CN101426612A - 由滚轧的涂镀板制造具有良好机械特性的焊接部件的方法 - Google Patents
由滚轧的涂镀板制造具有良好机械特性的焊接部件的方法 Download PDFInfo
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- CN101426612A CN101426612A CNA2007800138541A CN200780013854A CN101426612A CN 101426612 A CN101426612 A CN 101426612A CN A2007800138541 A CNA2007800138541 A CN A2007800138541A CN 200780013854 A CN200780013854 A CN 200780013854A CN 101426612 A CN101426612 A CN 101426612A
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- steel
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
一种由钢制的基体(1)和预镀层(2)构成的板材,所述预镀层由其上置有金属合金层(4)的金属间化合物合金层(3)构成,所述金属间化合物合金层与所述基体相接触,其特征在于,在所述板材的至少一个预镀表面上,位于所述板材的周边的区域(6)被除去所述金属合金层。
Description
技术领域
[01]本发明涉及涂镀钢板或坯件的制造,其用于被焊接并且然后进行热处理以获得具有优良的机械特性和优良的耐腐蚀性的部件。
背景技术
[02]某些应用中需要结合有高机械强度、高冲击抗力和优良的耐腐蚀性的钢部件。在汽车工业中特别希望存在该类结合,所述汽车工业要求车辆自重明显降低并且在碰撞事故中能极好地吸引能量。这尤其可以通过使用具有马氏体或贝氏体-马氏体微观结构的机械特性良好的钢来实现:例如,机动车辆的抗侵入部件、结构部件或***件如保险杆、门加强件、B柱加强件或车顶加强件需要上述性质。
[03]专利EP 0971044公开了一种以涂镀有铝或铝合金的热轧或冷轧钢板为原材料的制造方法。在成型生产出一部件之后,并且在高于Ac1的温度进行热处理之前,加热镀层以通过在钢和铝镀层之间的相互扩散来形成一表面合金。该合金在炉中的热处理期间防止金属的脱碳和氧化。因此,其消除了对包含特殊气氛的炉的需要。该合金的存在还消除了在被加工部件上进行的某些表面操作如喷砂处理,所述操作对于没有镀层的板材来说是必需的。然后,在适于赋予可超过1500MPa的抗张强度的情况下冷却部件。
[04]为了降低车辆自重,部件已经发展成由连续对接焊在一起的不同组分或不同厚度的钢坯件所组成。这些焊接部件被称为“对焊坯件”。激光束焊接是组装这类坯件的一种优选方法,利用了处理过程的灵活性、质量和生产率。在所述焊接坯件已经被冷压之后,获得了具有在部件自身内部变化的机械强度、可冲压性能、冲击吸收性能的部件。因此,在所有部件上不需要增加不必要的或昂贵的代价而能在适当场所提供所需要的性能。
[05]专利EP 0971044中描述的制造方法可以下述方式应用于对焊坯件:从可能具有不同组分或厚度、并具有金属预镀层的钢板开始,通过焊接工艺获得对焊坯件。然后,所述焊接坯件经受热处理以形成表面合金,并且然后被热压和淬火。这生产出具有厚度和内在机械特性的淬火部件,所述厚度和内在机械特性变化并完美地响应局部负荷的要求。
[06]然而,该制造方法遇到了相当大的困难:当焊接涂镀的钢坯件时,最初的预镀表面的一部分被传送到由焊接操作形成的熔化区域中。特别是这些外来的金属成分通过液态金属中的强对流而积聚。特别是,这些成分在枝晶空间中分开,具有最富有分解成分的液体部分位于所述枝晶空间中。如果随后使焊接坯件奥氏体化以便进行淬火,则所述富有区域通过与基体的铁或其他成分的相互扩散而合金化在一起并形成金属间化合区域。在随后的机械荷载中,在静力或动力学条件下,所述金属间化合区域趋于成为破裂的开始处。因此,在加热处理后,焊接接头的总变形由于来自焊接和随后的合金化及奥氏体化的所述金属间化合区域的存在而显著变小。
[07]因此,希望消除形成这些金属间化合区域的来源,即在对接焊期间易于熔化的最初表面金属镀层。然而,消除该来源本身引起一严重的问题:焊接接头两边上的预镀区域可能被除去,例如,通过一机械方法。预镀层被除去的该区域的宽度必须至少等于将来被焊接熔化的区域的宽度,以便随后不会激发金属间化合区域的形成。实际上,考虑到在组装操作期间熔化区域的宽度的变动,这应当更为重要。因此,在焊接操作之后,在焊接接头的两侧上存在不再具有任何表面金属预镀层的区域。此外,在进一步的合金化和奥氏体化的热处理期间,在紧挨着焊接部的这些区域内发生结垢和脱碳。因为这些区域没有被任何镀层保护,因此所述区域是当部件被使用时趋于侵蚀的区域。
[08]因此,需要一种防止焊接组件内部形成金属间化合区域的制造方法,所述金属间化合区域是引发破裂的起源。
[09]还需要一种使得焊接和热处理部件具有优良耐腐蚀性的制造方法。
[10]还要求一种可以轻易地结合到现有的焊接作业线中并且与随后的冲压或热处理阶段相适应的经济的制造方法。
[11]还需要一种产品,对其进行对接焊操作、然后热处理、冲压和淬火操作导致制出具有良好的延展性和优良的耐腐蚀性的部件。一个特殊的需要是通过焊接接头的总伸长率大于或等于4%。
发明内容
[12]本发明的一目的是解决上述问题。
[13]因此,本发明在于一种由钢制的基体和预镀层(precoat)构成的板材,所述预镀层包括与所述基体接触的金属间化合物合金层,金属合金层置于所述金属间化合物合金层之上。在板材的至少一个预镀表面上,位于板材周边上的区域被除去了金属合金层。
[14]预镀层优选为铝合金或铝基的合金。
[15]预镀层的金属合金层(按重量计)优选包括:8-11%的硅、2-4%的铁、其余组分为铝和必然的杂质。
[16]已被除去金属合金层的所述区域的宽度优选在0.2到2.2毫米之间。
[17]已被除去金属层的区域的宽度优选是变化的。
[18]金属间化合物合金层的厚度优选为3到10微米之间。
[19]优选通过刷擦的方式部分地除去板材的至少一个预镀表面上的金属合金层,来制出被除去金属合金的区域。
[20]通过一激光束来部分地除去板材的至少一个预镀表面上的金属合金层,而制出被除去金属合金的区域。
[21]本发明还在于通过对接焊至少两块按上述任一实施例的板材来获得的焊接坯件,在与已被除去金属合金的区域邻接的边缘上形成焊接接头。
[22]此外,本发明在于通过对上述实施例的焊接坯件进行热处理和变形来获得一部件,所述预镀层在其整个厚度上通过所述热处理转变为金属间合金化合物,从而为所述钢制的基体提供防腐蚀和防脱碳保护。
[23]此外,本发明在于根据上述任一实施例的板材、坯件或部件,钢的组分包括(按重量计):0.10%≤C≤0.5%,0.5%≤Mn≤3%,0.1%≤Si≤1%,0.01%≤Cr≤1%,Ti≤0.2%,Al≤0.1%,S≤0.05%,P≤0.1%,0.0005%≤B≤0.010%,其余组分为铁和生产过程中必然产生的杂质。
[24]钢的组分优选包括(按重量计):0.15%≤C≤0.25%,0.8%≤Mn≤1.8%,0.1%≤Si≤0.35%,0.01%≤Cr≤0.5%,Ti≤0.1%,Al≤0.1%,S≤0.05%,P≤0.1%,0.002%≤B≤0.005%,其余组分为铁和生产过程中必然产生的杂质。
[25]此外,本发明在于按上述任一实施例的部件,其中所述钢的微观结构为马氏体、贝氏体或贝氏体-马氏体。
[26]此外,本发明在于一种方法,其中:
[27]-涂镀一钢板以获得预镀层,所述预镀层包括其上置有一金属合金层的金属间化合物合金层,
[28]-在板材的至少一个表面上,板材周边上的一区域被除去了金属合金层。
[29]所述区域的宽度优选为0.2到2.2毫米之间。
[30]此外,本发明还在于一种制造预镀钢制板材的方法,其中:
[31]-涂镀一钢板以获得预镀层,所述预镀层包括其上置有一金属合金层的金属间化合物合金层,然后
[32]-在板材的至少一个表面上,在没有完全邻接板材周边的一区域中,金属合金层被除去了,然后
[33]-按一平面切割板材,以便已经除去了金属合金的区域位于切割板材的周边上。
[34]已经除去了金属合金并且与板材周边不完全邻接的区域的宽度优选在0.4到30毫米之间。
[35]预涂镀优选通过浸镀铝实施。
[36]该层优选通过刷擦来除去。
[37]在一优选实施例中,通过激光束冲击预镀层来除去该层。
[38]本发明还在于根据上述任一实施例的方法,其中测量其上被除去了金属合金层的区域的发射率或反射率,将所述测定值与表示金属合金层的发射率或反射率的一参考值进行比较,并且当所述测定值和参考值之间的差值大于一临界值时停止该除去操作。
[39]本发明还在于一种方法,其中通过一激光束来除去所述金属合金层,其特征在于,测量激光束的冲击点处的放射的辐射线的强度或波长,将该测定值与表示金属合金层的发射率的一参考值进行比较,并且当所述测定值和参考值之间的差值大于一临界值时停止所述除去操作。
[40]本发明还在于一种方法,其中根据上述任一实施例制造的至少两块板材被对接焊,在与已经除去了金属合金层的区域邻接的边缘上形成焊接接头。
[41]在焊接板材周边上已经除去了金属层的区域之前,所述区域的宽度优选比焊接部宽度的一半大20-40%。
[42]已经除去了金属合金并且与板材周边不完全邻接的区域的宽度优选比焊接部的宽度大20-40%。
[43]本发明还在于一种部件的制造方法,其中加热按照上述实施例制造的焊接坯件,以便通过钢制的基体和涂镀层之间的合金化形成金属间合金化合物,并且以便在钢上具有部分或完全的奥氏体结构,然后
[44]-坯件被加热变形以获得一部件,
[45]-部件按适合于具有目标机械特性的速度冷却。
[46]冷却速度优选在用于马氏体淬火的临界速度以上。
[47]在一优选的实施例中,焊接是由激光束来实现的。
[48]焊接更优选是由电弧来实现的。
[49]本发明还在于使用上述任一实施例的板材、坯件或部件,来制造用于机动化的陆上机动车辆的结构部件或***件。
附图说明
[50]在下文通过举例并参照以下附图来进行描述的过程中,本发明的其他特征和优点将变得显而易见:
[51]-图1是显示按本发明的板材在焊接之前的一实施例的示意图。
[52]-图2是显示按本发明的板材的第二实施例的示意图。
[53]-图3是本发明的对接焊接头的一实例的示意图。
[54]-图4是本发明的焊接接头在奥氏体化和合金化的加热处理之后的一宏观图。
[55]-图5是显示熔融金属内部的有害金属间化合区域的外形的一参照焊接接头的宏观图。
[56]-图6是按本发明的板材在焊接之前的宏观图,已经使用激光束从所述板材上局部地除去了金属合金。
具体实施方式
[57]如上述说明,焊接之前在焊接接头两边上的金属镀层的总消除已经引起了局部腐蚀的问题。本发明人已经惊奇地发现:除去镀层的一确切部分能解决以上涉及的问题。
[58]为了说明本发明,首先,说明了通常通过沉浸在熔融的锌或铝或者锌或铝合金的镀液中所产生的涂镀带或板的某些特征。
[59]这些连续的、所谓“浸入”的方法生产出镀层的以下总结构:
[60]-在板材的钢制基体的表面上,沉淀了通过浸在熔池中发生的非常快速的反应所形成的几微米厚的金属间化合物合金。所述金属间化合物合金是比较脆弱的,为了限制该层的生长而向熔池中加入了抑制剂。在锌或铝合金镀层的情况下,组成该层的合金通常是Fex Aly类,特别是Fe2Al5。在锌合金镀层的情况下,通过镀锌池经常包含少量起抑制剂作用的铝来说明该富含铝的金属间化合物合金层的存在。
[61]该金属间化合物合金层有时可以具有复合的特性,例如,被分成两个金属间化合亚层,所述亚层与富含铁的基体接触。
[62]-该金属间化合物合金层之上放置有组分非常接近镀液组分的一金属合金层。当板材离开熔池时产生一更厚或更薄的金属层,并且可以通过空气或氮的射流来控制该厚度。
[63]本发明人已经表明了特别有益地必须局部地除去该层以解决以上涉及的问题。
[64]更特别是考虑图1,其显示了本发明的板材。术语板材在广义上被理解并特别表示为通过切割条带、卷体或薄板而获得的任何条带或物品。在该特定的实例中,板材具有两个表面和四个边缘。当然,本发明并不局限于该矩形的几何结构。图1显示了:
[65]-钢制的基体1。该基体可以是根据所要求的厚度进行热轧或冷轧的板材,或为任何其他适当形式。
[66]-预镀层2叠置在所述基体上并且与之接触,且存在于所述部件的两个表面上。该预镀层本身包括:
[67]-与基体1接触的金属间化合物合金层3。如已经说明过的,该层是由基体和镀液中的熔融金属之间的反应所形成的。
[68]有利的是,预镀层为铝合金或铝基。该类型的预镀层特别适合于随后的热处理,其通过与基体1的相互扩散形成金属间化合物并导致表面层的局部除去(参见下文)。特别是,预镀层的金属合金可以包含8-11%(按重量计)的硅和2-4%的铁,其余部分包括铝和必然的杂质。增加硅能够减小金属间化合物合金层3的厚度。
[69]-还显示了板材的周边5。根据本发明,所述周边的一部分6未携带金属合金层4却保留了金属间化合物合金层3。该部分6用于被放置到与另一块板材接触,并且用于然后在由边缘11形成的平面内被对接焊以形成一坯件。
[70]-在第一实施例中,有利的是,通过在周边5上的刷擦操作来除去层4:被刷子除去的材料实质上是表面层即金属合金层4,其具有最低的硬度。当刷子通过时,更硬的层3将保持在位。当金属间化合物合金层3和金属层4之间的硬度差异非常大时,使用铝或铝基的预镀层是特别有益的。
[71]本领域技术人员知道通过使参数适应预镀层的特别性质,如何适配不同的特定参数以适于刷擦操作,以实现尽可能完全并迅速地去除,所述参数如刷种类的选择、相对平移及转动的速度、垂直于表面的压力。例如,可以使用安装在一旋转轴上的钢丝刷,所述旋转轴被驱动平行于部分6的边缘平移。
[72]-在第二实施例中,通过指向板材周边的一激光束来除去层4:该高能量密度的射束和预镀层之间的相互作用促使预镀层表面的汽化和去除。由于金属合金层4和金属间化合物合金层3的不同的热量和物理性能,本发明人已经表明了:具有适当参数的一连串短激光脉冲引起了金属层4的选择性消融,并使层3保持在位。因此,指向涂镀板材周边的、并相对于板材平动的脉冲激光光束的相互作用使得除去了周边的金属层4。本领域技术人员知道如何采用不同的参数以尽可能迅速和完全地实现消融,所述参数如激光束的选择、入射能量、脉冲持续时间、在射束与板材之间的相对平移速度和射束在表面上的聚焦,使它们适应预镀层的特殊性质。例如,可以使用Q开关型的激光,其具有几百瓦的额定功率并且在50毫微秒左右的持续时间内输送脉冲。可以通过连续邻接的消融来自然地改变被除去的区域6的宽度。
[73]已经除去了金属层的区域6的宽度必须加以调节以能够:
[74]-焊接,而不会将预镀层的任何成分引入到熔化区域中,
[75]-在随后的合金化和奥氏体化的热处理中,焊接组件具有足够的耐腐蚀性。
[76]如果区域6的宽度比对接焊坯件时产生的熔化区域的宽度的一半大20%-40%,则本发明已经表明上述条件得到满足。
[77]20%的最小值确保了:在焊接期间预镀层不会被导入到熔融金属中,并且40%的值确保了良好的耐腐蚀性。
[78]考虑到用于1到3毫米厚度的板材的焊接条件,则区域6的宽度在0.2到2.2毫米之间。
[79]该情况表示在图3中,其以剖面图概略地显示了在焊接之后,板材包括由金属间化合物合金层3和金属层4所形成的预镀层2。熔化区域10的轴平面9位于焊接方向上。虚线显示了被焊接操作熔化的区域6的初始范围。
[80]图3图解了焊接部在板材的两个相对表面上总体是对称的。在所述条件下,区域6的宽度在两个表面上确切地相同。然而,根据所使用的焊接工艺和该工艺的参数,焊接部可能具有非对称的外形。根据本发明,然后可以调整区域6的宽度以适于该非对称性,以便该宽度比相应的两表面中的每一表面上的熔化区域10的宽度的一半略大。在这些条件下,区域6的宽度不同于图3所示的区域6’的宽度。
[81]如果在组装操作期间焊接条件发生变化,例如,考虑到几何结构或厚度的局部改变,区域6的宽度还可以与沿板材的焊接周边的熔化区域的宽度的相应变化相协调。如果局部条件导致形成了更宽的焊接部,则区域6的宽度当然要增大。
[82]在焊接不同厚度的两个涂镀板材的情况下,在两块板材中的每一块的被焊接周边部分上,所述区域6的宽度还可以不同。
[83]在图2所述的本发明的一变型中,在涂镀板材的区域7上除去了所述层4,所述区域7与板材的周边5没有完全邻接。然后,例如,通过切开工艺,按与板块垂直的一轴平面8切割所述板件。然后获得如图1所示的板材。被除去的宽度比熔化区域的宽度大20%到40%,所述熔化区域是按轴平面8进行的焊接操作所产生的。
[84]在本发明的一个变型中,除去的宽度在0.4到30毫米之间。该最小值相当于这样的宽度:所述宽度允许按轴平面8中进行的切割形成两块板材,所述板材在两块板材的每一块上具有0.2毫米宽的一非常狭窄的除去区域。30毫米的最大值对应于非常适合于用于执行所述除去操作的产业工具的一除去宽度。不在位于除去区域中部的轴平面8上、而在适合于生产板材的部位处可以完成随后的切削操作,所述板材的除去宽度比由焊接操作(由本发明的条件所限定的)产生的熔化区域的宽度的一半要略微大。
[85]如以上说明的,除去宽度确保了:金属镀层在板材随后的焊接期间不会被导入到熔融金属中,并且焊接坯件在经过热处理之后是耐腐蚀的。
[86]可以通过显微照相检验来监控金属层4的去除。然而,此外已经表明了,可以通过光学检验来迅速地检验除去操作的效率:在金属层4和下面的金属间化合物合金层3之间在外观上存在差异,所述金属间化合物合金层3更黑。因此,必须继续进行除去操作,并且当在区域6中看到了相对于表面镀层有一显著的色调变化时停止所述操作。因此,可能通过分光计测量反射率或发射率来监控去除操作:利用光源来照亮区域6,将一个或多个光学传感器指向该区域。所述测定数值对应于反射能量。将所述数值与对应金属层4的发射率或反射率的一参考值相比较,或者将其与指向金属层的另一传感器所测量到的数值相比较。此外,还可以测量反射能量随时间的变化。如果层6与表面齐平,则聚集的能量低于对应金属合金层4的能量。因此,可以通过上述校准来确定除去操作到达层3的准确时间。
[87]在通过激光消融来去除镀层的情况下,还可以分析激光束在预镀板材上的冲击点所放射的辐射的强度或波长。当层4已经被除去并且激光束冲击到层3上时,所述强度和波长发生了改变。因此,可以按以下的方式来监控被除去层的厚度:测量激光束冲击点处放射的辐射线的强度或波长,将测定值与金属合金层4的发射率的特征参考值相比较,并且当所述测定值和参考值之间的差值大于一预定的临界值时停止所述除去操作。
[88]根据特有的约束,可以在生产过程的不同阶段来执行该除去金属合金层的步骤,并且特别是:
[89]-或者展开在连续轧机机组上制造的卷片之后,在切割以形成更小型号的板材之前,
[90]-或者在焊接被切割的板材之前。
[91]在本发明的方法中,具有以下组分(按重量计)的热轧或冷轧的钢板材作为原材料:按重量计,碳含量在0.10-0.5%之间,并且优选在0.15-0.25%之间。该成分大大影响了在焊接坯件进行合金化和奥氏体化后的冷却之后所获得的可淬火性和机械强度。低于0.10%的含量(按重量计),则可淬火性太差并且强度性能不足。相反,超过0.5%的含量(按重量计),则在淬火期间出现缺陷的危险增加了,特别是对于最厚的部分。在0.15-0.25%之间的碳含量产生的抗张强度在大约1250-1650MPa之间。
[92]-锰除了作为脱氧剂的作用外,还对可淬火性具有显著的影响,特别是如果其按重量计的含量至少为0.5%,并且优选为0.8%时。然而,太高的数量(按重量计为3%,或优选为1.8%)导致了过度离析的危险。
[93]-钢的含硅量必须在0.1-1%(按重量计)之间,并且优选在0.1-0.35%之间。除了其起到使液态钢脱氧的作用外,该成分还有助于硬化。然而,必须限制其含量以防止氧化物的过度形成并且激发可涂镀性能。
[94]-当铬的含量超过0.01%时,铬提高了可淬火性,并且有助于在热成型操作之后获得很高的强度,这是在奥氏体化和合金化的热处理后的冷却之后在部件的不同部分中。在超出1%(优选0.5%)的含量时,铬获得均一机械性能的作用达到了饱和。
[95]-铝有利于去氧和氮的析出。总计超出0.1%(按重量计)时,在生产期间形成粗铝酸盐,其起到将含量限制于该数值的作用。
[96]-过量的硫和磷导致了脆弱性加强。因此,优选将其相应的含量限制为0.05-0.1%(按重量计)。
[97]-硼,其含量必须在0.0005-0.010%之间(按重量计),并且优选在按重量计的0.002-0.005%之间,硼对可淬火性具有很大的影响。低于0.0005%的含量,则达不到可淬火性的足够效果。含量为0.002%时获得了全部效果。为了不降低韧性,硼的最大含量必须小于0.010%,并且优选为0.005%。
[98]-钛对于氮具有很高的亲合力,因此有助于保护硼,以便该成分处于自由形式而具有其对可淬火性的全部影响。然而超过0.2%,更特别是超过0.1%,则存在在液态钢中形成粗氮化钛的危险,其对韧性具有不良的影响。
[99]根据上述任一种方法制备好板材之后,通过焊接将它们组装在一起以获得焊接坯件。当然可以将多于两块的板材组合在一起以制造复合的成品部件。板材可以具有不同厚度或组分以部分地提供所需要的性能。
[100]在将板材边缘对边缘地放置好之后实施焊接,没有金属合金层的区域彼此接触。因此,沿与区域6邻接的边缘实施焊接,所述区域6上的金属合金层已经被除去了。
[101]在本发明的上下文中,可以使用适应焊接接头所需要的厚度和生产率及质量条件的任何连续焊接的方法,并且特别是:
[102]-激光束焊接,
[103]-电弧焊,并且特别是通过GTAW(钨极气体保护电弧焊),等离子体、MIG(金属惰气电弧焊)或MAG(金属活性气体保护电弧焊)的方法。
[104]在本发明的条件下,焊接操作不会导致金属镀层4的一部分重新熔化而使得此后其成分会出现在熔化区域中。仅极小量的金属间化合物合金层3被该操作重新熔入到熔化区域中。如以下实例所显示的,该极其有限的数量在合金化和奥氏体化的热处理之后不会影响冶金质量或焊接接头的机械性能。
[105]然后,加热焊接坯件以共同实施:
[106]-表面合金化处理,其中钢制基体的成分特别是铁、锰和硅扩散到预镀层中。这形成了表面金属间合金化合物,其熔点显著比金属合金层4的熔点要高。在热处理期间该化合物的存在阻止下层钢的氧化和脱碳。
[107]-钢基局部或总体产生奥氏体化。有利地在炉中实施加热,以便部件达到Ac1到Ac3+100℃的温度。Ac1和Ac3分别是在加热情况下发生奥氏体转变的开始温度和最终温度。根据本发明,维持该温度的时间长于或等于20秒,以便在部件的不同位点呈现一致的温度和微观结构。
[108]在本发明的条件下,在该加热阶段期间,在熔融金属的内部未形成对部件的机械性能有害的脆弱的金属间化合区域。
[109]这继之以坯件的热变形而形成作为部件的成品形状,通过减小蠕变极限并利用温度来增加钢制品的延展性对该步骤是有利的。从在高温下部分或全部奥氏体化的结构开始,然后在适当条件下冷却部件以获得目标机械特性:特别是,在冷却期间部件可以被保持在一工具中,并且所述工具本身可以被冷却以促进热量的排出。为了获得优良的机械性能,优选产生马氏体、贝氏体或贝氏体-马氏体的微观结构。
[110]在焊接接头两边上的区域6中,金属间化合物层3与钢制的基体合金化并且产生良好的耐腐蚀性,所述金属间化合物层在热处理之前的厚度在3到10微米之间。
[111]实例:
[112]以下实施例通过举例来显示本发明获得的其他优点。这涉及厚度为1.5毫米的冷轧钢带,其具有以下组分(按重量计):
C | Mn | Si | S | P | Al | Cr | Ti | B |
0.224 | 1.160 | 0.226 | 0.005 | 0.013 | 0.044 | 0.189 | 0.041 | 0.0031 |
表1:钢的组分(按重量计的%)
[113]通过将所述钢带浸入铝合金熔池中来预镀该钢带,所述铝合金包含9.3%的硅和2.8%的铁,其余组分为铝和必然的杂质。然后,将钢带切割成300×500平方毫米规格的板材。所述板材在其每一表面上包括预镀层,所述预镀层具有主要包含Fe2Al3、Fe2Al5和FexAlySiz的金属间化合物合金层。与钢制基体接触的该5微米厚的层上面置有20微米厚的Al-Si金属合金层。
[114]在激光束焊接之前,使用了四种不同的制备方法:
[115]-方法I(根据本发明):在500毫米长的边侧上,通过纵向刷擦在1.1毫米的宽度上将Al-Si金属合金层从板材边缘除去。使用安装在一倾斜的旋转***上的直径为80毫米的“Spiraband”型的钢丝刷,在两个表面上完全相同地执行刷擦操作,其在一配重架上引导该旋转***平动。在刷子/坯件的接触位点处的刷擦力大致为35N,并且刷子的移动速度大致为10米/分钟。该刷擦操作除去了金属合金层,仅在被刷擦过的区域上留下了5微米厚的金属间化合物合金层。
[116]-方法II(根据本发明):通过激光消融从板材边缘上除去0.9毫米宽的Al-Si金属合金层。使用额定能量为450W、传送70ns脉冲的Q开关型激光,来在两个表面上执行完全相同的激光消融。脉冲能量为42毫焦耳(mJ)。激光束相对于板材平动的恒定速度为20米/分钟(m/min)。图6图示了该激光消融除去了金属合金层4,而在已加工区域上仅留下了5微米的金属间化合物合金层3。
[117]-方法R1(未根据本发明):借助用于快速加工的硬质合金板式工具,按纵向平移,并在因此和方法1相同的1.1毫米的宽度上,机械地除去所有预镀层——所述预镀层包括金属合金层和金属间化合物合金。结果,随后在接头的两个侧边上完全除去了所有预镀层的区域上进行焊接。
[118]-方法R2(未根据本发明):在周边没有经过特殊制备的预镀板材上执行激光束焊接。
[119]在以下条件下对上述板材进行激光束焊接:额定功率:6千瓦(kW),焊接速度:4米/分钟。在方法I中,考虑到焊接宽度,发现:焊接接头形成之后出现一在大致0.3毫米的宽度上没有金属合金的区域。
[120]焊接坯件受到合金化和奥氏体化的热处理,所述热处理包括加热到920℃的温度,并且将该温度维持7分钟。这些条件促使基体的钢发生完全奥氏体转变。在该加热和恒温阶段期间,发现铝硅基的预镀层在其整个厚度上通过与钢基合金化而形成了金属间化合物。该合金镀层具有高熔点和高硬度、高耐腐蚀性的特征,并且在加热阶段期间和加热阶段之后防止底层钢基的氧化和脱碳。
[121]在加热到920℃的阶段之后,部件发生热变形并且被冷却。
[122]随后在夹具之间冷却以产生一马氏体结构。在所述处理之后获得的钢制基体的抗张力Rm高于1450MPa。
[123]然后使用以下技术来表征按该方式在部件中获得的焊接接头:
[124]-显微图像的剖面显示了焊接接头内部存在的任何金属间化合区域。
[125]-在12.5×50平方毫米的样品中对穿过焊接接头的机械张力的测试确定了抗张强度Rm和总伸长率。
[126]-按照DIN 50021、50017和50014标准来进行加速腐蚀试验。这些测试在盐雾喷射之后包括:在23℃的干燥状态和在40℃的潮湿状态交替的循环。
[127]表2表示了这些特性表征的结果:
方法 | 焊接接头内部的脆性的金属间化合区域 | Rm(MPa) | A(%) | 耐腐蚀性 |
I(根据本发明) | 无 | >1450 | ≥4 | o |
II(根据本发明) | 无 | >1450 | ≥4 | o |
R1(未根据本发明) | 无 | >1450 | ≥4 | ● |
R2(未根据本发明) | 存在 | 1230 | ≤1 | o |
表2:热处理之后的焊接接头的特性
o:符合要求 ●:不符合要求
[128]在热处理之后所需的淬火条件下,对于上述四种方法,焊接期间基底金属和熔化区域的微观结构完全为马氏体。
[129]在本发明的方法I的情况下,如图4所示,熔化区域不包含金属间化合区域。
[130]另一方面,在方法R2中可注意到:出现了金属间化合区域(参见图5),特别是在朝向熔化区域的周边处,而在熔化区域的周边处,预镀层的成分通过在由马兰各尼效应所引起的液池中自发对流而积聚。所述宽大的金属间化合区域可以基本垂直于机械载荷来定向,并起到了应力集中和引发破裂效果的作用。特别是在交叉方向上的伸长由于这些金属间化合区域的存在而减小:在没有这些区域的情况下,所述伸长大于4%。当存在所述区域的时候,伸长降低到1%以下。
[131]注意到:在本发明的方法I和方法R1之间在机械特性(强度和伸长率)方面无显著差异。这显示出,通过刷擦留在原地并且通过焊接重新熔化的金属间化合物合金薄层不会引起在熔融金属内部形成脆性区域,如图4所示。
[132]在方法R1的情况下,耐腐蚀性降低:通过完全除去预镀层,钢完全裸露在焊接接头的两侧上。没有了抗腐蚀保护,然后会看到在焊接部的两侧受热影响的区域中出现了红锈。
[133]因此,本发明的方法同时获得了焊接接头在处理后具有优良延展性和优良耐腐蚀性。
[134]根据钢的组分,特别是其碳含量和其锰、铬和硼的含量,部件的最大强度可以适合于目标用途。使用所述部件有益于用于机动车辆结构的***件、并且特别是抗侵入或车身底座部件、加强杆、B柱的制造。
Claims (30)
1.一种由钢制的基体(1)和预镀层(2)构成的板材,所述预镀层由其上置有金属合金层(4)的金属间化合物合金层(3)构成,所述金属间化合物合金层与所述基体相接触,
其特征在于,在所述板材的至少一个预镀表面上,位于所述板材的周边的区域(6)被除去所述金属合金层。
2.如权利要求1所述的板材,其特征在于,所述预镀层(2)为铝合金或为铝基。
3.如权利要求2所述的板材,其特征在于,所述预镀层(2)的金属合金层(4)按重量计包括:8-11%的硅、2-4%的铁,而其余组分为铝和必然的杂质。
4.如权利要求1到3中任一项所述的板材,其特征在于,被除去所述金属合金层的所述区域(6)的宽度在0.2到2.2毫米之间。
5.如权利要求1到4中任一项所述的板材,其特征在于,被除去所述金属合金层的所述区域(6)的宽度是变化的。
6.如权利要求1到5中任一项所述的板材,其特征在于,所述金属间化合物合金层(3)的厚度在3到10微米之间。
7.如权利要求1到6中任一项所述的板材,其特征在于,在所述板材的至少一预镀表面上,通过利用刷擦来部分地除去所述金属合金层(4),而获得被除去金属合金的所述区域(6)。
8.如权利要求1到6中任一项所述的板材,其特征在于,在所述板材的至少一预镀表面上,通过借助激光束来部分地除去所述金属合金层(4),而获得被除去金属合金的所述区域(6)。
9.一种焊接坯件,其通过对接焊至少两块如权利要求1到8中任一项所述的板材所获得,其特征在于,焊接接头实施在与已被除去金属合金层的所述区域(6)邻接的边缘(11)上。
10.一种通过对如权利要求9所述的焊接坯件进行热处理和变形所获得的部件,其特征在于,所述预镀层在其整个厚度上通过所述热处理转变为金属间合金化合物,从而为所述钢制的基体提供防腐蚀和防脱碳保护。
11.如权利要求1到10中任一项所述的板材、坯件或部件,其特征在于,所述钢的组分按重量计包括:
10%≤C≤0.5%
5%≤Mn≤3%
1%≤Si≤1%
01%≤Cr≤1%
Ti≤0.2%
Al≤0.1%
S≤0.05%
P≤0.1%
0005%≤B≤0.010%
其余组分包括铁和生产过程中必然产生的杂质。
12.如权利要求11所述的板材、坯件或部件,其特征在于,钢的组分按重量计包括:
15%≤C≤0.25%
8%≤Mn≤1.8%
1%≤Si≤0.35%
01%≤Cr≤0.5%
Ti≤0.1%
Al≤0.1%
S≤0.05%
P≤0.1%
002%≤B≤0.005%
其余组分包括铁和生产过程中必然产生的杂质。
13.如权利要求10到12中任一项所述的部件,其特征在于,所述钢的微观结构为马氏体、贝氏体或贝氏体-马氏体。
14.一种制造预镀钢制板材的方法,其中涂镀一钢板以获得预镀层,所述预镀层由金属合金层(4)置于其上的金属间化合物合金层(3)构成,其特征在于,在所述板材的至少一个表面上,在所述板材的周边的区域(6)除去所述金属合金层。
15.如权利要求14所述的制造方法,其特征在于,所述区域(6)的宽度在0.2到2.2毫米之间。
16.一种制造预镀钢制板材的方法,其中:
-涂镀一钢板,以获得预镀层,所述预镀层由金属合金层(4)置于其上的金属间化合物合金层(3)构成,然后
-在所述板材的至少一个表面上,在没有完全邻接所述板材的周边(5)的区域(7)除去所述金属合金层,然后
-按一平面(8)切割所述板材,以便金属合金已被除去的所述区域(7)位于所述切割板材的周边上。
17.如权利要求16所述的制造方法,其特征在于,所述区域(7)的宽度在0.4到30毫米之间。
18.如权利要求14到17中任一项所述的制造方法,其特征在于,预涂镀通过浸镀铝来实施。
19.如权利要求14到18中任一项所述的制造方法,其特征在于,通过刷擦来除去所述金属合金层(4)。
20.如权利要求14到18中任一项所述的制造方法,其特征在于,通过激光束冲击在所述预镀层(2)上来除去所述金属合金层(4)。
21.如权利要求14到20中任一项所述的板材制造方法,其特征在于,测量其上被除去所述金属合金层(4)的所述区域(6)的发射率或反射率,将测定值与所述金属合金层(4)的发射率或反射率的特征参考值进行比较,并且当所述测定值和所述参考值之间的差值大于一临界值时,停止所述除去操作。
22.如权利要求20所述的板材制造方法,其特征在于,测量在所述激光束的冲击点处发射的辐射的强度或波长,将测定值与所述金属合金层(4)的发射率的特征参考值进行比较,并且当所述测定值和所述参考值之间的差值大于一临界值时,停止所述除去操作。
23.一种焊接坯件的制造方法,其中对接焊至少两块如权利要求1到8中任一项所述的、或者如权利要求14到22中任一项所述制造的板材,焊接接头实施在与已除去所述金属合金层的所述区域相邻接的边缘(11)上。
24.如权利要求14所述的制造方法,其特征在于,所述区域(6)的宽度比按照权利要求23所产生的焊接部的宽度的一半大20-40%。
25.如权利要求16所述的制造方法,其特征在于,所述区域(7)的宽度比按照权利要求23所产生的焊接部的宽度大20-40%。
26.一种部件制造方法,其中加热如权利要求23所制造的焊接坯件,以便通过所述钢制的基体(1)和镀层(2)之间的合金化来形成金属间合金化合物,并且以便在所述钢上获得部分或完全奥氏体化的结构,然后
使所述坯件发生热变形以获得一部件,
按适合于获得目标机械特性的速度来冷却所述部件。
27.如权利要求26所述的方法,其特征在于,冷却速度高于用于马氏体淬火的临界速度。
28.如权利要求23、26或27中任一项所述的制造方法,其特征在于,焊接由激光束实施。
29.如权利要求23、26或27中任一项所述的制造方法,其特征在于,焊接采用电弧实施。
30.如权利要求1到13中任一项所述的、或由权利要求14到29中任一项所述的方法制造的板材、坯件或部件的应用,其用于机械化的陆上机动车辆的结构部件或***件的制造。
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