EP1651789B1 - Method for producing hardened parts from sheet steel - Google Patents

Method for producing hardened parts from sheet steel Download PDF

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Publication number
EP1651789B1
EP1651789B1 EP20040739756 EP04739756A EP1651789B1 EP 1651789 B1 EP1651789 B1 EP 1651789B1 EP 20040739756 EP20040739756 EP 20040739756 EP 04739756 A EP04739756 A EP 04739756A EP 1651789 B1 EP1651789 B1 EP 1651789B1
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EP
European Patent Office
Prior art keywords
oxygen
component
sheet
forming
zinc
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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EP20040739756
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German (de)
French (fr)
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EP1651789A1 (en
Inventor
Martin Fleischanderl
Siegfried Kolnberger
Gerald Landl
Anna Elisabeth Raab
Werner BRANDSTÄTTER
Josef Faderl
Robert Vehof
Wolfgang Stall
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Voestalpine Stahl GmbH
Voestalpine Metal Forming GmbH
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Voestalpine Stahl GmbH
Voestalpine Metal Forming GmbH
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Priority claimed from AT0120303A external-priority patent/AT412878B/en
Priority claimed from AT12022003A external-priority patent/AT412403B/en
Application filed by Voestalpine Stahl GmbH, Voestalpine Metal Forming GmbH filed Critical Voestalpine Stahl GmbH
Priority to PL04739756T priority Critical patent/PL1651789T3/en
Priority to EP20090015813 priority patent/EP2177641B1/en
Priority to PL09015813T priority patent/PL2177641T3/en
Publication of EP1651789A1 publication Critical patent/EP1651789A1/en
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C23C2/022—Pretreatment of the material to be coated, e.g. for coating on selected surface areas by heating
    • C23C2/0224—Two or more thermal pretreatments
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/62—Quenching devices
    • C21D1/673—Quenching devices for die quenching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02—Stamping using rigid devices or tools
    • B21D22/04—Stamping using rigid devices or tools for dimpling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
    • C23C2/06—Zinc or cadmium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/26—After-treatment
    • C23C2/28—Thermal after-treatment, e.g. treatment in oil bath
    • C23C2/29—Cooling or quenching
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/34—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the shape of the material to be treated
    • C23C2/36—Elongated material
    • C23C2/40—Plates; Strips
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/34—Pretreatment of metallic surfaces to be electroplated
    • C25D5/36—Pretreatment of metallic surfaces to be electroplated of iron or steel
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/48—After-treatment of electroplated surfaces
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2221/00—Treating localised areas of an article
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2251/00—Treating composite or clad material
    • C21D2251/02—Clad material
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/46—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for sheet metals
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49982—Coating
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49995—Shaping one-piece blank by removing material
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12785—Group IIB metal-base component
    • Y10T428/12792—Zn-base component
    • Y10T428/12799—Next to Fe-base component [e.g., galvanized]
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal

Definitions

  • the invention relates to a method for producing hardened components from sheet steel.
  • the most widely used raw material in bodybuilding is steel. With no other material can be in such large areas cost components with different material properties available.
  • a perspective, in particular for bodies in the automotive industry are components made of steel sheet with a strength depending on the alloy composition in a range of 1000 up to 2000 MPa.
  • a scale layer forms on the surface. This is removed after forming and cooling. This is usually done with sandblasting. Before or after this descaling, the final trimming and the insertion of holes is carried out. If the final trimming and the insertion of the holes are carried out before sandblasting, it is disadvantageous that the cut edges and hole edges are affected. Irrespective of the order of the processing steps after curing, it is disadvantageous in the case of final scaling by sandblasting and comparable methods that the component is often distorted as a result. After said processing steps, a so-called piece coating with a corrosion protection layer takes place. For example, a cathodically effective corrosion protection layer is applied.
  • the post-processing of the cured component is extremely expensive and is subject to very high wear due to the hardening of the component. Further is disadvantageous that the piece coating usually causes a corrosion protection, which is not particularly pronounced. In addition, the layer thicknesses are not uniform, but fluctuate over the component surface.
  • this method it is also known to cold form a component from a sheet metal blank and then heat to the Austenitmaschinestemperatur and then cool rapidly in a calibration tool, wherein the calibration tool is responsible for the component, which is warped by the warm-up, with respect the reshaped areas are calibrated. Subsequently, the post-processing described above. Compared with the method described above, this method allows more complex geometries, since essentially only linear shapes can be produced during simultaneous forming and hardening, but complex shapes can not be realized in such forming processes.
  • a method for producing a hardened steel component in which a sheet of hardenable steel is heated to the hardening temperature and then placed in a shaping device in which the sheet is formed into the desired final shape, wherein simultaneously cooled rapidly during the forming, so that a martensitic or bainitic structure is obtained while the sheet remains in the molding apparatus.
  • a starting material for example, a boron-alloyed carbon steel or carbon manganese steel is used.
  • the deformation is preferably a compression but can also be used with other methods.
  • the forming and cooling should preferably be carried out and carried out so rapidly that a fine-grained martensitic or bainitic structure is obtained.
  • From the EP 1 253 208 A1 is a method for producing a hardened sheet metal profile from a board, which is hot formed and cured in a pressing tool to the sheet metal profile known.
  • On the sheet metal profile projecting reference points or collars are generated from the plane of the board, which serve for positional orientation of the sheet metal profile in subsequent manufacturing operations.
  • the collars should be formed during the forming process of non-perforated areas of the board, the reference points are generated in the form of marginal stampings or as enforcements or collar in the sheet metal profile.
  • the hot forming and hardening in the pressing tool should generally have advantages due to the efficient by the combination of forming and tempering process in a tool operation. Due to the clamping of the sheet metal profile in the tool and due to thermal stresses, however, it should come to not exactly predeterminable delay on the component. This can adversely affect downstream manufacturing operations, which is why the reference points are created on the sheet metal profile.
  • a method of making steel sheet products wherein a steel sheet product is molded in a pair of cooled tools while hot and hardened into a martensitic structure while still in the tool so that the tools act as a fixture during the process Hardening serve.
  • the steel shall be kept in the mild steel area, with inserts in the tools used to prevent rapid cooling and thereby a martensitic structure in these areas.
  • the same effect should also be achieved by recesses in the tools, so that a gap between the steel sheet and the tools occurs.
  • this method is disadvantageous because of the significant delay that can occur here, the present method for press hardening of components with more complex structure is disabled.
  • a method for producing locally reinforced sheet metal formed parts wherein the base sheet of the structural part connected in a flat state with the reinforcing sheet and defined this so-called patched composite sheet is then formed together.
  • the patched composite sheet is heated to at least about 800 to 850 ° C before forming, quickly inserted, rapidly formed in the hot state and then with mechanical maintenance of the forming state by Contacting with the internally forced-cooled forming tool defines cooled.
  • the extent relevant temperature range 800 to 500 ° C is to be traversed with a defined cooling rate.
  • the step of connecting reinforcing sheet and base sheet should be readily integrated in the forming process, wherein the parts are brazed together whereby an effective corrosion protection at the contact zone can be achieved at the same time.
  • the tools are very expensive, in particular due to the defined internal cooling.
  • a method and a device for pressing and hardening a steel part are known.
  • the aim is to press and harden sheet steel pieces in the form of avoiding the disadvantages of known methods, in particular that parts made of steel sheet are produced in successive separate steps for compression molding and hardening.
  • the hardened or quenched products to the desired shape show a delay, so that additional steps are required.
  • it is intended to place a piece of steel, after the piece has been heated to a temperature attaining its austenitic condition, between a pair of cooperating mold members, whereupon the piece is pressed and at the same time heat is rapidly dissipated from the piece to the mold pieces.
  • the mold parts are kept at a cooling temperature throughout the process, so that a quenching effect is exerted on the piece under a molding pressure.
  • a method of producing a part having very high mechanical properties is known, wherein the part is to be produced by punching a strip from a rolled steel sheet, and in particular a hot rolled and coated part is coated with a metal or metal alloy covering the surface of the steel to protect, wherein the steel sheet is cut to obtain a steel sheet preform, the steel sheet preform is cold or hot formed and is either cooled and hardened after hot working or heated after cold working and then cooled.
  • An intermetallic alloy is supposed to be on the surface before or after
  • this intermetallic mixture can also have a lubricating function. Subsequently, the supernatant material is removed from the molding.
  • the coating should generally be based on zinc or zinc-aluminum. In this case, a steel can be used which is electrolytically galvanized on both sides, with an austenitization to take place at 950 ° C. This electrolytically galvanized layer is completely converted into an iron-zinc alloy during austenitisation. It is stated that during forming and while being held for cooling, the coating does not hinder the heat flow through the tool and even improves heat dissipation.
  • this document proposes as an alternative to an electrolytically galvanized tape to use a coating of 45% to 50% zinc, balance aluminum.
  • a cathodic corrosion protection is practically no longer available.
  • such a layer is so brittle that cracks occur during forming.
  • a coating with a mixture of 45 to 50% zinc and 55 to 45% aluminum also exhibits no significant cathodic corrosion protection. While it is claimed in this reference that the use of zinc or zinc alloys as a coating would provide galvanic protection even to the edges, this can not be achieved in practice. In practice, the coatings described can not even achieve sufficient galvanic protection in the surface.
  • a method of manufacturing a rolled steel strip component, and in particular a hot rolled strip is known.
  • the aim is to be able to offer rolled steel sheets of 0.2 to 2.0 mm in thickness, which are coated, inter alia, after hot rolling and the one Deformation, either cold or hot, followed by a thermal treatment, whereby the increase in temperature without steel decarburization and without oxidation of the surface of the aforementioned sheets is to be ensured before, during and after the hot working or the thermal treatment.
  • the sheet should be provided with a metal or a metal alloy, which ensures the protection of the surface of the sheet, then the sheet is subjected to a temperature increase for the forming, then a transformation of the sheet are performed and the part are finally cooled.
  • the coated sheet is to be pressed while hot and the part formed by the deep drawing to be cooled to be cured and that at a speed which is higher than the critical curing rate.
  • a steel alloy which should be suitable, said steel sheet to be austenitized at 950 ° C before it is deformed and hardened in the tool.
  • the applied coating should consist in particular of aluminum or an aluminum alloy, whereby not only an oxidation and decarburization protection, but also a lubricating effect should result.
  • the steel used should be an air-hardening steel, which may be heated under a protective gas atmosphere in order to avoid scaling during heating. Otherwise, a scale layer is descaled in front of the mold component after hot working of the mold component.
  • the component blank is shaped close to the final contour, "near net shape" being understood to mean that those parts of the geometry of the finished component which are associated with a macroscopic flow of material completely into the component blank after completion of the cold forming process are formed. After completion of the cold forming process Thus, for the production of the three-dimensional shape of the component only slight form adjustments to be necessary, which require a minimum local material flow.
  • the object of the invention is to provide a method for producing hardened components made of sheet steel, which is simple and quick to carry out and which makes it possible to produce hardened components made of sheet steel in particular steel sheet with a cathodic corrosion protection dimensionally accurate and without finishing such as descaling and sandblasting.
  • the forming of the components as well as the trimming and punching of the components is carried out essentially in the uncured state.
  • the relatively good deformability of the particular material used in the unhardened state allows the realization of complex component geometries and replaces expensive subsequent trimming in the cured state by significantly less expensive mechanical cutting operations before the hardening process.
  • the unavoidable dimensional changes due to the heating of the component are already taken into account in forming the cold sheet, so that the component is made approximately 0.5 to 2% smaller than the final dimensions. At least the expected thermal expansion during forming is considered.
  • the areas of high complexity and forming depth and possibly the narrow toleranced areas of the component such as in particular the cut edges, the shape edges, the forming surfaces and possibly the hole pattern, such as
  • the reference holes with the desired final tolerances, in particular the trimming and position tolerances, of the finished, hardened component, in which case the thermal expansion of the component is taken into account or compensated for by the heating.
  • the component after the cold forming is about 0.5% to 2% smaller than the nominal final dimensions of the finished, hardened component.
  • Smaller here means that the component after cold forming in all three spatial axes is thus three-dimensionally finished molded.
  • the thermal expansion is thus considered equally for all three spatial axes.
  • the thermal expansion can not be taken into account for example by the incomplete closure of the mold for all spatial axes, since only in the Z direction, by an incomplete formation, an elongation could be considered.
  • the three-dimensional geometry or contour of the tool is preferably made smaller in all three spatial axes.
  • the corrosion protection according to the invention for steel sheets, which are first subjected to a heat treatment and then reformed and thereby hardened, is a cathodic corrosion protection which is essentially based on zinc.
  • an oxygen-affine element such as magnesium, silicon, titanium, calcium and aluminum are added to the zinc forming the coating. It has been found that such small amounts of an oxygen-affine element as magnesium, silicon, titanium, calcium and aluminum induce a surprising effect in this particular application.
  • oxygen-affine elements at least Mg, Al, Ti, Si, Ca in question.
  • aluminum is mentioned below, this is representative of the other elements mentioned.
  • an approximately two-layer corrosion protection layer is formed, which consists of a cathodically highly effective layer, with a high proportion of zinc and an oxidation protective layer of an oxide (Al 2 O 3 , MgO, CaO, TiO , SiO 2 ) is protected against oxidation and evaporation.
  • an oxidation protective layer of an oxide Al 2 O 3 , MgO, CaO, TiO , SiO 2
  • This means that the heat treatment must be carried out in an oxidized atmosphere.
  • protective gas oxygen-free atmosphere
  • the corrosion protection layer according to the invention for the press-hardening process also has such a high mechanical stability that a forming step following the austenitizing of the sheets this Layer not destroyed.
  • the cathodic protection is at least significantly greater than the protective effect of the known anticorrosive layers for the press hardening process.
  • a zinc alloy with a content of aluminum in weight percent of greater than 0.1 but less than 15%, in particular less than 10%, more preferably less than 5% on a Steel plate, in particular an alloyed steel sheet are applied, whereupon in a second step, parts of the coated sheet are machined and in particular cut out or punched out and heated on access of atmospheric oxygen to a temperature above the Austenitmaschinestemperatur the sheet metal alloy and then cooled at an increased speed.
  • a transformation of the cut out of the sheet metal part (the board) can be carried out before or after the heating of the sheet to the Austenitmaschinestemperatur.
  • a thin barrier phase is formed, in particular Fe 2 Al 5 -x Zn x , which forms the Fe-Zn Diffusion in a liquid metal coating process, which takes place in particular at a temperature up to 690 ° C, hindered.
  • the sheet is formed with a zinc-metal coating with an addition of aluminum, which is effective only towards the sheet surface, as in the proximal region of the support an extremely thin barrier phase, which is effective against rapid growth of an iron-zinc compound phase, having.
  • the metal layer on the sheet is liquefied for the time being.
  • the oxygen-containing aluminum from the zinc reacts with atmospheric oxygen to form solid oxide, thereby causing a decrease in the concentration of aluminum metal, which causes a steady diffusion of aluminum towards depletion, that is to the distal region.
  • This Tonerdeanreichtation, at the air exposed layer area now acts as oxidation protection for the layer metal and as Abdampfungssperre for the zinc.
  • the aluminum is withdrawn from the proximal blocking phase by continuous diffusion towards the distal region and is available there for the formation of the superficial Al 2 O 3 layer.
  • the formation of a sheet metal coating is achieved, which leaves a cathodically highly effective layer with a high zinc content.
  • Well suited is for example a zinc alloy with a content of aluminum in weight percent of greater than 0.2 but less than 4, preferably of size 0.26 but less than 2.5 wt .-%.
  • the zinc alloy layer is applied to the sheet surface passing through a liquid metal bath at a temperature higher than 425 ° C, but lower than 690 ° C, especially at 440 ° C to 495 ° C, followed by cooling of the coated sheet, not only the proximal locking phase can be effectively formed, or a very good diffusion inhibition can be observed in the region of the barrier layer, but it takes place thus also an improvement of the thermoforming properties of the sheet material.
  • An advantageous embodiment of the invention is given in a method in which a hot or cold rolled steel strip having a thickness of for example greater than 0.15 mm and having a concentration range of at least one of the alloying elements within the limits in wt .-% carbon to 0.4, preferably 0.15 to 0.3 silicon to 1.9, preferably 0.11 to 1.5 manganese to 3.0, preferably 0.8 to 2.5 chrome to 1.5, preferably 0.1 to 0.9 molybdenum to 0.9, preferably 0.1 to 0.5 nickel to 0.9, titanium to 0.2 preferably 0.02 to 0.1 vanadium to 0.2 tungsten to 0.2, aluminum to 0.2, preferably 0.02 to 0.07 boron to 0.01, preferably 0.0005 to 0.005 sulfur Max. 0.01, preferably max. 0.008 phosphorus Max. 0.025, preferably max. 0.01 Rest iron and impurities is used.
  • the surface structure of the cathodic corrosion protection according to the invention is particularly favorable for a high adhesion of paints and varnishes.
  • such a zinc layer is apparently not significantly impaired during cold forming. Rather, in the invention in an advantageous manner when trimming and punching the cold board zinc material is carried by the tool from the zinc layer in the cutting edge and smeared along the cutting edge.
  • a coating with zinc also has the advantage that the component loses less heat after heating and when transferred to a mold hardening tool, so that the component does not have to be heated so high. As a result, lower thermal expansions occur, so that a tolerance-accurate production is simplified, since the total strains are smaller.
  • the component at the lower temperature has a higher stability which allows better handling and faster insertion into the mold.
  • the uncured, galvanized special sheet is first cut into blanks.
  • the processed boards may be rectangular, trapezoidal or shaped boards. All can be used for cutting the boards known cutting processes are applied. Preferably, cutting processes are used which do not introduce heat into the sheet during the cutting process.
  • the final trimming is carried out in said conventional tools.
  • the molded part which has been formed in the cold state, is made smaller by 0.5 to 2% than the nominal geometry of the end component, so that the thermal expansion during heating is thereby compensated.
  • the moldings produced by the processes mentioned should be cold formed, the dimensions of which are within the required by the customer for the finished part tolerance field. If larger tolerances occur in the aforesaid cold forming, they may be partially corrected later, minimally, during the molding hardening process, which will be discussed later.
  • the tolerance correction in the form hardening process is preferably performed only for shape deviations. Such form deviations can thus be corrected in the manner of a hot calibration.
  • the correction process should as far as possible be limited to one bending operation, wherein cutting edges that are dependent on the amount of material (in relation to the forming edge) should not and can not subsequently be influenced, ie, if the geometry of the cutting edges in the parts is not correct , in the form hardening tool no correction can be made.
  • the tolerance range with respect to the cutting edges corresponds to the tolerance range during the cold forming and the shape hardening process.
  • no distinctive folds should be present within a molded part, because then the uniformity of the printed image and a uniform shape hardening process can not be guaranteed.
  • the deformed and cut part is heated to an annealing temperature above 780 ° C, especially 800 ° C to 950 ° C, and held at that temperature for a few seconds to a few minutes, at least until a desired austenitization has occurred ,
  • the component is subjected to the inventive form hardening step.
  • the component is inserted into a tool within a press, wherein this mold hardening tool preferably corresponds to the desired final geometry of the finished component, that is to say the size of the cold-formed component including the thermal expansion.
  • the shape-hardening tool has a geometry or contour that substantially corresponds to the geometry or contour of the cold-forming tool, but is 05 to 2% larger (with respect to all three spatial axes).
  • the aim is to form-hardening a full-surface fit between the mold hardening tool and the workpiece or component to be cured immediately after de close the tool.
  • the molding is placed at a temperature of about 740 ° C to 910 ° C, preferably 780 ° C to 840 ° C in the mold hardening tool, the previous cold forming as already considered takes into account the thermal expansion of the part at this EinlegeTemperatur range.
  • an insertion temperature of 780 ° C to 840 ° C can be achieved even if the annealing temperature of the cold-formed component between 800 ° C and 850 ° C, since the special zinc coating according to the invention - compared to uncoated Sheet metal - reduces rapid cooling.
  • This has the advantage that the parts must be heated less high and in particular a heating to over 900 ° C can be avoided. This in turn results in an interaction with the zinc coating since the zinc coating is less affected at somewhat lower temperatures.
  • a part is first removed by a robot from a conveyor belt and placed in a marking station, so that each part can be traceably marked before it is hardened. Then the robot places the part on an intermediate carrier, wherein the intermediate carrier passes over a conveyor belt in an oven and the part is heated.
  • a continuous furnace with convection heating for example, a continuous furnace with convection heating is used.
  • any other heat aggregates or ovens can be used, in particular ovens, in which the moldings are heated electromagnetically or with microwaves.
  • the molding passes through the furnace on the support, the support being provided so that the corrosion protection coating is not transferred to rolls of the continuous furnace or is rubbed off by it during heating.
  • the parts are heated to a temperature which is above the austenitizing temperature of the alloy used.
  • the maximum temperature of the parts is kept as low as possible, which, as already stated, is made possible in particular by the part being cooled more slowly by the zinc layer.
  • a robot takes the part, depending on the thickness at 780 ° C to 950 ° C, especially 860 ° C to 900 ° C from the oven and places it in the mold hardening tool.
  • the molded part loses approximately 10 ° C. to 80 ° C., in particular 40 ° C., whereby the insertion robot is preferably designed such that it inserts the part accurately into the mold hardening tool at high speed.
  • the molding is The robot places it on a part lifter and then quickly shuts down the press, displacing the lifter and fixing the part. This will ensure that the component is properly positioned and guided until the tool is closed.
  • the part still has a temperature of at least 780 ° C.
  • the surface of the tool has a temperature of less than 50 ° C, whereby the part is rapidly cooled to 80 ° C to 200 ° C. The longer the part is held in the tool, the better the dimensional accuracy.
  • the tool is subjected to thermal shock, wherein the method according to the invention makes it possible to design the tool with respect to its base material for a high thermal shock resistance, in particular if no forming steps are carried out during the mold hardening step.
  • the tools In conventional methods, the tools must also have a high abrasion resistance, but in the present case does not play a significant role and thus reduces the cost of the tool.
  • a robot takes the parts out of the press and places them on a rack, where they continue to cool down.
  • the Cooling may, if desired, be accelerated by additional blowing on of air.
  • the inventive mold hardening without appreciable forming steps and with a substantially full-surface fit of the tool and the tool piece, it is ensured that all areas of the workpiece are defined and uniformly cooled on all sides.
  • a comprehensible defined cooling takes place only when the forming process has progressed so far that the material rests against both mold halves.
  • the material is preferably immediately on all sides positively against the mold halves.
  • An additional advantage is the low stress on the mold hardening tool due to the complete cold end geometry. This can be a much higher Tool life and dimensional accuracy can be achieved, which in turn means a cost reduction.
  • the form hardening is performed so that a concern of the workpiece to the mold halves or a positive connection between the workpiece and tool only at the narrow toleranced areas such as the cutting and shaping edges, the forming surfaces and optionally in the areas of the Lochndues done.
  • the positive connection in these areas is brought about such that these areas are held and clamped so securely that less tightly tolerated areas can hot working in the tooling process, without the already dimensionally accurate and tolerated narrowly tolerated areas are adversely affected and warped in particular.
  • the not tightly tolerated areas either by not applying one or both mold halves slower to cool down and reach there by the slower cooling other degrees of hardness, or to achieve a desired hot forming in these areas, without the tightly tolerated areas are affected. This can be done for example by additional stamp in the mold halves. It is essential, as already stated, however, also in this preferred embodiment, that the tightly tolerated areas remain unaffected in terms of shape hardening with respect to forming.

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Abstract

Method for production of a hardened profile part from a hardenable steel alloy having cathodic corrosion protection by: (a) application of a Zn coating to a hardenable steel alloy sheet; (b) roll profiling of the coated sheet with shaping into a roll-shaped profile strand; (c) heating of the coated steel sheet to the hardening temperature with admission of atmospheric oxygen, formation of a superficial oxide skin from oxygen-affine elements; and (d) cooling. Independent claims are included for: (1) a corrosion protection Zn layer for a steel sheet; (2) a hardened and profiled component in hardenable steel with a cathodically protected layer obtained as above.

Description

Die Erfindung betrifft ein Verfahren zum Herstellen von gehärteten Bauteilen aus Stahlblech.The invention relates to a method for producing hardened components from sheet steel.

Im Bereich des Automobilbaus besteht ein Bestreben das Fahrzeuggesamtgewicht abzusenken oder bei verbesserten Ausstattungen das Fahrzeuggesamtgewicht nicht ansteigen zu lassen. Dies kann nur realisiert werden, wenn das Gewicht bestimmter Fahrzeugkomponenten abgesenkt wird. Hierbei wird insbesondere versucht das Gewicht der Fahrzeugrohkarosserie deutlich gegenüber früher abzusenken. Gleichzeitig sind jedoch die Anforderungen an die Sicherheit, insbesondere die Personensicherheit im Kraftfahrzeug und an das Verhalten bei Verunfallung des Fahrzeuges gestiegen. Während für die Absenkung des Karosserierohgewichts die Anzahl der Teile verringert und insbesondere auch die Dicke reduziert wird, wird erwartet, dass die Rohkarosserie mit verringertem Gewicht bei einer Verunfallung eine erhöhte Festigkeit und Steifigkeit bei einem definierten Verformungsverhalten zeigt.In the automotive industry there is a desire to lower the total vehicle weight or not to increase the total vehicle weight with improved equipment. This can only be realized if the weight of certain vehicle components is lowered. In this case, in particular the weight of the vehicle bodywork is trying to lower significantly compared to earlier. At the same time, however, the requirements for safety, in particular personal safety in the motor vehicle and the behavior at accident of the vehicle have increased. While the number of parts is reduced and, in particular, the thickness is reduced for the lowering of the body weight, it is expected that the reduced weight body of an accident will show increased strength and rigidity with a defined deformation behavior.

Der am meisten angewandte Rohstoff bei der Karosseriehersteldung ist Stahl. Mit keinem anderen Werkstoff lassen sich in derart großen Bereichen kostengünstig Bauteile mit den unterschiedlichsten Werkstoffeigenschaften zur Verfügung stellen.The most widely used raw material in bodybuilding is steel. With no other material can be in such large areas cost components with different material properties available.

Aus den geänderten Anforderungen resultiert, dass bei hohen Festigkeiten, auch hohe Dehnungswerte und damit eine verbesserte Kaltumformbarkeit gewährleistet ist. Ferner ist der Bereich der darstellbaren Festigkeiten für Stähle erweitert worden.From the changed requirements results that with high strengths, also high strain values and thus an improved Cold workability is guaranteed. Furthermore, the range of representable strengths for steels has been extended.

Eine Perspektive insbesondere für Karosserien im Automobilbau sind dabei Bauteile aus Stahlfeinblech mit einer Festigkeit in Abhängigkeit der Legierungszusammensetzung in einem Bereich von 1000 bis zu 2000 MPa. Um derart hohe Festigkeiten im Bauteil zu erreichen, ist es bekannt, aus Blechen entsprechende Platinen zu schneiden, die Platinen auf eine Temperatur zu erwärmen die über der Austenitisierungstemperatur liegt und anschließend das Bauteil in einer Presse umzuformen, wobei während des Umformvorganges gleichzeitig ein rasches Abkühlen zum Härten des Werkstoffes durchgeführt wird.A perspective, in particular for bodies in the automotive industry are components made of steel sheet with a strength depending on the alloy composition in a range of 1000 up to 2000 MPa. In order to achieve such high strengths in the component, it is known to cut from sheets corresponding boards to heat the boards to a temperature above the Austenitisierungstemperatur and then to reshape the component in a press, during the forming simultaneously a rapid cooling to Hardening of the material is performed.

Während des Glühens, um die Bleche zu austenitisieren, bildet sich an der Oberfläche eine Zunderschicht. Diese wird nach dem Umformen und Abkühlen entfernt. Dies geschieht üblicherweise mit Sandstrahlverfahren. Vor oder nach diesem Entzundern wird der Endbeschnitt und das Einfügen von Löchern durchgeführt. Werden der Endbeschnitt und das Einfügen der Löcher vor dem Sandstrahlen durchgeführt, ist von Nachteil, dass die Schnittkanten und Lochkanten in Mitleidenschaft gezogen werden. Unabhängig von der Reihenfolge der Bearbeitungsschritte nach dem Härten ist beim Endzundern durch Sandstrahlen und vergleichbaren Verfahren von Nachteil, dass hierdurch das Bauteil häufig verzogen wird. Nach dem genannten Bearbeitungsschritten erfolgt eine sogenannte Stückbeschichtung mit einer Korrosionsschutzschicht. Beispielsweise wird eine kathodisch wirksame Korrosionsschutzschicht aufgebracht.During annealing to austenitize the sheets, a scale layer forms on the surface. This is removed after forming and cooling. This is usually done with sandblasting. Before or after this descaling, the final trimming and the insertion of holes is carried out. If the final trimming and the insertion of the holes are carried out before sandblasting, it is disadvantageous that the cut edges and hole edges are affected. Irrespective of the order of the processing steps after curing, it is disadvantageous in the case of final scaling by sandblasting and comparable methods that the component is often distorted as a result. After said processing steps, a so-called piece coating with a corrosion protection layer takes place. For example, a cathodically effective corrosion protection layer is applied.

Hierbei ist von Nachteil, dass die Nachbearbeitung des gehärteten Bauteils außerordentlich aufwendig ist und aufgrund der Härtung des Bauteils sehr hohem Verschleiß unterliegt. Ferner ist von Nachteil, dass die Stückbeschichtung üblicherweise einen Korrosionsschutz bewirkt, der nicht besonders stark ausgeprägt ist. Zudem sind die Schichtdicken nicht einheitlich, sondern schwanken über die Bauteilfläche.It is disadvantageous that the post-processing of the cured component is extremely expensive and is subject to very high wear due to the hardening of the component. Further is disadvantageous that the piece coating usually causes a corrosion protection, which is not particularly pronounced. In addition, the layer thicknesses are not uniform, but fluctuate over the component surface.

In einer Abwandlung dieses Verfahrens ist es auch bekannt, ein Bauteil aus einer Blechplatine kalt umzuformen und anschließend auf die Austenitisierungstemperatur aufzuheizen und dann in einem Kalibrierwerkzeug schnell abzukühlen, wobei das Kalibrierwerkzeug dafür verantwortlich ist, dass das Bauteil, welches durch das Aufwärmen verzogen wird, bezüglich der umgeformten Bereiche kalibriert wird. Anschließend erfolgt die zuvor beschriebene Nachbearbeitung. Dieses Verfahren ermöglicht gegenüber dem zuvor beschriebenen Verfahren komplexere Geometrien, da sich beim gleichzeitigen Umformen und Härten im Wesentlichen nur lineare Formen erzeugen lassen, komplexe Formen jedoch bei derartigen Umformvorgängen nicht realisierbar sind.In a modification of this method, it is also known to cold form a component from a sheet metal blank and then heat to the Austenitisierungstemperatur and then cool rapidly in a calibration tool, wherein the calibration tool is responsible for the component, which is warped by the warm-up, with respect the reshaped areas are calibrated. Subsequently, the post-processing described above. Compared with the method described above, this method allows more complex geometries, since essentially only linear shapes can be produced during simultaneous forming and hardening, but complex shapes can not be realized in such forming processes.

Aus der GB 1 490 535 ist ein Verfahren zum Herstellen eines gehärteten Stahlbauteils bekannt, bei dem ein Blech aus härtbaren Stahl auf die Härtetemperatur erhitzt wird und anschließend in einer Formgebungseinrichtung angeordnet wird in der das Blech in die gewünschte Endform geformt wird, wobei während der Umformung simultan schnell abgekühlt wird, so dass eine martensitische oder bainitische Struktur erhalten wird während das Blech in der Formvorrichtung verbleibt. Als Ausgangsmaterial wird beispielsweise ein borlegierter Kohlenstoffstahl oder Kohlenstoffmanganstahl verwendet. Nach dieser Druckschrift ist die Umformung vorzugsweise eine Pressung kann aber auch mit anderen Verfahren angewendet werden. Die Umformung und das Abkühlen sollen vorzugsweise so ausgeführt werden und so schnell durchgeführt werden, dass eine feinkörnige martensitische oder bainitische Struktur erhalten wird.From the GB 1 490 535 a method for producing a hardened steel component is known, in which a sheet of hardenable steel is heated to the hardening temperature and then placed in a shaping device in which the sheet is formed into the desired final shape, wherein simultaneously cooled rapidly during the forming, so that a martensitic or bainitic structure is obtained while the sheet remains in the molding apparatus. As a starting material, for example, a boron-alloyed carbon steel or carbon manganese steel is used. According to this document, the deformation is preferably a compression but can also be used with other methods. The forming and cooling should preferably be carried out and carried out so rapidly that a fine-grained martensitic or bainitic structure is obtained.

Aus der EP 1 253 208 A1 ist ein Verfahren zur Herstellung eines gehärteten Blechprofils aus einer Platine, die in einem Presswerkzeug zum Blechprofil warm umgeformt und gehärtet wird, bekannt. Am Blechprofil werden hierbei aus der Ebene der Platine vorstehende Referenzpunkte beziehungsweise Kragen erzeugt, die zur Lageorientierung des Blechprofils in nachfolgenden Fertigungsoperationen dienen. Die Kragen sollen beim Umformvorgang aus ungelochten Bereichen der Platine ausgeformt werden, wobei die Referenzpunkte in Form von randseitigen Verprägungen oder als Durchstellungen beziehungsweise Kragen im Blechprofil erzeugt werden. Das Warmumformen und Härten im Presswerkzeug soll aufgrund der durch die Kombination von Umform- und Vergütungsvorgang in einem Werkzeug rationellen Arbeitsweise generell Vorteile haben. Aufgrund der Einspannung des Blechprofils im Werkzeug und aufgrund von Wärmespannungen soll es jedoch zu nicht exakt vorhehrbestimmbaren Verzug am Bauteil kommen. Dieser kann sich nachteilig auf nachgeschaltete Fertigungsoperationen auswirken, weshalb die Referenzpunkte am Blechprofil geschaffen werden.From the EP 1 253 208 A1 is a method for producing a hardened sheet metal profile from a board, which is hot formed and cured in a pressing tool to the sheet metal profile known. On the sheet metal profile projecting reference points or collars are generated from the plane of the board, which serve for positional orientation of the sheet metal profile in subsequent manufacturing operations. The collars should be formed during the forming process of non-perforated areas of the board, the reference points are generated in the form of marginal stampings or as enforcements or collar in the sheet metal profile. The hot forming and hardening in the pressing tool should generally have advantages due to the efficient by the combination of forming and tempering process in a tool operation. Due to the clamping of the sheet metal profile in the tool and due to thermal stresses, however, it should come to not exactly predeterminable delay on the component. This can adversely affect downstream manufacturing operations, which is why the reference points are created on the sheet metal profile.

Aus der DE 197 23 655 A1 ist ein Verfahren zur Herstellung von Stahlblechprodukten bekannt, wobei ein Stahlblechprodukt in einem Paar gekühlter Werkzeuge geformt wird, solange es heiß ist und in eine martensitische Struktur gehärtet wird, während es immer noch im Werkzeug befindlich ist, so dass die Werkzeuge als eine Fixierung während des Härtens dienen. In den Bereichen in denen nach dem Härten eine Bearbeitung stattfinden soll, soll der Stahl im Flussstahlbereich gehalten werden, wobei Einsätze in den Werkzeugen dazu verwendet werden, eine schnelle Abkühlung und dadurch eine martensitische Struktur in diesen Bereichen zu verhindern. Die gleiche Wirkung soll auch durch Ausnehmungen in den Werkzeugen erreicht werden können, so dass ein Spalt zwischen dem Stahlblech und den Werkzeugen auftritt. Bei diesem Verfahren ist von Nachteil, dass aufgrund des erheblichen Verzuges, der hierbei auftreten kann, das vorliegende Verfahren zum Presshärten von Bauteilen mit komplexerer Struktur untauglich ist.From the DE 197 23 655 A1 For example, a method of making steel sheet products is known wherein a steel sheet product is molded in a pair of cooled tools while hot and hardened into a martensitic structure while still in the tool so that the tools act as a fixture during the process Hardening serve. In the areas where machining is to take place after hardening, the steel shall be kept in the mild steel area, with inserts in the tools used to prevent rapid cooling and thereby a martensitic structure in these areas. The same effect should also be achieved by recesses in the tools, so that a gap between the steel sheet and the tools occurs. In this method is disadvantageous because of the significant delay that can occur here, the present method for press hardening of components with more complex structure is disabled.

Aus der DE 100 49 660 A1 ist ein Verfahren zum Herstellen lokalverstärkter Blechumformteile bekannt, wobei das Basisblech des Strukturteils im Flachzustand mit dem Verstärkungsblech lagedefiniert verbunden und dieses sogenannte gepatchte Verbundblech anschließend gemeinsam umgeformt wird. Um das Herstellungsverfahren hinsichtlich Verfahrenserzeugnis und Ergebnis zu verbessern, sowie bezüglich der verfahrensübenden Mittel zu entlasten wird das gepatchte Verbundblech vor dem Umformen mindestens auf etwa 800 bis 850°C erwärmt, rasch eingelegt, im warmen Zustand zügig umgeformt und anschließend bei mechanischer Aufrechterhaltung des Umformzustandes durch Kontaktierung mit dem von innen her zwangsgekühlten Umformwerkzeug definiert abgekühlt. Insbesondere der insoweit maßgebende Temperaturbereich 800 bis 500°C soll mit einer definierten Abkühlgeschwindigkeit durchfahren werden. Der Schritt des Verbindens von Verstärkungsblech und Basisblech soll ohne weiteres in dem Umformprozess integriert werden können, wobei die Teile miteinander hartverlötet werden wodurch zugleich ein wirksamer Korrosionsschutz an der Kontaktzone erreicht werden kann. Bei diesem Verfahren ist von Nachteil, dass die Werkzeuge insbesondere durch die definierte Innenkühlung sehr aufwendig sind.From the DE 100 49 660 A1 a method for producing locally reinforced sheet metal formed parts is known, wherein the base sheet of the structural part connected in a flat state with the reinforcing sheet and defined this so-called patched composite sheet is then formed together. In order to improve the manufacturing process in terms of process product and result, as well as to relieve the procedural means the patched composite sheet is heated to at least about 800 to 850 ° C before forming, quickly inserted, rapidly formed in the hot state and then with mechanical maintenance of the forming state by Contacting with the internally forced-cooled forming tool defines cooled. In particular, the extent relevant temperature range 800 to 500 ° C is to be traversed with a defined cooling rate. The step of connecting reinforcing sheet and base sheet should be readily integrated in the forming process, wherein the parts are brazed together whereby an effective corrosion protection at the contact zone can be achieved at the same time. In this method, it is disadvantageous that the tools are very expensive, in particular due to the defined internal cooling.

Aus der DE 2 003 306 sind ein Verfahren und eine Einrichtung zum Pressen und Härten eines Stählteils bekannt. Ziel ist es Stahlblechstücke in Form zu pressen und zu härten, wobei die Nachteile bekannter Verfahren vermieden werden sollen, insbesondere, dass Teile aus Stahlblech in aufeinanderfolgenden gesonderten Schritten zum Formpressen und Härten hergestellt werden. Insbesondere soll vermieden werden, dass die gehärteten oder abgeschreckten Erzeugnisse gegenüber der gewünschten Form einen Verzug zeigen, so dass zusätzliche Arbeitsschritte erforderlich sind. Zur Verwirklichung ist es vorgesehen ein Stahlstück, nachdem das Stück auf eine seinen austenitischen Zustand herbeiführenden Temperatur erwärmt worden ist, zwischen einem Paar zusammenwirkender Formelemente zu legen, worauf das Stück gepresst und gleichzeitig schnell Wärme von dem Stück in die Formteile abgeleitet wird. Die Formteile werden während des gesamten Vorganges auf einer Kühltemperatur gehalten, so dass auf das Stück eine Abschreckwirkung unter einem Formdruck ausgeübt wird.From the DE 2 003 306 For example, a method and a device for pressing and hardening a steel part are known. The aim is to press and harden sheet steel pieces in the form of avoiding the disadvantages of known methods, in particular that parts made of steel sheet are produced in successive separate steps for compression molding and hardening. In particular, it should be avoided that the hardened or quenched products to the desired shape show a delay, so that additional steps are required. To accomplish this, it is intended to place a piece of steel, after the piece has been heated to a temperature attaining its austenitic condition, between a pair of cooperating mold members, whereupon the piece is pressed and at the same time heat is rapidly dissipated from the piece to the mold pieces. The mold parts are kept at a cooling temperature throughout the process, so that a quenching effect is exerted on the piece under a molding pressure.

Aus der DE 101 20 063 C2 ist es bekannt, metallische Profilbauteile für Kraftfahrzeuge aus einem in Bandform bereitgestelltem Ausgangsmaterial einer Walzprofiliereinheit zuzuführen und zu einem Walzprofil umzuformen, wobei nach dem Austritt aus der Walzprofiliereinheit partielle Bereiche des Walzprofils induktiv auf eine zum Härten erforderliche Temperatur erwärmt und anschließend in einer Abkühleinheit abgeschreckt werden. Im Anschluss hieran sollen die Walzprofile zu den Profilbauteilen abgelängt werden.From the DE 101 20 063 C2 It is known to feed metallic profiled components for motor vehicles from a strip-formulated starting material of a roll forming and to form a rolled profile, wherein after exiting the Walzprofiliereinheit partial areas of the rolled section are inductively heated to a temperature required for curing and then quenched in a cooling unit. Following this, the rolled sections are to be cut to the profile components.

Aus der US 6,564,604 B2 ist ein Verfahren zum Herstellen eines Teils mit sehr hohen mechanischen Eigenschaften bekannt, wobei das Teil durch das Stanzen eines Streifens aus einem gewalzten Stahlblech hergestellt werden soll und insbesondere ein warmgewalztes und beschichtetes Bauteil mit einer Metall- oder Metalllegierung beschichtet ist, welches die Oberfläche des Stahls schützen soll, wobei das Stahlblech geschnitten wird, um ein Stahlblechvorformling zu erhalten, der Stahlblechvorformling kalt oder warm umgeformt wird und entweder nach dem Warmumformen gekühlt und gehärtet wird oder nach dem Kaltumformen erhitzt und anschließend abgekühlt wird. Eine intermetallische Legierung soll auf die Oberfläche vor oder nach demFrom the US 6,564,604 B2 For example, a method of producing a part having very high mechanical properties is known, wherein the part is to be produced by punching a strip from a rolled steel sheet, and in particular a hot rolled and coated part is coated with a metal or metal alloy covering the surface of the steel to protect, wherein the steel sheet is cut to obtain a steel sheet preform, the steel sheet preform is cold or hot formed and is either cooled and hardened after hot working or heated after cold working and then cooled. An intermetallic alloy is supposed to be on the surface before or after

Umformen aufgebracht werden und einen Schutz gegen Korrosion und Stahlentkohlung bieten, wobei diese intermetallische Mischung zudem eine Schmierfunktion haben kann. Anschließend wird das überstehende Material von dem Formling abgenommen. Die Beschichtung soll hierbei allgemein auf der Basis von Zink oder Zink-Aluminium beruhen. Hierbei kann ein Stahl verwendet werden der beidseitig elektrolytisch verzinkt ist, wobei eine Austenitisierung bei 950°C erfolgen soll. Diese elektrolytisch verzinkte Schicht wird bei der Austenitisierung komplett in eine Eisen-Zink-Legierung umgesetzt. Es wird ausgeführt, dass beim Umformen und während des Haltens zum Kühlen die Beschichtung den Wärmeabfluss durch das Werkzeug nicht behindert und den Wärmeabfluss sogar verbessert. Zudem schlägt diese Druckschrift vor als Alternative zu einem elektrolytisch verzinkten Band eine Beschichtung aus 45 % bis 50 % Zink, Rest Aluminium zu verwenden. Bei dem genannten Verfahren in seinen beiden Ausführungsformen ist von Nachteil, dass ein kathodischer Korrosionsschutz praktisch nicht mehr vorhanden ist. Zudem ist eine derartige Schicht so spröde, dass beim Umformen Risse auftreten. Eine Beschichtung mit einer Mischung aus 45 bis 50 % Zink und 55 bis 45 % Aluminium entfaltet ebenfalls keinen nennenswerten kathodischen Korrosionsschutz. Zwar wird in dieser Druckschrift behauptet, dass die Verwendung von Zink oder Zink-Legierungen als Beschichtung sogar für die Kanten einen galvanischen Schutz ergeben würde, dies kann jedoch in der Praxis nicht erreicht werden. In der Praxis kann durch die beschriebenen Beschichtungen nicht einmal ein ausreichender galvanischer Schutz in der Fläche erreicht werden.Forming applied and provide protection against corrosion and steel decarburization, this intermetallic mixture can also have a lubricating function. Subsequently, the supernatant material is removed from the molding. The coating should generally be based on zinc or zinc-aluminum. In this case, a steel can be used which is electrolytically galvanized on both sides, with an austenitization to take place at 950 ° C. This electrolytically galvanized layer is completely converted into an iron-zinc alloy during austenitisation. It is stated that during forming and while being held for cooling, the coating does not hinder the heat flow through the tool and even improves heat dissipation. In addition, this document proposes as an alternative to an electrolytically galvanized tape to use a coating of 45% to 50% zinc, balance aluminum. In the aforementioned method in its two embodiments is disadvantageous that a cathodic corrosion protection is practically no longer available. In addition, such a layer is so brittle that cracks occur during forming. A coating with a mixture of 45 to 50% zinc and 55 to 45% aluminum also exhibits no significant cathodic corrosion protection. While it is claimed in this reference that the use of zinc or zinc alloys as a coating would provide galvanic protection even to the edges, this can not be achieved in practice. In practice, the coatings described can not even achieve sufficient galvanic protection in the surface.

Aus der EP 1 013 785 A1 ist ein Herstellungsverfahren eines Bauteils aus einem gewalzten Stahlband und insbesondere einem warmgewalzten Band bekannt. Ziel soll es sein, gewalzte Stahlbleche von 0,2 bis 2,0 mm Dicke anbieten zu können, die unter anderem nach der Warmwalzung beschichtet werden und die einer Verformung entweder kalt oder warm, gefolgt von einer thermischen Behandlung unterworfen werden, wobei der Anstieg der Temperatur ohne Stahlentkohlung und ohne Oxidation der Oberfläche der vorgenannten Bleche vor, während und nach der Warmverformung oder der thermischen Behandlung gesichert werden soll. Hierzu soll das Blech mit einem Metall oder einer Metalllegierung, die den Schutz der Oberfläche des Bleches sichert, versehen werden, anschließend das Blech einer Temperaturerhöhung für die Umformung unterworfen werden, anschließend eine Umformung des Bleches durchgeführt werden und das Teil abschließend abgekühlt werden. Insbesondere soll das beschichtete Blech in heißem Zustand gepresst werden und das durch das Tiefziehen entstandene Teil abgekühlt werden um gehärtet zu werden und zwar mit einer Geschwindigkeit die höher ist als die kritische Härtungsgeschwindigkeit. Es wird ferner eine Stahllegierung angegeben, welche geeignet sein soll, wobei dieses Stahlblech bei 950°C austenitisiert werden soll, bevor es im Werkzeug verformt und gehärtet wird. Die aufgebrachte Beschichtung soll insbesondere aus Aluminium oder einer Aluminiumlegierung bestehen, wobei hierdurch nicht nur ein Oxidations- und Entkohlungsschutz, sondern auch eine Schmierwirkung resultieren soll. Bei diesem Verfahren kann es zwar im Gegensatz zu den anderen bekannten Verfahren vermieden werden, dass das Blechteil nach dem Aufheizen auf die Austenitisierungstemperatur verzundert, ein Kaltumformen wie dies in dieser Schrift dargestellt ist, ist jedoch mit feueraluminierten Blechen grundsätzlich nicht möglich, da die feueraluminierte Schicht eine zu geringe Duktilität für eine größere Verformung aufweist. Insbesondere Tiefziehprozesse komplexerer Formen sind mit derartigen Blechen im kalten Zustand nicht realisierbar. Mit einer derartigen Beschichtung sind Warmumformungen, dass heißt das Umformen und Härten in einem einzigen Werkzeug möglich, das Bauteil weist danach jedoch keinen kathodischen Schutz auf. Zu dem muss auch ein solches Bauteil nach dem Härten mechanisch oder mittels Laser bearbeitet werden, so dass der bereits beschriebene Nachteil eintritt, dass nachfolgende Bearbeitungsschritte durch die Härte des Materials sehr aufwendig sind. Darüber hinaus ist von Nachteil, dass alle Bereiche des Formteils, welche mittels Laser oder mechanisch geschnitten werden über keinerlei Korrosionsschutz mehr verfügen.From the EP 1 013 785 A1 For example, a method of manufacturing a rolled steel strip component, and in particular a hot rolled strip, is known. The aim is to be able to offer rolled steel sheets of 0.2 to 2.0 mm in thickness, which are coated, inter alia, after hot rolling and the one Deformation, either cold or hot, followed by a thermal treatment, whereby the increase in temperature without steel decarburization and without oxidation of the surface of the aforementioned sheets is to be ensured before, during and after the hot working or the thermal treatment. For this purpose, the sheet should be provided with a metal or a metal alloy, which ensures the protection of the surface of the sheet, then the sheet is subjected to a temperature increase for the forming, then a transformation of the sheet are performed and the part are finally cooled. In particular, the coated sheet is to be pressed while hot and the part formed by the deep drawing to be cooled to be cured and that at a speed which is higher than the critical curing rate. There is further provided a steel alloy, which should be suitable, said steel sheet to be austenitized at 950 ° C before it is deformed and hardened in the tool. The applied coating should consist in particular of aluminum or an aluminum alloy, whereby not only an oxidation and decarburization protection, but also a lubricating effect should result. In this method, it can indeed be avoided in contrast to the other known methods that the sheet metal part after heating to the austenitizing temperature verzallert, cold forming as shown in this document, but is basically not possible with hot-dip aluminized sheets, as the feueraluminierte layer has too low ductility for greater deformation. In particular, deep-drawing processes of more complex shapes can not be realized with such sheets in the cold state. With such a coating hot forming, that is, the forming and curing in a single tool possible, but then the component has no cathodic protection. In addition, such a component must after hardening be processed mechanically or by laser, so that the disadvantage already described occurs that subsequent processing steps are very expensive due to the hardness of the material. In addition, it is disadvantageous that all areas of the molded part which are cut by laser or mechanically no longer have any corrosion protection.

Aus der DE 102 54 695 B3 ist es bekannt, zur Herstellung eines metallischen Formbauteils, insbesondere eines Karosseriebauteils aus einem Halbzeug, aus einem ungehärteten warmformbaren Stahlblech, das Halbzeug zunächst durch ein Kaltumformverfahren, insbesondere durch Tiefziehen zu einem Bauteilrohling umzuformen. Anschließend soll der Bauteilrohling randseitig auf eine dem herzustellenden Bauteil näherungsweise entsprechende Berandungskontur beschnitten werden. Schließlich wird der beschnittene Bauteilrohling erwärmt und in einem Warmumformwerkzeug pressgehärtet. Das dabei erzeugte Bauteil weist bereits nach dem Warmumformen die gewünschte Berandungskontur auf, so dass eine abschließende Beschneidung des Bauteilrandes entfällt. Auf diese Weise sollen die Zykluszeiten bei der Herstellung gehärteter Bauteile aus Stahlblech erheblich gesenkt werden. Der verwendete Stahl soll ein lufthärtender Stahl sein, der ggf. unter einer Schutzgasatmosphäre aufgeheizt wird, um eine Verzunderung während des Aufheizens zu vermeiden. Anderenfalls wird eine Zunderschicht vor das Formbauteil nach dem Warmumformen des Formbauteils entzundert. In dieser Druckschrift wird erwähnt, dass im Rahmen des Kaltumformprozesses der Bauteilrohling endkonturennah ausgeformt wird, wobei unter "endkonturnah" verstanden werden soll, dass diejenigen Teile der Geometrie des fertigen Bauteils, welche mit einem makroskopischen Materialfluss einhergehen, nach Abschluss des Kaltumformprozesses vollständig in den Bauteilrohling eingeformt sind. Nach Abschluss des Kaltumformprozesses sollen somit zur Herstellung der dreidimensionalen Form des Bauteils nur noch geringe Formanpassungen notwendig sein, welche einen minimalen lokalen Materialfluss erfordern. Bei diesem Verfahren ist von Nachteil, dass nach wie vor ein Endformschritt der gesamten Kontur im warmen Zustand erfolgt, wobei zur Vermeidung von Verzunderung entweder der bekannte Weg gegangen werden muss, das unter Schutzgas geglüht werden muss oder die Teile entzundert werden müssen. Beiden Prozessen muss eine anschließende Korrosionsstückbeschichtung nachfolgen.From the DE 102 54 695 B3 It is known for the production of a metallic mold component, in particular a body component from a semi-finished, from an uncured thermoformable steel sheet, the semi-finished first by a cold forming process, in particular by deep drawing to form a component blank. Subsequently, the component blank is intended to be trimmed on the edge side to a boundary contour approximately corresponding to the component to be produced. Finally, the clipped component blank is heated and press-cured in a hot-forming tool. The component produced thereby already has the desired boundary contour after hot forming, so that a final trimming of the component edge is eliminated. In this way, the cycle times in the production of hardened steel sheet components are to be significantly reduced. The steel used should be an air-hardening steel, which may be heated under a protective gas atmosphere in order to avoid scaling during heating. Otherwise, a scale layer is descaled in front of the mold component after hot working of the mold component. In this document, it is mentioned that, as part of the cold forming process, the component blank is shaped close to the final contour, "near net shape" being understood to mean that those parts of the geometry of the finished component which are associated with a macroscopic flow of material completely into the component blank after completion of the cold forming process are formed. After completion of the cold forming process Thus, for the production of the three-dimensional shape of the component only slight form adjustments to be necessary, which require a minimum local material flow. In this method, it is disadvantageous that there is still a final forming step of the entire contour in the warm state, which must be done to avoid scaling either the known way, which must be annealed under protective gas or the parts must be descaled. Both processes must be followed by a subsequent corrosive coating.

Zusammenfassend kann gesagt werden, dass bei allen vorgenannten Verfahren sämtlichst von Nachteil ist, dass die hergestellten Teile nach dem Umformen und Härten weiter bearbeitet werden müssen was teuer und aufwendig ist. Zudem besitzen die Bauteile entweder keinen oder nur einen ungenügenden Korrosionsschutz.In summary, it can be stated that in all the above-mentioned methods, it is extremely disadvantageous that the produced parts have to be further processed after forming and hardening, which is expensive and expensive. In addition, the components have either no or only insufficient corrosion protection.

Aufgabe der Erfindung ist es, ein Verfahren zum Herstellen von gehärteten Bauteilen aus Stahlblech zu schaffen, welches einfach und schnell durchführbar ist und welches es ermöglicht, gehärtete Bauteile aus Stahlblech insbesondere Stahlfeinblech mit einem kathodischen Korrosionsschutz dimensionsgenau und ohne Nachbearbeitung wie Entzundern und Sandstrahlen herzustellen.The object of the invention is to provide a method for producing hardened components made of sheet steel, which is simple and quick to carry out and which makes it possible to produce hardened components made of sheet steel in particular steel sheet with a cathodic corrosion protection dimensionally accurate and without finishing such as descaling and sandblasting.

Die Aufgabe wird mit einem Verfahren mit den Merkmalen des Anspruchs 1 gelöst. Vorteilhafte Weiterbildungen sind in den Unteransprüchen gekennzeichnet.The object is achieved by a method having the features of claim 1. Advantageous developments are characterized in the subclaims.

Erfindungsgemäß wird das Umformen der Bauteile sowie das Beschneiden und Lochen der Bauteile im Wesentlichen im ungehärteten Zustand durchgeführt. Die relativ gute Verformbarkeit des verwendeten speziellen Materials im ungehärteten Zustand lässt die Realisierung komplexer Bauteilgeometrien zu und ersetzt teures nachträgliches Beschneiden im gehärteten Zustand durch wesentlich preisgünstigere mechanische Schneidoperationen vor dem Härteprozess.According to the invention, the forming of the components as well as the trimming and punching of the components is carried out essentially in the uncured state. The relatively good deformability of the particular material used in the unhardened state allows the realization of complex component geometries and replaces expensive subsequent trimming in the cured state by significantly less expensive mechanical cutting operations before the hardening process.

Die unvermeidlichen Dimensionsänderungen durch das Erhitzen des Bauteils werden bei dem Umformen des kalten Blechs bereits berücksichtigt, so dass das Bauteil circa 0,5 bis 2 % kleiner hergestellt wird, als es die Endabmessungen sind. Zumindest wird die erwartete Wärmedehnung bei der Umformung berücksichtigt.The unavoidable dimensional changes due to the heating of the component are already taken into account in forming the cold sheet, so that the component is made approximately 0.5 to 2% smaller than the final dimensions. At least the expected thermal expansion during forming is considered.

Bei dem kaltem Bearbeiten des Bauteils, das heißt dem Umformen, Schneiden und Lochen ist es ausreichend, die Bereiche mit hoher Komplexität und Umformtiefe und gegebenenfalls die eng tolerierten Bereiche des Bauteils wie insbesondere die Schnittkanten, die Formkanten, die Formflächen und gegebenenfalls das Lochbild, wie insbesondere die Referenzlöcher mit den gewünschten Endtoleranzen, insbesondere den Beschnitt- und Lagetoleranzen, des fertigen, gehärteten Bauteils zu fertigen, wobei hierbei die Wärmedehnung des Bauteils durch das Aufheizen berücksichtigt bzw. kompensiert wird.In the cold working of the component, that is, the forming, cutting and punching, it is sufficient, the areas of high complexity and forming depth and possibly the narrow toleranced areas of the component such as in particular the cut edges, the shape edges, the forming surfaces and possibly the hole pattern, such as In particular, to manufacture the reference holes with the desired final tolerances, in particular the trimming and position tolerances, of the finished, hardened component, in which case the thermal expansion of the component is taken into account or compensated for by the heating.

Dies bedeutet, dass das Bauteil nach dem kalten Umformen ca. 0,5 % bis 2 % kleiner ist als die Soll-Endabmessungen des fertigen, gehärteten Bauteils. Kleiner bedeutet hierbei, dass das Bauteil nach dem kalten Umformen in allen drei Raumachsen also dreidimensional fertiggeformt ist. Die Wärmedehnung wird somit für alle drei Raumachsen gleichermaßen berücksichtigt. Im Stand der Technik kann die Wärmedehnung durch beispielsweise das nicht vollständige Schließen der Form nicht für alle Raumachsen berücksichtigt werden, da hier nur in Z-Richtung, durch eine unvollständige Ausformung, eine Dehnung berücksichtigt werden könnte. Erfindungsgemäß wird vorzugsweise die dreidimensionale Geometrie bzw. Kontur des Werkzeugs in allen drei Raumachsen kleiner gefertigt.This means that the component after the cold forming is about 0.5% to 2% smaller than the nominal final dimensions of the finished, hardened component. Smaller here means that the component after cold forming in all three spatial axes is thus three-dimensionally finished molded. The thermal expansion is thus considered equally for all three spatial axes. In the prior art, the thermal expansion can not be taken into account for example by the incomplete closure of the mold for all spatial axes, since only in the Z direction, by an incomplete formation, an elongation could be considered. According to the invention, the three-dimensional geometry or contour of the tool is preferably made smaller in all three spatial axes.

Bislang ist die Fachwelt davon ausgegangen, dass verzinkte Stahlbleche für derartige Prozesse, bei denen vor oder nach dem Umformen ein Aufheizschritt stattfindet, nicht geeignet sind. Dies liegt zum einen daran, dass Zinkschichten oberhalb der bislang üblicherweise angewendeten Ofentemperatur von etwa 900 bis 950°C stark oxidieren oder unter Schutzgas (sauerstofffreie Atmosphäre) flüchtig sind.So far, the art has assumed that galvanized steel sheets are not suitable for such processes in which a heating step takes place before or after the forming. This is partly due to the fact that zinc layers above the previously commonly used furnace temperature of about 900 to 950 ° C strongly oxidize or under protective gas (oxygen-free atmosphere) are volatile.

Der erfindungsgemäße Korrosionsschutz für Stahlbleche, die zunächst einer Wärmebehandlung unterzogen und anschließend umgeformt und dabei gehärtet werden, ist ein kathodischer Korrosionsschutz, der im Wesentlichen auf Zink basiert. Erfindungsgemäß sind dem die Beschichtung ausbildenden Zink 0,1% bis 15% eines sauerstoffaffinen Elements wie Magnesium, Silizium, Titanium, Calcium und Aluminium zugefügt. Es konnte herausgefunden werden, dass derart geringe Mengen eines sauerstoffaffinen Elements wie Magnesium, Silizium, Titanium, Calcium und Aluminium bei dieser speziellen Anwendung einen überraschenden Effekt herbeiführen.The corrosion protection according to the invention for steel sheets, which are first subjected to a heat treatment and then reformed and thereby hardened, is a cathodic corrosion protection which is essentially based on zinc. According to the invention, 0.1% to 15% of an oxygen-affine element such as magnesium, silicon, titanium, calcium and aluminum are added to the zinc forming the coating. It has been found that such small amounts of an oxygen-affine element as magnesium, silicon, titanium, calcium and aluminum induce a surprising effect in this particular application.

Als sauerstoffaffine Elemente kommen erfindungsgemäß zumindest Mg, Al, Ti, Si, Ca in Frage. Wenn nachfolgend Aluminium genannt wird, steht dies stellvertretend auch für die genannten anderen Elemente.As oxygen-affine elements according to the invention at least Mg, Al, Ti, Si, Ca in question. When aluminum is mentioned below, this is representative of the other elements mentioned.

Es hat sich überraschend herausgestellt, dass sich trotz der geringen Menge eines sauerstoffaffinen Elements wie insbesondere Aluminium, beim Aufheizen offensichtlich eine im Wesentlichen aus Al2O3 bzw. einem Oxid des sauerstoffaffinen Elements (MgO, CaO, TiO, SiO2) bestehende, sehr wirksame und nachheilende oberflächliche Schutzschicht bildet. Diese sehr dünne OxidSchicht schützt die darunter liegende Zn-haltige Korrosionsschutzschicht selbst bei sehr hohen Temperaturen vor Oxidation. D.h., dass sich während der speziellen Weiterverarbeitung des verzinkten Bleches im Presshärteverfahren, eine angenähert zweischichtige Korrosionsschutzschicht ausbildet, die aus einer kathodisch hochwirksamen Schicht, mit hohem Anteil Zink besteht und von einer Oxidationsschutzschicht aus einem Oxid (Al2O3, MgO, CaO, TiO, SiO2) gegenüber Oxidation und Abdampfen geschützt ist. Es ergibt sich somit eine kathodische Korrosionsschutzschicht mit einer überragenden chemischen Beständigkeit. Dies bedeutet, dass die Wärmebehandlung in einer oxidierten Atmosphäre zu erfolgen hat. Unter Schutzgas (sauerstofffreie Atmosphäre) kann eine Oxidation zwar vermieden werden, das Zink würde jedoch aufgrund des hohen Dampfdrucks abdampfen.It has surprisingly been found that, despite the small amount of an oxygen-affine element such as aluminum in particular, an essentially consisting of Al 2 O 3 or an oxide of the oxygen-affine element (MgO, CaO, TiO, SiO 2 ) during heating, very much forms an effective and healing superficial protective layer. This very thin oxide layer protects the underlying Zn-containing corrosion protection layer from oxidation even at very high temperatures. That is, during the special processing of the galvanized sheet in the press hardening process, an approximately two-layer corrosion protection layer is formed, which consists of a cathodically highly effective layer, with a high proportion of zinc and an oxidation protective layer of an oxide (Al 2 O 3 , MgO, CaO, TiO , SiO 2 ) is protected against oxidation and evaporation. This results in a cathodic corrosion protection layer with a superior chemical resistance. This means that the heat treatment must be carried out in an oxidized atmosphere. Although under protective gas (oxygen-free atmosphere) oxidation can be avoided, the zinc would evaporate due to the high vapor pressure.

Es hat sich zudem herausgestellt, dass die erfindungsgemäße Korrosionsschutzschicht für das Presshärteverfahren auch eine so große mechanische Stabilität aufweist, dass ein auf das Austenitisieren der Bleche folgender Umformschritt diese Schicht nicht zerstört. Selbst wenn Mikrorisse auftreten, ist die kathodische Schutzwirkung jedoch zumindest deutlich stärker als die Schutzwirkung der bekannten Korrosionsschutzschichten für das Presshärteverfahren.It has also been found that the corrosion protection layer according to the invention for the press-hardening process also has such a high mechanical stability that a forming step following the austenitizing of the sheets this Layer not destroyed. However, even if microcracks occur, the cathodic protection is at least significantly greater than the protective effect of the known anticorrosive layers for the press hardening process.

Um ein Blech mit dem erfindungsgemäßen Korrosionsschutz zu versehen, kann in einem ersten Schritt eine Zinklegierung mit einem Gehalt an Aluminium in Gewichtsprozent von größer als 0,1 jedoch geringer als 15%, insbesondere geringer als 10%, weiter bevorzugt geringer als 5% auf ein Stahlblech, insbesondere ein legiertes Stahlblech aufgebracht werden, worauf in einem zweiten Schritt Teile aus dem beschichteten Blech herausgearbeitet und insbesondere herausgeschnitten oder herausgestanzt werden und bei Zutritt von Luftsauerstoff auf eine Temperatur oberhalb der Austenitisierungstemperatur der Blechlegierung erwärmt und danach mit erhöhter Geschwindigkeit abgekühlt werden. Eine Umformung des aus dem Blech herausgeschnittenen Teils (der Platine) kann vor oder nach dem Erwärmen des Bleches auf die Austenitisierungstemperatur erfolgen.To provide a sheet with the corrosion protection according to the invention, in a first step, a zinc alloy with a content of aluminum in weight percent of greater than 0.1 but less than 15%, in particular less than 10%, more preferably less than 5% on a Steel plate, in particular an alloyed steel sheet are applied, whereupon in a second step, parts of the coated sheet are machined and in particular cut out or punched out and heated on access of atmospheric oxygen to a temperature above the Austenitisierungstemperatur the sheet metal alloy and then cooled at an increased speed. A transformation of the cut out of the sheet metal part (the board) can be carried out before or after the heating of the sheet to the Austenitisierungstemperatur.

Es wird angenommen, dass im ersten Schritt des Verfahrens, und zwar bei der Beschichtung des Bleches an der Blechoberfläche bzw. im proximalen Bereich der Schicht, eine dünne Sperrphase aus insbesondere Fe2Al5-xZnx gebildet wird, die die Fe-Zn-Diffusion bei einem Flüssigmetallbeschichtungsverfahren, welches insbesondere bei einer Temperatur bis 690°C erfolgt, behindert. Somit wird im ersten Verfahrensschritt das Blech mit einer Zink-Metallbeschichtung mit einer Zugabe von Aluminium erstellt, welche nur zur Blechoberfläche hin, als im proximalen Bereich der Auflage eine äußerst dünne Sperrphase, welche gegen ein rasches Wachsen einer Eisen-Zink-Verbindungsphase wirksam ist, aufweist. Zudem ist denkbar, dass allein die Anwesenheit von Aluminium die Eisen-Zink-Diffusionsneigung im Bereich der Grenzschicht senkt.It is assumed that in the first step of the process, namely when the sheet is coated on the sheet surface or in the proximal region of the layer, a thin barrier phase is formed, in particular Fe 2 Al 5 -x Zn x , which forms the Fe-Zn Diffusion in a liquid metal coating process, which takes place in particular at a temperature up to 690 ° C, hindered. Thus, in the first process step, the sheet is formed with a zinc-metal coating with an addition of aluminum, which is effective only towards the sheet surface, as in the proximal region of the support an extremely thin barrier phase, which is effective against rapid growth of an iron-zinc compound phase, having. In addition, it is conceivable that only the presence of aluminum lowers the iron-zinc diffusion tendency in the region of the boundary layer.

Erfolgt nun im zweiten Schritt ein Anwärmen des mit einer Zink-Aluminium-Metallschicht versehenen Bleches auf die Austenitisierungstemperatur des Blechwerkstoffes unter Luftsauerstoffzutritt, so wird vorerst die Metallschicht am Blech verflüssigt. An der distalen Oberfläche reagiert das sauerstoffafinere Aluminium aus dem Zink mit Luftsauerstoff unter Bildung von festem Oxid bzw. Tonerde, wodurch in dieser Richtung ein Abfall der Aluminiummetallkonzentration entsteht, welche eine stetige Diffusion von Aluminium zur Abreicherung hin, also zum distalen Bereich hin bewirkt. Diese Tonerdeanreicherung, an dem der Luft ausgesetzte Schichtbereich wirkt nun als Oxidationsschutz für das Schichtmetall und als Abdampfungssperre für das Zink.If, in the second step, heating of the sheet provided with a zinc-aluminum-metal layer to the austenitizing temperature of the sheet metal material with access of atmospheric oxygen occurs, the metal layer on the sheet is liquefied for the time being. At the distal surface, the oxygen-containing aluminum from the zinc reacts with atmospheric oxygen to form solid oxide, thereby causing a decrease in the concentration of aluminum metal, which causes a steady diffusion of aluminum towards depletion, that is to the distal region. This Tonerdeanreicherung, at the air exposed layer area now acts as oxidation protection for the layer metal and as Abdampfungssperre for the zinc.

Zudem wird beim Anwärmen das Aluminium aus der proximalen Sperrphase durch stetige Diffusion zum distalen Bereich hin abgezogen und steht dort zur Bildung der oberflächlichen Al2O3-Schicht zur Verfügung. Somit wird die Ausbildung einer Blechbeschichtung erreicht, welche eine kathodisch hochwirksame Schicht mit hohem Zinkanteil hinterlässt.In addition, during heating, the aluminum is withdrawn from the proximal blocking phase by continuous diffusion towards the distal region and is available there for the formation of the superficial Al 2 O 3 layer. Thus, the formation of a sheet metal coating is achieved, which leaves a cathodically highly effective layer with a high zinc content.

Gut geeignet ist beispielweise eine Zinklegierung mit einem Gehalt an Aluminium in Gewichtsprozent von größer als 0,2 jedoch kleiner als 4, vorzugsweise von Größe 0,26 jedoch kleiner 2,5 Gew.-%.Well suited is for example a zinc alloy with a content of aluminum in weight percent of greater than 0.2 but less than 4, preferably of size 0.26 but less than 2.5 wt .-%.

Wenn in günstiger Weise im ersten Schritt die Aufbringung der Zinklegierungsschicht auf die Blechoberfläche im Durchlauf durch ein Flüssigmetallbad bei einer Temperatur von höher als 425°C, jedoch niedriger als 690°C, insbesondere bei 440°C bis 495°C erfolgt, mit anschließender Abkühlung des beschichteten Blechs, kann nicht nur die proximale Sperrphase wirkungsvoll gebildet werden, bzw. eine sehr gute Diffusionsbehinderung im Bereich der Sperrschicht beobachtet werden, sondern es erfolgt damit auch eine Verbesserung der Warmvorformungseigenschaften des Blechmaterials.Conveniently, in the first step, the zinc alloy layer is applied to the sheet surface passing through a liquid metal bath at a temperature higher than 425 ° C, but lower than 690 ° C, especially at 440 ° C to 495 ° C, followed by cooling of the coated sheet, not only the proximal locking phase can be effectively formed, or a very good diffusion inhibition can be observed in the region of the barrier layer, but it takes place thus also an improvement of the thermoforming properties of the sheet material.

Eine vorteilhafte Ausgestaltung der Erfindung ist bei einem Verfahren gegeben, bei welchem ein warm- oder kaltgewalztes Stahlband mit einer Dicke von beispielsweise größer als 0,15 mm und mit einem Konzentrationsbereich mindestens einer der Legierungselemente in den Grenzen in Gew.-% Kohlenstoff bis 0,4, vorzugsweise 0,15 bis 0,3 Silizium bis 1,9, vorzugsweise 0,11 bis 1,5 Mangan bis 3,0, vorzugsweise 0,8 bis 2,5 Chrom bis 1,5, vorzugsweise 0,1 bis 0,9 Molybdän bis 0,9, vorzugsweise 0,1 bis 0,5 Nickel bis 0,9, Titan bis 0,2 vorzugsweise 0,02 bis 0,1 Vanadin bis 0,2 Wolfram bis 0,2, Aluminium bis 0,2, vorzugsweise 0,02 bis 0,07 Bor bis 0,01, vorzugsweise 0,0005 bis 0,005 Schwefel Max. 0,01, vorzugsweise Max. 0,008 Phosphor Max. 0,025, vorzugsweise Max. 0,01 Rest Eisen und Verunreinigungen eingesetzt wird.An advantageous embodiment of the invention is given in a method in which a hot or cold rolled steel strip having a thickness of for example greater than 0.15 mm and having a concentration range of at least one of the alloying elements within the limits in wt .-% carbon to 0.4, preferably 0.15 to 0.3 silicon to 1.9, preferably 0.11 to 1.5 manganese to 3.0, preferably 0.8 to 2.5 chrome to 1.5, preferably 0.1 to 0.9 molybdenum to 0.9, preferably 0.1 to 0.5 nickel to 0.9, titanium to 0.2 preferably 0.02 to 0.1 vanadium to 0.2 tungsten to 0.2, aluminum to 0.2, preferably 0.02 to 0.07 boron to 0.01, preferably 0.0005 to 0.005 sulfur Max. 0.01, preferably max. 0.008 phosphorus Max. 0.025, preferably max. 0.01 Rest iron and impurities is used.

Es konnte festgestellt werden, dass die Oberflächenstruktur des erfindungsgemäßen kathodischen Korrosionsschutzes besonders günstig für eine hohe Haftfähigkeit von Farben und Lacken ist.It has been found that the surface structure of the cathodic corrosion protection according to the invention is particularly favorable for a high adhesion of paints and varnishes.

Die Haftung der Beschichtung am Stahlblechgegenstand kann weiter verbessert werden, wenn die Oberflächenschicht eine zinkreiche, intermetallische Zink -Eisen-Aluminium-Phase und eine eisenreich Eisen-Zink-Aluminium-Phase besitzt, wobei die eisenreiche Phase ein Verhältnis Zink zu Eisen von höchstens 0,95 (Zn/Fe ≤ 0,95), vorzugsweise von 0,20 bis 0,80 (Zn/Fe = 0,20 bis 0,80) und die zinkreiche Phase ein Verhältnis Zink zu Eisen von mindestens 2,0 (Zn/Fe ≥ 2,0) vorzugsweise von 2,3 bis 19,0 (Zn/Fe = 2,3 bis 19,0) aufweist.The adhesion of the coating to the steel sheet article can be further improved if the surface layer comprises a zinc-rich, zinc-iron-aluminum intermetallic phase and a iron-zinc-aluminum phase, the iron-rich phase having a zinc to iron ratio of at most 0.95 (Zn / Fe ≦ 0.95), preferably from 0.20 to 0.80 (Zn / Fe = 0, 20 to 0.80) and the zinc rich phase has a zinc to iron ratio of at least 2.0 (Zn / Fe ≥ 2.0), preferably from 2.3 to 19.0 (Zn / Fe = 2.3 to 19.0 ) having.

Bei dem erfindungsgemäßen Verfahren wird eine solche Zinkschicht beim kalten Umformen offenbar nicht wesentlich beeinträchtigt. Vielmehr wird bei der Erfindung in vorteilhafter Weise beim Beschneiden und Lochen der kalten Platine Zinkmaterial durch das Werkzeug aus der Zinkschicht in die Schnittkante getragen und an der Schnittkante entlang verschmiert.In the method according to the invention, such a zinc layer is apparently not significantly impaired during cold forming. Rather, in the invention in an advantageous manner when trimming and punching the cold board zinc material is carried by the tool from the zinc layer in the cutting edge and smeared along the cutting edge.

Eine Beschichtung mit Zink hat zudem den Vorteil, dass das Bauteil nach dem Erhitzen und beim Überführen in ein Formhärtewerkzeug weniger Wärme verliert, so dass das Bauteil nicht so hoch aufgeheizt werden muss. Hierdurch treten geringere thermische Dehnungen auf, so dass eine toleranzgenaue Fertigung vereinfacht wird, da die Gesamtdehnungen geringer sind.A coating with zinc also has the advantage that the component loses less heat after heating and when transferred to a mold hardening tool, so that the component does not have to be heated so high. As a result, lower thermal expansions occur, so that a tolerance-accurate production is simplified, since the total strains are smaller.

Zudem hat das Bauteil bei der geringeren Temperatur eine höhere Stabilität was eine besseres Handling und ein schnelleres Einlegen in die Form ermöglicht.In addition, the component at the lower temperature has a higher stability which allows better handling and faster insertion into the mold.

Die Erfindung wird beispielhaft anhand einer Zeichnung erläutert. Die einzige Figur zeigt den Verfahrensablauf des erfindungsgemäßen Verfahrens.The invention will be explained by way of example with reference to a drawing. The single figure shows the procedure of the method according to the invention.

Zur Durchführung des Verfahrens wird das ungehärtete, verzinkte spezielle Feinblech zunächst in Platinen geschnitten.To carry out the process, the uncured, galvanized special sheet is first cut into blanks.

Die verarbeiteten Platinen können, Rechteck-, Trapez- oder Formplatinen sein. Für das Schneiden der Platinen können alle bekannten Schneidprozesse angewandt werden. Vorzugsweise werden Scheidprozesse angewandt, die während des Schneidprozesses keine Wärme in das Blech einbringen.The processed boards may be rectangular, trapezoidal or shaped boards. All can be used for cutting the boards known cutting processes are applied. Preferably, cutting processes are used which do not introduce heat into the sheet during the cutting process.

Aus den geschnittenen Platinen werden anschließend mittels Kalt-Umformwerkzeugen Formteile hergestellt. Diese Herstellung von Formteilen umfasst alle Verfahren und/oder Prozesse, die in der Lage sind, diese Formteile herzustellen. Beispielsweise sind folgende Verfahren und/oder Prozesse geeignet:

  • Folgeverbundwerkzeuge,
  • Einzelwerkzeuge in Verkettung,
  • Stufenfolgewerkzeuge,
  • Hydraulische Pressestraße,
  • Mechanische Pressestraße,
  • Explosionsumformen, elektromagnetisches Umformen, Rohr-Hydroformen, Platinen-Hydroformen
  • und alle Kaltumformprozesse.
The cut blanks are then used to produce molded parts by means of cold forming tools. This production of moldings includes all processes and / or processes capable of producing these moldings. For example, the following methods and / or processes are suitable:
  • Progressive dies,
  • Individual tools in a chain,
  • Gradation tools,
  • Hydraulic press line,
  • Mechanical Press Street,
  • Explosion forming, electromagnetic forming, tube hydroforming, sink hydroforming
  • and all cold forming processes.

Nach dem Umformen und insbesondere dem Tiefziehen erfolgt der Endbeschnitt in den genannten herkömmlichen Werkzeugen.After forming, and in particular deep drawing, the final trimming is carried out in said conventional tools.

Erfindungsgemäß wird das Formteil, welches im kalten Zustand geformt wurde um 0,5 bis 2 % kleiner hergestellt als die nominale Geometrie des Endbauteils, so dass die Wärmedehnung beim Aufheizen hierdurch kompensiert wird.According to the invention, the molded part, which has been formed in the cold state, is made smaller by 0.5 to 2% than the nominal geometry of the end component, so that the thermal expansion during heating is thereby compensated.

Die durch die genannten Prozesse hergestellten Formteile sollen kalt umgeformt sein, wobei deren Dimensionen innerhalb des vom Kunden für das Fertigteil geforderten Toleranzfeldes liegen. Wenn bei der vorgenannten Kaltumformung größere Toleranzen auftreten, so können diese teilweise nachträglich, geringfügigst, während des Formhärteprozesses, auf den noch eingegangen wird, korrigiert werden. Die Toleranzkorrektur im Formhärteprozess wird jedoch vorzugsweise nur für Formabweichungen durchgeführt. Derartige Formabweichungen können somit nach Art eines Warmkalibrierens korrigiert werden. Der Korrekturprozess soll jedoch möglichst nur auf einen Biegevorgang beschränkt werden, wobei Schneidkanten, die von der Werkstoffmenge abhängig sind (in Relation zur Formkante) nachträglich nicht beeinflusst werden sollen und können, d.h., dass, wenn die Geometrie der Schneidkanten in den Teilen nicht korrekt ist, im Formhärtewerkzeug keine Korrektur durchgeführt werden kann. Zusammenfassend kann man somit feststellen, dass der Toleranzbereich bzgl. der Schneidkanten dem Toleranzbereich während des Kaltumformens und des Formhärteprozesses entspricht.The moldings produced by the processes mentioned should be cold formed, the dimensions of which are within the required by the customer for the finished part tolerance field. If larger tolerances occur in the aforesaid cold forming, they may be partially corrected later, minimally, during the molding hardening process, which will be discussed later. The tolerance correction in the form hardening process However, it is preferably performed only for shape deviations. Such form deviations can thus be corrected in the manner of a hot calibration. However, the correction process should as far as possible be limited to one bending operation, wherein cutting edges that are dependent on the amount of material (in relation to the forming edge) should not and can not subsequently be influenced, ie, if the geometry of the cutting edges in the parts is not correct , in the form hardening tool no correction can be made. In summary, it can thus be stated that the tolerance range with respect to the cutting edges corresponds to the tolerance range during the cold forming and the shape hardening process.

Vorzugsweise sollen innerhalb eines Formteils keine markanten Falten vorhanden sein, da dann die Gleichmäßigkeit des Druckbildes und ein gleichmäßiger Formhärteprozess nicht zu gewährleisten sind.Preferably, no distinctive folds should be present within a molded part, because then the uniformity of the printed image and a uniform shape hardening process can not be guaranteed.

Nachdem das Bauteil vollständig geformt wurde wird das verformte und beschnitte Teil auf eine Glühtemperatur von über 780°C insbesondere 800°C bis 950°C erhitzt und einige Sekunden bis zu einigen Minuten auf dieser Temperatur gehalten, zumindest jedoch solange bis eine gewünschte Austenitisierung stattgefunden hat.After the component has been fully formed, the deformed and cut part is heated to an annealing temperature above 780 ° C, especially 800 ° C to 950 ° C, and held at that temperature for a few seconds to a few minutes, at least until a desired austenitization has occurred ,

Nach dem Glühprozess wird das Bauteil dem erfindungsgemäßen Formhärteschritt unterzogen. Für den erfindungsgemäßen Formhärteschritt wird das Bauteil in ein Werkzeug innerhalb einer Presse eingelegt, wobei dieses Formhärtewerkzeug der Soll-Endgeometrie des fertigen Bauteils, das heißt der Größe des kalt hergestellten Bauteils inklusive der Wärmedehnung vorzugsweise entspricht.After the annealing process, the component is subjected to the inventive form hardening step. For the inventive mold hardening step, the component is inserted into a tool within a press, wherein this mold hardening tool preferably corresponds to the desired final geometry of the finished component, that is to say the size of the cold-formed component including the thermal expansion.

Hierzu besitzt das Formhärtewerkzeug eine Geometrie bzw. Kóntur die im Wesentlichen der Geometrie bzw. Kontur des Kalt-Umformwerkzeuges entspricht, jedoch 05, bis 2 % größer ist (bezüglich aller drei Raumachsen). Angestrebt wird beim Formhärten ein vollflächiger Formschluss zwischen dem Formhärtewerkzeug und dem zu härtenden Werkstück bzw. Bauteil unmittelbar nach de schließen des Werkzeuges.For this purpose, the shape-hardening tool has a geometry or contour that substantially corresponds to the geometry or contour of the cold-forming tool, but is 05 to 2% larger (with respect to all three spatial axes). The aim is to form-hardening a full-surface fit between the mold hardening tool and the workpiece or component to be cured immediately after de close the tool.

Das Formteil wird mit einer Temperatur von ca. 740°C bis 910°C, vorzugsweise 780°C bis 840°C in das Formhärtewerkzeug gelegt, wobei die vorhergegangene Kaltumformung wie bereits ausgeführt die Wärmedehnung des Teiles bei diesem EinlegeTemperatur-Bereich berücksichtigt.The molding is placed at a temperature of about 740 ° C to 910 ° C, preferably 780 ° C to 840 ° C in the mold hardening tool, the previous cold forming as already considered takes into account the thermal expansion of the part at this EinlegeTemperatur range.

Durch die erfindungsgemäße Verzinkung des Bauteils kann eine Einlegetemperatur von 780°C bis 840°C auch noch dann erreicht werden, wenn die Glühtemperatur des kalt umgeformten Bauteils zwischen 800°C und 850°C liegt, da die spezielle, erfindungsgemäße Zinkschicht - gegenüber nicht beschichteten Blechen - eine schnelle Auskühlung vermindert. Dies hat zum Vorteil, dass die Teile weniger hoch erhitzt werden müssen und insbesondere eine Erhitzung auf über 900°C vermieden werden kann. Dies hat wiederum eine Wechselwirkung mit der Zinkbeschichtung zur Folge, da die Zinkbeschichtung bei etwas niedrigeren Temperaturen weniger in Mitleidenschaft gezogen wird.Due to the galvanizing of the component according to the invention, an insertion temperature of 780 ° C to 840 ° C can be achieved even if the annealing temperature of the cold-formed component between 800 ° C and 850 ° C, since the special zinc coating according to the invention - compared to uncoated Sheet metal - reduces rapid cooling. This has the advantage that the parts must be heated less high and in particular a heating to over 900 ° C can be avoided. This in turn results in an interaction with the zinc coating since the zinc coating is less affected at somewhat lower temperatures.

Nachfolgend wird das Aufheizen und Formhärten beispielhaft näher erläutert.Hereinafter, the heating and mold hardening will be explained in more detail by way of example.

Für die Durchführung des Formhärteprozesses wird insbesondere ein Teil zunächst von einem Roboter von einem Transportband abgenommen und in eine Markierstation eingelegt, damit jedes Teil nachvollziehbar vor dem Formhärten markiert werden kann. Anschließend legt der Roboter das Teil auf einen Zwischenträger, wobei der Zwischenträger über ein Transportband in einem Ofen läuft und das Teil erwärmt wird.For carrying out the mold hardening process, in particular, a part is first removed by a robot from a conveyor belt and placed in a marking station, so that each part can be traceably marked before it is hardened. Then the robot places the part on an intermediate carrier, wherein the intermediate carrier passes over a conveyor belt in an oven and the part is heated.

Für das Aufheizen wird beispielsweise ein Durchlaufofen mit Konvektionserwärmung verwendet. Jedoch sind auch jegliche andere Wärmeaggregate bzw. Öfen verwendbar, insbesondere auch Öfen, in denen die Formteile elektromagnetisch oder mit Mikrowellen aufgeheizt werden. Das Formteil durchläuft auf dem Träger den Ofen, wobei der Träger vorgesehen ist, damit die Korrosionsschutzbeschichtung beim Erwärmen nicht auf Rollen des Durchlaufofens übertragen oder von diesem abgerieben wird.For heating, for example, a continuous furnace with convection heating is used. However, any other heat aggregates or ovens can be used, in particular ovens, in which the moldings are heated electromagnetically or with microwaves. The molding passes through the furnace on the support, the support being provided so that the corrosion protection coating is not transferred to rolls of the continuous furnace or is rubbed off by it during heating.

Im Ofen werden die Teile auf eine Temperatur erwärmt, die über der Austenitisierungstemperatur der verwendeten Legierung liegt. Da die Zinkschicht, wie bereits ausgeführt, nicht besonders stabil ist, wird die maximale Temperatur der Teile so niedrig wie möglich gehalten, wobei dies, wie bereits ausgeführt, insbesondere dadurch ermöglicht wird, dass das Teil durch die Zinkschicht anschließend langsamer auskühlt.In the oven, the parts are heated to a temperature which is above the austenitizing temperature of the alloy used. As already stated, since the zinc layer is not particularly stable, the maximum temperature of the parts is kept as low as possible, which, as already stated, is made possible in particular by the part being cooled more slowly by the zinc layer.

Nach dem Erwärmen der Teile auf Maximaltemperatur muss, um eine vollständige Härtung und einen ausreichenden Korrosionsschutz zu erhalten, ab einer bestimmten Mindesttemperatur (>700°C) mit einer minimalen Abkühlgeschwindigkeit von >20K/s abgekühlt werden. Diese Abkühlgeschwindigkeit wird beim anschließenden Formhärten erreicht.After heating the parts to their maximum temperature, they must be cooled above a certain minimum temperature (> 700 ° C) with a minimum cooling rate of> 20K / s to ensure complete hardening and adequate corrosion protection. This cooling rate is achieved during the subsequent mold hardening.

Hierfür nimmt ein Roboter das Teil, abhängig auch von der Dicke bei 780°C bis 950°C, insbesondere 860°C bis 900°C aus dem Ofen und legt es in das Formhärtewerkzeug ein. Während des Manipulierens verliert das Formteil ungefähr 10°C bis 80°C insbesondere 40°C, wobei der Roboter zum Einlegen vorzugsweise so ausgeführt ist, dass er mit hoher Geschwindigkeit das Teil maßgenau in das Formhärtewerkzeug einlegt. Das Formteil wird vom Roboter auf einem Teileheber abgelegt und anschließend die Presse rasch heruntergefahren, wobei der Teilheber verdrängt und das Teil fixiert wird. Hierdurch wird sichergestellt, dass das Bauteil sauber positioniert und geführt wird, bis das Werkzeug geschlossen ist. Zu dem Zeitpunkt zu dem die Presse und somit das Formhärtewerkzeug geschlossen sind, hat das Teil noch eine Temperatur von mindestens 780°C. Die Oberfläche des Werkzeuges hat eine Temperatur von weniger als 50°C, wodurch das Teil rasch auf 80°C bis 200°C abgekühlt wird. Je länger das Teil im Werkzeug festgehalten wird, desto besser ist die Maßgenauigkeit.For this purpose, a robot takes the part, depending on the thickness at 780 ° C to 950 ° C, especially 860 ° C to 900 ° C from the oven and places it in the mold hardening tool. During the manipulation, the molded part loses approximately 10 ° C. to 80 ° C., in particular 40 ° C., whereby the insertion robot is preferably designed such that it inserts the part accurately into the mold hardening tool at high speed. The molding is The robot places it on a part lifter and then quickly shuts down the press, displacing the lifter and fixing the part. This will ensure that the component is properly positioned and guided until the tool is closed. By the time the press and thus the mold hardening tool are closed, the part still has a temperature of at least 780 ° C. The surface of the tool has a temperature of less than 50 ° C, whereby the part is rapidly cooled to 80 ° C to 200 ° C. The longer the part is held in the tool, the better the dimensional accuracy.

Das Werkzeug wird hierbei durch Thermoschock belastet, wobei es das erfindungsgemäße Verfahren ermöglicht, insbesondere wenn beim Formhärteschritt keine Umformschritte durchgeführt werden, das Werkzeug bzgl. seines Grundwerkstoffs auf eine hohe Thermoschockbeständigkeit auszulegen. Bei herkömmlichen Verfahren müssen die Werkzeuge zudem noch eine hohe Abrasionsbeständigkeit aufweisen, die jedoch im vorliegenden Fall keine wesentliche Rolle spielt und insofern das Werkzeug verbilligt.In this case, the tool is subjected to thermal shock, wherein the method according to the invention makes it possible to design the tool with respect to its base material for a high thermal shock resistance, in particular if no forming steps are carried out during the mold hardening step. In conventional methods, the tools must also have a high abrasion resistance, but in the present case does not play a significant role and thus reduces the cost of the tool.

Beim Einlegen des Formteils ist darauf zu achten, dass das komplett beschnittene und gelochte Teil korrekt passend in das Formhärtewerkzeug eingelegt wird, wobei kein überschlüssiges Material und kein Materialüberstand vorhanden sein soll. Winkel können durch einfaches Biegen korrigiert werden, es kann jedoch kein überschüssiger Werkstoff eliminiert werden. Deshalb müssen am kaltumgeformten Teil die Schnittkanten in Relation zu den Formkanten maßgenau geschnitten sein. Die Beschneidkanten sollen beim Formhärten fixiert werden, um Versetzungen der Schnittkanten zu vermeiden.When inserting the molded part, make sure that the completely trimmed and perforated part fits correctly into the mold hardening tool, with no excess material and no material overhang. Angles can be corrected by simple bending, but no excess material can be eliminated. Therefore, the cut edges must be accurately cut in relation to the shape edges on cold-formed part. The trimming edges should be fixed during mold hardening to avoid dislocations of the cut edges.

Anschließend nimmt ein Roboter die Teile aus der Presse und legt diese auf einem Gestell ab, wo sie weiter abkühlen. Die Abkühlung kann, wenn dies gewünscht ist, durch zusätzliches Anblasen von Luft beschleunigt werden.Then a robot takes the parts out of the press and places them on a rack, where they continue to cool down. The Cooling may, if desired, be accelerated by additional blowing on of air.

Durch die erfindungsgemäße Formhärtung ohne nennenswerte Umformschritte und bei einem im Wesentlichen vollflächigen Formschluss von Werkzeug und Werkzeugstück ist es gewährleistet, dass alle Bereiche des Werkstücks definiert und von allen Seiten gleichzeitig uniform gekühlt werden. Bei üblichen Umformprozessen erfolgt eine nachvollziehbare definierte Abkühlung erst dann, wenn der Umformprozess soweit gediehen ist, dass das Material an beiden Formhälften anliegt. Im vorliegenden Fall liegt das Material jedoch vorzugsweise sofort allseitig formschlüssig an den Formhälften an.By means of the inventive mold hardening without appreciable forming steps and with a substantially full-surface fit of the tool and the tool piece, it is ensured that all areas of the workpiece are defined and uniformly cooled on all sides. In conventional forming processes, a comprehensible defined cooling takes place only when the forming process has progressed so far that the material rests against both mold halves. In the present case, however, the material is preferably immediately on all sides positively against the mold halves.

Zudem ist von Vorteil, dass auf der Blechoberfläche vorhandene Korrosionsschutzschichten und insbesondere Schichten, die durch das Feuerverzinken aufgebracht wurden, nicht verletzt werden.In addition, it is advantageous that existing on the sheet surface corrosion protection layers and in particular layers that were applied by the hot-dip galvanizing, are not violated.

Ferner ist von Vorteil, dass im Gegensatz zu bisherigen Verarbeitungsprozessen ein teures Endbeschneiden nach dem Härten nicht mehr notwendig ist. Hierdurch ergibt sich ein erheblicher Kostenvorteil. Da das Verformen beziehungsweise Umformen im Wesentlichen im kaltem Zustand vor dem Härten geschieht, wird die Komplexität des Bauteils im Wesentlichen nur durch die Verformungseigenschaften des kaltem ungehärteten Materials bestimmt. Mit dem erfindungsgemäßen Verfahren lassen sich dadurch erheblich komplexere gehärtete Bauteile in höherer Qualität herstellen, als bisher.Furthermore, it is advantageous that, in contrast to previous processing processes, expensive end cutting after hardening is no longer necessary. This results in a significant cost advantage. Since the deformation or deformation occurs substantially in the cold state before curing, the complexity of the component is essentially determined only by the deformation properties of the cold uncured material. With the method according to the invention, significantly more complex hardened components of higher quality can be produced than hitherto.

Ein zusätzlicher Vorteil ist die geringe Beanspruchung des Formhärtewerkzeugs aufgrund der vollständig vorhandenen Endgeometrie im kalten Zustand. Hierdurch kann eine wesentlich höhere Werkzeugstandzeit und Maßhaltigkeit erreicht werden, was wiederum eine Kostenreduktion bedeutet.An additional advantage is the low stress on the mold hardening tool due to the complete cold end geometry. This can be a much higher Tool life and dimensional accuracy can be achieved, which in turn means a cost reduction.

Dadurch, dass die Teile nicht so hoch geglüht werden müssen kann Energie gespart werden.The fact that the parts do not have to be so highly annealed saves energy.

Aufgrund der definierten Abkühlung des Werkstücks in allen Teilen ohne einen die Kühlung negativ beeinflussenden zusätzlichen Umformprozess kann die Anzahl der Bauteile die nicht innerhalb der Vorgaben liegen deutlich gesenkt werden, so dass wiederum die Herstellkosten gesenkt werden können.Due to the defined cooling of the workpiece in all parts without a cooling process negatively influencing additional forming process, the number of components that are not within the specifications can be significantly reduced, so that in turn the manufacturing cost can be reduced.

Bei einer weiteren vorteilhaften Ausführungsform der Erfindung wird das Formhärten so durchgeführt, dass ein Anliegen des Werkstücks an den Formhälften bzw. ein Formschluss zwischen Werkstück und Werkzeug lediglich an den eng tolerierten Bereichen wie den Schnitt- und Formkanten, den Formflächen und gegebenenfalls in den Bereichen des Lochbildes erfolgt.In a further advantageous embodiment of the invention, the form hardening is performed so that a concern of the workpiece to the mold halves or a positive connection between the workpiece and tool only at the narrow toleranced areas such as the cutting and shaping edges, the forming surfaces and optionally in the areas of the Lochbildes done.

Hierbei wird der Formschluss in diesem Bereichen derart herbeigeführt, dass diese Bereiche so sicher gehalten und geklemmt werden, dass weniger eng tolerierte Bereiche eine Warmumformung im Werkzeug Verfahren können, ohne dass die bereits maß- und lagegenau eng tolerierten Bereiche negativ beeinflusst und insbesondere Verzogen werden.In this case, the positive connection in these areas is brought about such that these areas are held and clamped so securely that less tightly tolerated areas can hot working in the tooling process, without the already dimensionally accurate and tolerated narrowly tolerated areas are adversely affected and warped in particular.

Selbstverständlich wird auch bei dieser vorteilhaften Ausführungsform die Wärmedehnung, die das Bauteil beim Einlegen in das Formwerkzeug noch inne hat, in bereits beschriebener Weiseberücksichtigt.Of course, in this advantageous embodiment, too, the thermal expansion which the component still has when it is inserted into the mold is taken into account in the manner already described.

Bei dieser vorteilhaften Ausführungsform ist es jedoch zudem möglich, die nicht eng tolerierten Bereiche, entweder durch Nichtanliegen einer oder beiden Formwerkzeughälften langsamer abzukühlen und dort durch das langsamere Abkühlen andere Härtegrade zu erreichen, oder in diesen Bereichen eine gewünschte Warmumformung zu erzielen, ohne dass die eng tolerierten Bereiche beeinflusst werden. Dies kann beispielsweise durch zusätzliche Stempel in den Formwerkzeughälften erfolgen. Wesentlich ist, wie bereits ausgeführt jedoch auch bei dieser bevorzugten Ausführungsform, dass die eng tolerierten Bereiche beim Formhärten bzgl. einer Umformung unbeeinflusst bleiben.In this advantageous embodiment, however, it is also possible, the not tightly tolerated areas, either by not applying one or both mold halves slower to cool down and reach there by the slower cooling other degrees of hardness, or to achieve a desired hot forming in these areas, without the tightly tolerated areas are affected. This can be done for example by additional stamp in the mold halves. It is essential, as already stated, however, also in this preferred embodiment, that the tightly tolerated areas remain unaffected in terms of shape hardening with respect to forming.

Claims (10)

  1. Method for producing hardened components from steel sheet, comprising the method steps:
    cold forming of formed parts from a steel sheet provided with a corrosion protection; followed by a heat treatment for the purpose of austenitization, characterised in that
    a) a final trimming of the formed part and necessary punching processes or the production of a hole pattern are being carried out prior to, during or subsequent to the cold forming of the formed part, wherein
    b) the cold forming and the trimming as well as the punching processes and the arrangement of the hole pattern on the component are carried out such that the formed part is 0.5 % to 2% smaller than the finished hardened component, wherein
    c) the formed part cold-formed for heat treatment is then heated at least in partial areas under the admission of atmospheric oxygen to a temperature which permits an austenitization of the steel material, and
    d) the heated component is then transferred to a form hardening tool, and a form hardening is carried out in the form hardening tool, wherein the component is cooled by contacting and pressing (holding) of the component by the form hardening tools and is hardened thereby, and
    e) the cathodic corrosion-protective coating consists of a mixture of, substantially, zinc, and the mixture additionally contains one or more oxygen-affine elements in a total amount of 0.1 % by wt to 15 % by wt relative to the total mixture, wherein magnesium and/or silicon and/or titanium and/or calcium and/or aluminium are used as oxygen-affine elements in the mixture.
  2. Method according to claim 1, characterised in that the cathodic corrosion-protective coating is a coating which is applied by means of the hot-dip process, wherein a surface skin of an oxide of the oxygen-affine element(s) is formed on the coating during the heating of the steel sheet to the temperature required for hardening.
  3. Method according to any one of the preceding claims, characterised in that 0.2 % by wt to 5 % by wt of the oxygen-affine elements are used.
  4. Method according to any one of the preceding claims, characterised in that 0.26 % by wt to 2.5 % by wt of the oxygen-affine elements are used.
  5. Method according to one of the preceding claims, characterised in that, substantially, aluminium is used as the oxygen-affine element.
  6. Method according to any one of the preceding claims, characterised in that coating is carried out with the mixture of zinc and the oxygen-affine elements in the course of passing through a liquid metal bath at a temperature of 425°C to 690°C, with subsequent cooling of the coated sheet.
  7. Method according to any one of the preceding claims, characterised in that coating is carried out with the mixture of zinc and the oxygen-affine elements in the course of passing through a liquid metal bath at a temperature of 440°C to 495°C, with subsequent cooling of the coated sheet.
  8. Method according to any one of the preceding claims, characterised in that the holding time above the austenitizing temperature is up to 10 minutes.
  9. Method according to any one of the preceding claims, characterised in that the holding temperature in the heating phase is maximally 780 to 950°C.
  10. Method according to any one of the claims 1 to 10, characterised in that the formed part is pressed and hardened by the forming tool halves substantially simultaneously over the entire surface and with the same force.
EP20040739756 2003-07-29 2004-06-09 Method for producing hardened parts from sheet steel Expired - Lifetime EP1651789B1 (en)

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PL04739756T PL1651789T3 (en) 2003-07-29 2004-06-09 Method for producing hardened parts from sheet steel
EP20090015813 EP2177641B1 (en) 2003-07-29 2004-06-09 Steel plate having a galvanized corrosion protection layer
PL09015813T PL2177641T3 (en) 2003-07-29 2004-06-09 Steel plate having a galvanized corrosion protection layer

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AT0120303A AT412878B (en) 2003-07-29 2003-07-29 Method for production of a hardened profile part from a hardenable steel alloy having cathodic corrosion protection useful in the production of hardened steel sections, e.g. for automobile construction
AT12022003A AT412403B (en) 2003-07-29 2003-07-29 Corrosion-protection layer for hardened metallic profiled structural part of motor vehicle, has roller-formed profiled elements having affinity to oxygen, and oxide skin comprising oxides of elements
PCT/EP2004/006252 WO2005021821A1 (en) 2003-07-29 2004-06-09 Method for producing hardened parts from sheet steel

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EP20040739756 Expired - Lifetime EP1651789B1 (en) 2003-07-29 2004-06-09 Method for producing hardened parts from sheet steel
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