TW202120697A - 具有優異漆膜附著力的熱成形部件及其製造方法 - Google Patents
具有優異漆膜附著力的熱成形部件及其製造方法 Download PDFInfo
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- TW202120697A TW202120697A TW109140496A TW109140496A TW202120697A TW 202120697 A TW202120697 A TW 202120697A TW 109140496 A TW109140496 A TW 109140496A TW 109140496 A TW109140496 A TW 109140496A TW 202120697 A TW202120697 A TW 202120697A
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- paint film
- film adhesion
- thermoformed part
- layer
- excellent paint
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 43
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- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
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Classifications
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- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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- C21D1/74—Methods of treatment in inert gas, controlled atmosphere, vacuum or pulverulent material
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- C21D2211/008—Martensite
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- C21—METALLURGY OF IRON
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- 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
- C21D2261/00—Machining or cutting being involved
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- Chemical & Material Sciences (AREA)
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- Organic Chemistry (AREA)
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- Metallurgy (AREA)
- Crystallography & Structural Chemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
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Abstract
本發明公開了一種具有優異漆膜附著力的熱成形部件,其包括基材層以及鍍覆在基材層的至少一個表面上的鍍鋁層;熱成形部件表面的平均粗糙度Ra為1.0~3.0μm,峰高與峰谷的高度Rt為8~30μm,粗糙度峰計數Rpc≥50。此外,本發明還公開了上述的具有優異漆膜附著力的熱成形部件的製造方法,其包括步驟:(1)將基材浸入鋁鍍液,得到表面具有鍍鋁層的板材;(2)平整;(3)落料:將板材沖裁或切割成部件所需形狀的坯料;(4)熱處理;(5)傳輸和熱衝壓:將熱的坯料快速傳輸到模具中進行冷卻衝壓成形,以形成熱成形部件。
Description
本發明涉及一種材料及其製造方法,尤其涉及一種熱成形材料及其製造方法。
近年來,熱成形部件在汽車工業中的應用變得很重要,特別是在汽車的安全結構件方面,在一些高強度,形狀複雜的零件上具有不可替代的優勢。用於熱成形部件的材料分為帶塗覆層和不帶塗覆層的,塗覆層的主要目的是鋼板在熱衝壓成形過程中,防止鋼板表面氧化。成形後的部件可以直接進行塗裝及焊接使用,目前不帶塗覆層的材料在熱成形後必須進行表面噴丸處理以去掉表面產生的氧化物層,否則影響後續的零件塗裝及焊接。熱鍍鋁塗覆層的材料在熱成形後表面無法進行正常磷化,電泳後的漆膜附著力完全依靠塗層表面形貌來保證。現有材料在使用過程中會存在漆膜附著力無法滿足使用的問題。
例如:公開號為CN104651590A,公開日為2015年5月27日,名稱為“衝壓產品的製造方法及由其製造的衝壓產品”的中國專利文獻公開了一種鋁或鋁合金塗覆的熱成形材料及製造方法,該方法針對性控制了塗覆層的厚度及五層結構,從而保證熱成形件的焊接性能。
又例如:公開號為CN108588612A,公開日為2018年9月28日,名稱為“熱衝壓成形構件、熱衝壓成形用預塗鍍鋼板及熱衝壓成形工藝”的中國專利文獻公開了一種熱衝壓成形構件。在該專利文獻所公開的技術方案中,降低了塗層厚度的同時,也降低了塗層的保護作用,由此,熱成形技術的波動對構件的表面性能很容易造成影響,從而影響後續的使用性能。
再例如:公開號為CN101583486,公開日為2009年11月18日,名稱為“塗覆的鋼帶材、其製備方法、其使用方法、由其製備的衝壓坯料、由其製備的衝壓產品和含有這樣的衝壓產品的製品”的中國專利文獻公開了一種塗覆鋼帶材的熱衝壓產品及方法。在該專利文獻所公開的技術方案中,其包括加熱、轉移及冷卻,而未涉及熱衝壓過程,由此會造成衝壓產品品質不穩定,如緊縮、開裂等,對加熱過程中爐膛氣氛不控制,導致加熱過程中爐內氣氛發生變化,尤其是氧氣含量發生較大變化,帶來產品外觀顏色很容易發生變化,實際生產發現相同來料在同一技術下,所得衝壓產品外觀顏色呈現較大不同。
本發明的目的之一在於提供一種具有優異漆膜附著力的熱成形部件,該熱成形部件具有較好的塗裝性、好的漆膜附著力以及較好的耐蝕性,非常適合用於汽車零部件,例如:前、後門左右防撞杆/梁、前、後保險槓、A柱加強板、B柱加強板、地板中通道等。
為了實現上述目的,本發明提出了一種具有優異漆膜附著力的熱成形部件,其包括基材層以及鍍覆在基材層的至少一個表面上的鍍鋁層,熱成形部件表面的平均粗糙度Ra為1.0~3.0μm,峰高與峰谷的高度Rt為8~30μm,粗糙度峰計數Rpc≥50。
在本發明所述的技術方案中,鍍鋁層包括鋁相和鋁矽相,在加熱過程中,鍍鋁層中的鋁向基材層擴散,同時基材層的鐵向鍍鋁層擴散形成Al8
Fe2
Si相,新相形成導致表面粗糙度顯著增加,隨著鐵鋁進一步擴散,進而形成Fe2
Al5
相,表面粗糙度基本維持,最終鍍鋁層中全部形成FeAl合金,表面粗糙度反而略有下降。
熱處理後的熱成形部件表面主要由Fe2
Al5
和FeAl合金組成,同時由於表面氧化產生的矽的氧化物、鋁的氧化物以及鐵的氧化物不能與磷化液發生化學反應,即不能形成正常的磷化膜,因此,熱成形部件的漆膜附著力完全靠表面的凹凸不平結構來保證,即熱成形部件的粗糙度對漆膜附著力有著重要影響。
鍍鋁層表面粗糙度越大,粗糙度峰計數Rpc值越大,鐵鋁擴散路徑不同,新相形成的快慢不同,從而導致熱處理後的成形件表面粗糙度越大,對漆膜附著力越好。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,鍍鋁層包括:與基材層鄰接的擴散層和位於鍍鋁層表面的合金層,其中擴散層的厚度與鍍鋁層總厚度的比值為0.08-0.5。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,擴散層的厚度≤16µm;鍍鋁層總厚度≤60µm。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,擴散層的厚度為5~16µm;鍍鋁層總厚度20~60µm。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,熱成形部件表面的平均粗糙度Ra為1.5~2.5μm。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,熱成形部件表面的峰高與峰谷的高度Rt為10~25μm。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,熱成形部件表面的粗糙度峰計數Rpc為50~250,如80~180。
進一步地,本發明所述的具有優異漆膜附著力的熱成形部件的表面含有Fe2
Al5
和FeAl合金。進一步地,本發明所述的具有優異漆膜附著力的熱成形部件的表面還含有矽的氧化物、鋁的氧化物和鐵的氧化物。進一步地,本發明所述的具有優異漆膜附著力的熱成形部件的表面主要由Fe2
Al5
和FeAl合金組成,同時還含有矽的氧化物、鋁的氧化物和鐵的氧化物。而且,本發明所述的具有優異漆膜附著力的熱成形部件的表面中Fe2
Al5
的含量高於40wt%。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,鍍鋁層的化學成分重量百分比為:Si:4~14%,Fe:0~4%,Mg:0~10%,Zn:0~20%,餘量為Al及其他不可避免的雜質。進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,鍍鋁層的化學成分重量百分比為:Si:4~14%,Fe:2~4%,Mg:0~10%,Zn:0~20%,餘量為Al及其他不可避免的雜質。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,鍍鋁層的重量平均值為20~120g/m2
每單面。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,鍍鋁層的重量平均值為30~100g/m2
每單面。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,基材層的化學成分質量百分比為:
C:0.01~0.8%,Si:0.05~1.0%,Mn:0.1~5%,P≤0.3%,S≤0.1%,Al≤0.3%,Ti≤0.5%,B:0.0005~0.1%,Cr:0.01~3%,Nb≤0.5%,V≤0.5%,餘量為Fe及其他不可避免的雜質。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,基材層的各化學元素質量百分比還滿足下列各項的至少其中之一:
C:0.05~0.6%,
Si:0.07~0.8%,
Mn:0.3~4%,
P≤0.2%,
S≤0.08%,
Al≤0.2%,
Ti≤0.4%,
B:0.0005~0.08%,
Cr:0.01~2%,
Nb≤0.3%,
V≤0.3%。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,基材層的各化學元素質量百分比還滿足下列各項的至少其中之一:
C:0.15~0.5%,
Si:0.1~0.5%,
Mn:0.5~3%,
P≤0.1%,
S≤0.05%,
Al≤0.1%,
Ti≤0.2%,
Cr:0.01~1%。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件的基材層中,Al含量為0.03-0.09%,Ti含量為0.01-0.2%、優選0.01-0.1%。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件的基材層中,Cr含量為0.1-0.8%。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件的基材層中,含有時,Nb的含量為0.001-0.1%;含有時,V的含量為0.001-0.01%。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,基材層的化學成分質量百分比為:C:0.02~0.8%,Si:0.05~0.5%,Mn:0.1~3%,P≤0.1%,S≤0.05%,Al:0.04-0.09%,Ti:0.02-0.2%,B:0.0005~0.09%,Cr:0.15~0.8%,Nb為0%或0.001-0.1%,V為0%或0.002-0.008%,餘量為Fe及其他不可避免的雜質。
進一步地,在本發明所述的具有優異漆膜附著力的熱成形部件中,其屈服強度為400~1400MPa,抗拉強度為500~2100MPa,延伸率≥4%。
優選地,在本發明所述的具有優異漆膜附著力的熱成形部件的基材的微觀組織中麻田散體的體積百分比≥70%,優選85≥%,更優選≥95%。
相應地,本發明的另一目的在於提供上述的具有優異漆膜附著力的熱成形部件的製造方法,通過該製造方法可以獲得漆膜附著力優異的熱成形部件。
為了實現上述目的,本發明提出了上述的具有優異漆膜附著力的熱成形部件的製造方法,其包括步驟:
(1)將基材浸入鋁鍍液,得到表面具有鍍鋁層的板材;
(2)平整:採用粗糙度Ra為0.5~3.0μm的平整輥對板材進行平整,控制平整率≤2.0%,以使所述板材表面熱輻射係數為0.1~0.8,板材表面粗糙度Ra為0.3~2.0μm,板材表面粗糙度峰計數Rpc為30~150;
(3)落料:將板材沖裁或切割成部件所需形狀的坯料;
(4)熱處理:將坯料放入加熱爐中加熱並保溫,加熱爐溫度為880~960℃,加熱爐內的氣氛採用空氣或氮氣,坯料在加熱爐中的停留時間為2.5~10min;
(5)傳輸和熱衝壓:將熱的坯料快速傳輸到模具中進行冷卻衝壓成形,以形成所述熱成形部件。
在本發明所述的製造方法中,在步驟(4)中,加熱爐溫度太低或是坯料在加熱爐中的停留時間過短,均會導致鐵鋁擴散不夠充分,進而使得表面粗糙度太低,影響最終熱成形部件的粗糙度。而當加熱爐溫度過高或是坯料在加熱爐中的停留時間過長,則會導致鐵鋁擴散過度,完全形成FeAl合金,這也會導致最終的熱成形部件的粗糙度降低,同時擴散過程中元素遷移形成的孔洞會影響表面導電性,電泳過程中會導致縮孔,進而影響塗裝性。
進一步地,在本發明所述的製造方法中,在步驟(1)中,鋁鍍液的化學成分質量百分含量為:Si:5~11%,Fe:2~4%,Zn:0~15%,Mg:0~8%,餘量為Al及其他不可避免的雜質。
進一步地,在本發明所述的製造方法中,在步驟(1)中,鋁鍍液的化學成分質量百分含量為:Si:8~11%,Fe:2~4%,Zn:0~11%,Mg:0~8%,餘量為Al及其他不可避免的雜質。
進一步地,在本發明所述的製造方法中,在步驟(1)中,鋁鍍液的化學成分質量百分含量為:Si:5~11%,Fe:2~4%,餘量為Al及其他不可避免的雜質。
進一步地,在本發明所述的製造方法中,在步驟(1)中,鋁鍍液的化學成分質量百分含量為:Si:5~11%,Fe:2~4%,任選的Zn:2~15%,任選的Mg:0.5~8%,餘量為Al及其他不可避免的雜質。
進一步地,在本發明所述的製造方法中,在步驟(4)中,在坯料加熱的升溫過程中,在升溫至400~600℃的範圍內加熱速率不超過10℃/s,以使鍍層中鋅及鋁的預合金化,避免鍍層破壞或出現裂紋。
進一步地,在本發明所述的製造方法中,在步驟(5)中,坯料在20s以內被傳輸到模具中。
進一步地,在本發明所述的製造方法,在步驟(5)的熱衝壓過程中,模具合模後持續保壓淬火4~20s,對坯料表面施加的保壓壓強≥8MPa。在一些實施方案中,保壓壓強為10~20MPa。
進一步地,在本發明所述的製造方法中,在步驟(5)中,模具的材質滿足:在700℃時的熱擴散係數大於3.8mm2
/s。
進一步地,在本發明所述的製造方法中,在步驟(5)中,衝壓時模具的合模速度為30~150mm/s,以使熱成形部件可以保證良好的成形性能,減少衝壓缺陷例如開裂、縮頸的發生。
進一步地,在本發明所述的製造方法中,在步驟(5)中,將坯料以30~150℃/s的冷卻速度冷卻至50~200℃,以使得熱成形部件的內部組織轉變為所需要的組織結構,同時保證熱成形部件在冷卻過程中依然保持良好的尺寸形狀。
本發明也包括採用上述方法製造得到的熱成形部件。
本發明所述的具有優異漆膜附著力的熱成形部件及其方法相較於現有技術具有如下所述的優點以及有益效果:
本發明所述的具有優異漆膜附著力的熱成形部件具有較好的塗裝性、好的漆膜附著力以及較好的耐蝕性,非常適合用於汽車零部件,例如:前、後門左右防撞槓/梁、前、後保險槓、A柱加強板、B柱加強板、地板中通道等。
此外,本發明所述的製造方法也同樣具有上述的優點以及有益效果。
下面將結合具體的實施例對本發明所述的具有優異漆膜附著力的熱成形部件及其製造方法做進一步的解釋和說明,然而該解釋和說明並不對本發明的技術方案構成不當限定。
實施例1-10以及比較例1
實施例1-10的具有優異漆膜附著力的熱成形部件和比較例1採用以下步驟製得:
(1)將基材浸入鋁鍍液,得到表面具有鍍鋁層的板材。
(2)平整:採用粗糙度Ra為0.5~3.0μm的平整輥對板材進行平整,控制平整率≤2.0%,以使所述板材表面熱輻射係數為0.1~0.8,板材表面粗糙度Ra為0.3~2.0μm,板材表面粗糙度峰計數Rpc為30~150。
(3)落料:將板材沖裁或切割成部件所需形狀的坯料。
(4)熱處理:將坯料放入加熱爐中加熱並保溫,加熱爐溫度為880~960℃,加熱爐內的氣氛採用空氣或氮氣,坯料在加熱爐中的停留時間為2.5~10min,在坯料加熱的升溫過程中,在升溫至400~600℃的範圍內加熱速率不超過10℃/s。
(5)傳輸和熱衝壓:將熱的坯料快速(例如在20s內)傳輸到模具中進行冷卻衝壓成形,以形成熱成形部件。其中,在熱衝壓過程中,模具合模後持續保壓淬火4~20s,對坯料表面施加的保壓壓強≥8MPa,模具的材質滿足:在700℃時的熱擴散係數大於3.8mm2
/s,衝壓時模具的合模速度為30~150mm/s,將坯料以30~150℃/s的冷卻速度冷卻至50~200℃。
其中,各個實施例和比較例的製造方法如下所述:
實施例1
採用平整輥對1.2mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:8.5%,Fe:2.6%,Zn:15%,Mg:4%,其餘為鋁及不可避免雜質,坯料進入加熱爐,加熱爐溫度950℃,停留時間3.5min,400~600℃的範圍內加熱速率為2℃/s,傳輸時間4s,保壓時間5s,保壓壓強10MPa,合模速度50mm/s,冷速為50℃/s,冷卻至200℃,模具在700℃時的熱擴散係數為4mm2
/s。
實施例2
採用平整輥對0.9mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:5%,Fe:2.4%,Zn:8%,Mg:8%,其餘為鋁及不可避免雜質,坯料進入加熱爐,加熱爐溫度940℃,停留時間5min,400~600℃的範圍內加熱速率為5℃/s,傳輸時間6s,保壓時間15s,保壓壓強20MPa,合模速度150mm/s, 冷速為150℃/s, 冷卻至50℃,模具在700℃時的熱擴散係數為5mm2
/s。
實施例3
採用平整輥對1.0mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:9.0%,Fe:2.7%,其餘為鋁及不可避免雜質,坯料進入加熱爐,400-600℃的加熱速率為5℃/s,加熱爐溫度930℃,停留時間7min,8s內傳輸至模具,700℃左右模具的熱擴散係數為7 mm2
/s。合模速度70mm/s,保壓時間6s,保壓壓強12MPa,冷速100℃/s, 冷卻至100℃。所得熱成形部件基材微觀組織中麻田散體比例高於96%。
實施例4
採用平整輥對2.8mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:8.8%,Fe:2.7%,其餘為鋁及不可避免雜質,坯料進入加熱爐,加熱爐溫度920℃,停留時間7min,400-600℃的加熱速率為10℃/s,8s內傳輸至模具,合模速度70mm/s,保壓時間6s,保壓壓強15MPa,冷速60℃/s, 冷卻至60℃,模具在700℃時的熱擴散係數為6mm2
/s。所得熱成形部件基材微觀組織中麻田散體比例高於98%。
實施例5
採用平整輥對1.1mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:10%,Fe:3.5%,Zn:2%,Mg:1%,其餘為鋁及不可避免雜質,坯料進入加熱爐,加熱爐溫度935℃,停留時間4.5min,400~600℃的範圍內加熱速率為4℃/s,7s內傳輸至模具,上下模具合模速度80mm/s,保壓時間5s,保壓壓強15MPa,模具在700℃時的熱擴散係數為4mm2
/s,冷卻至100℃。所得熱成形部件基材微觀組織中麻田散體比例高於95%。
實施例6
採用平整輥對1.5mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:10%,Fe:3.5%,Mg:0.5%,其餘為鋁及不可避免雜質,坯料進入加熱爐,加熱爐溫度935℃,停留時間5min,400~600℃的範圍內加熱速率為6℃/s,7s內傳輸至模具,上下模具合模速度80mm/s,保壓時間5s,保壓壓強15MPa,模具在700℃時的熱擴散係數為4mm2
/s,冷卻至120℃。所得熱成形部件基材微觀組織中麻田散體比例高於95%。
實施例7
採用平整輥對1.8mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:10%,Fe:3.5%,其餘為鋁及不可避免雜質,坯料進入加熱爐,加熱爐溫度945℃,停留時間2.5min,400~600℃的範圍內加熱速率為7℃/s,7s內傳輸至模具,上下模具合模速度80mm/s,保壓時間5s,保壓壓強15MPa,模具在700℃時的熱擴散係數為6.8mm2
/s,冷卻至140℃。所得熱成形部件基材微觀組織中麻田散體比例高於95%。
實施例8
採用平整輥對2.0mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:10%,Fe:3.5%,其餘為鋁及不可避免雜質,坯料進入加熱爐,加熱爐溫度940℃,停留時間3min,400~600℃的範圍內加熱速率為3℃/s,爐內氣氛氧含量為22%,7s內傳輸至模具,上下模具合模速度80mm/s,保壓時間5s,保壓壓強15MPa,模具在700℃時的熱擴散係數為7mm2
/s,冷卻至110℃。所得熱成形部件基材微觀組織中麻田散體比例高於95%。
實施例9
採用平整輥對2.4mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:10%,Fe:3.5%,其餘為鋁及不可避免雜質,坯料進入加熱爐,加熱爐溫度935℃,停留時間5min,400~600℃的範圍內加熱速率為8℃/s,爐內氣氛氧含量為22%,7s內傳輸至模具,上下模具合模速度80mm/s,保壓時間5s,保壓壓強15MPa,模具在700℃時的熱擴散係數為4mm2
/s,冷卻至100℃。所得熱成形部件基材微觀組織中麻田散體比例高於95%。
實施例10
採用平整輥對2.8mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:10%,Fe:3.5%,其餘為鋁及不可避免雜質,坯料進入加熱爐,加熱爐溫度950℃,停留時間2.5min,400~600℃的範圍內加熱速率為4℃/s,爐內氣氛氧含量為20%,15s內傳輸至模具,上下模具合模速度80mm/s,保壓時間5s,保壓壓強15MPa,模具在700℃時的熱擴散係數為5mm2
/s,冷卻至80℃。所得熱成形部件基材微觀組織中麻田散體比例高於95%。
比較例1
採用平整輥對1.5mm帶鋁合金鍍層鋼板進行平整,得到表面粗糙度如表2所示的熱處理和熱衝壓前的板材,雷射落料成一定尺寸和形狀的坯料,鋁鍍液的化學成分質量百分含量為Si:10%,Fe:3.5%,其餘為鋁及不可避免雜質,坯料進入加熱爐,加熱爐溫度935℃,停留時間5min,400~600℃的範圍內加熱速率為6℃/s,7s內傳輸至模具,上下模具合模速度80mm/s,保壓時間5s,保壓壓強15MPa,模具在700℃時的熱擴散係數為4mm2
/s,冷卻至120℃。所得熱成形部件基材微觀組織中麻田散體比例高於95%。
表1列出了實施例1-10的具有優異漆膜附著力的熱成形部件的基材層以及比較例1的基材層的各化學元素的質量百分比。
表1.(wt%,餘量為Fe和其他不可避免的雜質)
實施例 | C | Si | Mn | P | S | Al | Ti | B | Cr | Nb | V |
1 | 0.02 | 0.05 | 0.12 | 0.059 | 0.038 | 0.09 | 0.090 | 0.0005 | 0.15 | - | - |
2 | 0.06 | 0.23 | 1.19 | 0.015 | 0.001 | 0.04 | 0.030 | 0.040 | 0.27 | - | - |
3 | 0.49 | 0.50 | 2.51 | 0.024 | 0.04 | 0.08 | 0.027 | 0.0052 | 0.51 | 0.002 | 0.002 |
4 | 0.39 | 0.36 | 3.00 | 0.044 | 0.03 | 0.07 | 0.05 | 0.0062 | 0.71 | 0.003 | 0.005 |
5 | 0.78 | 0.48 | 0.50 | 0.081 | 0.02 | 0.05 | 0.48 | 0.0071 | 0.20 | 0.1 | - |
6 | 0.15 | 0.10 | 2.90 | 0.059 | 0.038 | 0.09 | 0.090 | 0.0031 | 0.15 | - | - |
7 | 0.25 | 0.23 | 1.19 | 0.015 | 0.001 | 0.04 | 0.030 | 0.0040 | 0.27 | - | - |
8 | 0.49 | 0.50 | 2.51 | 0.024 | 0.04 | 0.08 | 0.027 | 0.0052 | 0.51 | 0.005 | 0.008 |
9 | 0.39 | 0.36 | 3.00 | 0.044 | 0.03 | 0.07 | 0.05 | 0.0062 | 0.71 | - | - |
10 | 0.50 | 0.9 | 0.50 | 0.081 | 0.02 | 0.05 | 0.20 | 0.09 | 0.20 | - | - |
比較例1 | 0.25 | 0.23 | 1.19 | 0.015 | 0.001 | 0.04 | 0.030 | 0.0040 | 0.27 | - | - |
為了驗證本案的實施效果,同時證明本案較之現有技術的優異效果,本案將實施例1-10的具有優異漆膜附著力的熱成形部件以及比較例1的對比熱成形部件進行測試,表2列出了各個實施例以及比較例的測試結果。
表2
*漆膜附著力的測試方法:
實施例 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 比較例1 | |
鍍鋁層的重量平均值,g/m2 每單面 | 23 | 30 | 50 | 60 | 100 | 70 | 80 | 85 | 80 | 75 | 75 | |
厚度,mm | 1.2 | 0.9 | 1 | 2.8 | 1.1 | 1.5 | 1.8 | 2 | 2.4 | 2.8 | 1.5 | |
平整率/% | 0.5 | 0.8 | 1.5 | 0.3 | 0.6 | 0.7 | 1 | 1.2 | 1.8 | 2 | 0.7 | |
平整輥粗糙度/μm | 0.5 | 1.2 | 3 | 1 | 1.5 | 1.5 | 1.8 | 1.2 | 1.9 | 2.8 | 0.3 | |
板材熱處理和熱衝壓前的粗糙度 | Ra/μm | 0.3 | 0.8 | 2 | 0.9 | 1.3 | 1 | 1.1 | 0.8 | 0.7 | 1.5 | 0.2 |
Rpc | 50 | 90 | 150 | 90 | 50 | 100 | 70 | 130 | 90 | 80 | 25 | |
熱處理和熱衝壓後的成品粗糙度 | Ra/μm | 1.8 | 1.8 | 1.9 | 2 | 2.3 | 2 | 1.9 | 1.9 | 1.8 | 2.4 | 1.3 |
Rt/μm | 12 | 13 | 18 | 19 | 20 | 21 | 18 | 19 | 19 | 22 | 9 | |
Rpc | 90 | 100 | 120 | 120 | 160 | 170 | 150 | 160 | 140 | 170 | 40 | |
合金層中50%Al層厚度/μm | 15 | 18 | 20 | 25 | 35 | 26 | 20 | 28 | 26 | 20 | 20 | |
擴散層的厚度/μm | 5 | 6 | 7 | 8 | 16 | 10 | 8 | 8 | 8 | 8 | 8 | |
鍍鋁層總厚度/μm | 22 | 25 | 30 | 33 | 60 | 40 | 35 | 40 | 38 | 30 | 30 | |
衝壓後產品抗拉強度/MPa | 500 | 700 | 1820 | 2000 | 1900 | 1000 | 1550 | 1590 | 1600 | 1580 | 1500 | |
衝壓後產品屈服強度/MPa | 400 | 500 | 1250 | 1350 | 1200 | 1050 | 1000 | 980 | 1100 | 1100 | 1100 | |
延伸率/% | 19 | 15 | 5 | 4 | 4.5 | 6 | 7 | 6 | 6 | 6 | 6 | |
塗裝性 | 漆膜前處理後表面均勻 | 不均勻 | ||||||||||
塗裝後漆膜附著力 | 1級 | 1級 | 2級 | 2級 | 1級 | 1級 | 2級 | 1級 | 2級 | 1級 | 5級 | |
耐蝕性,mm | 1 | 1.5 | 3 | 3.5 | 2 | 2.3 | 3.5 | 3 | 3.8 | 3 | 5 |
參考GB/T 9286-1998 百格法,用刀在表面劃百格,用膠帶貼在形成的格子中心,然後平穩的扯離,觀察漆膜脫落的現象,並通過計算劃格中格子中的狀態對應標準進行評級判定。
塗裝性的評價方法參考GMW16170標準。
耐蝕性的測試方法參考GMW14872。
由表2可以看出,本案各個實施例的屈服強度為400~1350MPa,抗拉強度為500~2000MPa,延伸率為4~19%。
此外,由表2還可以看出,比較例1中的對比熱成形部件在熱衝壓後的成品表面粗糙度Ra低於1.8μm,Rt低於12μm,Rpc低於90,並且比較例1的熱成形件的塗裝性較差,漆膜附著力不滿足要求,其性能遠遠不如本案的各個實施例的熱成形部件。另外,由表2可以看出,熱成形部件所採用的熱處理和熱衝壓前的材料表面粗糙度越高,熱處理和熱衝壓後產品粗糙度也相對較高,對漆膜附著力更好。
綜上所述可以看出,本發明所述的具有優異漆膜附著力的熱成形部件具有較好的塗裝性、好的漆膜附著力以及較好的耐蝕性,非常適合用於汽車零部件,例如:前、後門左右防撞槓/梁、前、後保險槓、A柱加強板、B柱加強板、地板中通道等。
此外,本發明所述的製造方法也同樣具有上述的優點以及有益效果。
需要說明的是,本發明的保護範圍中現有技術部分並不局限於本申請檔所給出的實施例,所有不與本發明的方案相矛盾的現有技術,包括但不局限於先前專利文獻、先前公開出版物,先前公開使用等等,都可納入本發明的保護範圍。
此外,本案中各技術特徵的組合方式並不限本案申請專利範圍中所記載的組合方式或是具體實施例所記載的組合方式,本案記載的所有技術特徵可以以任何方式進行自由組合或結合,除非相互之間產生矛盾。
還需要注意的是,以上所列舉的實施例僅為本發明的具體實施例。顯然本發明不局限於以上實施例,隨之做出的類似變化或變形是本領域技術人員能從本發明公開的內容直接得出或者很容易便聯想到的,均應屬於本發明的保護範圍。
無。
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Claims (20)
- 一種具有優異漆膜附著力的熱成形部件,其包括基材層以及鍍覆在基材層的至少一個表面上的鍍鋁層;其特徵在於,所述熱成形部件表面的平均粗糙度Ra為1.0~3.0μm,峰高與峰谷的高度Rt為8~30μm,粗糙度峰計數Rpc≥50。
- 如請求項1所述的具有優異漆膜附著力的熱成形部件,其特徵在於,所述鍍鋁層包括:與基材層鄰接的擴散層和位於鍍鋁層表面的合金層,其中擴散層的厚度與鍍鋁層總厚度的比值為0.08-0.5。
- 如請求項1或2所述的具有優異漆膜附著力的熱成形部件,其特徵在於,所述擴散層的厚度≤16µm;所述鍍鋁層總厚度≤60µm。
- 如請求項1所述的具有優異漆膜附著力的熱成形部件,其特徵在於,所述的鍍鋁層的化學成分重量百分比為:Si:4~14%,Fe:0~4%,Mg:0~10%,Zn:0~20%,餘量為Al及其他不可避免的雜質;優選地,所述鍍鋁層的化學成分重量百分比為:Si:4~14%,Fe:2~4%,Mg:0~10%,Zn:0~20%,餘量為Al及其他不可避免的雜質。
- 如請求項1所述的具有優異漆膜附著力的熱成形部件,其特徵在於,所述鍍鋁層的重量平均值為20~120g/m2 每單面。
- 如請求項5所述的具有優異漆膜附著力的熱成形部件,其特徵在於,所述鍍鋁層的重量平均值為30~100g/m2 每單面。
- 如請求項1所述的具有優異漆膜附著力的熱成形部件,其特徵在於,所述基材層的化學成分質量百分比為: C:0.01~0.8%,Si:0.05~1.0%,Mn:0.1~5%,P≤0.3%,S≤0.1%,Al≤0.3%,Ti≤0.5%,B:0.0005~0.1%,Cr:0.01~3%,Nb≤0.5%,V≤0.5%,餘量為Fe及其他不可避免的雜質。
- 如請求項7所述的具有優異漆膜附著力的熱成形部件,其特徵在於,所述基材層的各化學元素質量百分比還滿足下列各項的至少其中之一: C:0.05~0.6%, Si:0.07~0.8%, Mn:0.3~4%, P≤0.2%, S≤0.08%, Al≤0.2%, Ti≤0.4%, B:0.0005~0.08%, Cr:0.01~2%, Nb≤0.3%, V≤0.3%。
- 如請求項7或8所述的具有優異漆膜附著力的熱成形部件,其特徵在於,所述基材層的各化學元素質量百分比還滿足下列各項的至少其中之一: C:0.15~0.5%, Si:0.1~0.5%, Mn:0.5~3%, P≤0.1%, S≤0.05%, Al≤0.1%, Ti≤0.2%, Cr:0.01~1%。
- 如請求項1所述的具有優異漆膜附著力的熱成形部件,其特徵在於,其屈服強度為400~1400MPa,抗拉強度為500~2100MPa,延伸率≥4%。
- 如請求項1所述的具有優異漆膜附著力的熱成形部件,其特徵在於,所述的具有優異漆膜附著力的熱成形部件的表面含有Fe2 Al5 和FeAl合金;或主要由Fe2 Al5 和FeAl合金組成,同時還含有矽的氧化物、鋁的氧化物和鐵的氧化物。
- 如請求項9所述的具有優異漆膜附著力的熱成形部件,其特徵在於,所述的具有優異漆膜附著力的熱成形部件的基材層的顯微組織中麻田散體的體積百分比≥95%。
- 如請求項1-12中任意一項所述的具有優異漆膜附著力的熱成形部件的製造方法,其特徵在於,包括步驟: (1)將基材浸入鋁鍍液,得到表面具有鍍鋁層的板材; (2)平整:採用粗糙度Ra為0.5~3.0μm的平整輥對板材進行平整,控制平整率≤2.0%,所述板材表面熱輻射係數為0.1~0.8,板材表面粗糙度Ra為0.3~2.0μm,板材表面粗糙度峰計數Rpc為30~150; (3)落料:將板材沖裁或切割成部件所需形狀的坯料; (4)熱處理:將坯料放入加熱爐中加熱並保溫,加熱爐溫度為880~960℃,加熱爐內的氣氛採用空氣或氮氣,坯料在加熱爐中的停留時間為2.5~10min; (5)傳輸和熱衝壓:將熱的坯料快速傳輸到模具中進行冷卻衝壓成形,以形成所述熱成形部件。
- 如請求項13所述的製造方法,其特徵在於,在所述步驟(1)中,鋁鍍液的化學成分質量百分含量為:Si:5~11%,Fe:2~4%,Zn:0~15%,Mg:0~8%,餘量為Al及其他不可避免的雜質;優選為:Si:8~11%,Fe:2~4%,Zn:0~11%,Mg:0~8%,餘量為Al及其他不可避免的雜質。
- 如請求項13所述的製造方法,其特徵在於,在所述步驟(4)中,在坯料加熱的升溫過程中,在升溫至400~600℃的範圍內加熱速率不超過10℃/s。
- 如請求項13所述的製造方法,其特徵在於,在所述步驟(5)中,坯料在20s以內被傳輸到模具中。
- 如請求項13所述的製造方法,其特徵在於,在所述步驟(5)的熱衝壓過程中,所述模具合模後持續保壓淬火4~20s,對坯料表面施加的保壓壓強≥8MPa。
- 如請求項13所述的製造方法,其特徵在於,在所述步驟(5)中,所述模具的材質滿足:在700℃時的熱擴散係數大於3.8m2 /s。
- 如請求項13所述的製造方法,其特徵在於,在所述步驟(5)中,衝壓時模具的合模速度為30~150mm/s。
- 如請求項13所述的製造方法,其特徵在於,在所述步驟(5)中,將坯料以30~150℃/s的冷卻速度冷卻至50~200℃。
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