Dual Phase Steel with Improved Properties
A method for processing a dual phase steel sheet. The method includes heating the steel sheet to a first temperature (T1), cooling the steel sheet to a second temperature (T2), transitioning the steel sheet to a third temperature (T3), and cooling the steel sheet to room temperature. T1 is at least above the temperature at which the steel sheet transforms to austenite and ferrite. T2 is below the martensite start temperature (Ms). The cooling rate to T2 is sufficiently rapid to transform at least some austenite to martensite.
The present application claims priority from provisional patent application Ser. No. 62/103,286, entitled “Lean Dual Phase Steel with Improved Properties,” filed on Jan. 14, 2015. The disclosure of application Ser. No. 62/103,286 is incorporated herein by reference.
BACKGROUNDIt is desirable to produce steels with high strength and good formability characteristics. The present invention relates to steel compositions and processing methods for production of steel using thermal processing techniques such that the resulting steel exhibits high strength and/or cold formability.
SUMMARYThe present steel is produced using a composition and a modified thermal process that together produces a resulting microstructure consisting of generally ferrite and a second phase generally comprising martensite and bainite (among other constituents). To achieve such a microstructure, the composition includes certain alloying additions and the thermal process includes a hot-dip galvanizing/galvannealing (HDG) or other thermal process with certain process modification.
The accompanying figures, which are incorporated in and constitute a part of this specification, illustrate embodiments, and together with the general description given above, and the detailed description of the embodiments given below, serve to explain the principles of the present disclosure.
The solid line in
As stated above, in the typical thermal profile (10) the steel sheet is held at the peak metal temperature (12) for a first predetermined amount of time. It should be understood that the particular amount of time that the steel sheet is held at the peak metal temperature (12) may be varied by a number of factors such as the particular chemistry of the steel sheet, or the desired volumetric quantity of the second phase in the steel sheet at the conclusion of the thermal cycle. Additionally, in some circumstances the time held at the peak metal temperature (12) may be reduced to zero or near zero. In circumstances where the hold time is reduced, the peak metal temperature can be increased to compensate for such a reduction.
Once the first predetermined period of time has elapsed, the typical thermal profile (10) involves rapidly cooling the steel sheet to an intermediate temperature (14). The steel sheet is then held at the intermediate temperature (14) for a second predetermined period of time. Generally, the steel sheet is held at the intermediate temperature (14) for a sufficient amount of time to permit the steel sheet to reach a temperature that is near the temperature of the zinc bath.
Still referring to the typical thermal profile (10), the steel sheet is next inserted into a liquid zinc galvanizing tub or galvannealing apparatus. During this stage, the temperature of the steel sheet is slightly reduced to a bath temperature (16) that is below the intermediate temperature (14). The bath temperature (16) is generally below the intermediate temperature (14) to avoid dross formation upon entry of the steel sheet into the liquid zinc.
The steel sheet remains at the bath temperature (16) for the duration of the galvanizing Where galvannealing is used, the steel sheet is removed from the bath at some period of time and then elevated to an annealing temperature. The particular temperature of the bath temperature (16) is at least above the melting point of zinc (e.g., 419° C., 787° F.). However, it should be understood that in some examples the bath temperature (16) may be even higher depending on the particular configuration of the galvanizing bath or galvannealing apparatus. It should be also understood that in circumstances where the bath temperature (16) is higher relative to the melting point of zinc, the intermediate temperature (14) may remain the same as shown, be correspondingly raised, or even lowered.
At the conclusion of the galvanizing or galvanealing process, the steel sheet is cooled below the martensite start temperature (Ms), thereby transforming at least some austenite into martensite. Of course, as described above, other constituents may form such as bainite, pearlite, or retained austenite. These constituents, along with the formation of martensite, form what is collectively described herein as the second phase. As described above, although the second phase may contain one or more of martensite, bainite, pearlite and/or retained austenite, it should be understood that the second phase is generally characterized by formation of predominately martensite.
In some instances, modification to the typical thermal profile (10) described above is desirable. For example, because of the galvanizing or galvannealing step in the typical thermal profile (10), the average cooling rate from the peak metal temperature (12) to the martensite start temperature (Ms) may be insufficient to form a desirable volumetric quantity of martensite—instead forming non-martensitic transformation products (e.g., bainite, cementite, pearlite, and/or etc.). This may be the case regardless of how quickly the steel sheet is cooled after galvanizing or galvannealing. To account for this relatively slow average cooling rate, conventional dual phase steels used in such a process often includes high alloy content to increase hardenability and thereby avoid formation of non-martensitic transformation products. However, relatively high alloying additions may be undesirable due to increased cost and reduced mechanical properties. Thus, it can be desirable to modify the typical thermal profile (10) described above to maintain a desired amount of martensite in dual phase steels without high alloying additions. Further modifications described below, such as reheating from below the martensite start temperature (Ms) to the intermediate temperature (14), may additionally be desirable to improve mechanical properties such as hole expansion ratio (HER) or yield strength (regardless of the particular amount of alloying additions).
In the present embodiments of the modified thermal profile, improvements to the mechanical properties were more significant than expected, especially when considering the relatively short tempering time (e.g., duration of time during which the steel sheet is exposed to the zinc bath).
As shown in
In the present example, the quench temperature is below the martensite start temperature (Ms). The difference between the quench temperature (20) and the martensite start temperature (Ms) can vary depending on the individual composition of the steel sheet being used. However, in many embodiments the difference between quench temperature (20) and Ms is sufficiently great to form a predominately martensitic second phase.
Once the quench temperature (20) is reached, the temperature of the steel sheet is maintained at the quench temperature for a predetermined quench time. Because formation of martensite is nearly instantaneous, the particular amount of time during which the steel sheet is at the quench temperature is generally insignificant.
After quenching to the quench temperature (20), the steel sheet is reheated to the intermediate temperature (14) or to another temperature at or near the bath temperature (16). In the present example, reheating is relatively quick and may be performed using various methods such as induction heating, torch heating, and/or other methods known in the art. Once reheated, the steel sheet is inserted into a zinc bath. In the zinc bath, the steel sheet will reach the bath temperature (16), as described above, where the steel sheet will remain for the remainder of the galvanizing. The particular amount of time during which the steel sheet is in the zinc bath is largely determined by the galvanizing/galvannealing process. However, it should be understood that during this time, the martensite is tempered to thereby improve the mechanical properties of the steel sheet. Where a galvannealing process is used, the steel sheet may be heated to an annealing temperature after removal from the bath.
Although the reheating step is described herein as being in connection with a coating step, such as galvanizing or galvannealing, it should be understood that no such limitation is intended. For instance, in some examples the reheating step may merely be performed and then the process may proceed as described below. In such examples, the steel sheet is held at the intermediate temperature (14) or the bath temperature (16) despite not actually being subjected to a galvanizing or galvannealing treatment. Additionally, in some examples the steel sheet may be held at a lower temperature (e.g., 400° C.) relative to the bath temperature (16) because heating the steel sheet to the melting point of zinc is not necessary without application of zinc. The steel sheet may be held at such a temperature for any suitable time as will be apparent to those of ordinary skill in the art in view of the teachings herein.
Once the galvanizing, galvannealing, or other similar thermal process is completed, the steel sheet is cooled to room temperature, as similarly described above. Accordingly, in the present example, the steel sheet is first heated to a peak metal temperature (12) to form austenite and optionally ferrite. Next the steel sheet is cooled from the peak metal temperature (12) to the quench temperature (20) to form martensite or other constituents of the second phase. After quenching, the steel sheet is reheated to approximately the zinc bath temperature for galvanizing and optionally galvannealing. Finally, the steel sheet is cooled to ambient temperature.
Regardless of the particular cooling rate achieved, it should be understood that improved mechanical properties of the steel sheet can be achieved by reheating the steel sheet as described above. These improvements can be achieved whether the steel sheet includes conventional dual-phase alloy compositions or compositions with relatively low alloying elements described herein.
In embodiments where reduced cooling rates are achieved, it should be understood that because of the reduction in the average cooling rate, martensite is more readily formed when the quench step (18) is added to the typical thermal profile (10). Since the conditions increase the propensity to form martensite, less alloying elements are required in the steel sheet. Thus, when the quench step (18) is applied to the typical thermal profile (10) described above, dual phase steel can be galvanized or galvannealed with substantially less alloying elements. Despite having less alloying elements, the steel sheet can have similar post heat treatment martensite content as conventional dual phase steels treated using only the typical thermal profile (10).
It should be understood that in some examples it may be desirable to modify the typical thermal profile (10) such that the quench step (18) is performed after galvanizing/galvannealing instead of before. One such example can be seen in
In some variations of the process where the quench step (18) is applied after galvanizing or galvannealing, a tempering step (40) may also be performed, where the steel sheet is heated to a predetermined temperature above or below the martensite start temperature (Ms) for a predetermined period of time after the quench step (18). When such a tempering step is used, the average cooling rate is also similar to the average cooling rate (30) for the typical thermal profile (10) shown in
The steel sheet may include various alloying elements typically present in conventional dual phase steels. For instance, in some embodiments, carbon provides increased strength. For instance, increasing carbon concentration generally lowers the Ms temperature, lowers transformation temperatures for other non-martensitic constituents (e.g., bainite, ferrite, pearlite), and increases the time required for non-martensitic products to form. Additionally, increased carbon concentrations may improve the hardenability of the material thus retaining formation of non-martensitic constituents near the core of the material where cooling rates may be locally depressed. However, it should be understood that carbon additions may be limited as significant carbon concentrations can lead to detrimental effects on weldability. Furthermore, in greater concentrations carbon can have a detrimental effect of formability. Therefore, the carbon content is generally kept around 0.067-0.14 by weight.
In some embodiments manganese provides increased strength by lowering transformation temperatures of other non-martensitic constituents and increasing the amount of martensite. Manganese can further improve the propensity of the steel sheet to form martensite by increasing hardenability. Manganese can also increase strength through solid solution strengthening. However, the presence of manganese in large concentrations can degrade formability. Therefore the manganese content is generally present in the concentration of about 1.65-2.9 by weight.
In some embodiments aluminum additions are made to provide deoxidization. However, aluminum additions beyond certain levels can lead to formability being degraded. Accordingly, aluminum is generally present in the concentration of about 0.015-0.07 by weight.
In some embodiments silicon can be added to promote a dual phase structure consisting of predominately ferrite and martensite. However, when silicon is increased beyond certain concentrations, zinc will not adhere as effectively to the steel sheet. Accordingly, silicon is generally present in the concentration of about 0.1-0.25 by weight.
In some embodiments niobium is added to refine ferrite grains. Such grain refinement is desirable to improve formability and improve weld quality. However, if niobium concentrations exceed a certain amount, formability of the steel sheet will degrade. Accordingly, niobium is generally present in the concentration of about 0-0.045 by weight. Alternatively, in some examples niobium is present in the concentration of about 0.015-0.045 by weight.
In some embodiments vanadium is added to increase hardenability and/or refine ferrite grains. When added, vanadium is generally included in a concentration less than or equal to 0.05 by weight.
In some examples chromium is added to improve formability and weld quality. However, chromium additions exceeding certain concentrations will result in low quality surface properties. Accordingly, chromium may be included in the concentration of about 0-0.67, or 0.2-0.67 by weight.
In other embodiments molybdenum may be used to increase hardenability. When molybdenum is used, molybdenum can be included in a concentration of about 0.08-0.45 by weight. In other embodiments the lower limit concentration of molybdenum is reduced further, or even eliminated entirely.
In some embodiments titanium and boron are added to increase strength. It should be understood that in some embodiments titanium and boron may be used together, separately in lieu of the other, or neither element may be used. When titanium is used, titanium is present in the concentration of about 0.01-0.03 by weight. When boron is used, boron is present in the concentration of about 0.0007-0.0013 by weight.
In embodiments where titanium and boron are added together, titanium is generally present in suitable concentrations to substantially prevent boron from forming nitrides. Thus, titanium may be included to combine with nitrogen prior to the nitrogen combining with boron. In some circumstances titanium is included in concentrations of about 3.43 times the weight percent of nitrogen. When included in this concentration, titanium generally combines with nitrogen, thereby preventing boron from forming nitrides.
In other embodiments, variations in the concentrations of elements and the particular elements selected may be made. Of course, where such variations are made, it should be understood that such variations may have a desirable or undesirable effect on the steel sheet microstructure and/or mechanical properties in accordance with the properties described above for each given alloying addition.
Example 1Embodiments of the steel sheet were made with the compositions set forth in Table 1 below.
Embodiments of the steel sheet made with the compositions set forth above in Table 1 were subjected to mechanical testing. Mechanical properties for a selected number of the compositions set forth in Table 1 are set forth below in Table 2.
Embodiments of the steel sheet were made with the compositions set forth in Table 3 below. The particular compositions shown in Table 3 are based on the compositional ranges set forth in Table 1.
Embodiments of the steel sheet made with the compositions set forth above in Table 3 were subjected to mechanical testing. Mechanical properties for each of the compositions set forth in Table 3 are set forth below in Tables 4 through 15.
It will be understood various modifications may be made to this invention without departing from the spirit and scope of it. Therefore, the limits of this invention should be determined from the appended claims.
Claims
1. A method for processing a dual phase steel sheet, the method comprising:
- (a) heating the steel sheet to a first temperature (T1), wherein T1 is at least above the temperature at which the steel sheet transforms to austenite and ferrite to form at least some austenite in the steel sheet;
- (b) cooling the steel sheet to a second temperature (T2) by cooling at a cooling rate, wherein T2 is below the martensite start temperature (Ms), wherein the cooling rate is sufficiently rapid to transform at least some the austenite to martensite;
- (c) transitioning the steel sheet to a third temperature (T3); and
- (e) cooling the steel sheet to room temperature.
2. The method of claim 1, further comprising hot dip galvanizing or galvannealing the steel sheet after the steel sheet is transitioned to T3.
3. The method of claim 1, wherein the hot dip galvanizing or galvannealing occurs above Ms.
4. The method of claim 1, wherein the step of cooling the steel sheet to T2 is performed prior to the step of transitioning the steel sheet to T3.
5. The method of claim 4, wherein the step of transitioning the steel sheet to T3 includes reheating the steel sheet from T2 to T3.
6. The method of claim 1, wherein the step of cooling the steel sheet to T2 is performed after the step of transitioning the steel sheet to T3.
7. The method of claim 1, wherein the step of cooling the steel sheet to T2 is sufficiently rapid to transform substantially all austenite to martensite.
8. The method of claim 1, wherein the steel sheet comprises the following elements by weight percent:
- 0.080-0.1 carbon;
- 1.7-1.9 manganese;
- 0.15-0.25 silicon;
- 0.02 or less molybdenum;
- 0.015-0.025 niobium;
- 0.2-0.3 chromium; and
- the balance being iron and other incidental impurities.
9. The method of claim 1, wherein the steel sheet comprises the following elements by weight percent:
- 0.067-0.080 carbon;
- 1.65-1.82 manganese;
- 0.15-0.25 silicon;
- 0.16-0.02 molybdenum;
- 0.001 or less niobium; and
- the balance being iron and other incidental impurities.
10. The method of claim 1, wherein the steel sheet comprises the following elements by weight percent:
- 0.10-0.12 carbon;
- 2.1-2.3 manganese;
- 0.15-0.25 silicon;
- 0.003 or less niobium;
- 0.2-0.3 chromium; and
- the balance being iron and other incidental impurities.
11. The method of claim 10, wherein the steel sheet further comprises 0.25-0.35 molybdenum.
12. The method of claim 1, wherein the steel sheet comprises the following elements by weight percent:
- 0.10-0.12 carbon;
- 1.75-1.9 manganese;
- 0.15-0.25 silicon;
- 0.035-0.045 niobium;
- 0.2-0.3 chromium; and
- the balance being iron and other incidental impurities.
13. The method of claim 12, wherein the steel sheet further comprises 0.15-0.2 molybdenum.
14. The method of claim 1, wherein the steel sheet comprises the following elements by weight percent:
- 0.11-0.13 carbon;
- 2.4-2.7 manganese;
- 0.15-0.25 silicon;
- 0.35-0.45 molybdenum;
- 0.004 or less niobium;
- 0.3-0.4 chromium; and
- the balance being iron and other incidental impurities.
15. The method of claim 1, wherein the steel sheet comprises the following elements by weight percent:
- 0.80-0.10 carbon;
- 2.0-2.2 manganese;
- 0.40-0.50 silicon;
- 0.04-0.060 niobium;
- 0.2-0.3 chromium; and
- the balance being iron and other incidental impurities.
16. The method of claim 15, wherein the steel sheet further comprises 0.30-0.40 molybdenum.
17. The method of claim 1, wherein the steel sheet comprises the following elements by weight percent:
- 0.09-0.10 carbon;
- 2.25-2.42 manganese;
- 0.10-0.20 silicon;
- 0.035-0.045 niobium;
- 0.57-0.67 chromium; and
- the balance being iron and other incidental impurities.
18. The method of claim 17, wherein the steel sheet further comprises 0.08-0.12 molybdenum.
19. The method of claim 1, wherein the steel sheet comprises the following elements by weight percent:
- 0.12-0.14 carbon;
- 2.7-2.9 manganese;
- 0.15-0.25 silicon;
- 0.004 or less niobium;
- 0.3-0.4 chromium; and
- the balance being iron and other incidental impurities.
20. The method of claim 19, wherein the steel sheet further comprises 0.35-0.45 molybdenum.
21. The method of claim 1, wherein the steel sheet comprises the following elements by weight percent:
- 0.11-0.13 carbon;
- 2.45-2.60 manganese;
- 0.420-0.580 silicon;
- 0.05 or less molybdenum;
- 0.035-0.045 niobium; and
- the balance being iron and other incidental impurities.
22. The method of claim 21, wherein the steel sheet further comprises 0.57-0.63 chromium.
Type: Application
Filed: Jan 14, 2016
Publication Date: Jul 14, 2016
Inventors: Grant Aaron Thomas (Liberty Township, OH), Jose Mauro Barros Losz (Middletown, OH), Luis Gonzalo Garza-Martinez (Wyoming, OH), Eddie Ray Case (Oxford, OH), Eric Petersen (West Alexandria, OH), Prabhat Rastogi (Munster, IN)
Application Number: 14/995,409