Method for producing a steel component which is shaped by hot-forming a steel sheet which has a metal coating, such a steel sheet, and a steel component produced from said steel sheet by means of a hot-forming process

Patent metadata

Field	Value
Publication number	US-10323292-B2
Application number	US-201515309365-A
Country	US
Kind code	B2
Filing date	Apr 29, 2015
Priority date	May 12, 2014
Publication date	Jun 18, 2019
Grant date	Jun 18, 2019

Abstract

A process for producing a three-dimensionally shaped steel component from a steel sheet with a metallic coating may involve hot forming the steel sheet into the steel component. The metallic coating may involve an Fe—Al-based alloy. To protect the steel sheet or the steel component against scale formation, the Fe—Al-based alloy may be applied directly to the steel sheet by galvanic coating and/or physical vapor deposition. The coating produced in this way may contain 30-60% by weight Fe, a balance of Al, and, in some cases, 0.1-10% by weight Mg, 0.1-5% by weight Ti, 0.1-10% by weight Si, 0.1-10% by weight Li, and/or 0.1-10% by weight Ca. Before heating the coated steel sheet as part of the hot forming process, the coated steel sheet may have an Fe—Al phase is stable to above 900° C.

First claim

What is claimed is:

1. A process for producing a three-dimensionally shaped steel component from a steel sheet, the process comprising:
applying a metallic coating comprising an Fe—Al based alloy directly to a steel sheet by at least one of hot dip coating or physical vapor deposition, wherein the metallic coating applied in this way includes 30-60% by weight Fe, and a balance of Al; wherein the deposition of one of Fe or Al to the steel sheet occurs in a separate coating process than the deposition of the remaining alloying element; and
hot forming the steel sheet into a steel component, and wherein prior to heating the steel sheet as part of the hot forming, the steel sheet has an Fe—Al phase that is stable to above 900° C.

2. The process of claim 1 , wherein the metallic coating further includes
0.1-10% by weight Mg;
0.1-5% by weight Ti;
0.1-10% by weight Si;
0.1-10% by weight Li; and
0.1-10% by weight Ca.

3. The process of claim 1 , wherein the metallic coating further includes at least one of
0.1-10% by weight Mg;
0.1-5% by weight Ti;
0.1-10% by weight Si;
0.1-10% by weight Li; or
0.1-10% by weight Ca.

4. The process of claim 1 , wherein the Fe—Al based alloy includes at least 28% by weight Al.

5. The process of claim 1 , wherein the Fe—Al based alloy includes at least 38% by weight Al.

6. The process of claim 1 , wherein the Fe—Al based alloy includes at least one of 0.1-10% by weight Mg or 0.1-5% by weight Ti.

7. The process of claim 1 , wherein the Fe—Al based alloy includes at least one of 0.1-10% by weight Li or 0.1-10% by weight Ca.

8. The process of claim 1 , wherein the Fe—Al based alloy includes not more than 20% by weight of alloying elements from a group consisting of Mg, Ti, Si, Li, and Ca.

9. The process of claim 1 , further comprising hardening the steel sheet by rapid cooling during hot forming or during and after hot forming.

10. A steel sheet for producing one or more steel components by hot forming, the steel sheet comprising a metallic coating including an Fe—Al based alloy applied directly to the steel sheet by a physical vapor deposition or a combination of a hot dip coating and a physical vapor deposition, wherein the metallic coating applied in this way includes 30-60% by weight Fe and a balance of at least 28% by weight of Al, wherein the deposition of one of Fe or Al to the steel sheet is in a separate coating process than the deposition of the remaining alloying element, and wherein prior to heating the steel sheet as part of any hot forming the steel sheet has an Fe—Al phase that is stable to above 900° C.

11. The steel sheet of claim 10 , wherein the metallic coating further includes
0.1-10% by weight Mg;
0.1-5% by weight Ti;
0.1-10% by weight Si;
0.1-10% by weight Li; and
0.1-10% by weight Ca.

12. The steel sheet of claim 11 , wherein the metallic coating further includes at least one of
0.1-10% by weight Mg;
0.1-5% by weight Ti;
0.1-10% by weight Si;
0.1-10% by weight Li; or
0.1-10% by weight Ca.

13. The steel sheet of claim 11 wherein the Fe—Al based alloy includes at least 28% by weight Al.

14. The steel sheet of claim 11 wherein the Fe—Al based alloy includes at least 38% by weight Al.

15. The steel sheet of claim 11 wherein the Fe—Al based alloy includes at least one of 0.1-10% by weight Mg or 0.1-5% by weight Ti.

16. The steel sheet of claim 11 wherein the Fe—Al based alloy includes at least one of 0.1-10% by weight Li or 0.1-10% by weight Ca.

17. The steel sheet of claim 11 wherein the Fe—Al based alloy includes not more than 20% by weight of alloying elements from a group consisting of Mg, Ti, Si, Li, and Ca.

18. The process of claim 1 , wherein the deposition of one of Fe or Al to the steel sheet may be electron-beam physical vapor deposition or thermal physical vapor deposition.

19. A process for producing a three-dimensionally shaped steel component from a steel sheet, the process comprising:
applying a metallic coating comprising an Fe—Al based alloy by a physical vapor deposition or a combination of a hot dip coating and a physical vapor deposition directly to a steel sheet, wherein the metallic coating applied in this way includes
30-60% by weight Fe,
at least one alloying element selected from the group of:
0.1-10% by weight Mg;
0.1-5% by weight Ti;
0.1-10% by weight Si;
0.1-10% by weight Li; or
0.1-10% by weight Ca, and
a balance of at least 28% by weight Al;
wherein the coating includes not more than 20% by weight of alloying elements from the group consisting of Mg, Ti, Si, Li and Ca, and wherein the deposition of one of Fe or Al to the steel sheet is in a separate coating process than the deposition of the remaining alloying elements and the remaining alloying elements are applied to the steel sheet simultaneously, and

hot forming the steel sheet into the three-dimensionally shaped steel component,
wherein a heat treatment of the steel sheet to 250-500° C. is performed before or subsequent to vapor deposition, so that prior to heating the steel sheet as part of the hot forming, the steel sheet has an Fe—Al phase that is stable to above 900° C.

20. The process of claim 19 , wherein the metallic coating includes at least 38% by weight Al.

21. The process of claim 19 , further comprising hardening the steel sheet by rapid cooling during hot forming or during and after hot forming.

Assignees

• Thyssenkrupp Steel Europe Ag
• Thyssenkrupp Ag

Inventors

• Schuhmacher Bernd
• Schwerdt Christian
• Schrooten Axel
• Bause Ralf

Classifications

• C21D8/00

  Modifying the physical properties of ferrous metals or ferrous alloys by deformation combined with, or followed by, heat treatment (hardening articles or materials formed by forging or rolling with no further heating beyond that required for the formation C21D1/02) · CPC title

• C23C14/5806

  Thermal treatment · CPC title

• C22C21/06

  with magnesium as the next major constituent · CPC title

• C22C30/00

  Alloys containing less than 50% by weight of each constituent · CPC title

• B32B15/012

  one layer being formed of an iron alloy or steel, another layer being formed of aluminium or an aluminium alloy · CPC title