EP4511522A1 - Flat steel product having an al coating, method for the production thereof, steel component, and method for production thereof - Google Patents

Abstract

The invention relates to a steel component consisting of a steel substrate made of a steel comprising 0.1-3 wt.% Mn and optionally up to 0.01 wt.% B, and of an Al-based protective coating applied to the steel substrate. The protective coating has, in total, an iron-free and manganese-free mass fraction of up to 30% of additional alloy constituents. The iron-free and manganese-free mass fraction of the protective coating of Si as an additional alloy constituent is between 3% and 15% Si. In addition, the iron-free and manganese-free mass fraction of the protective coating of Mg as an additional alloy constituent is up to 1.0% Mg. The iron-free and manganese-free fraction of the protective coating of Zn as an additional alloy constituent is between 0.4% and 25.0% Zn. The protective coating also has a near-surface first Zn-rich layer which has a Zn content higher than an average Zn content of the protective layer, and wherein the Zn content of the first Zn-rich layer is more than 5 wt.%.

Description

Flat steel product with an Al coating, process for its production, steel component and process for its production

The invention relates to a flat steel product for hot forming, which consists of a steel substrate consisting of a steel containing 0.1-3% by weight of Mn and optionally up to 0.01% by weight of B, and a protective coating applied to the steel substrate based on AI, which optionally contains a total of up to 30% by weight of other alloying elements.

The invention also relates to a steel component and a method for producing such a steel component.

The term “flat steel product” includes all rolled products whose length is much greater than their thickness. This includes steel strips and sheets as well as blanks and blanks obtained from them.

During hot forming, also called hot forming, press hardening or hot press hardening, steel blanks, which are separated from cold or hot rolled steel strip, are heated to a deformation temperature that is usually above the austenitization temperature (Ac3) of the respective steel and, in the heated state, are placed in the tool of a forming press placed. During the subsequent forming process, the sheet metal blank or the component formed from it experiences rapid cooling through contact with the cool tool. The cooling rates are set so that a hardened structure is created in the steel substrate. The structure is transformed into a martensitic structure, which is referred to as a hardness structure.

Typical steels that are suitable for hot press hardening are steels A-E, whose chemical composition is listed in Table 10.

For hot-rolled MnB steel sheets provided with an Al coating and intended for the production of steel components by hot forming, EP 0971 044 Bl specifies an alloying specification according to which an MnB steel, in addition to iron and unavoidable impurities (in weight %) a carbon content of more than 0.20% but less than 0.5%, a manganese content of more than 0.5% but less than 3%, a silicon content of more than 0.1% but less than 0 .5%, a chromium content of more than 0.01% but less than 1%, a titanium content of less than 0.2%, an aluminum content of less than 0.1%, a phosphorus content of less than 0.1%, a sulfur content of less than 0.05% and a boron content of more than 0.001% , but should be less than 0.08%. The Al coating is a so-called AISi coating, which consists of 9-10% by weight of Si, 2-3.5% by weight of iron and the remainder of aluminum. The flat steel products prepared and coated in this way are heated to a heating temperature of more than 700 °C and kept at the heating temperature for a certain holding time. During this heating and holding process, the protective coating melts and the protective coating alloys through. Here, iron diffuses from the steel substrate into the protective coating, so that phases are formed that have a higher temperature stability. The melted protective coating thus solidifies. A solidified, temperature-stable protective coating is a prerequisite for the subsequent forming step. During the forming step, the flat steel product is placed in a press molding tool, where it is warmly formed into the steel component and cooled so quickly that a hardness structure is created in the steel substrate of the flat steel product.

The AISi coating described has the disadvantage that the temperatures during hot press forming lead to very strong oxidation of the aluminum-rich surface. This aluminum oxide layer in turn means that a subsequent phosphating step does not work adequately. The aluminum oxide layer prevents the formation of firmly adhering metal phosphates during phosphating, since during phosphating the process parameters are typically not sufficient to break up the aluminum oxide layer. In this case, the resulting steel component is highly susceptible to cosmetic corrosion. Although this does not affect the structural stability of the steel component, it does result in a reduced aesthetics of the steel component, which is not desired by the end customer.

DE 10 2009 007 909 A1 discloses a method for producing high-strength steel components, in which, on the one hand, an optimized deformation behavior of the coating is guaranteed during the hot press forming of the respective flat steel product and, on the other hand, the steel components obtained have optimized cathodic corrosion protection. The steel component according to the invention has a zinc-alloyed surface with a zinc content of at least 60% by weight, in particular at least 80% by weight. This results in cathodic corrosion protection that can be clearly detected electrochemically. EP 2 045 360 A1 discloses a method for producing high-strength steel components that have optimized corrosion protection and are particularly suitable for use in automobile bodies. After hot forming, a steel component according to the invention has a zinc-alloyed surface with a zinc content of at least 60% by weight, in particular at least 80% by weight. This results in cathodic corrosion protection that can be clearly detected electrochemically. This results in a resistance to corrosion that is at least comparable to pure zinc coatings.

Zn contents of over 25% by weight increase the risk of liquid metal embrittlement. Zinc in the protective coating has the disadvantage that it has a relatively low melting point. During the production of the steel component by hot forming, liquid Zn phases can form. On the one hand, these can penetrate into the steel substrate and contribute to the formation of cracks (liquid metal embrittlement) and, on the other hand, they can stick to forming tools or furnace rollers, which leads to contamination and layer detachment.

The object of the present invention is to provide a steel component that can be produced by hot forming and has improved phosphating properties.

This task is solved by a steel component, which consists of a steel substrate, which consists of a steel containing 0.1-3% by weight of Mn and optionally up to 0.01% by weight of B, and a protective coating applied to the steel substrate Based on AI, which optionally has a total iron and manganese-free mass fraction of up to 30% of additional alloy components. The iron and manganese-free mass fraction of the protective coating of Si as an additional alloy component is between 3% and 15% Si, in particular between 6% and 12% Si. In addition, the iron and manganese-free mass fraction of the protective coating of Mg as an additional alloy component is up to 1.0% and the iron and manganese-free mass fraction of the protective coating of Zn as an additional alloy component is between 0.4% and 25.0% Zn. Furthermore, the protective coating has a first Zn-rich layer near the surface with a Zn content that is higher than the average Zn content of the protective coating. In addition, the Zn content of the first Zn-rich layer is more than 5% by weight. The protective coating is in particular an AlSi coating.

For the purposes of this application, an iron and manganese-free mass fraction of an alloy component in the protective coating means the proportion of the total mass of this alloy component understood as the total mass of all elements in the protective coating except iron and manganese. The use of the iron and manganese-free mass fraction to characterize the protective coating has the advantage that the numerical values do not change due to the diffusion of iron and manganese from the steel substrate. Iron and manganese-free mass fractions are given in [%]. In contrast, the element contents based on total mass are usually given in [% by weight].

The protective coating therefore comprises a proportion of up to 30%, preferably up to 20%, based on the total mass without iron and manganese, of additional alloying elements, with 3 to 15% of this being Si, up to 1.0% Mg and between 0. 4 and 25% Zn.

In particular, the mass fraction of Mn is more than 0.1% by weight and less than 2.5% by weight, preferably more than 0.2% by weight and preferably less than 2.0% by weight, particularly preferred more than 0.4% by weight and preferably less than 1.8% by weight. During hot forming, a certain proportion of Mn diffuses from the steel substrate into the protective coating and forms an additional alloy component there.

In addition to Fe, Si, Mg, Zn and optionally Mn, the protective coating preferably consists only of Al and unavoidable impurities. For the purposes of this application, an element is an unavoidable contamination of the protective coating if the iron and manganese-free mass fraction in the protective coating is less than 0.5%. This definition only refers to unavoidable contamination of the protective coating. The usual technical limit values apply to the unavoidable impurities in the steel substrate mentioned later.

For the purposes of this application, a layer close to the surface is to be understood as meaning a layer which extends over an area with a thickness of 500 nm which adjoins the surface of the protective coating. The first Zn-rich layer therefore extends in an area with a thickness of 500 nm, which adjoins the surface of the protective coating. In other words, the first Zn-rich layer extends into the top 500nm of the protective coating.

It has been shown that an increased Zn content in this area near the surface enables reliable phosphating. The zinc near the surface is converted into zinc during phosphating phosphates converted. A zinc phosphate layer also offers better corrosion protection than an iron phosphate layer that would otherwise form. Furthermore, zinc phosphate is an excellent basis for paint adhesion.

The iron- and manganese-free mass fraction of the protective coating of Zn as an additional alloy component is preferably at least 0.6%, particularly preferably at least 1.0%, in particular at least 1.5%.

Furthermore, the Zn content of the first Zn-rich layer is more than 10.0% by weight, particularly preferably more than 18.0% by weight.

The higher the Zn content of the first Zn-rich layer, the better the phosphating behavior is, since more zinc phosphates and fewer iron phosphates are formed. With a higher iron and manganese-free mass fraction of Zn in the protective coating, it is easier to achieve a high Zn content in the first Zn-rich layer in a process-safe manner. Therefore, a high iron and manganese-free mass fraction of the protective coating of Zn is preferred.

However, zinc in the protective coating has the disadvantage that it has a relatively low melting point. During the production of the steel component by hot forming, liquid Zn phases can form. On the one hand, these can penetrate into the steel substrate and contribute to the formation of cracks (liquid metal embrittlement) and, on the other hand, they can stick to forming tools or furnace rollers, which leads to contamination and layer detachment. Therefore, the zinc content cannot be chosen too high. In tests, iron and manganese-free mass fractions of the protective coating of Zn of at most 5.0%, in particular less than 5%, preferably at most 2.3%, particularly preferably at most 1.8%, have proven to be particularly favorable for the flat steel product.

Magnesium has proven to be an advantageous additional alloy component in the protective coating, which can be easily alloyed into Al protective coatings of the type in question here. The amount of Mg added is adjusted so that the iron and manganese-free mass fraction of magnesium is at least 0.10%, preferably at least 0.15%. In particular, iron- and manganese-free mass fractions of magnesium of less than 0.50% or less than 0.4% or less than 0.35% have proven to be particularly favorable in practice. That in go- Magnesium added in small amounts to the protective coating is characterized by a higher affinity for oxygen than the main component aluminum of the protective coating. Even in the presence of such small amounts of magnesium, a thin oxide layer forms on the surface of the protective coating, which covers the aluminum lying between it and the steel substrate. This thin layer prevents the aluminum from reacting with the moisture present in the atmosphere of the furnace used to heat the flat steel product during the heating required for hot forming of the flat steel product. Oxidation of the aluminum of the coating and the associated release of hydrogen, which could diffuse into the coating and the steel substrate of the flat steel product, are thus effectively prevented. Surprisingly, this also applies in particular if the Al-based coating becomes locally molten as a result of heating and its surface tears open, so that molten coating material comes into contact with the furnace atmosphere. Particularly with longer annealing times, flat steel products according to the invention have a lower hydrogen concentration in the component hot-formed from the flat steel product compared to flat steel products conventionally provided with an Al coating.

Therefore, alloying magnesium has the advantage that it reduces the entry of hydrogen into the steel substrate. If a locally very high hydrogen concentration is reached, this weakens the bond at the grain boundaries of the steel substrate structure to such an extent that a crack occurs along the grain boundary during use as a result of the stress that occurs.

The element contents of the protective coating are determined in particular by optical glow discharge spectroscopy (GD-OES Glow Discharge Optical Emission Spectroscopy). Alternatively, wet chemical removal followed by ICP-OES (Inductively coupled plasma - optical emission spectrometry) is used to determine the element contents.

The layer thickness of the protective coating is typically in the range of at least 5 pm and a maximum of 35 pm, in particular at least 10 pm and a maximum of 25 pm.

The steel substrate is made of a steel that has 0.1-3% by weight of Mn and optionally up to 0.01% by weight of B. In particular, the structure of the steel can be converted into a martensitic or partially martensitic structure by hot forming. The structure of the steel substrate of the steel component is therefore preferably a martensitic or at least partially martensitic structure, since this has a particularly high hardness. The steel substrate is particularly preferably a steel which, in addition to iron and unavoidable impurities (in wt.%)

C: 0.04 - 0.45% by weight,

Si: 0.02 - 1.2% by weight, Mn: 0.5 - 2.6% by weight, Al: 0.02 - 1.0% by weight, P: <0.05% by weight. -%,

S: <0.02% by weight,

N: <0.02% by weight,

Sn: <0.03% by weight,

As: <0.01% by weight,

Ca: <0.005% by weight, and optionally one or more of the elements “Cr, B, Mo, Ni, Cu, Nb, Ti, V” in the following contents:

Cr: 0.08 - 1.0% by weight,

B: 0.001 - 0.005% by weight,

Mo: <0.5% by weight,

Ni: <0.5% by weight,

Cu: <0.2% by weight,

Nb: 0.02 - 0.08% by weight,

Ti: 0.01 - 0.08% by weight,

V: <0.1% by weight.

The elements P, S, N, Sn, As, Ca are impurities that cannot be completely avoided during steel production. In addition to these elements, other elements can also be present as impurities in the steel. These other elements are grouped together as “unavoidable impurities”. The total content of unavoidable impurities is preferably a maximum of 0.2% by weight, preferably a maximum of 0.1 % by weight. The optional alloying elements Cr, B, Nb, Ti, for which a lower limit is specified, can also occur in levels below the respective lower limit as unavoidable impurities in the steel substrate. In this case, they are also counted among the unavoidable impurities, the total content of which is limited to a maximum of 0.2% by weight, preferably a maximum of 0.1% by weight. The individual upper limits for the respective contamination of these elements are preferably as follows:

Cr: <0.050% by weight,

B: <0.0005% by weight

Nb: <0.005% by weight,

Ti: <0.005% by weight

These preferred upper limits should be viewed as alternative or together. Preferred variants of steel therefore meet one or more of these four conditions.

In a preferred embodiment, the C content of the steel is a maximum of 0.37% by weight and/or at least 0.06% by weight. In particularly preferred embodiment variants, the C content is in the range of 0.06-0.09% by weight or in the range of 0.12-0.25% by weight or in the range of 0.33-0.37% by weight .-%.

In a preferred embodiment, the Si content of the steel is a maximum of 1.00% by weight and/or at least 0.06% by weight.

In a preferred variant, the Mn content of the steel is a maximum of 2.4% by weight and/or at least 0.75% by weight. In particularly preferred embodiment variants, the Mn content is in the range of 0.75-0.85% by weight or in the range of 1.0-1.6% by weight.

In a preferred variant, the Al content of the steel is a maximum of 0.75% by weight, in particular a maximum of 0.5% by weight, preferably a maximum of 0.25% by weight. Alternatively or additionally, the Al content is preferably at least 0.02%.

It has also been shown that it can be helpful if the sum of the silicon and aluminum contents is limited. In a preferred variant, the sum of the contents of Si and Al (usually referred to as Si+Al) is a maximum of 1.5% by weight, preferably a maximum of 1.2 % by weight. Additionally or alternatively, the sum of the Si and Al contents is at least 0.06% by weight, preferably at least 0.08% by weight.

The elements P, S, N are typical impurities that cannot be completely avoided during steel production. In preferred variants, the P content is a maximum of 0.03% by weight. Regardless of this, the S content is preferably a maximum of 0.012%. In addition or in addition, the N content is preferably a maximum of 0.009% by weight.

The steel also optionally contains chromium with a content of 0.08 - 1.0% by weight. The Cr content is preferably a maximum of 0.75% by weight, in particular a maximum of 0.5% by weight.

In the case of an optional addition of chromium, the sum of the chromium and manganese contents is preferably limited. The total is a maximum of 3.3% by weight, in particular a maximum of 3.15% by weight. Furthermore, the sum is at least 0.5% by weight, preferably at least 0.75% by weight.

The steel preferably optionally also contains boron with a content of 0.001-0.005% by weight. In particular, the B content is a maximum of 0.004% by weight.

Optionally, the steel can contain molybdenum with a content of a maximum of 0.5% by weight, in particular a maximum of 0.1% by weight.

Furthermore, the steel can optionally contain nickel with a content of a maximum of 0.5% by weight, preferably a maximum of 0.15% by weight.

Optionally, the steel can also contain copper with a content of a maximum of 0.2% by weight, preferably a maximum of 0.15% by weight.

In addition, the steel can optionally contain one or more of the microalloying elements Nb, Ti and V. The optional Nb content is at least 0.02% by weight and at most 0.08% by weight, preferably at most 0.04% by weight. The optional Ti content is at least 0.01% by weight and at most 0.08% by weight, preferably at most 0.04% by weight. The optional V content is a maximum of 0.1% by weight, preferably a maximum of 0.05% by weight. In the case of an optional alloying of several of the elements Nb, Ti and V, the sum of the contents of Nb, Ti and V is preferably limited. The sum is a maximum of 0.1% by weight, in particular a maximum of 0.068% by weight. Furthermore, the sum is preferably at least 0.015% by weight.

The steel substrate is particularly preferably a steel from the group of steels A-E, the chemical analysis of which is given in Table 10. Table 10 should be understood as meaning that the element proportions are given in percent by weight for each steel from the group of steels A-E. A minimum and a maximum weight percentage is specified here. For example, steel A includes a carbon content C: 0.05% by weight - 0.10% by weight.

The above explanations regarding preferred steel substrates naturally also apply to the steel substrate of the flat steel product described below, as well as the manufacturing processes described.

In a preferred embodiment variant of the steel component, the surface of the protective coating is largely formed from Zn enrichments in metallic and/or oxidic form. For the purposes of this application, the surface of the protective coating is largely formed from Zn enrichments in metallic and/or oxidic form if there are point Zn enrichments on more than 50% (area percent), preferably on more than 70% of the surface of the protective coating. This proportion can be determined, for example, using electron micrographs and subsequent image analysis. For each point, both AI and Zn are recorded according to their signal intensity, so that zinc enrichments can be identified.

In a preferred embodiment variant of the steel component, the protective coating comprises a low-silicon phase and a silicon-rich phase, the silicon-rich phase being distributed in an island shape in the low-silicon phase. The Zn content of the silicon-rich phase is less than 90%, preferably less than 80%, of an average Zn content of the protective coating. At the same time, the Zn content of the low-silicon phase is more than 105%, preferably more than 110%, of the average Zn content of the protective coating. In other words, the ratio of the mass fraction of Zn (indicated in wt.%) in the silicon-rich phase to the mass fraction of Zn (indicated in wt.%) in the entire protective coating is less than 90%, preferably less than 80%. Likewise, the ratio of the mass fraction of Zn (indicated in wt.%) in the low-silicon phase to the mass fraction of Zn (indicated in wt.%) in the entire protective coating is greater than 105%, preferably greater than 110%.

So there is a concentration of zinc in the silicon-poor phases, while the zinc content in the silicon-rich phases drops below the average.

In special embodiments, the Si content of the low-silicon phases is less than 10% by weight, preferably less than 7% by weight, particularly preferably less than 5% by weight.

Further special embodiments have an Si content of the silicon-rich phase that is greater than 10% by weight, preferably greater than 12% by weight.

For the purposes of this application, “island-shaped” is understood to mean an arrangement in which discrete, unconnected areas are enclosed by another material - i.e. there are “islands” of a certain material in another material. In the vertical metallographic cut, the “islands” can have aspect ratios of length to width in the range of 1:1. The length is measured parallel to the surface and the width is measured perpendicular to the surface. The “islands” have a similar length and width. However, significantly larger aspect ratios can also occur where the length is significantly greater than the width. The islands are therefore strip-shaped.

The object according to the invention is also achieved by a flat steel product for hot forming, which consists of a steel substrate made of a steel which has 0.1-3% by weight of Mn and optionally up to 0.01% by weight of B, and one on the A protective coating based on Al is applied to the steel substrate, which optionally has a total iron and manganese-free mass fraction of up to 30% of additional alloy components. Furthermore, the iron- and manganese-free mass fraction of the protective coating of Si as an additional alloying component is between 3% and 15% Si, in particular between 6% and 12% Si, the iron- and manganese-free mass fraction of Mg of the protective coating as an additional alloying component being between 0. 10% and 0.50% Mg, preferably between 0.1 and 0.35% Mg. In addition, the iron and Manganese-free mass fraction of Zn of the protective coating as an additional alloy component between 0.4 and 5.0% Zn, preferably between 0.4 and 2.3% Zn.

The protective coating therefore comprises a proportion of up to 30%, preferably up to 20%, based on the total mass without iron, of additional alloying elements, of which 3 to 15% are Si, between 0.10% and 0.50% Mg and between 0.4 and 2.3% Zn.

In particular, the mass fraction of Mn is more than 0.1% by weight and less than 2.5% by weight, preferably between 0.2% by weight and 2.0% by weight and particularly preferably between 0.4 % by weight and 1.8% by weight. When the protective coating is applied, a certain proportion of Mn can diffuse from the steel substrate into the protective coating and forms an additional alloy component there. This is particularly the case with hot-dip coating due to the high temperatures in the melt pool.

The protective coating of the flat steel product preferably consists of Fe, Si, Mg, Zn and optionally Mn only of Al and unavoidable impurities. For the purposes of this application, an element is an unavoidable contamination of the protective coating if the iron and manganese-free mass fraction in the protective coating is less than 0.5%. This definition only refers to unavoidable contamination of the protective coating. The usual technical limit values apply to the unavoidable impurities in the steel substrate mentioned later.

It has been shown that from an iron and manganese-free mass fraction of Zn of 0.4% after hot forming, there is a sufficiently high Zn content in the area near the surface to enable reliable phosphating. During phosphating, zinc close to the surface combines to form zinc phosphates, which offer better corrosion protection than an iron phosphate layer that would otherwise form. Furthermore, zinc phosphate is an excellent basis for paint adhesion.

The iron- and manganese-free mass fraction of the protective coating of Zn as an additional alloy component is preferably at least 0.6%, particularly preferably at least 1.0%, in particular at least 1.5%. The higher the iron and manganese-free mass fraction of zinc, the higher the Zn content in the area near the surface after hot forming and the better the phosphating behavior, since more zinc phosphates and fewer iron phosphates are formed.

With a higher iron and manganese-free mass fraction of Zn in the protective coating, a high Zn content of the first Zn-rich layer can be reliably achieved. Therefore, a high iron and manganese-free mass fraction of the protective coating of Zn is preferred.

However, zinc in the protective coating has the disadvantage that it has a relatively low melting point. During the production of the steel component by hot forming, liquid Zn phases can form. On the one hand, these can penetrate into the steel substrate and contribute to the formation of cracks (liquid metal embrittlement) and, on the other hand, they can stick to forming tools or furnace rollers, which leads to contamination and layer detachment. Therefore, the zinc content cannot be chosen too high. In tests, iron and manganese-free mass fractions of the protective coating of Zn of at most 2.3%, preferably at most 1.8%, have proven to be particularly favorable.

Magnesium has proven to be an advantageous additional alloy component in the protective coating, which can be easily alloyed into Al protective coatings of the type in question here. The amount of Mg added is adjusted so that the iron and manganese-free mass fraction of magnesium is at least 0.10%, preferably at least 0.15%. In particular, iron- and manganese-free mass fractions of magnesium of less than 0.50% or less than 0.4% or less than 0.35% have proven to be particularly favorable in practice. The magnesium added to the protective coating in small quantities is characterized by a higher affinity for oxygen than the main component aluminum of the protective coating. Even in the presence of such small amounts of magnesium, a thin oxide layer forms on the surface of the protective coating, which covers the aluminum lying between it and the steel substrate. This thin layer prevents the aluminum from reacting with the moisture present in the atmosphere of the furnace used to heat the flat steel product during the heating required for hot forming of the flat steel product. Oxidation of the aluminum of the coating and the associated release of hydrogen, which could diffuse into the coating and the steel substrate of the flat steel product, are thus effectively prevented. Surprisingly, this also applies in particular if the Al-based coating becomes locally molten as a result of heating and its surface tears open, so that molten coating material comes into contact with the furnace atmosphere. Particularly with longer annealing times, flat steel products according to the invention show a difference compared to conventional ones Flat steel products with an Al coating have a lower hydrogen concentration in the component hot-formed from the flat steel product.

Therefore, alloying magnesium has the advantage that it reduces the entry of hydrogen into the steel substrate. If a locally very high hydrogen concentration is reached, this weakens the bond at the grain boundaries of the steel substrate structure to such an extent that a crack occurs along the grain boundary during use as a result of the stress that occurs.

In a particularly preferred variant of the flat steel product, the protective coating is applied by hot-dip coating. Hot-dip coating, also known as “fire aluminizing” in technical terms, is a particularly economical process for applying a protective coating.

The layer thickness of the protective coating is typically in the range of at least 5 pm and a maximum of 35 pm, in particular at least 10 and a maximum of 25 pm.

The object according to the invention is also achieved by a method for producing a phosphated steel component comprising the following steps:

- Heating the above-described flat steel product to a heating temperature for hot forming and holding it at the heating temperature, so that diffusion leads to a concentration of the Zn, in particular with the formation of metallic and oxide Zn enrichments, in the area near the surface of the protective coating

- Hot forming the coated steel substrate into the steel component

- Phosphating of the hot-formed steel component

Heating the above-described flat steel product to a heating temperature for hot forming and holding it at the heating temperature leads to a concentration of the Zn in the area near the surface. In particular, a first Zn-rich layer is formed, as has already been explained in connection with the steel component, and for the formation of oxide and/or metallic Zn enrichments on the surface of the protective coating, which has also been explained in connection with the steel component became. This Concentration of Zn in the area near the surface leads to significantly improved phosphating behavior and in particular to the formation of zinc phosphates instead of iron phosphates.

The heating temperature is preferably 830°C to 980°C, preferably 830°C to 910°C. Furthermore, a holding time that the flat steel product is kept at the heating temperature is at least 1 and at most 18 minutes. The heating and holding takes place in an oven.

Thermoforming includes in particular the following two sub-steps:

- Removing the flat steel product from the furnace and placing it in a forming tool

- Forming the flat steel product into a steel component in the forming tool

To avoid major heat losses, the transfer time between the furnace and the forming tool is typically a maximum of 10 seconds.

Optionally, the flat steel product can be cooled in the forming tool during forming at cooling rates of 20-1000 K/s, preferably 25-500 K/s, in order to harden the steel substrate.

Alternatively, the flat steel product can first be formed into a steel component in the forming tool and then the steel component can be cooled at cooling rates of 20-1000 K/s, preferably 25-500 K/s, in order to harden the steel substrate.

Furthermore, the object according to the invention is also achieved by a method for producing a phosphated steel component comprising the following work steps:

- Providing a steel substrate made of a steel that has 0.1-3% by weight of Mn and optionally up to 0.01% by weight of B

- Hot-dip coating of the steel substrate using a melt with a protective coating based on Al, which optionally has a total iron and manganese-free mass fraction of up to 30% of additional alloy components, whereby the iron- and manganese-free mass fraction of the protective coating of Si as an additional alloying component is between 3% and 15% Si, in particular between 6% and 12% Si, whereby the iron- and manganese-free mass fraction of the protective coating of Mg as an additional alloying component is up to 1% and whereby the iron and manganese-free mass fraction of the protective coating of Zn as an additional alloy component is between 0.4% and 25.0% Zn

- Heating the coated steel substrate to a heating temperature for hot forming and holding it at the heating temperature, so that diffusion leads to a concentration of the Zn, in particular with the formation of metallic and oxide Zn enrichments, on the surface of the protective coating

- Hot forming the coated steel substrate into the steel component

- Phosphating of the hot-formed steel component.

The iron and manganese-free mass fractions have preferred minimum values and maximum values, which are explained above with reference to the steel component together with their advantages.

In particular, the steel substrate is hot-dip coated using a melt with a protective coating based on Al, which in total has an iron and manganese-free mass fraction of up to 30% of additional alloy components, the additional alloy components having Si, Mg and Zn, the iron - and manganese-free mass fraction of the protective coating of Si as an additional alloying component is between 3% and 15% Si, in particular between 6% and 12% Si, whereby the iron- and manganese-free mass fraction of Mg of the protective coating as an additional alloying component is between 0.10-0, 50% Mg, preferably between 0.1-0.35% Mg, and that the iron and loose mass fraction of Zn of the protective coating as an additional alloy component is between 0.4-5% Zn, preferably between 0.4-2, 3 % Zn is.

Heating the above-described flat steel product to a heating temperature for hot forming and holding it at the heating temperature leads to a concentration of the Zn in the area near the surface. In particular, a first Zn-rich layer is formed, as has already been explained in connection with the steel component, and for the formation of oxidic and metallic Zn enrichments on the surface of the protective Coating, which were also explained in connection with the steel component. This concentration of Zn in the area near the surface leads to significantly improved phosphating behavior and in particular to the formation of zinc phosphates instead of iron phosphates.

The heating temperature is preferably 830°C to 980°C, preferably 830°C to 910°C. Furthermore, a holding time that the flat steel product is kept at the heating temperature is at least 1 and at most 18 minutes. The heating and holding takes place in an oven.

Thermoforming includes in particular the following two sub-steps:

- Removing the flat steel product from the furnace and placing it in a forming tool

- Forming the flat steel product into a steel component in the forming tool

To avoid major heat losses, the transfer time between the furnace and the forming tool is typically a maximum of 10 seconds.

Optionally, the flat steel product can be cooled in the forming tool during forming at cooling rates of 20-1000 K/s, preferably 25-500 K/s, in order to harden the steel substrate.

Alternatively, the flat steel product can first be formed into a steel component in the forming tool and then the steel component can be cooled at cooling rates of 20-1000 K/s, preferably 25-500 K/s, in order to harden the steel substrate.

Phosphating means full-surface phosphating of the steel component, in which a phosphate layer is deposited on the steel component, for example a thickness of 0.5 to 3.0 pm. The phosphate layer increases paint adhesion and prevents corrosion of the steel substrate in the event of paint damage.

In a special embodiment of the aforementioned method for producing a phosphated steel component, a silicon layer is formed during heating and holding by diffusion. poor phase and a silicon-rich phase, the silicon-rich phase being distributed in an island shape in the silicon-poor phase. The Zn content of the low-silicon phase is between 25% and 60%, preferably between 30% and 50%, of the Zn content in the melt.

In a further special embodiment of the aforementioned method for producing a phosphated steel component, the heating temperature is greater than the Ac3 temperature, so that the structure of the steel substrate is austenitic. In addition, the coated steel substrate is quenched after hot forming or in the course of hot forming, so that hardness structures are formed in the structure of the steel substrate of the flat steel product.

The invention is explained in more detail using the following exemplary embodiments in conjunction with the figures. Show:

1 shows a scanning electron microscope photograph of the surface of a hot-formed steel component before phosphating;

2 is a scanning electron microscope photograph of the surface of a hot-formed steel component after phosphating;

Fig. 3 is a schematic representation of a micrograph.

As the steel substrate, a steel sheet with a thickness of 1.5 mm made of a steel having a composition as shown in Table 1, the balance being iron and unavoidable impurities, was used. The steel is therefore a steel in Group D of Table 10.

Table 1: Steel composition of the steel substrate (in wt.%)

Based on this steel substrate, four different variants were examined in more detail. For this purpose, the steel substrate was first coated with a protective coating based on Al by hot-dip coating. The thickness of the protective coating was 20 pm in each case. Table 2 below gives the target composition of the respective melt, with the remainder being formed by iron and unavoidable impurities: Table 2: Melt compositions

The element contents of the protective coating were then determined for the steel substrates coated in this way using GD-OES (Glow Discharge Optical Emission Spectroscopy). From this, the iron and manganese-free mass fractions of the respective elements can be determined. The results are shown in Table 3.

Table 3: Iron and manganese-free mass fractions of the protective coating of the coated steel substrates (flat steel products)

Variant A is therefore not according to the invention, since the iron and manganese-free mass fraction of zinc of 0.2% is outside the range according to the invention. The variant serves as a comparison sample.

In addition to the element contents in the entire protective coating, the element contents in the area close to the surface (ie in the top 500 nm) were also determined using GD-OES. The results are shown in Table 4 below: Table 4: Element contents of the protective coating of the coated steel substrates in the area close to the surface

* Contents below the detection limit

The steel flat products prepared in this way, i.e. the coated steel substrates, were then heated to a heating temperature of 920 ° C, which is greater than Ac3. They were held at this heating temperature for a holding time of between 5 and 10 minutes and then hot-formed into steel components. The heating and holding were carried out in a roller hearth furnace with a dew point control. The dew point was set at 15°C. The entire process took place under ambient atmosphere. The flat steel products were then formed into steel components in a tool and quenched to room temperature. The cooling rate was more than 50°C per second. The process parameters of the heat treatment are summarized again in Table 5 below:

Table 5: Heat treatment process parameters

The steel components produced in this way were analyzed again in a next step. The element contents of the protective coating were first determined using GD-OES and the iron and manganese-free mass fractions were determined from this. Table 6: Iron and manganese-free mass fractions of the protective coating on the steel components

* Contents below the detection limit

Here, too, it can be seen that variant A is not according to the invention, since the mass fraction of zinc without iron and manganese is 0.1%, which is outside the range according to the invention.

In addition to the element contents in the entire protective coating, the element contents in the area close to the surface (i.e. in the top 500 nm) were also determined using GD-OES. The results are shown in Table 7 below:

Table 7: Element contents of the protective coating of the steel components in the area near the surface

It can be clearly seen that variants B, C and D have a first Zn-rich layer near the surface with a Zn content that is higher than the average Zn content of the protective coating. The average Zn content of the protective coating is in any case lower than the Zn content of the melt and is therefore less than 2.26% by weight in variants B and C, for example. The diffusion process can only further reduce the average Zn content because no Zn is supplied. In addition, the Zn content of the first Zn-rich layer is 5% or more in all three variants B, C and D. There has been a drastic concentration of zinc near the surface. In Figure 1, an example of variant B is an electron microscope Photo of the surface of the protective coating shown. It can be clearly seen that the surface is formed largely from Zn enrichments in metallic and/or oxidic form, which are present in small crystallites distributed over the surface. The surface area of Zn enrichments was determined by image analysis to be 56% for variant B and 58% and 16% for variants C and D, respectively.

Figure 2 shows an example of variant B, an electron micrograph of the surface of the protective coating after phosphating. A uniform, closed phosphate layer is clearly visible.

Figure 3 shows a schematic representation of a micrograph of variant B that can be recorded using scanning electron microscopy. The steel component 11 shown consists of a steel substrate 13 and a protective coating 15. The protective coating 15 comprises a low-silicon phase A and a silicon-rich phase R, the silicon-rich phase R being distributed in an island shape in the low-silicon phase A. The Zn content in the two phases was determined using energy-dispersive X-ray spectroscopy (EDX). It has been shown that here too there is a concentration of zinc in the silicon-poor phases. The results are shown in Table 8 below.

Table 8: Zn contents and Si contents of the silicon-rich and silicon-poor phases

It is clear that the Zn content of the low-silicon phase is between 25% and 60% of the Zn content of the melt. For variant B, the ratio of the Zn contents of the low-silicon phase and melt is 30.1%, for variant B 26.5% and for variant C 46.1%. The hot-formed steel components were phosphated in a next step. For this purpose, the samples were subjected to a normal, industrial phosphating treatment. This included the following sub-steps:

- Degreasing in a degreasing bath for 150s at a temperature of 60°C. Chemetall Gardoclean S 5176 was used as a degreasing agent.

- Activate the surface for 30s with Chemetall Gardolene ZL 6. The activating agent concentration was 6g/l.

- Phosphating in a phosphating bath for 150s at a temperature of 60°C. Chemetall Gardobond 24 was used as the phosphating agent.

After phosphating was completed, the element contents in the area close to the surface (i.e. in the top 500 nm) were determined again. The results are shown in Table 9 below:

Table 9: Element contents of the protective coating of the phosphated steel components in the area close to the surface

It can be clearly seen again that variants B, C and D have a first Zn-rich layer near the surface with a Zn content that is higher than the average Zn content of the protective coating, which is listed in Table 6. In addition, the Zn content of the first Zn-rich layer is 5% or more in all three variants B, C and D. The values are even higher than before phosphating. However, this is due to the fact that material was applied during phosphating, so that the measuring range of 500nm thickness moved even further into the very zinc-containing range. It is also clear that variants B, C and D show improved phosphating behavior. The near-surface phosphorus contents are more than a factor of 5 higher than comparison sample A.

Claims

Patent claims 1. Steel component (11), which consists of a steel substrate (13) made of a steel that has 0.1-3% by weight of Mn and optionally up to 0.01% by weight of B, and a steel substrate (13 ) applied protective coating (15) based on Al, which in total has an iron and manganese-free mass fraction of up to 30% of additional alloy components, the additional alloy components having Si, Mg and Zn, the iron and manganese-free mass fraction of the Protective coating of Si as an additional alloy component is between 3% and 15% Si, in particular between 6% and 12% Si, the iron and manganese-free mass fraction of the protective coating of Mg as an additional alloy component being up to 1.0%, the iron-free and manganese-free mass fraction of the protective coating of Zn as an additional alloy component is between 0.4% and 25.0% Zn, the protective coating (15) having a first Zn-rich layer near the surface with a Zn content that is higher than an average Zn -Content of the protective coating, and wherein the Zn content of the first Zn-rich layer is more than 5% by weight and wherein the layer thickness of the protective coating is at least 5 pm and the layer near the surface extends over an area with a thickness of 500 nm, which adjoins the surface of the protective coating. 2. Steel component according to claim 1, characterized in that the iron and manganese-free mass fraction of the protective coating of Mg as an additional alloy component is in total at least 0.10%, preferably at least 0.15% and / or the iron and manganese-free mass fraction of the protective coating of Mg as an additional alloy component in total is at most 0.50%, preferably at most 0.35% and/or the iron and manganese-free mass fraction of the protective coating of Zn as an additional alloy component in total is at least 0.6%, preferably at least 1.0% is and/or the iron- and manganese-free mass fraction of the protective coating of Zn as an additional alloy component is in total at most 5.0%, preferably at most 2.3% and/or the Zn content of the first Zn-rich layer is more than 10.0 % by weight, preferably more than 18% by weight. Steel component according to one of claims 1 to 2, characterized in that the surface of the protective coating is largely formed from Zn enrichments in metallic and/or oxidic form. Steel component according to one of claims 1 to 3, characterized in that the protective coating (15) comprises a low-silicon phase (A) and a silicon-rich phase (R), the silicon-rich phase being distributed in an island shape in the low-silicon phase, the Zn content of the silicon-rich phase is less than 90% of an average Zn content of the protective coating and the Zn content of the silicon-poor phase is more than 105% of the average Zn content of the protective coating. Steel component according to claim 4, characterized in that the Si content of the low-silicon phase is less than 10% by weight, preferably less than 7% by weight, particularly preferably less than 5% by weight. Steel component according to one of claims 4 to 5, characterized in that the Si content of the silicon-rich phase is greater than 10% by weight, preferably greater than 12% by weight. Flat steel product for hot forming, which consists of a steel substrate (13) made of a steel containing 0.1-3% by weight of Mn and optionally up to 0.01% by weight of B, and one applied to the steel substrate (13). Protective coating (15) based on Al, which has a total iron and manganese-free mass fraction of up to 30% of additional alloy components, the additional alloy components having Si, Mg and Zn, the iron and manganese-free mass fraction of the protective coating of Si as an additional alloy component is between 3% and 15% Si, in particular between 6% and 12% Si, the iron and manganese-free mass fraction of Mg of the protective coating as an additional alloy component being between 0.10-0.50% Mg, preferably between 0 .1-0.35% Mg, characterized in that the iron- and manganese-free mass fraction of Zn of the protective coating as an additional alloy component is between 0.4-5% Zn, preferably between 0.4-2.3% Zn. Flat steel product according to claim 7, characterized in that the protective coating (15) is applied by hot-dip coating. Method for producing a phosphated steel component comprising the following steps: - Heating the flat steel product according to claim 7 to a heating temperature of at least 700 ° C for hot forming and holding it at the heating temperature, so that diffusion leads to a concentration of the Zn with the formation of metallic and oxide Zn enrichments in the area near the surface of the protective coating; - Thermoforming the coated steel substrate into the steel component; - Phosphating of the hot-formed steel component. Method for producing a phosphated steel component comprising the following steps: - Providing a steel substrate made of a steel that has 0.1-3% by weight of Mn and optionally up to 0.01% by weight of B; - Hot-dip coating of the steel substrate using a melt with a protective coating (15) based on Al, which in total has an iron and manganese-free mass fraction of up to 30% of additional alloy components, the additional alloy components comprising Si, Mg and Zn, whereby the iron- and manganese-free mass fraction of the protective coating of Si as an additional alloying component is between 3% and 15% Si, in particular between 6% and 12% Si, whereby the iron- and manganese-free mass fraction of the protective coating of Mg as an additional alloying component is up to 1%, where the iron and manganese-free mass fraction of the protective coating of Zn as an additional alloy component is between 0.4% and 25.0% Zn, in particular between 0.4 and 5% Zn, - Heating the coated steel substrate to a heating temperature of at least 700 ° C for hot forming and holding it at the heating temperature, so that through diffusion there is a concentration of the Zn with the formation of metallic and oxide Zn enrichments on the surface of the protective coating; - Thermoforming the coated steel substrate into the steel component; - Phosphating of the hot-formed steel component. Method according to one of claims 9 or 10, characterized in that a low-silicon phase (A) and a silicon-rich phase (R) are formed during heating and holding by diffusion, the silicon-rich phase being distributed in an island shape in the silicon-poor phase, and where the Zn content of the low-silicon phase is between 25% and 60% of the Zn content of the melt. Method according to one of claims 9 to 11, characterized in that the heating temperature is greater than the Ac3 temperature, so that the structure of the steel substrate is austenitic, and wherein the coated steel substrate (13) is quenched after hot forming or in the course of hot forming , so that a hardness structure is formed in the structure of the steel substrate of the flat steel product.