiently firm bonding of the finishing coat formed by the
coating liquid to the protective metal coating on the flat steel
product. Contents of between 2 and 10% wt. of a suitable binder in
the coating liquid have proven adequate.
[0059] The respective binder can be an organic or an inorganic
binder, such as sodium silicate or cellulose, for example. The
respective binder fixes the coating applied as per the invention to
the protective coating and prevents the coating applied as per the
invention from flaking prior to sheet forming.
[0060] If a natural or artificially produced organic binder is
used, said binder should be water-soluble and easily dispersible so
that water can be easily used as a solvent for the coating liquid.
Examples of organic binders are: cellulose ester, cellulose
nitrate, cellulose acetate butyrate, styrene acrylic acetate,
polyvinyl acetate, polyacrylate, silicon resin and polyester resin.
The organic binder should also be selected such that it burns
residue-free as far as possible during application or drying of the
coating liquid or during heating for the purpose of hot stamping.
This has the advantage that weldability is not adversely affected
by the binder. The organic binder should also not contain any
halogens such as fluoride, chloride or bromide, which, during the
combustion process (hot stamping), lead to the release of compounds
that are harmful to health, explosive or corrosive.
[0061] Particularly good coating results are also achieved if an
inorganic binder is used. Such inorganic binders remain on the flat
steel product after heating and the press hardening step, and
consequently they are also generally identifiable in the finis coat
of the finished product. Typical examples of inorganic binders of
the type under discussion are silicates, potassium silicate
(K.sub.2O--SiC.sub.2), sodium silicate (Na.sub.2O--SiO.sub.2),
silicon dioxide (H.sub.2SiO.sub.3) or SiO.sub.2.
[0062] Water acts as a liquid carrier, i.e. solvent, which contains
the other components of the coating liquid applied as per the
invention, which evaporates easily while the finishing coat is
drying and can be drawn off as steam and disposed of in an
environmentally-friendly manner without greater effort. The water
content of a coating liquid applied as per the invention is
typically between 15 and 80% wt., more particularly generally more
than 50% wt.
[0063] In addition to its main components `base metal compounds
(oxide, nitride, sulphide, sulphate, carbide, hydrate or
phosphate)` and `hinder`, the coating liquid applied to the flat
steel product as per the invention, more particularly to the
optional metal anti-corrosion coating, contains components, which
improve, for example, its wetting properties or the distribution of
the compound it contains as per the invention.
[0064] Practical tests have shown that optimum coating results are
achieved if the coating liquid contains between 5 and 35% . of
oxide, nitride, sulphate, sulphide, carbide, carbonate, fluoride,
hydrate, hydroxide or phosphate compound components. Finishing
coats are produced with such contents of the relevant compound
components of the coating liquid, which consist of up to 94% wt. of
a base metal compound (oxide, nitride, sulphide, sulphate, carbide,
carbonate, fluoride, hydrate, hydroxide or phosphate).
[0065] With regard to minimising processing times and the coating
result, a positive effect is achieved if the temperature of the
coating liquid is between 20 and 90.degree. C., more particularly
between 40 and 70.degree. C. upon application, wherein the
finishing coat can be applied particularly effectively if the
coating liquid is at a temperature of at least 60.degree. C. It
serves the same purpose if the temperature of the flat steel
product is between 5 and 150.degree. C., more particularly between
40 and 120.degree. C., when the coating liquid is applied. Here, if
the flat steel product is to be coated with an anti-corrosion
coating applied to its base, the desired temperature of the flat
steel product for the `application of the finishing coat` step can
be taken in the event of suitably close succession from the
previous step `application of the protective metal coating`. An
additional heating appliance is not required in this case.
[0066] Alternatively, it is also possible to apply the finishing
coat as per the invention during a preparatory step prior to heat
treatment, more particularly prior to hot press working. The
heating required for heat treatment can be used here to dry the
finishing coat. This proves advantageous particularly if the heat
treatment involves heating for hot press working.
[0067] In the event that the flat steel product is provided for hot
press working and is coated with an anti-corrosion coating, it may
be advisable to transport the flat steel product after coating with
the anti-corrosion coating firstly for further processing and to
apply the finishing coat there shortly before the flat steel
product enters the hot-forming furnace in which the flat steel
product is heated to the temperature required for hot working.
[0068] The coating liquid can be applied by dipping, spraying or
other conventional application methods.
[0069] Coating thickness can also be adjusted to the respective
specified coating thickness of between 0.1 and 0.3 .mu.m in a
conventional manner by squeeze rolling, blowing off excess
quantities of liquid, varying the solid content of the coating
liquid or changing the temperature of the coating liquid.
[0070] The finishing coat applied as per the invention is typically
dried at temperatures of between 100 and 300.degree. C., wherein
the typical drying time is between 5 and 180 seconds. Both the
drying temperature and the drying times are measured here such that
the drying process can be completed without difficulty in
conventional drying appliances through which the respective flat
steel product is guided in a continuous cycle.
[0071] A steel strip coated in a manner as per the invention can
then be wound into coils and transported for further processing.
The other process steps required to create a component from the
flat steel product as per the invention can be carried out by the
processor in a separate place and at another time.
[0072] Due to the reduced friction, which occurs, during working,
upon contact of the flat steel products provided with a finishing
coat in the manner as per the invention with the forming die,
crack-free components can be produced from flat steel products
coated as per the invention by hot press forming, where the forming
of said components requires high degrees of stretching or complex
forming. To produce a hot press formed component, a blank can be
cut from a flat steel product provided with a finishing coat of the
type as per the invention in a manner known per se, for example by
laser cutting or with the help of another conventional cutting
device, which is then heated to a deformation temperature above
700.degree. C. and formed into the component in a forming die. In
practice, typical deformation temperatures are between 700 and
950.degree. C. with heating times of between 3 and 15 minutes.
[0073] The presence of the finishing coat as per the invention on
the flat steel product to be formed allows rapid heating to the
respective desired temperature that saves time and energy.
[0074] Optimum results are achieved for example, when processing a
flat steel product, the base of which is made of steel containing
between 0.3 and 3% wt. of Mn, if the temperature of the blank or
component is no higher than 920.degree. C., more particularly
between 830 and 905.degree. C. This applies particularly if the
steel component is hot formed after being heated to the temperature
of the blank or component such that the heated blank (`direct`
method) or the heated steel component (`indirect method`) is placed
into the respective next forming die accepting that there will he a
certain loss of temperature. The ultimate hot forming can then be
carried out in a particularly reliable manner if the temperature of
the blank or component respectively is between 850 and 880.degree.
C. on leaving the respectively used heating furnace. Depending on
transport routes, transport times and environmental conditions, the
temperature of the component in the die is in practice usually
between 100 and 150.degree. C. lower than the temperature on
leaving the heating furnace.
[0075] Components obtained by forming at high temperatures of this
kind can be cooled rapidly in a manner known per se proceeding from
the respective deformation temperature in order to create a
martensitic structure in the component and thus achieve optimum
resilience.
[0076] The reduced friction in the forming die as a result of the
finishing coat applied as per the invention makes a flat steel
product as per the invention suitable, on account of the
insensitivity of the flat steel product coated in a manner as per
the invention to cracks in the steel substrate and abrasion, for
single-stage hot press forming in particular, in which hot forming
and the cooling of the steel component are carried out in the
respective forming die using the heat from the previous heating
process.
[0077] The properties of a flat steel product coated as per the
invention naturally have an equally positive effect in multi-stage
hot press hardening. In this variation of the method, firstly the
blank is created and the steel component is then formed from this
blank without intervening heat treatment. The steel component is
then typically formed in a cold forming step in which one or a
plurality of cold forming operations is performed. The degree of
cold forming can be so great here that the steel component obtained
is essentially formed completely finished. However, it is also
conceivable to perform the initial forming as preforming and to
complete the forming of the steel component in a forming die after
heating. Said finished forming can be combined with the hardening
step by performing the hardening as form hardening in a suitable
forming die. Here the steel component is placed in a die
reproducing its finished end form and cooled sufficiently rapidly
in order to form the desired martensitic or tempered structure.
Form hardening thus enables particularly good form retention of the
steel component.
[0078] Regardless of which of the two versions of the method as per
the invention is used, neither the forming nor the cooling required
to form a martensitic or tempered structure have to be performed in
a particular way that is different from the prior art. In actual
fact, known methods and existing devices can be used for this
purpose.
[0079] The components obtained as per the invention can be
subsequently subjected to conventional joining and coating
processes.
[0080] In connection with flat steel products, which are provided
with an anti-corrosion coating, the invention is based on the
following fundamental considerations:
[0081] The heating behaviour of anti-corrosion coatings, more
particularly AS type coatings, is significantly poorer in the
standard temperature range for hot forming of between 850 and
950.degree. C. than that of non-coated, hot press form hardened
sheet steel, which is typically a sheet steel made from a boracic
Mn steel. For electromagnetic waves in the region of 1 .mu.m, the
absorption factor is a maximum of 0.3. Also in the wavelength range
of approx. 2 to 3 .mu.m applicable to temperatures in the region of
900.degree. C., the absorption behaviour of AS is still
significantly below that of uncoated steel.
[0082] The maximum possible absorption behaviour at an absorption
factor of 1 is described by the `black body` model. However,
substances, which are able to absorb a large amount of energy
particularly in the infrared wavelength range of between 1 and 3
.mu.m, do not necessarily have to be black.
[0083] It should be noted here that if the flat steel product
includes an Al or Zn-based anti-corrosion coating and is not coated
with a finishing coat in a manner as per the invention, the
anti-corrosion coating reflects light and thermal radiation
generally by more than 90%, i.e. has a degree of absorption of less
than 10%. Since a degree of absorption of over 50% is achieved by
applying a finishing coat as per the invention, significantly more
heat is absorbed by the flat steel product thus also significantly
reducing the time and energy required for heating.
[0084] There is also a positive influence on the minimisation of
the time and energy required in this context in that some of the
metal compounds provided as per the invention for the finishing
coat change colour under the influence of heat and thus demonstrate
even better absorption behaviour. It proves particularly beneficial
here that compounds provided as per the invention for the finishing
coat are particularly suited to rapid heating since their degree of
absorption improves significantly at high energy densities and in
the event of short-wave thermal radiation.
[0085] The absorption factor .epsilon. (<1) is determined by the
chemical composition of the substance and in the form where the
molecules convert as much radiation energy as possible into
vibrations (phonons) in the desired wavelength range or where
energy is absorbed through displacement of the outer electrons
(more visible IR range>600.degree. C.)
[0086] The transferable amount of heat is also determined by the
surface morphology and thus by the roughness of the respective
substrate. The following formula shows that increased roughness
results in a larger surface and consequently better energy
absorption:
Q=.sigma. .epsilon. A (Ts.sup.4-T.infin..sup.4)
[0087] Where Q: thermal flow through radiation
[0088] .sigma.: Stefan-Boltzman constant=5.67*10.sup.-8 W/m.sup.2
K
[0089] .epsilon.: emission ratio, 0.ltoreq..epsilon..ltoreq.1
[0090] A: surface of the irradiated body
[0091] Ts: surface temperature in K
[0092] T.infin.: ambient temperature in K
[0093] Taking account of the absorption factor, the energy absorbed
therefore increases to the power of four in relation to the
increase in temperature. If a thin coating is considered, which is
much thinner than the wavelength of 2 to 3 .mu.m, the absorbed
energy still increases here to the power of three in relation to
the increase in temperature. The flat steel product heats up due to
stationary heat conduction from the finishing coat to the
underlying substrate of the flat steel product, in particular,
however due to the highly reduced reflection of thermal
radiation.
[0094] If the thickness of the finishing coat is less than the
wavelength, the non-reflected part of the radiation directly heats
the substrate underneath the finishing coat. Thus the effect of
better heatability does not depend primarily on the thickness of
the coating, but above all on the absorption characteristics of the
finishing coat. Finishing coats with a thickness of just 0.1 .mu.m
offer measurable advantages here.
[0095] The degree of absorption of various substances depends on
the band structure of the material, in which the photons of
specific energy (IR spectrum) excite molecules which have quantum
transitions with exactly this energy differential in their
molecular vibrations. Most metallic salts are also characterised in
addition to their high temperature stability by the fact that when
applied as pigment with a small particle size, they have a high
degree of absorption for light in the visible and near infrared
(IR-A and IR-B) wavelength range.
[0096] Table 2 shows the measured absorption coefficients in the
case of NIR radiation for some materials from which the finishing
coat provided as per the invention can be formed.
[0097] Optimum absorption results can be achieved using a finishing
coat which is procured and produced as follows:
[0098] a) Coating liquid applied to produce the finishing coat:
[0099] Solid content of inorganic components resistant to
temperatures of up to 900.degree. C.: 5 to 45% wt., more
particularly 20 to 35% wt., [0100] Content of a binder resistant to
temperatures of up to 900.degree. C., more particularly a
silicate-based binder: 1 to 15% wt., more particularly 7 to 12%
wt.; [0101] Solvent content (water): 50 to 94% wt., more
particularly 30 to 75%; [0102] Solid composition: 0.05 to 1 .mu.m
particle size, a particle size in the dry coating thickness range
produces optimum coating roughness.
[0103] b) Thickness of the finishing coat obtained [0104] 0.05 to 1
.mu.m, more particularly 0.1 to 0.3 .mu.m, as no specific
absorption characteristics can be adjusted below 0.05 .mu.m,
however at coating thickness above 0.5 .mu.m the direct transition
of IR radiation into the protective metal coating is reduced.
[0105] c) Drying of the finishing coat applied as a wet coat [0106]
Temperature range: 120 to 1000.degree. C. The large temperature
range is possible since no cross-linking and few
temperature-related reactions of the coating take place. Drying
that occurs as rapidly as possible increases roughness and thus the
capacity to absorb IR waves. The coating can therefore also be
applied immediately prior to the hot forming process.
[0107] d) Roughness of the finishing coat obtained: Ra=1.0 to 2.0
.mu.m
[0108] The invention is explained in greater detail below on the
basis of test results:
Test 1:
[0109] Steel blanks made of 28MnB5 steel coated using the hot dip
method with a 20 .mu.m thick, AlSi anti-corrosion coating, were
sprayed with a coating liquid directly in terms of time and place
after the production of the anti-corrosion coating to produce a
finishing coat as per the invention. In addition to water, the
coating liquid contained 25% wt. of a sulphide present as zinc
sulphide producing the desired surface characteristics and 7% wt.
of silicate as a binder to attach the finishing coat to the
anti-corrosion coating. The thickness of the wet coat was set such
that a finishing coat was obtained after drying which was completed
during passage within 2 seconds by means of an NIR drier, where, at
a surface weight of the finishing coat of 1 g/m.sup.2, said
finishing coat was 0.2 .mu.m thick on each side.
[0110] The blanks coated in this manner reached the desired
temperature of 890.degree. C. within 190 seconds in the heating
furnace through which they were conveyed during passage on ceramic
rollers. The heating time was therefore 50 seconds shorter than the
time taken to heat a blank coated only with the AlSi anti-corrosion
coating and without the finishing coat as per the invention. It was
also demonstrated that fewer deposits were left on the ceramic
rollers in the heating furnace. A component was formed from the
blanks heated in this manner and provided with a finishing coat as
per the invention by hot press forming and subsequent hardening.
Said component had a martensitic structure and could be welded and
painted without the need for further cleaning or irradiation.
Test 2
[0111] Steel blanks made of 22MnB5 steel coated using the hot dip
method with a 25 um thick, AlSi anti-corrosion coating, were coated
with a coating directly in terms of time and place after the
in-line production of the protective coating by means of a
conventional coil coater to produce a finishing coat as per the
invention. In addition to water, the coating liquid contained 5%
wt. of a base metal fluoride in the form of hexafluorotitanic acid
producing the desired characteristics of the finishing coat and 7%
wt. of siloxane as a binder to attach the finishing coat to the
protective metal coating.
[0112] The wet coat applied in this manner was then dried in an NIR
drier and a convective holding line. The thickness of the wet coat
was set here to produce a dry finishing coat with a thickness of
0.02 .mu.m and a surface weight of 40 mg/m.sup.2 per side. Drying
took place during passage in a time of 5 seconds.
[0113] The blanks coated in this manner were heated in the heating
furnace to a temperature of 900.degree. C. within 180 seconds. This
heating time was 50 seconds shorter than the time taken to heat a
blank coated only with the AlSi anti-corrosion coating and without
the finishing coat as per the invention. Fewer deposits were also
apparent on the rollers of the ceramic furnace in which the blanks
were heated. Moreover, it transpired that a component with a
martensitic structure could be formed easily from the blanks coated
with the finishing coat as per the invention by hot press forming
and subsequent hardening. Said component could be welded and
painted without the need for further cleaning or irradiation.
Test 3
[0114] Steel blanks made of 22MnB5 steel coated using the hot dip
method with a 15 .mu.m thick, AlSi anti-corrosion coating, were
coated with a coating liquid directly in terms of time and place
after the in-line production of the protective coating by means of
a reverse roll coating method to produce a finishing coat as per
the invention. The coating liquid contained water and, as per the
invention, 10% wt. of carbon black and graphite as well as the
hydroxide compound producing the desired surface characteristics,
10% wt. of sodium hydroxide and 5% wt. of an alkaline silicate
binder.
[0115] The finishing coat was applied as a wet coat with a surface
density of 250 mg/m.sup.2, which, at a density of 2.2 g/cm.sup.3,
corresponds to a finishing coat thickness of approx. 0.1 .mu.m in a
wet state. The finishing coat applied in this manner was then dried
in a convective drier at 250.degree. C. as a result of which the
thickness of the finishing coat was reduced to 0.01 .mu.m in the
fully dried state. Drying took place during passage in a time of 30
seconds. During the course of drying, the colour of the finishing
coat changed to a darker shade which resulted in a further increase
in the heat absorption capacity of the finishing coat.
[0116] The blanks coated with the finishing coat were heated in the
heating furnace to 900.degree. C. in 170 seconds thus requiring
approx. 70 seconds less heating time than the blanks provided with
an A1Si coating, which had not been coated with a finishing coat in
a manner as per the invention. This test also confirmed that the
finishing coat meant that significantly fewer deposits were left on
the rollers on which the blanks were conveyed through the heating
furnace. Deposits were also not observed in the die in the case of
the blanks coated as per the invention, whereas in the case of
conventional blanks not provided with the finishing coat,
corresponding deposits and deposit build-up were apparent. The
component obtained following hot press forming had a full
martensitic structure and a coating alloyed in the expected manner.
The finishing coat remaining on the surface does not lead to a
deterioration of suitability for cathode dip painting. The
component obtained also had excellent spot welding properties.
Test 4
[0117] Steel blanks made of 22MnB5 steel coated using the hot dip
method with a 20 .mu.m thick, AlSi anti-corrosion coating, were
spray coated with a coating liquid to produce a finishing coat as
per the invention in continuous passage following the in-line
production of the protective coating. The coating liquid contained
water and 15% wt. of an earth metal carbon in the form of calcium
carbonate (CaCO.sub.3) and a further 8% wt. of silicic acid as a
binder to attach the finishing coat to the protective metal
coating.
[0118] The finishing coat applied as a wet coat was then dried in
an NIR drier with adjacent convective holding line. During
application, the thickness of the wet coat was set such that a
finishing coat with a thickness of 0.18 .mu.m and a surface density
of 500 mg/m.sup.2per side was produced after drying. Drying took
place during passage in a time of 10 seconds.
[0119] The blanks coated in this manner were heated in the heating
furnace to 900.degree. C. in 195 seconds. The time required for
said heating was approx. 45 seconds shorter than the time required
to heat blanks conventionally coated with an AlSi protective
coating, however not with a finishing coat as per the
invention.
[0120] In the course of heating the blanks as per the invention no
deposits appeared on the rollers of the continuous furnace used for
heating purposes. Fewer deposits were also observed in the die. The
component obtained from the blanks coated as per the invention
following hot press form hardening had a full martensitic structure
and the expected alloying in the coating. The remains of the
finishing coat on the surface did not lead to any deterioration of
suitability for cathode dip painting and the required scot welding
properties were also achieved.
Test 5
[0121] Steel blanks made of 34MnB5 steel coated using the hot dip
method with a 15 .mu.m chick, AlSi anti-corrosion coating, were
provided with a finishing coat by dipping in a coating liquid spray
in line to produce a finishing coat on the protective coating
directly in terms of time following the production of the
protective coating. In addition to water, the coating liquid
contains, in a manner as per the invention, 22% wt. of a base metal
sulphide in the form of tin (II) sulphide (SnS) and a further 5%
wt. of siloxane as a binder to attach the finishing coat to the
protective metal coating.
[0122] The finishing coat applied in this manner as a wet coat with
a surface density of 4 g/m.sup.2 per side was dried in an NIR
drier. Drying resulted in a dry coat with a surface density of 1.5
g/m.sup.2 per side. Drying took place during passage in a time of 6
seconds.
[0123] The blanks provided with the finishing coat in this manner
were heated in the heating furnace to a temperature of 890.degree.
C. in 190 seconds thus requiring approx. 50 seconds less than
blanks coated in a conventional manner with an AlSi ant corrosion
coating, but not provided with a finishing coat as per the
invention. No build-up of coating material was identified on parts
of the furnace or the forming die, either during heating in the
continuous furnace or during subsequent hot press form hardening.
The hot press formed and hardened components obtained from the
blanks coated as per the invention had a martensitic structure in
their basic material in the same way as the components obtained in
the other tests and could be welded and painted without the need
for further cleaning or irradiation.
Test 6
[0124] Steel blanks made of 22MnB5 steel coated using the hot dip
method with a 25 .mu.m thick, AlSi anti-corrosion coating, were
spray coated in line with a coating liquid immediately after
coating with the protective coating to produce a finishing coat.
The coating fluid contained water and, as per the invention, 12%
wt. of an alkaline metal carbon in the form of potassium carbonate
(K.sub.2CO.sub.3). The coating liquid also contained a further 6%
wt. of Na.sub.2O--Si.sub.2 as a binder for attaching the finishing
coat to the protective metal coating.
[0125] The wet coat applied in this manner was then dried in a NIR
drier with a convective holding line. The thickness of the wet coat
was set in the process to produce a finishing coat with a surface
density of 250 mg/m.sup.2 on each side in the dried state, which at
a density of 2.5 g/cm.sup.3 corresponds to a coating thickness of
0.1 to 0.15 .mu.m on each side. Drying took place during passage in
a time of 10 seconds.
[0126] The blanks coated in this manner were heated in a heating
furnace to a temperature of 900.degree. C. in 190 seconds thus
requiring approx. 50 seconds less than blanks coated with AlSi
without an additional coating as per the invention. No deposits
were apparent on the ceramic furnace rollers of the heating
furnace. Unlike in the processing of the blanks provided only with
an AlSi coating and not equipped with a finishing coat as per the
invention, only very few deposits were apparent in the die used for
hot press form hardening.
[0127] Consequently, an exploitable speeding up of the heating
phase in heating systems emitting IR radiation occurs in all
finishing coats applied as per the invention at coating thicknesses
of between 0.01 and 0.2 .mu.m. This has the following
advantages:
[0128] 1. The finishing coat does not need to be removed at any
point during processing.
[0129] 2. Due to the short drying times, in-line application, i.e.
continuously integrated into the heat treatment process, is
possible.
[0130] 3. The coating costs are low due to the small amount of
coating liquid required.
[0131] 4. The weldability of the components formed from the flat
steel products coated as per the invention is not influenced by the
finishing coat.
[0132] 5. Standard cleaning processes are not contaminated by
components of the finishing coat.
[0133] 6. The ability to paint a flat steel product coated as per
the invention or a component formed therefrom is comparable with
the ability to paint products, which are formed from flat steel
products that have no finishing coat as per the invention.
[0134] 7. In the case of coatings containing iron or flat steel
products provided with a non-metallic coating, the finishing coat
as per the invention produces secondary corrosion protection. This
applies particularly if the finishing coat is formed from oxidic
compounds.
[0135] 8. In the event that the flat steel product is coated with a
metal anti-corrosion coating, the finishing coat applied as per the
invention minimises the occurrence of abrasion and deposit
build-up.
TABLE-US-00001 TABLE 1 Effective content of other Reduction in
Coating elements in the heating time Symbol base coating (5% wt.)
Coating method (%) AS Al Si: 8 to 12 Hot dip coated 20 to 30 Z Zn
Al: 0.1 to 0.2 Hot dip coated 25 to 35 ZF Zn Fe: 8 to 15 Hot dip
coated, 0 to 10 diffusion annealed ZN Zn Ni: 8 to 12 Galvanically
10 to 20 coated ZA Zn Al: 5 Hot dip coated 25 to 35 AZ Al Zn: 43.4
Hot dip coated 25 to 35 Si: 1.6 ZM Zn Mg: 0.5 to 5 Hot dip coated
10 to 20 Al: 0.2 to 3
TABLE-US-00002 TABLE 2 Absorption factor Description Formula 0.2 to
0.3 Aluminium oxide Al.sub.2O.sub.3 0.2 to 0.3 Titanium oxide
TiO.sub.2 0.3 to 0.4 Zinc oxide ZnO 0.4 to 0.5 Magnesium oxide MgO
0.4 to 0.6 Silicium oxide SiO.sub.2 0.5 to 0.7 Soda (anhydrous)
Na.sub.2CO.sub.3 0.6 to 0.7 Titanium fluoride TiF.sub.3 0.6 to 0.7
Potash K2CO3 0.7 to 0.8 Chalk CaCO3 0.7 to 0.8 Gypsum
Ca[SO4].cndot.2H2O 0.85 Titanium spinel TiMg2O4
* * * * *