TW201726407A - 複合鋼 - Google Patents

複合鋼 Download PDF

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TW201726407A
TW201726407A TW105141050A TW105141050A TW201726407A TW 201726407 A TW201726407 A TW 201726407A TW 105141050 A TW105141050 A TW 105141050A TW 105141050 A TW105141050 A TW 105141050A TW 201726407 A TW201726407 A TW 201726407A
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steel
spacer
composite
composite steel
sheet
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TW105141050A
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羅伯特 詹姆士 二世 康斯達克
傑弗瑞 道格拉斯 奧德
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Ａｋ鋼鐵資產公司
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
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    • B32B7/02—Physical, chemical or physicochemical properties
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
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    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
    • B23K2103/05—Stainless steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/16—Composite materials, e.g. fibre reinforced
    • B23K2103/166—Multilayered materials
    • B23K2103/172—Multilayered materials wherein at least one of the layers is non-metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/30—Organic material
    • B23K2103/42—Plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • B23K2103/54—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)

Abstract

為改良薄單層或單片鋼之剛度，複合鋼包含至少兩個利用間隔物隔開之外部鋼層。間隔物材料可包括任何緻密性小於鋼之金屬、或視情況包含碳或玻璃纖維或克維拉(Kevlar)材料之聚合物或樹脂。此一複合鋼可產生較具有相同總片材厚度之單片鋼高之剛度。舉例而言，利用該間隔物使該鋼材料遠離中性軸可增加彎曲時之應變，以提供維持剛度同時亦提供合意之重量節省之高強度複合鋼。

Description

複合鋼
高強度鋼通常在汽車工業中用於車輛結構部件。在一些情形中，鋼強度之增加已容許減小鋼之規格，以提供材料之重量節省。汽車結構部件之此規格減小可犧牲材料之剛度。因此，仍需要維持剛度同時亦容許使用輕量規格鋼之結構材料。
為改良薄片材之剛度，複合鋼片材包含兩個或更多個可利用至少一個間隔物隔開之鋼片材。間隔物材料可包括較輕重量之金屬或具有或不具有填充物之聚合物或樹脂，該填充物可包括碳纖維、玻璃纖維或克維拉(Kevlar)材料。此一複合鋼片可產生較具有相同厚度之單片(或單層)鋼高之剛度。舉例而言，在彎曲時，在鋼中間厚度或中性軸處可發生低應變。利用間隔物使鋼材料遠離中性軸可增加彎曲時之應變，以提供維持剛度同時亦提供期望重量節省之高強度複合鋼。
本申請案主張於2015年12月11日提出申請之標題為COMPOSITE STEEL之美國臨時申請案第62/266,314號之優先權，其揭示內容以引用方式併入本文中。 本發明之以下說明及實施例不應用於限制本發明之範疇。熟習此項技術者自以下說明將可明瞭本發明之其他實例、特徵、態樣、實施例及優勢。如將瞭解，本發明可涵蓋除本文所明確論述之彼等示例性實施例外之替代實施例，而不偏離本發明範疇。因此，圖式及說明應被視為在本質上係說明性而非限制性。 複合鋼包含至少一個分隔兩個或更多個外部鋼層之間隔物。此複合鋼可維持單鋼之高強度及剛度，同時亦提供合意的重量節省。複合鋼片材(10)之一個實施例顯示於圖1中。如所圖解說明，外部鋼層(22)係由經黏合之間隔物(20)隔開，該間隔物在鋼與間隔物之間提供良好的剪切強度，使得外部鋼層(22)維持強度，同時間隔物(20)可在容許鋼維持充足剛度的同時具有低密度以減少重量。若間隔物與外部鋼層充分黏合，則在彎曲時間隔物將外部鋼層與中性軸(零應變) (A)隔開，使得彎曲時在鋼與間隔物材料之間不發生滑動。 儘管任何組成之鋼片材皆可用於此複合鋼中，但高強度或先進高強度鋼係最有利的。該等鋼之較高拉伸強度容許在維持剛度的同時減小製成組件之厚度。提供耐腐蝕性之不銹鋼亦可用於複合材料中。複合鋼之外部鋼層可包含相同類型之鋼，或其可包含不同類型之鋼。類似地，兩個或更多個外部鋼層可各自具有相同厚度或其可各自具有不同厚度。 間隔物(20)可自任何較外部鋼層輕之材料製得。其可包含輕重量金屬，包括鎂、鋁或其各別合金。其可自可進一步包含碳或玻璃纖維、克維拉等之多種聚合物或樹脂製得。間隔物(20)之厚度可在複合材料總厚度之約5%與90%間之範圍內，包括其間(10)之任何間隔。 由間隔物(20)提供之外部鋼片材(22)間之隔開可增加剛度。舉例而言，頂部及底部鋼厚度各為0.5 mm、鋼厚度總計為1.0 mm之複合鋼可獲得較具有1.0 mm之相同總片材厚度之單片鋼更高之剛度。彎曲時，在片材中間厚度或中性軸(A)處發生低應變。剛度隨遠離中性軸之材料體積減小而減小。因此，使材料自中性軸遠離增加彎曲時之應變。 如圖1中所示，複合鋼(10)可藉由使外部鋼層(22)與間隔物材料(20)交錯，使得每兩個外部鋼層之間具有間隔物來製備。在進一步使用所得複合鋼之前，可將外部鋼層(22)黏合至內部間隔物材料(20)。此黏合可藉由在外部鋼層與間隔物材料之間施加眾多種黏著材料形成。不使用單獨的黏著材料，在一些實施例中，諸如聚合物或樹脂之間隔物材料可能夠在不使用額外黏著材料之情形下黏合至外部鋼層。外部鋼層(22)與內部間隔材料(20)間之高強度黏合可用於將彎曲應力轉移至外部鋼層(22)並維持剛度。 一旦製造出複合片材，其即可用於形成在例如汽車之應用中使用之部件。為改良此等部件之成型，鋼片材(22)及間隔物(20)在成型期間可允許相對於彼此滑動。在此情形中，在部件成型後之前，黏著劑(若存在)或樹脂可不完全固化，以容許兩個外部鋼層之間之相對滑動。此將使每一外部鋼層中之應變在成型製程期間保持至最小。間隔物與外部鋼層間之界面黏合可在部件成型製程之後(例如)藉由供應熱或一些其他固化方法形成，以改良部件剛度。此加熱可在成型製程期間(例如)藉由使用加熱壓機發生，或成型後在隨後操作中(例如在塗刷步驟或專用固化製程中)發生。 鑒於本文中之教示，熟習此項技術者將明瞭製造複合鋼(10)之又其他方法。 藉由使用此一複合鋼(10)，亦可在複合結構中使用不同金屬及鋼，以調整諸如耐腐蝕性或美學之性質。舉例而言，可在一個表面上提供耐腐蝕鋼層，同時可在相對表面上使用較廉價之背襯鋼用於增加之強度。舉例而言，可在複合鋼一側使用不銹鋼外層並在另一側使用碳鋼外層。由於汽車應用中之振動，利用複合鋼(10)增加剛度亦可減小噪音。 鑒於本文中之教示，熟習此項技術者將明瞭複合鋼(10)之又其他應用。實例 1 使用如圖2中所示之結構性軌條，將複合鋼片材之性能與單鋼片材作比較。圖3a中所示之單鋼片材係具有約2 mm厚度之單一DP600片材。圖3b中所示之複合鋼包括由間隔物分隔之兩片DP980鋼片材。每一DP980鋼片材具有約0.61 mm之厚度。DP600鋼片材之拉伸強度係約600 MPa。因此，1 mm寬度之DP600軌條之拉伸負荷承載能力係1200 N。DP980鋼片材之拉伸強度係約980 MPa。1 mm寬度之兩片DP980鋼片材之拉伸負荷承載能力亦係大約1200 N。因此，兩片0.61 mm厚之DP980材料等效於1 mm長度之DP600軌條上之拉伸負荷承載能力。 間隔物之厚度決定DP980框架之剛度。將0.134 Nm/mm長度之扭矩施加至2 mm DP600鋼片材產生約0.1%之表面應變。此應變在鋼上產生1 m曲率半徑。在單一1.22 mm厚(2 × 0.61 mm) DP980鋼片材上施加相同1 m曲率半徑所需要之扭矩僅為0.031 Nm/mm長度。此值不到較厚DP600片材之25%。 因此，在兩片0.61 mm厚之DP980片材之間***間隔物藉由使鋼遠離中性軸而增加剛度，由此在所施加1 m曲率半徑下需要較大彈性應變。將兩片0.61 mm片材隔開0.82 mm產生彎曲至1 m曲率半徑之相同扭矩需求。因此，兩片DP980片材之間之間隔物等於0.82 mm，以獲得與較厚DP600部件相同之剛度。複合材料中之鋼自2 mm厚減至1.22 mm厚(2 × 0.61 mm)，減少0.78 mm或約39%。因此，軌條之重量亦可減少約39%。實例 2 使用浸漬於玻璃纖維基質中之環氧樹脂(聚合物)將兩片18 Cr-Cb™鋼黏合在聚合物之每一側上，以形成複合鋼。在利用施加至結構之小負荷使複合材料就位的同時容許其固化。每一鋼片材具有約0.018英吋之厚度。然後將複合材料與具有約0.059英吋之厚度及約0.079英吋之厚度之18 Cr-Cb單鋼片材比較。將樣品剪切為2英吋× 6英吋。18 Cr-Cb 0.059英吋厚之單鋼片材具有約88克之重量。18 Cr-Cb 0.079英吋厚之單鋼片材具有約120克之重量。複合鋼具有約72克之重量，其較0.079英吋厚之鋼片材輕約40%。 在三點彎曲測試中將彎曲負荷施加至每一樣品。每一樣品居中穿過具有0.75英吋模具半徑之4英吋沖模。以1.0英吋/分鐘之速度加載具有12 mm半徑之居中沖頭抵靠每個樣品。將彎曲負荷量測為沖頭位移之函數。 複合鋼片材能夠應對較單鋼片材更高之負荷，如圖4中所示。舉例而言，在0.05英吋之撓度下，複合鋼片材具有約67 lbs之負荷，而0.079英吋厚之單鋼片材具有約30 lbs之負荷，且0.059英吋厚之單鋼片材具有約15 lbs之負荷。複合鋼在較低重量下顯示較高剛度。實例 3 然後評估具有碳纖維之複合鋼片。碳纖維用黏合樹脂預浸漬。將310型鋼片材定位於碳纖維之每一側上並在400華氏度下在具有加熱板之液壓機中固化。每一鋼片材之厚度係約0.010英吋且複合材料重約76克。碳纖維複合鋼與實例2中之彼等相比之經改良負荷承載能力顯示於圖5中。舉例而言，碳纖維複合鋼在0.05英吋之彎曲撓度下能應對107 lbs。
10‧‧‧複合鋼片材、複合鋼 20‧‧‧間隔物、內部間隔物材料 22‧‧‧外部鋼層、鋼片材、外部鋼片材 A‧‧‧中性軸
據信，自以下結合附圖對某些實施例所作之說明，將更好地理解本發明，其中相同參考數字表示相同元件。 圖1繪示覆合鋼之實施例之局部剖視圖。 圖2繪示由單片鋼形成之軌條之俯視圖。 圖3a繪示圖2之軌條之局部剖視圖。 圖3b繪示由複合鋼形成之軌條之另一實施例之局部剖視圖。 圖4顯示厚度為0.059英吋之鋼帶、厚度為0.079英吋之鋼帶及聚合物複合鋼帶之彎曲負荷-位移曲線。 圖5顯示厚度為0.079英吋之鋼帶、聚合物複合鋼帶及碳纖維複合鋼帶之彎曲負荷-位移曲線。` 該等圖式並不意欲以任何方式進行限制，且預計本發明之各種實施例可以多種其他方式(包括圖式中未必繪示之彼等)來實施。併入且形成本說明書之一部分之附圖圖解說明本發明之若干態樣，且連同說明書一起用於闡釋本發明之原理及概念；然而，應理解本發明不限於所顯示之精確配置。
10‧‧‧複合鋼片材、複合鋼
20‧‧‧間隔物、內部間隔物材料
22‧‧‧外部鋼層、鋼片材、外部鋼片
A‧‧‧中性軸

Claims (14)

  1. 一種複合鋼，其包含至少兩個外部鋼層及至少一個將該至少兩個外部鋼層彼此隔開之間隔物。
  2. 如請求項1之複合鋼，其進一步包含施加於每一外部鋼層與該間隔物之間之黏著劑。
  3. 如請求項1之複合鋼，其中該兩個外部鋼層中之至少一者包含不銹鋼。
  4. 如請求項1之複合鋼，其中該間隔物包含緻密性小於鋼之金屬。
  5. 如請求項4之複合鋼，其中該間隔物包含鋁、鎂或鋁或鎂之合金。
  6. 如請求項1之複合鋼，其中該間隔物包含聚合物或樹脂。
  7. 如請求項6之複合鋼，其中該間隔物進一步包含碳纖維、玻璃纖維或克維拉(Kevlar)材料。
  8. 一種製造複合鋼之方法，其包含利用至少一個間隔物使至少兩個外部鋼層交錯，使得該至少一個間隔物隔開該等外部鋼層之每一者之步驟。
  9. 如請求項8之方法，其進一步包含將該間隔物黏合至該等外部鋼層之每一者之步驟。
  10. 如請求項9之方法，其中該黏合係藉由加熱該複合鋼而達成。
  11. 一種製造成型部件之方法，其包含由如請求項8之複合鋼形成部件之步驟。
  12. 如請求項11之方法，其進一步包含在成型製程期間將該間隔物黏合至該等外部鋼層之每一者之步驟。
  13. 如請求項11之方法，其進一步包含在該成型製程之後在隨後步驟中將該間隔物黏合至該等外部鋼層之每一者之步驟。
  14. 如請求項13之方法，其中該隨後步驟係塗刷步驟或加熱步驟。
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