[Technical Field of the Invention]
[0001]
The present invention relates to a manufacturing method of a hot press-formed
article and a hot press-formed article.
Priority is claimed on Japanese Patent Application No. 2020-074701, filed
April 20, 2020, the content of which is incorporated herein by reference.
[Related Art]
[0002]
In recent years, there has been a request for suppressing the consumption of
chemical fuels in order for environmental protection and global warming prevention.
Regarding such a request, for example, automobiles, which are indispensable for daily
lives and activities as a movement unit, are no exception. In response to such a
request, for automobiles, studies are underway about improvement in fuel efficiency by
the weight reduction of vehicle bodies or the like. Since the majority of automobile
structures are formed of iron, particularly, steel sheets, the weight reduction of steel
sheets by thinning is significantly effective for the weight reduction of vehicle bodies.
However, when the weight of a steel sheet is reduced simply by thinning the thickness
of the steel sheet, there is a concern that the strength of the structure may decrease and
the safety may deteriorate. Therefore, in thinning the thickness of the steel sheet, it is
required to increase the mechanical strength of the steel sheet to be used so as not to
decrease the strength of the structure.
Therefore, research and development are underway regarding steel sheets
- 1 -
capable of maintaining or increasing the mechanical strength in spite of a thinner
thickness compared with steel sheets used ever by increasing the mechanical strength of
the steel sheet. Such a request for steel sheets is true not only in the automobile
manufacturing industry but also in a variety of manufacturing industries.
[0003]
In general, materials having a high mechanical strength tend to have poor
shape fixability in forming such as bending, and, in the case of processing the material
into a complicated shape, the processing itself becomes difficult. As one of methods
for solving this problem regarding formability, a so-called "hot pressing method (also
referred to as a hot pressing method, a hot stamping method, a high-temperature
pressing method, a warm pressing method, or a diequenching method)" is an exemplary
example. In this hot pressing method, a material, which is a subject to be formed, is
once heated to a high temperature (for example, 850°C or higher) to be austenitized, the
material softened by heating is formed by pressing, and then, or at the same time as
forming, the material is rapidly cooled with a die to undergo martensitic transformation,
whereby it is possible to obtain a high-strength processed product after forming.
[0004]
According to this hot pressing method, since the material is once heated to a
high temperature to be softened and is pressed in a softened state, the material can be
easily pressed. Therefore, this hot pressing makes it possible to obtain a press-formed
article having both favorable shape fixability and a high mechanical strength.
Particularly, in a case where the material is steel, it is possible to increase the
mechanical strength of a press-formed ru.ticle by the quenching effect of cooling after
forming.
[0005]
- 2 -
However, in the case of applying this hot pressing method to a steel sheet,
heating of the steel sheet to, for example, a high temperature of 800°C to 850°C or
higher oxidizes iron or the like on the surface to form scale (oxide). Therefore, a step
of removing this scale (descaling step) is required after hot pressing, which degrades the
productivity. In addition, for a member or the like that requires corrosion resistance,
there is a need to perform an antirust treatment or metal coating on the surface of the
member after processing, and thus a surface cleaning step and a surface treatment step
are required, which also degrades the productivity.
[0006]
An example of a method for suppressing such degradation of the productivity,
a method in which a coating is provided on a steel sheet is an exemplary example.
Generally, as the coating on the steel sheet, a variety of materials such as organic
materials or inorganic materials are in use. Among them, zinc-based plating having a
sacrificial protection action is often applied to steel sheets from the viewpoint of the
anticorrosion performance and a steel sheet production technique. Incidentally, the
heating temperature in hot pressing is often a temperature higher than the Ac3
transformation point of steel in order t o obtain a quenching effect, and the heating
temperature is, for example, about 800°C to 1 000°C. However, this heating
temperature is higher than the decomposition temperatures of organic materials or the
boiling points of metallic materials such as Zn-based metallic material. Therefore, in a
case where a steel sheet coated with an organic material or a Zn-based metallic material
is heated for hot pressing, there is a case where a plating layer on the surface of the steel
sheet evaporates, which causes significant deterioration of surface properties.
[0007]
In the case of avoiding such deterioration of surface properties, it is preferable
- 3 -
to coat a steel sheet, on which hot pressing where the steel sheet is heated to a high
temperature is to be performed, with, for example, anAl-based metal having a higher
boiling point than organic material coatings or Zn-based metallic coatings.
The use of a steel sheet provided with anAl-based metallic coating, a so-called
Al-plated steel sheet makes it possible to prevent scale from adhering to the surface of
the steel sheet and makes steps such as the descaling step unnecessary, which improves
the productivity. In addition, since the Al-based metallic coating also has an antirust
effect, the corrosion resistance after coating also improves.
[0008]
For example, Patent Document 1 describes a method in which anAl-plated
steel sheet including anAl-based metallic coating provided on steel having a
predetermined steel component is used for hot pressing.
[0009]
However, when a conventional Al-plated steel sheet for hot press forming (a
plated steel sheet having Al plating layers on both surfaces of the steel sheet) is hot
press-formed, since anAl alloy plating layer on the surface of the Al plating layer or an
oxide film (alumina) that is formed on the surface of the Al alloy plating layer is hard,
there is a case where the surface of a die wears and consequently, in particular, the
shape of the die distorts, which is a problem.
[0010]
With respect to such a problem, Patent Document 2 discloses a plated steel
sheet for hot pressing in which a zinc-based metal soap coating is provided on the
surface of the plated steel sheet body on the Al plating layer side. Patent Document 2
discloses that the occurrence of wear of the sliding surface of a hot pressing die (die)
after hot press forming is suppressed.
- 4 -
[0011]
However, in the technique of Patent Document 2, there was a case where a
material and the die are rubbed against each other during hot forming, a part of the
metal soap coating is peeled off, which causes wear on the die, and, when hot pressing
is continued several times, the surface unevenness of the worn die increases. In this
case, there was a problem of galling occurring on the material side after press forming
or a problem of the deterioration of the sliding ability.
[0012]
With respect to such a problem, in recent years, studies have been underway
regarding enhancement of the wear resistance of a die by performing a treatment for
forming a hard layer such as a nitriding treatment or a PVD treatment on the surface of
a material of the die.
For example, Patent Document 3 discloses a technique in which a hard
membrane is provided on a die that is used for the hot pressing of zinc-plated steel
sheets. In addition, Patent Documents 4, 5, and 6 disclose a technique in which, in the
hot pressing of an aluminum or zinc-plated steel sheet or anAl-plated steel sheet having
a zinc compound or metallic zinc layer as the outermost layer on anAl plating layer, a
die provided with a hard PVD membrane such as a nitride is used.
Incidentally, press-formed articles that are used for automobiles and the like are
also required to have a low glossiness and a beautiful external appearance. This is
because, when the glossiness is high, it is considered that there are many defects on a
formed article, and there is a concern that the corrosion resistance may deteriorate.
However, in hot stamping, normally, a standing wall portion is rubbed against a die, the
glossiness increases, and the quality of external appearance deteriorates. In the case of
using a technique in which a die described in Patent Documents 3 to 6 provided with a
- 5 -
hard membrane such as a nitriding layer or PVD on the surface of the die, since the
surface of the die is hard, there is a problem in that a defect is likely to be generated on
the surface of the material. Particularly, in a case where a hot pressing method such as
hot stamping is used, since a material is quickly press-formed up to the bottom dead
point in a high-temperature state, the surface of the material is in a state of being
softened at a high temperature, a defect is more likely to be generated on the surface of
the material due to the die, and the external appearance of the surface of a press-formed
article is impaired.
[0013]
That is, conventionally, when a formed article (hot press-formed article) is
manufactured by hot pressing anAl-plated steel sheet, it was difficult to ensure an
excellent surface external appearance (low glossiness) of the formed article and then
suppress the wearing of the die.
[Prior Art Document]
[Patent Document]
[0014]
[Patent Document 1] Japanese Patent No. 3931251
[Patent Document 2] Japanese Patent No. 6369659
[Patent Document 3] Japanese Patent No. 6055324
[Patent Document 4] Japanese Patent No. 6477867
[Patent Document 5] Japanese Patent No. 6125313
[Patent Document 6] PCT International Publication No. WO 2019-198728
[Disclosure of the Invention]
[Problems to be Solved by the Invention]
[0015]
- 6 -
The present invention has been made in view of the above-described problem.
An object of the present invention is to provide a manufacturing method of a
hot press-formed article in order to obtain a hot press-formed article having an excellent
surface external appearance (external appearance) while suppressing the wear of a die
and a hot press-formed article having an excellent surface external appearance.
[Means for Solving the Problem]
[0016]
As a result of studies, the present inventors found that, at the time of hot
pressing anAl-plated steel sheet using a die having a hard layer formed on the surface in
order to enhance the wear resistance of the die (die), when the temperature of the Alplated
steel sheet at the start of the forming (when the moving die comes into contact
with the Al-plated steel sheet) is indicated by Tm in the unit of °C, and the average
movement velocity (so-called forming velocity) of the die from the start of the forming
to arrival of the bottom dead point (when the die reaches the bottom dead point) is
indicated by V in the unit of mm/s, the Tm and the V satisfy the following formula (1),
and,
800- (HVDie/40) :S Tm :S 850- (V/4)- (HVDie/100) ... Formula (1)
furthermore, a metal layer containing at least one metal of Mg, Ca, V, Ti, and
Zn, a metal oxide layer containing an oxide of Mg, Ca, V, Ti, or Zn, or a mixed layer of
the metal layer and the metal oxide layer is formed on the surface of the Al-plated steel
sheet that is subjected to forming, whereby it is possible to suppress the gloss of a
formed article at a low level and to obtain a hot press-formed article having excellent
surface external appearance.
This formula (1) means that, in a case where a hard layer that enhances wear
resistance is present on the surface of a die, the control of the forming start temperature
- 7 -
and the average movement velocity of the die in accordance with the hardness of the
hard layer is important in order to obtain a hot press-formed article having excellent
surface external appearance.
The formula Tm ::S 850- (V/4)- (HVDie/100) that decides the upper limit of the
forming start temperature means that 1) as the temperature increases, the hardness of the
surface of anAl-plated steel sheet is gradually softened, and a defect is more likely to be
generated, and thus it is important to suppress the forming start temperature at a certain
temperature or lower, 2) during forming, the Al-plated steel sheet comes into contact
with a die, whereby heat is removed, and the Al-plated steel sheet is cooled; however,
when the forming velocity is fast, the removal of heat is suppressed, and thus, even
when the forming start temperature is the same, as the forming velocity becomes faster,
the surface of the Al-plated steel sheet is processed in a more softened state, and thus
there is a need to lower the forming start temperature in accordance with the forming
velocity, and 3) the degree of easiness in the generation of a defect is affected by the
hardness of the hard layer on the surface of the die, and thus, as the hardness of the
surface of the die increases, there is a need to lower the forming start temperature.
In addition, the formula 800- (HVDie/40) ::S Tm that decides the lower limit of
the forming start temperature means that, when the forming start temperature is low, the
surface of the Al-plated steel sheet becomes hard, the die side is likely to be damaged,
and the wear resistance of the die deteriorates. When the wear resistance of the die
deteriorates, the surface of the die becomes uneven due to the defect generated in the
die, and as a result, the surface of the hot press-formed article is damaged due to the
local stress concentration attributed to protrusions of the die, and the surface external
appearance deteriorates.
The coefficients (1/4, 1/40, and 1/100) in the formula (1) are values for
- 8 -
converting the influence of the Vickers hardness or the forming velocity derived from
the experiences of the inventors obtained thus far and newly obtained experimental
results into temperature.
[0017]
The present invention has been made based on the above-described findings.
The gist of the present invention is as described below.
[1] A manufacturing method of a hot press-formed article according to one
aspect of the present invention includes a heating step of heating anAl-plated steel sheet
to 850°C to 1000°C and a forming step of forming the Al-plated steel sheet using a die
to obtain a hot press-formed article after the heating step, in which the Al-plated steel
sheet has a base steel sheet, anAl plating layer formed on a surface of the base steel
sheet, and a coating layer formed on a surface oftheAl plating layer, the coating layer is
a metal layer containing at least one metal of Mg, Ca, V, Ti, and Zn, a metal oxide layer
containing an oxide of one or more of Mg, Ca, V, Ti, and Zn, or a mixed layer including
the metal layer and the metal oxide layer, the die has a hard layer on a surface, HVDie
that is a surface hardness of the die at a position that the hard layer is present is HV1500
or more and HV3800 or less, and, when a temperature of the Al-plated steel sheet at a
start of forming is indicated by Tm in a unit of oc, and an average movement velocity of
the die from the start of forming to arrival of a bottom dead point is indicated by V in a
unit of mm/s, in the forming step, the Tm and the V satisfy the following formula (1).
800- (HVDie/40) :S Tm :S 850- (V/4)- (HVDie/100) ... Formula (1)
[2] In the manufacturing method of a hot press-formed article according to [1],
the HVDie, the Tm, and the V may satisfy the following formula (2).
800- (HVDie/40) :S Tm :S 850- (V/2)- (HVDiel50) ... Formula (2)
[3] In the manufacturing method of a hot press-formed article according to [1]
- 9 -
or [2] , a thickness of the coating layer may be 0.3 to 10.0 11m.
[4] In the manufacturing method of a hot press-formed article according to any
one of [1] to [3], a surface temperature of the die at the start of forming may be soc or
higher and 180°C or lower.
[5] A hot press-formed article according to another aspect of the present
invention is composed of anAl-plated steel sheet having anAl plating layer, in which
Gs60° that is glossiness regulated by JIS Z 8741: 1997 on a surface is 30 or less.
[6] In the hot press-formed article according to [5], the Gs60° may be 25 or
less.
[7] The hot press-formed article according to [5] or [6] includes a coating layer
on a surface of the Al plating layer, in which the coating layer may be a metal layer
composed of at least one metal of Mg, Ca, V, Ti, and Zn, a metal oxide layer composed
of an oxide of one or more of Mg, Ca, V, Ti, and Zn, or a mixed layer made up of the
metal layer and the metal oxide layer.
[8] In the hot press-formed article according to [7] , a thickness of the coating
layer may be 0.3 to 10.0 !liD.
[Effects of the Invention]
[0018]
According to the above-described aspects of the present invention, a
manufacturing method of a hot press-formed article for obtaining a hot press-formed
article having an excellent surface external appearance while suppressing the wear of a
die and a hot press-formed article having an excellent surface external appearance can
be obtained.
[Brief Description of the Drawings]
[0019]
- 10 -
FIG. 1 is a schematic view of anAl-plated steel sheet that is used in a
manufacturing method of a hot press-formed article according to the present
embodiment.
FIG. 2 is a view showing an evaluation device for a surface external
appearance of a hot press-formed article.
FIG. 3 is a view showing external appearances of sliding portions of hot
formed articles tested with the evaluation device of FIG. 2 and measurement examples
of glossiness.
[Embodiments ofthe Invention]
[0020]
A manufacturing method of a hot press-formed article according to one
embodiment of the present invention (a manufacturing method of a hot press-formed
article according to the present embodiment) and a hot press-formed article according to
one embodiment of the present invention (a hot press-formed article according to the
present embodiment) will be described.
[0021]

The present inventors investigated a reason for the damage of plating and a
consequent increase in the glossiness of a hot press-formed article in the case of a
process where anAl-plated (aluminum-plated) steel sheet is heated by a hot pressing
method and press-formed immediately afterwards. As a result, it was found that the
following four points are the cause.
1) After heating, a hard Al-Fe-based alloy layer that is formed on the surface of
Al plating by an alloying reaction between anAl plating layer and a base metal and/or
hard aluminum oxide peels off due to the surface of the Al-plated steel sheet and a die
- 11 -
being rubbed against each other during press forming, the peeled alloy layer and
aluminum oxide act like abrasive powder, and the plating on the surface oftheAl-plated
steel sheet is strongly damaged,
2) On the surface of the die provided with a hard membrane, when the hardness
is low, the die wears, conversely, when the hardness is high, the surface of the
aluminum-plated steel sheet rubbed by the die (for example, in a standing wall portion)
is damaged,
3) In the case of being press-formed immediately after heating, when the
temperature at the start of forming is high, the aluminum plating is softened, and thus
the surface of the aluminum-plated steel sheet likely to be damaged by being rubbed by
the die,
4) In the case of being press-formed, during forming after the start of the
forming, the temperature of the aluminum-plated steel sheet is heat-removed by the die
that came into contact with the aluminum-plated steel sheet, and the temperature of the
aluminum-plated steel sheet decreases; however, in a case where the forming velocity is
fast, the removal of heat is suppressed, the surface of the aluminum-plated steel sheet is
rubbed by the die in a state where the temperature of the aluminum-plated steel sheet is
further maintained at a high temperature, and the surface of the aluminum-plated steel
sheet is more likely to be damaged.
Based on these findings, the present inventors found that the problem can be
solved by covering the surface of Al plating with a layer of a metal having a low
hardness or a metal oxide having a low hardness and controlling the forming
temperature T CC) and the forming velocity V (mm/s) to satisfy a predetermined
relationship with respect to the surface hardness HVDie of a die.
[0022]
- 12 -
The manufacturing method of a hot press-formed article according to the
present embodiment includes a heating step of heating anAl-plated steel sheet to 850°C
to 1000oc and a forming step of forming the Al-plated steel sheet using a die to obtain a
hot press-formed article after the heating step. The forming step is performed, for
example, within 30 seconds after the steel sheet is taken out from a heating furnace.
In addition, the Al-plated steel sheet has a base steel sheet, anAl plating layer
formed on a surface of the base steel sheet, and a coating layer formed on the surface of
the Al plating layer, and the coating layer is a metal layer containing at least one metal
of Mg, Ca, V, Ti, and Zn, a metal oxide layer containing an oxide of one or more of Mg,
Ca, V, Ti, and Zn, or a mixed layer including the metal layer and the metal oxide layer.
In addition, the die has a hard layer on the surface of the die that comes into
contact with theAl-plated steel sheet in the forming step, and HVDie that is the surface
hardness of the die at the position of the hard layer is HV1500 or more and HV3800 or
less.
In addition, when the temperature (forming temperature) of the Al-plated steel
sheet at the start of forming in the forming step is indicated by Tm in the unit of oc, and
the average movement velocity (forming velocity) of the die from the start of forming to
the bottom dead point is indicated by V in the unit of mm/s, the Tm and the V satisfy the
following formula (1).
800- (HVDie/40)::; Tm::; 850- (V/4)- (HVDiellOO) ... Formula (1)
[0023]
In press forming, the steel sheet is drawn into the die hole of the die and
formed. In a case where the edge of the die hole (also referred to as the die shoulder
portion or the R portion) protrudes and curves toward the outside of the die hole, the
steel sheet shrinks and flange-distorts when drawn into the die hole.
- 13 -
In the case of draw forming, during shrinkage and flange distortion, the
thickness of the steel sheet increases toward the edge of the die hole (die shoulder
portion). When the thickness of the steel sheet increases, a high contact pressure is
applied to the steel sheet.
In the case of bending forming, during shrinkage and flange distortion,
wrinkles are generated in the steel sheet toward the edge of the die hole (die shoulder
portion). When wrinkles are generated in the steel sheet, a portion of the steel sheet
that has turned into the wrinkles in the vicinity of the die hole comes into contact with
the die, and a high contact pressure is applied to the contact site.
In the manufacturing method of a hot press-formed article according to the
present embodiment, in hot press forming, for example, the steel sheet is blanked
(punched), if necessary, and then heated to a high temperature, thereby softening the
plated steel sheet. In addition, the softened plated steel sheet is press-formed using a
die at a forming temperature Tm°C and a forming velocity V mm/s, and then rapidly
cooled by removing heat by holding the steel sheet in the die. As described above, in
hot press forming, the plated steel sheet is once softened, whereby subsequent pressing
can be easily performed. In addition, a press-formed article that has been hot pressformed
is quenched by heating and cooling and is turned into a formed article having a
high hardness of HV400 or more (load 1 kg-f (9.8 N)) in terms of the Vickers hardness.
[0024]
[Heat ing step]
In the heating step, the Al-plated steel sheet is heated to 850°C to 1000°C.
When the heating temperature is set to 85ooc or higher, which is the Ac3 point of the
base steel sheet, (the base material portion of) the Al-plated steel sheet is austenitized,
and it is possible to enhance the formability in the forming step, which is the next step.
- 14 -
In addition, when the Al-plated steel sheet is heated to 85ooc or higher, it is possible to
cause the martensitic transformation of the base steel sheet by rapidly cooling theAlplated
steel sheet with a die immediately afterwards, and as a result, a high tensile
strength as a hot press-formed article can be obtained. When the temperature of the
steel sheet lowers before the steel sheet is rapidly cooled in the die, transformation from
austenite to ferrite proceeds, and desired martensitic transformation cannot be obtained
even when the steel sheet is rapidly cooled with the die. Furthermore, the heating of
the Al-plated steel sheet to 85ooc or higher causes an alloying reaction between the Al
plating layer oftheAl-plated steel sheet and the base steel sheet to proceed and also
contributes to the formation of a hard Al-Fe-based alloy layer having favorable defect
resistance on the surface. When the heating temperature is lower than 850°C, there is
a case where ferritic transformation starts before cooling in the die and a sufficient
hardness cannot be obtained in formed articles. Therefore, the heating temperature is
set to 850°C or higher. In order to keep the temperature of the steel sheet at a high
temperature even in the forming step, the heating temperature is preferably 890°C or
higher, more preferably 910°C or higher, and still more preferably 925oc or higher.
On the other hand, when the heating temperature exceeds 1 000°C, oxidization
of the surface of aluminum plating (Al plating) proceeds excessively, and the wear of
the die increases. In addition, such a high temperature also leads to press forming at a
high temperature and makes the surface of the plating soft, which is likely to cause a
defect to be generated on the material side from the die. Therefore, the heating
temperature is set to 1 000°C or lower. The heating temperature is preferably 980°C or
lower and more preferably 960°C or lower.
As a heating method, in addition to radiation heating with a normal electric
furnace or radiant tube furnace, a heating method by infrared heating, energization
- 15 -
heating, induction heating, or the like can be adopted. The heating is performed in the
atmospheric atmosphere, a nitrogen atmosphere, or a combustion gas atmosphere, and
the dew point of the atmosphere is not particularly limited, but the heating atmosphere
preferably contains 10 vol% or more of oxygen. When 10 vol% or more of oxygen is
contained, evaporation of the coating layer on the surface of the Al plating can be
suppressed. More preferably, the oxygen content is 20 vol%, which is the same as in
the atmospheric atmosphere, or more.
The temperature rising rate by heating is preferably 7.0 ac/s or slower. In the
manufacturing method of a hot press-formed article according to the present
embodiment, in the Al-plated steel sheet to be heated, there is a case where the coating
layer formed on the surface of the Al plating layer contains Zn (Chemical Handbook
Revised 2nd Edition, Basic Edition I (Author: The Chemical Society of Japan,
Publisher: Maruzen Co., Ltd., Publication date 1975): boiling point of 907°C), Mg
(same: boiling point of 1107°C), orCa (same: boiling point of 1487°C), which is
relatively lower than the boiling point of Al (same; 2467°C). Therefore, the
evaporation of the coating layer is promoted by a rapid temperature rise, and there is a
possibility that the external appearance of a component after pressing may deteriorate.
When the temperature rising rate is set to 7.0 ac/s or slower, the coating layer is
oxidized by oxygen in the atmosphere, and excessive evaporation is suppressed. The
temperature rising rate is more preferably set to 6.0 ac/s or slower.
As a method for obtaining the temperature rising rate (0 C/s), a K-type
thermocouple is connected to the steel sheet by spot welding, the sheet temperatures are
measured while the heating temperature reaches 85oac from a temperature Ts (°C) in
the beginning of heating, and the temperatures raised is divided by a timet (seconds)
taken for the heating temperature to reach 85oac from the sheet temperature Ts CC)
- 16 -
after the beginning of heating, thereby obtaining the temperature rising rate. As a
formula, the temperature rising rate is obtained by (850- Ts)/t.
[0025]
(Al-plated steel sheet)
The Al-plated steel sheet that is subjected to the heating step has a base steel
sheet, anAl plating layer formed on the surface of the base steel sheet, and a coating
layer formed on the surface of the Al plating layer. This coating layer is a metal layer
containing at least one metal of Mg, Ca, V, Ti, and Zn, a metal oxide layer containing an
oxide of one or more of Mg, Ca, V, Ti, and Zn, or a mixed layer including the metal
layer and the metal oxide layer.
Specifically, for example, as shown in FIG. 1, anAl-plated steel sheet 1
includes Al plating layers 3A and 3B on both surfaces (the upper surface and the lower
surface) of a base steel sheet 2 and a coating layer (a metal layer, a metal oxide layer, or
a mixed layer thereof) 4A or 4B as the outermost layer on each of the Al plating layers
3Aand 3B.
[0026]
The base steel sheet 2 (steel sheet before plating) is, for example, preferably a
steel sheet having a high mechanical strength (which means a variety of properties
relating to mechanical distortion and fracture, for example, tensile strength, yield point,
elongation, reduction in area, hardness, impact value, fatigue strength, creep strength,
and the like). In the Al-plated steel sheet 1 that is used in the manufacturing method of
a hot press-formed article according to the present embodiment, the chemical
composition of the base steel sheet 2 is not limited; however, in the case of realizing a
high mechanical strength, an example of a preferable chemical composition of the base
steel sheet 2 is as described below. Hereinafter, the notation "%" regarding the
- 17 -
chemical composition means "mass%" unless particularly otherwise described.
That is, the chemical composition of the base steel sheet 2 contains, for
example, by mass%, C: 0.18% or more and 0.50% or less, Si: 2.00% or less, Mn: 0.30%
or more and 5.00% or less., Cr: 2.00% or less, P: 0.100% or less, S: 0.100% or less, N:
0.0100% or less, Al: 0.500% or less, and B: 0.0002% or more and 0.0100% or less and
further contains, if necessary, one or more ofW: 3.00% or less, Mo: 3.00% or less, V:
2.00% or less, Ti: 0.500% or less, Nb: 0.500% or less, Ni: 5.00% or less, Cu: 3.00% or
less, Co: 3.00% or less, Sn: 0.100% or less, Sb: 0.100% or less, Mg: 0.0050% or less,
Ca: 0.0050% or less, REM: 0.0070% or less, and 0: 0.0070% or less, and the remainder
of Fe and an impurity.
[0027]
The reason that the above-described chemical composition is preferable will be
described.
(C: 0.18% or more and 0.50% or less)
A hot press-formed article that is obtained by the hot stamping method is
required to have a high strength of, for example, 1000 MPa or more. In this case, the
structure (metallographic structure) of the hot press-formed article is required to be
transformed into a structure mainly composed of martensite by rapid cooling after hot
stamping.
When the carbon (C) content is less than 0.18%, the hardenability deteriorates,
and the strength is insufficient. Therefore, the C content is preferably 0.18% or more.
The C content is more preferably 0.20% or more and still more preferably 0.22% or
more.
On the other hand, when the C content exceeds 0.50%, the toughness of the
steel sheet significantly deteriorates, and the workability deteriorates. Therefore, the C
- 18 -
content is preferably set to 0.50% or less. The C content is more preferably 0.40% or
less and still more preferably 0.35% or less.
[0028]
(Si: 2.00% or less)
The lower limit of the silicon (Si) content is not particularly limited and may be
0%; however, in a case where the silicon (Si) content is less than 0.01 %, the
hardenability and the fatigue properties are poor. Therefore, the Si content is
preferably 0.01% or more. The Si content is more preferably 0.05% or more, still
more preferably 0.10% or more, and far still more preferably 0.30% or more.
On the other hand, since Si is an element that is more easily oxidized than Fe
(an easily oxidizable element), when the Si content exceeds 2.00% in a continuous
annealing plating line, a stable Si-based oxide film is formed on the surface of the base
steel sheet during an annealing treatment, the adhesiveness of hot-dip Al plating is
impaired, and there is a concern of non-plating. Therefore, the Si content is preferably
set to 2.00% or less. The Si content is more preferably 1.00% or less, still more
preferably 0.80% or less, and far still more preferably 0.70% or less or 0.60% or less.
[0029]
(Mn: 0.30% or more and 5.00% or less)
Manganese (Mn) is an element effective for enhancing the hardenability of the
steel sheet and, furthermore, suppressing the hot embrittlement caused by S that is
inevitably incorporated. In a case where the Mn content is less than 0.30%, there is a
case where the hardenability deteriorates and the strength is insufficient. Therefore,
the Mn content is preferably 0.30% or more. The Mn content is more preferably
0.50% or more, still more preferably 0.80% or more, and far still more preferably 1.00%
or more.
- 19 -
On the other hand, in a case where the Mn content exceeds 5.00%, the impact
characteristics after quenching deteriorate. Therefore, the Mn content is preferably set
to 5.00% or less. The Mn content is more preferably 4.00% or less, still more
preferably 3.00% or less, and far still more preferably 2.50% or less or 2.00% or less.
[0030]
(Cr: 2.00% or less)
The lower limit of the chromium (Cr) content is not particularly limited and
may be 0%, but chromium (Cr) is an element that exhibits an effect on enhancing the
hardenability of the steel sheet. In a case where the Cr content is less than 0.001%,
there is a case where the above-described hardenability-improving effect cannot be
obtained and the strength is insufficient. Therefore, the Cr content is preferably
0.001% or more. The Cr content is more preferably 0.05% or more and still more
preferably 0.10% or more.
On the other hand, since Cr is an element that is more easily oxidized than Fe
(an easily oxidizable element), in a case where the Cr content exceeds 2.00%, a stable
Cr-based oxide film is formed on the surface of the base steel sheet during the annealing
treatment, the adhesiveness of hot-dip Al plating is impaired, and there is a concern of
non-plating. Therefore, the Cr content is preferably set to 2.00% or less. The Cr
content is more preferably 1.60% or less, still more preferably 1.40% or less, and far
still more preferably 1.00% or less.
[0031]
(B: 0.0002% or more and 0.0100% or less)
Boron (B) is a useful element from the viewpoint of hardenability, and, when
0.0002% or more of B is contained, the hardenability improves. Therefore, the B
content is preferably set to 0.0002% or more. The B content is more preferably
- 20 -
0.0005% or more and still more preferably 0.0010% or more.
On the other hand, when the B content exceeds 0.0100%, the above-described
hardenability-improving effect is saturated, and the manufacturability deteriorates due
to the generation of a casting defect or cracks during hot rolling. Therefore, the B
content is preferably set to 0.0100% or less. The B content is more preferably
0.0080% or less, still more preferably 0.0070% or less, and far still more preferably
0.0060% or less.
[0032]
(Al: 0.500% or less)
Aluminum (Al) is contained in steel as a deoxidizing agent. Since Al is an
element that is more easily oxidized than Fe, in a case where the Al content exceeds
0.500%, a stable Al-based oxide film is formed on the surface of the base steel sheet
during the annealing treatment, the adhesiveness of hot-dip Al plating is impaired, and
there is a concern of non-plating. Therefore, the Al content is preferably set to 0.500%
or less. The Al content is more preferably 0.200% or less, still more preferably
0.100% or less, and far still more preferably 0.080% or less.
On the other hand, the lower limit of the Al content is not particularly limited
and may be 0%, but setting the Al content to be less than 0.001% is not economical in
view of refining limits. Therefore, the Al content may be set to 0.001% or more.
[0033]
(P: 0.100% or less)
Phosphorus (P) is an element that is contained as an impurity. P is also a solid
solution strengthening element and is also an element capable of increasing the strength
of the steel sheet at a relatively low cost. However, in a case where the P content
exceeds 0.100%, an adverse influence such as the deterioration of toughness
- 21 -
significantly appears. Therefore, the P content is preferably set to 0.100% or less.
The P content is more preferably 0.050% or less and still more preferably 0.020% or
less.
On the other hand, the lower limit of the P content is not particularly limited
and may be 0%, but setting the P content to be less than 0.001% is not economical in
view of refining limits. Therefore, the P content may be set to 0.001% or more.
[0034]
(S: 0.100% or less)
Sulfur (S) is an element that is contained as an impurity and becomes an
inclusion in steel as MnS. In a case where the S content exceeds 0.100%, MnS acts as
the starting point of fracture, ductility and toughness deteriorate, and workability
deteriorates. Therefore, the S content is preferably set to 0.100% or less. The S
content is more preferably 0.050% or less, still more preferably 0.010% or less, and far
still more preferably 0.005% or less.
On the other hand, since S is not required in the aluminum-based plated steel
sheet according to the present embodiment, the lower limit of the S content is not
particularly limited and may be 0%; however, the S content set to less than 0.0001% is
not economical in view of refining limits. Therefore, the S content may be set to
0.0001% or more.
[0035]
(N: 0.0100% or les s)
Nitrogen (N) is an element that is contained as an impurity and is preferably
fixed (made into a compound) using Ti, Nb, Al, and the like from the viewpoint of
stabilizing the characteristics. When the N content increases, the amount of the
elements that are contained to fix N becomes large, which leads to an increase in cost.
- 22 -
Therefore, theN content is preferably 0.0100% or less. TheN content is more
preferably 0.0080% or less. TheN content is preferably as small as possible and may
be 0%, but theN content set to less than 0.0010% is not economical in view of refining
limits. Therefore, theN content may be set to 0.0010% or more.
[0036]
The base steel sheet 2 of the Al-plated steel sheet 1 may have a chemical
composition in which the above-described elements are contained and the remainder
consists of Fe and an impurity. However, in order to further improve the
characteristics, the base steel sheet 2 may further contain elements to be described
below (optional elements), and the lower limits of the amounts of the optional elements
of the base steel sheet 2 to be described below are all 0%.
[0037]
(Wand Mo: each 3.00% or less)
The lower limits of the tungsten (W) and molybdenum (Mo) contents are not
particularly limited and may be 0%, but Wand Mo are each useful elements from the
viewpoint of hardenability and exhibit an effect on improvement in hardenability when
the contents thereof are 0.01% or more. In the case of obtaining the effect, theW
content and the Mo content are each preferably set to 0.01% or more. TheW content
and the Mo content are each more preferably 0.05% or more.
On the other hand, in a case where theW and Mo contents each exceed 3.00%,
the above-described effect is saturated, and the cost also increases. Therefore, theW
content and the Mo content are preferably 3.00% or less. TheW content and the Mo
content are each more preferably 1.00% or less.
[0038]
(V: 2.00% orless)
- 23 -
The lower limit of the vanadium (V) content is not particularly limited and may
be 0%, but Vis a useful element from the viewpoint of hardenability and exhibits an
effect on improvement in hardenability when the content thereof is 0.01% or more.
Therefore, in the case of obtaining the effect, the V content is preferably set to 0.01% or
more. The V content is more preferably 0.05% or more.
On the other hand, in a case where the V content exceeds 2.00%, the abovedescribed
effect is saturated, and the cost also increases. Therefore, the V content is
preferably set to 2.00% or less. The V content is more preferably 1.00% or less.
[0039]
(Ti: 0.500% or less)
The lower limit of the titanium (Ti) content is not particularly limited and may
be 0%, but Ti is an element effective for fixing Nand may be contained. In the case of
obtaining this effect, it is preferable to contain Ti about 3.4 times or more theN content
by mass%. Since theN content often becomes about 10 ppm (0.001 %) even when
attempted to be reduced, the Ti content is preferably 0.005% or more. The Ti content
is more preferably 0.010% or more.
On the other hand, when the Ti content becomes excessive, the hardenability
deteriorates, and the strength decreases. Such deterioration of the hardenability and
the strength become significant when the Ti content exceeds 0.500%. Therefore, the
Ti content is preferably set to 0.500% or less. The Ti content is more preferably
0.100% or less.
[0040]
(Nb: 0.500% or less)
The lower limit of the niobium (Nb) content is not particularly limited and may
be 0%, but Nb is an element effective for fixing N and may be contained. In the case
- 24 -
of obtaining this effect, it is preferable to contain Nb about 6.6 times or more theN
content by mass%. Since theN content often becomes about 10 ppm (0.001 %) even
when attempted to be reduced, the Nb content is preferably 0.006% or more. The Nb
content is more preferably 0.010% or more.
On the other hand, when the Nb content becomes excessive, the hardenability
deteriorates, and the strength decreases. Since such deterioration of the hardenability
and the strength become significant when the Nb content exceeds 0.500%, the Nb
content is preferably set to 0.500% or less. The Nb content is more preferably 0.100%
or less.
[0041]
In addition, even when Ni, Cu, Co, Sn, Sb, Mg, Ca, REM, 0, and the like are
contained as the chemical composition of the base steel sheet 2, the effects in the
present embodiment are not impaired as long as the contents are in ranges of upper
limits to be described below or lower.
[0042]
(Ni: 5.00% orless)
The lower limit of the nickel (Ni) content is not particularly limited and may be
0%, but Ni is a useful element for improving low temperature toughness, leading to
improvement in impact resistance, in addition to hardenability. In the case of
obtaining the above-described effect, the Ni content is preferably set to 0.01% or more.
On the other hand, when the Ni content exceeds 5.00%, the above-described
effect is saturated, and the cost increases. Therefore, the Ni content is preferably set to
5.00% or less.
[0043]
(Cu and Co: 3.00% or less)
- 25 -
The lower limit of the amount of each of copper (Cu) and cobalt (Co) is not
particularly limited and may be 0%, but both Cu and Co are both useful elements for
improving toughness in addition to hardenability. In the case of obtaining the effect,
the Cu content and the Co content are each preferably set to 0.01% or more.
On the other hand, when the amount of each of Cu and Co exceeds 3.00%, the
above-described effect is saturated, and the cost increases. In addition, when
excessively contained, Cu and Co both cause the deterioration of cast piece properties or
the generation of cracking or flaws during hot rolling. Therefore, the Cu content and
the Co content are each preferably set to 3.00% or less.
[0044]
(Sn and Sb: 0.100% or less)
The lower limits of the tin (Sn) and antimony (Sb) contents are not particularly
limited and may be each 0%, but Sn and Sb are both elements effective for improving
the wettability and adhesion of plating. In the case of obtaining this effect, 0.001% or
more of at least any one of Sn and Sb is preferably contained.
On the other hand, in a case where more than 0.100% of at least any one of Sn
or Sb is contained, a defect is likely to be generated during manufacturing or the
toughness deteriorates. Therefore, the Sn content and the Sb content are each
preferably 0.100% or less.
[0045]
(Mg and Ca: 0.0050% or less)
Mg and Ca are both elements that are contained as an impurity, and the lower
limits of the Mg content and theCa content are not particularly limited and may be each
set to 0%. When contained, Mg and Ca both have an effect on suppressing an
inclusion in the base metal in some cases and may be contained, but act as the starting
- 26 -
point of fracture when contained in a large quantity. Therefore, the Mg content and the
Ca content are each preferably 0.0050% or less.
[0046]
(REM and 0: 0.0070% or less)
REM and 0 are not essential elements and are contained in, for example, steel
as an impurity. REM and 0 are elements that cause the deterioration of the
characteristics of the steel sheet by forming an oxide and acting as the starting point of
fracture. In addition, there is a case where an oxide present in the vicinity of the
surface of the steel sheet causes a surface defect and deteriorates the external
appearance quality. Therefore, the REM content and the 0 content are preferably as
small as possible. In particular, when the REM content and the 0 content are more
than 0.0070%, the characteristics significantly deteriorate, and thus the REM content
and the 0 content are each preferably 0.0070% or less. The lower limits of the REM
content and 0 contents are not particularly limited and may be 0%, but the lower limits
are 0.0005% in actual operation in consideration of refining, and thus the substantial
lower limits of the REM content and the 0 content are each 0.0005%.
[0047]
(Regarding other components)
Other components are not particularly regulated, but there is a case where
elements such as Zr and As are incorporated from scrap. However, as long as the
amount of the elements incorporated is in a normal range, the characteristics
(mechanical strength and the like) of the base steel sheet 2 according to the present
embodiment are not affected.
The remainder of the chemical composition of the base steel sheet 2 is Fe and
an impurity. The impurity means a component that is incorporated from a raw material
- 27 -
such as an ore or a scrap or from a variety of causes in manufacturing steps during the
industrial manufacturing of a steel material and is allowed to be contained as long as the
impurity does not adversely affect the Al-plated steel sheet 1 according to the present
embodiment.
[0048]
(Al plating layer)
In the Al-plated steel sheet 1 that is used in the manufacturing method of a hot
press-formed article according to the present embodiment, the Al plating layers 3A and
3B are plating layers containing, by mass%, 50% or more of Al in the composition.
Elements other than Al are not particularly limited, but Si may be positively contained
for the following reasons.
[0049]
When Si is contained in the Al plating layers 3A and 3B, Al-Fe-Si alloy layers
are formed at the interfaces between the Al plating layers 3A and 3B and the base steel
sheet 2 (base metal), which makes it possible to suppress the formation of a brittle Al-Fe
alloy layer that is formed during hot-dip plating. In a case where the Si content is less
than 3% by mass%, the Al-Fe alloy layer grows thick at the stage of performing Al
plating, cracking of the plating layers is promoted during processing, and there is a
possibility that the corrosion resistance is adversely affected.
On the other hand, in a case where the Si content exceeds 15% by mass%,
conversely, the volume percentage of the layers containing Si increases, and there is a
concern that the workability and corrosion resistance of the plating layers may
deteriorate. Therefore, the Si content in the Al plating layer is preferably set to 3% to
15%.
As a manufacturing method of an Al-plated steel sheet by treating the Al
- 28 -
plating to the base steel sheet, a method in which a slab containing chemical
composition adjusted by normal pig iron making and steel making is subjected to
normal hot rolling, pickling, and cold rolling and subjected to Sendzimir-type
continuous annealing, immersion in a hot -dip Al plating bath, and the adjustment of the
thicknesses of the Al plating layers by wiping, thereby manufacturing anAl-plated steel
sheet is an exemplary example.
[0050]
The Al plating layers 3A and 3B prevent the corrosion of the steel sheet in the
case of being used as a vehicle component. In addition, even when the Al-plated steel
sheet 1 is heated to a high temperature in the case of being processed by hot press
forming, in the Al plating layers 3A and 3B, there is no case where scale (iron oxide) is
formed on the surface of the base metal. When the Al plating layers 3A and 3 B
prevent the formation of scale, it is possible to omit a step of removing scale, a surface
cleaning step, a surface treatment step, and the like, and the productivity of the hot
press-formed article improves. The iron oxide, which is scale, grows hard and coarse
when heated and thus also causes the die to wear. In addition, the Al plating layers 3A
and 3B have higher boiling point and melting point than plating layers composed of
other metal-based materials (for example, Zn-based materials). Therefore, when the
Al-plated steel sheet is formed by hot press forming, the Al plating layers are less likely
to evaporate, and hot press forming at a high temperature becomes possible.
Therefore, the formability in hot press forming is further enhanced, and it becomes
possible to easily form the Al-plated steel sheet.
[0051]
Generally, there is a case where anAl oxide coating having a thickness of 0.01
to 0.1 )liD is present on the surface of the Al plating layer of the Al-plated steel sheet 1.
- 29 -
There is a case where the thickness of this Al oxide coating increases up to 0.01 to 0.5
J.lm after hot pressing. The reason for the thickness of the Al oxide coating to increase
after hot pressing is that the Al oxide coating is oxidized by oxygen or water vapor in
the atmosphere after hot press forming.
The formation of this Al oxide coating and the increase in the thickness are
suppressed by the formation of a metal layer or a metal oxide layer on the surface of the
Al plating layer. However, in a case where coating layers 4A and 4B including a metal
layer or a metal oxide layer are present on the Al plating layers 3A and 3B as in the Atplated
steel sheet 1 according to the present embodiment, the formation of anAl oxide
coating is suppressed on the outermost surface side, but there is a case where a reaction
is caused at the interfaces between the metal layer and/or the metal oxide layer and the
Al plating layers and a metal oxide containing Al is formed on the metal oxide layer
after hot pressing.
[0052]
Al in the Al plating layers may be alloyed with Fe in the steel sheet by heating
during hot-dip plating and hot press forming. Therefore, it is not always true that the
Al plating layer is formed as a single layer having a constant composition, and the Al
plating layer includes a partially alloyed layer (alloy layer). The alloy layer is hard and
brittle and thus causes die wear during hot forming. However, when a metal layer or a
metal oxide layer is formed on the surface, it is possible to suppress this alloy layer
coming into contact with the die and wearing the die. Furthermore, a defect that is
generated in the alloy layer from the die is suppressed, and the deterioration of the
external appearance is suppressed.
[0053]
The thicknesses of the Al plating layers 3A and 3B are preferably 10 ).tm or
- 30 -
more and 60 )liD or less. When the thicknesses of the Al plating layers 3A and 3B are
less than 10 )liD, iron scale is formed on the base steel sheet 2 and the wear of the die is
promoted. The thicknesses of the Al plating layers 3A and 3B are more preferably 12
)liD or more and still more preferably 15 )liD or more.
On the other hand, when the adhesion amount of the Al plating layers 3A and
3B exceeds 60 )liD, the plating receives a large shear stress, and a large amount of Al
plating exfoliates. In this case, the die is damaged, and the wear of the die is
promoted. The thicknesses of the Al plating layers 3A and 3B are preferably 55 )liD or
less and more preferably 50 )liD or less.
[0054]
The thicknesses of the Al plating layers 3A and 3B can be obtained by
collecting a sample such that a cross section in the thickness direction can be observed,
polishing the cross section, and then observing the cross section with an optical
microscope at a magnification of 1,000 times.
[0055]
(Coating layer)
In the Al-plated steel sheet 1 that is used in the manufacturing method of a hot
press-formed article according to the present embodiment, metal layers, metal oxide
layers, or mixed layers thereof are provided on the Al plating layers 3A and 3B as the
coating layers 4A and 4B as the outermost layers.
These coating layers 4A and 4B are extremely important for suppressing the
wear of the die and obtaining a beautiful external appearance of a hot press-formed
article.
As described above, in a case where the Al-plated steel sheet 1 is hot-pressed,
one of the reasons for the plating to be damaged is the presence of a hard Al-Fe alloy
- 31 -
layer and aluminum oxide that is formed on the surface of the Al plating during heating
for hot stamping.
Therefore, in the manufacturing method of a hot press-formed article according
to the present embodiment, metal layers containing at least one metal of Mg, Ca, V, Ti,
and Zn, metal oxide layers containing an oxide of one or more of Mg, Ca, V, Ti, and Zn,
or mixed layers including the metal layer and the metal oxide layer are formed on the
surfaces of the Al plating layers 3A and 3B so as to cover the surfaces of the Al plating
layers 3A and 3B. The reason for the metal layer or the metal oxide layer to be
effective is not clear, but a possibility of a substance with a low Morse hardness
(Chemical Handbook Basic Edition p475, Maruzen Co., Ltd., published in 1966) being
effective is conceivable. For example, Mg (Morse hardness 2.0), Ca (same 1.5), and
Zn (same 2.5) are all lower than Al (same 2.9). In addition, MgO (Morse hardness 5.5
to 6), CaC03 (same 3), ZnO (same 4.5 to 5), and Ti02 (Morse hardness: 5.5 to 7.5) are
lower than Al oxide (same 9). However, it is not always true that wear is solved by
this alone, and it is conceivable that, for example, in the case of a metal, the melting
point may have an influence, and, in the case of an oxide, the size or the like may also
have an influence. The metal oxide that is contained in the coating layer, which is
mentioned in the present embodiment, includes not only oxides of the above-described
metals but also hydroxides and the carbon oxides of the above-described metals. This
is because most of hydroxides and carbon oxides are considered to be converted into
oxides after being heated in a heating furnace.
As the metal and metal oxide that configure the metal layer and the metal oxide
layer that are included in the coating layer, metallic Zn, metallic Mg, ZnO, or MgO is
preferable from the viewpoint of the cost and easy procurement.
Incidentally, from the viewpoint of suppressing the evaporation of the coating
- 32 -
layer in the heating step of hot pressing, a coating layer that is not a layer of Zn or ZnO
alone, which has a relatively low boiling point, and includes any of a metal layer
containing at least one metal of Mg, Ca, V, and Ti, a metal oxide layer containing an
oxide of one or more ofMg, Ca, V, and Ti, or a mixed layer thereof is preferable.
In the present embodiment, the metal layer, the metal oxide layer, or the mixed
layer including the metal layer and the metal oxide layer refers to a layer in which a
total of 8 mass% or more of at least one element of Mg, Ca, V, Ti, and Zn is contained.
The coating layer may be a mixed layer of a metal layer and a metal oxide
layer in which a part of the metal layer has turned into an oxide. In addition, the metal
layer or the metal oxide layer may be a layer composed of the above-described metal or
metal oxide, but may also be a layer in which a metal or a metal oxide and a resin are
mixed. Since the resin plays a role of a binder, when the resin is mixed, it is possible
to strongly attach the metal layer or the metal oxide layer to the surface of the Al
plating. The resin mentioned herein means a compound mainly composed of C or a
compound containing H, 0 , N, and S and being mainly composed of C. Even when
the resin is mixed, since the resin is easily combusted in a heating furnace and released
as carbon dioxide and disappears from the coating layer after press forming, the resin
has a small influence on the characteristics of the metal layer or the metal oxide layer.
[0056]
In the heating step during hot press forming, the Al-plated steel sheet I is
heated in an atmosphere containing oxygen or water vapor. Therefore, when the Alplated
steel sheet is taken out from the heating furnace and then hot-press-formed and
after the Al-plated steel sheet is hot-pressed (when the Al-plated steel sheet has turned
into a hot press-formed article), a part or all of the metal that was not an oxide before
hot pressing is oxidized, and the metal layer turns into a mixed layer of the metal layer
- 33 -
and a metal oxide layer or a metal oxide layer. For example, a metallic Zn layer
partially or wholly turns into a ZnO layer.
[0057]
A forming method of the coating layers 4A and 4B is not particularly limited,
and, for example, when the coating layer is a metal layer, the coating layer can be
formed on the Al-plated steel sheet by precipitation by an electro plating method or by
vapor deposition by a physical vapor deposition method. When the coating layer is a
metal oxide layer, for example, the coating layer can be formed by a method in which
the metal layer formed on the Al-plated steel sheet is heated in the air for a short period
of time to be oxidized or, additionally, can be formed by, for example, dispersing a
commercially available metal oxide sol in water applying the water dispersion liquid to
the Al-plated steel sheet, and drying moisture to form a membrane. At this time, it is
also possible to mix a resin with the water dispersion liquid.
[0058]
When the thicknesses of the coating layers 4A and 4B are set to 0.3 J.lm or
more, the wear of the die is suppressed, and furthermore, a beautiful external
appearance of a hot press-formed article can be obtained after hot forming (a low
glossiness can be obtained). Therefore, the thicknesses of the coating layers 4A and
4B are preferably set to 0.3 J.lm or more. The thicknesses are more preferably 0.4 J.lm
or more and still more preferably 0.5 J.lm or more.
On the other hand, when the thickness of the coating layer exceeds 10.0 J.lm,
there is a case where the external appearance is impaired by the metal layer or the metal
oxide layer itself. Therefore, the thickness of the coating layer is preferably set to 10.0
J.lm or less. The thickness of the coating layer is more preferably 7.0 J.lm or less and
still more preferably 5.0 J.lm or less.
- 34 -
The thicknesses of the coating layers 4A and 4B (the metal layers and/or the
metal oxide layers) can be measured by embedding the sample in a resin, polishing the
sample, and observing cross sections in the thickness direction using a scanning electron
microscope (SEM) at a magnification of 1000 times to 30000 times. The coating
layers 4A and 4B, which are the metal layers, the metal oxide layers, or mixed layers
including the metal layer and the metal oxide layer, refer to layers in which the content
ratio of at least one element of Mg, Ca, V, Ti, and Zn is 8 mass% or more in total, and
the content ratio is obtained by analyzing the cross section with an electron probe micro
analyzer (EPMA). If necessary, the surface of the material may be observed after
being deposited with gold before the material is embedded in order to clarify the
boundary between the coating layer and the embedding resin.
[0059]
[Forming step]
In the forming step, the heated Al-plated steel sheet 1 is formed using a die
after the completion of the heating step, thereby obtaining a hot press-formed article.
When the time taken from the completion of the heating step to the start of
forming is longer than 30 seconds, there is a case where the base metal of the steel sheet
austenitized by heating undergoes ferritic transformation and it becomes impossible to
obtain a high-strength martensite structure after pressing. Therefore, the time taken
from the completion of the heating step to the start of forming is preferably set to 30
seconds or shorter. Since the Al-plated steel sheet is preferably formed as soon as
possible, it is not necessary to limit the lower limit; however, when facility restrictions
such as the transportation speed from the heating furnace to a press machine and the
descending speed of a die of the press machine and the like are taken into account, the
time may be set to 3 seconds or longer. However, the time taken until forming is
- 35 -
controlled for the purpose of ensuring the temperature of the Al-plated steel sheet.
[0060]
(Die)
As a die that is used for forming, it is not necessary to use a die that is
particularly limited by use. General tool steel represented by SKDll and SKD61 of
JIS (JIS G 4404: 2015), high-speed steel, and the like are exemplary examples.
However, the die that is used in the present embodiment has a hard layer on the
surface of the die that comes into contact with the Al-plated steel sheet. In addition,
HVDie, which is the surface hardness of the die at the position of the hard layer, is
HV1500 or more and HV3800 or less.
This hard layer is extremely important for suppressing the wear of the die and
obtaining a beautiful external appearance of a hot press-formed article.
In order to further suppress the wear, the hard layer is preferably fom1ed in a
thickness of 1.0 ~m or more. The upper limit of the thickness of the hard layer is
preferably 20 ~m or less in order to suppress an excessive increase in the internal stress
or toughness deterioration of the hard layer.
In the manufacturing method of a hot press-formed article according to the
present embodiment, the upper die and the lower die of the die relatively move in a
constant direction, and the steel sheet installed between the upper die and the lower die
is drawn into the die hole of the die and formed by this movement. In such press
forming, a surface of the die in a direction parallel to the direction in which the die (the
upper die and the lower die) relatively moves (generally, the vertical direction) comes
into contact with the steel sheet to be processed and is slid. On the surface in the
direction parallel to the relative movement direction, for exan1ple, the surface of the R
portion of the die is in contact with the standing wall portion of the hot press-formed
- 36 -
article, and additional examples include the surface of a wrinkle-suppressing flange
portion of the die, in the case of a beaded die, the surface of the bead head top portion,
and the like.
When the hardness HVDie of the hard layer that is included in the die is
HV1500 or more, wear on the sliding surface (the surface that slides in contact with the
steel sheet) of the die during hot press forming is suppressed. At a hardness of less
than HV1500, the die wears. For example, the SKDll or SKD61 material is HV500 to
HV 1000, generally, in the case of performing a nitriding treatment, the hardness is
HV600 to HV1400, and the die wears. Therefore, HVDie is set to HV1500 or more.
HVDie is preferably HV2000 or more and more preferably HV2500 or more. The
upper limit is not provided for the surface hardness, but the hard layer becomes brittle in
the case of being excessively hard, and a phenomenon in which the hard layer and the
base metal of the die exfoliate occurs. Furthermore, the die damages the surface of the
Al-plated steel sheet during hot pressing, and the external appearance is degraded.
Therefore, HVDie is set to HV3800 or less. HVDie is preferably HV3600 or less and
more preferably HV3400 or less.
The surface hardness HVDie of the die is hardness that is measured at a test load
of 10 g-f to 25 g-f (0.098 N to 0.245 N) in the Vickers hardness testing method specified
by JIS Z 2244: 2009. As a micro Vickers tester for measuring hardness, HM-211
manufactured by Mitutoyo Corporation can be used. Regarding the measurement of
the hardness, the Micro Vickers indenter is indented at 2 or more points separated by 30
11m or more, and the diagonal length of the indentation is observed with SEM, thereby
obtaining the hardness.
[0061]
The material or forming method of the hard layer that is formed in the die is
- 37 -
not limited as long as the hard layer satisfies HVoie2: HV1500.
Examples thereof include a hard coating layer (deposited film) by the physical
vapor deposition method (PVD method), and specific examples include a nitride film, a
carbide film, and a carbonitride film, containing one or more selected from Ti, Cr, and
Alas main components, a diamond-like carbon (DLC) film, and the like.
Among them, the deposited film as the hard coating layer is preferably a film
containing Ti or Cr or combination thereof. For example, the deposited film is
preferably a film in which the metal element portion is any of a nitride, a carbide, and a
carbonitride containing one or more selected from Ti, Cr, and Al as main components.
Fw-thermore, the deposited film is more preferably a film in which the metal element
portion is any of a nitride, a carbide, and a carbonitride containing Ti or Cr as a main
component. The hardness HVoie of the PVD coating in which the metal element
portion contains Ti, Cr, orAl is between 2000 and 4000. In the case of using diamondlike
carbon, the hardness HVDie of the PVD coating is between 5000 and 8000.
[0062]
In the present embodiment, as a forming method of the hard layer in the die, a
forming method of a deposited film by physical vapor deposition is an exemplary
example. The type of the physical vapor deposition method is not particularly limited.
As the physical vapor deposition method, for example, an arc ion plating method and a
sputtering method are desirable. In addition, a chemical vapor deposition (CVD)
method may also be used.
For example, a variety of metal targets and reaction gases (N2 gas, CH4 gas,
and the like) that are the evaporation sources of metal components are used, and the
temperature and the gas pressure are adjusted to apply a bias voltage, whereby a PVD
film can be formed on the surface of the base metal of the die.
- 38 -
Before the formation of the hard coating layer (deposited film) by the physical
vapor deposition method (PVD method) in the die, a nitriding layer that acts as an
underlying layer is preferably formed (a surface-hardening treatment using diffusion
called a nitriding treatment). Here, the nitriding layer is generally less than HV1500
and is not included in the hard layer of the die necessary for wear resistance in the
present embodiment.
The nitriding layer is formed by performing, for example, an ion nitriding
treatment, that is, performing an ion nitriding treatment by adjusting the temperature in
a N2 and H2 gas atmosphere having a predetermined concentration on the base metal of
the die.
At this time, the compound layer such as the nitriding layer called a white layer
that is formed by the nitriding treatment causes the deterioration of the adhesion, and
thus it is desirable to prevent the formation of the compound layer by the control of the
treatment conditions or remove the compound layer by polishing or the like.
[0063]
In the manufacturing method of a hot press-formed article according to the
present embodiment, in hot press forming, when the temperature of the Al-plated steel
sheet 1 at the start of forming is indicated by Tm in the unit of °C, and the average
movement velocity of the die from the start of forming to the bottom dead point is
indicated by V in the unit of mm/s, the forming is performed such that Tm and V satisfy
the following formula (1) in accordance with HVDie-
800- (HVDiel40) :'S Tm :'S 850- (V/4)- (HVDiellOO) ... Formula (1)
This formula (1) is extremely important for suppressing the wear of the die and
obtaining a beautiful external appearance of a hot press-formed article.
The temperature (forming temperature: Tm) CCC) of the Al-plated steel sheet 1
- 39 -
at the start of forming needs to be ((850- V/4)- (HVDiel100)) or less. When the
forming temperature is higher than ((850- V/4)- (HVDie/100)), the surfaces of the Al
plating layers 3A and 3B on the surface of the Al-plated steel sheet 1 become soft and
are rubbed against the die, which makes a defect likely to be generated and degrades the
external appearance of a hot press-formed article after forming (the quality of the
external appearance deteriorates). The average movement velocity (forming velocity:
V) of the die from the start of forming to the arrival of the bottom dead point can be
obtained from a relationship of V =Sit using a timet (seconds) taken for the movement
of both the Al-plated steel sheet 1 and the die to stop from the start of forming
(generally, also called the bottom dead point) and a movement distanceS (mm) of the
die while the movement of both the Al-plated steel sheet and the die stops from the start
of forming. The reason for the external appearance of the hot press-formed article to
depend on the average movement velocity V (forming velocity) of the die during
forming is that, as the forming velocity becomes faster, the removal of heat from the
steel sheet by the contact with the die is further suppressed, it is more likely that the
steel sheet receives an impact from the die at a high temperature and a defect is
generated, and the external appearance is more likely to deteriorate. Here, the start of
forming refers to a timing at which the moving die comes into contact with the Atplated
steel sheet.
In addition, since an appropriate temperature for suppressing the damage on the
material (Al-plated steel sheet) side is also affected by the hardness of the die surface,
Tm and V preferably sati sfy the formula (2).
800- (HVDiel40)::; Tm::; 850 - (V/2)- (HVDie/50) ... Formula (2)
That is, the temperature (forming temperature: Tm) (°C) oftheAl-plated steel
sheet at the start of forming is preferably ((850 - V /2) - (HVDiel50)) or lower. This is
- 40 -
because the surface of a press-formed article is more likely to be damaged in a case
where the hardness HVDie of the surface of the die is high, and thus a more beautiful hot
press-formed article can be obtained by further suppressing the forming temperature in
accordance with HVDie.
On the other hand, when the forming temperature Tm (°C) is lower than (800 -
(HVDie/40)), the surface of the steel sheet becomes hard, and thus the die and the steel
sheet are strongly rubbed against each other during pressing, and the die wears.
Therefore, the forming temperature (°C) is set to (800 - (HVDie/40)) or higher. The
forming temperature Tm (°C) is preferably (805- (HVDie/40)) or higher and more
preferably (810- (HVDie/40)) or higher.
The average movement velocity V (mm/s) of the die from the start of forming
to the bottom dead point is not particularly limited as long as the formula (1) and the
formula (2) are satisfied. Heat of the formed article is removed by the contact with the
die; however, when the average movement velocity is set to be slow, the amount of heat
removed becomes large, and the formed article comes into contact with the die at a
lower temperature, and thus the damage of the surface of the formed article decreases,
and the glossiness decreases. Therefore, in terms of the external appearance, the
average movement velocity (forming velocity) is preferably 95 mm/s or slower and
more preferably 85 mm/s or slower. However, when the average movement velocity is
too slow, heat is excessively removed from the formed article, and the wear of the die is
promoted due to the impairing of the martensitic transformation of the material and the
surface of the material becoming hard. Therefore, the average movement velocity
(forming velocity) is preferably 15 mm/s or faster and more preferably 25 mm/s or
faster. The average movement velocity V (mm/s) is obtained by dividing the
movement distance (mm) of the die by the time (seconds) taken from the start of
- 41 -
forming (when the die is initiated) to the bottom dead point (when the movement of the
die and the press-formed article stops).
As a measurement method of the temperature (forming temperature: Tm) CC)
of the Al-plated steel sheet 1 at the start of forming, the temperature can be measured
with a radiation-type thermometer or by attaching a thermocouple to the Al-plated steel
sheet 1. Generally, in a case where a thermocouple is attached, a portion to which the
thermocouple is attached becomes convex and impairs hot press forming, and thus a
method in which the thermocouple is attached to the side surface of the end portion of
the steel sheet of the Al-plated steel sheet (a surface perpendicular to the surface where
the Al plating layer is present) may be used. The forming temperature Tm CC) is not
particularly limited as long as the formula (1) and the formula (2) are satisfied, but is
preferably 550°C or higher, more preferably 600°C or higher, and still more preferably
650°C or higher from the viewpoint of increasing the mechanical strength of the pressformed
article by causing the material to undergo martensitic transformation during hot
pressmg. On the other hand, from the viewpoint of ensuring the movement time from
the heating furnace to press forming, the forming temperature Tm CC) is preferably
850°C or lower, more preferably 830°C or lower, and still more preferably 810°C or
lower.
[0064]
The surface temperature of the die at the start of forming is preferably 180°C
or lower. When the die side is damaged, unevenness is formed, damage on the
material side increases, and the external appearance deteriorates; however, when the
surface temperature of the die is set to 180°C or lower, the damage of the die can be
more stably suppressed. The surface temperature of the die at the start of forming is
more preferably 170°C or lower and still more preferably 160oc or lower. The lower
- 42 -
limit of the surface temperature of the die is not particularly determined, but is
preferably soc or higher. In addition, the die temperature increases due to the contact
with the Al-plated steel sheet heated during forming or, when forming is performed
continuously, the heat is stored in the die, and the die temperature gradually increases,
and thus the lower limit is more preferably 20°C or higher and still more preferably
50°C or higher.
The surface temperature of the die can be measured by attaching a
thermocouple to the die by spot welding.
[0065]
The movement distance of the die is preferably 150 mm or less. The
movement distance mentioned herein means the movement distance of the die in the
direction in which the die (the upper die and the lower die) relatively moves while the
die and the Al-plated steel sheet come into contact with each for the first time and the
descending of the die stops upon the end of forming (generally also referred to as the
bottom dead point) during hot press forming. As the movement distance of the die
becomes longer, the distance of the Al-plated steel sheet and the die being rubbed
against each other and sliding becomes longer. As the sliding distance increases, the
Al-Fe alloy layer orAl oxide in the exfoliated plating starts to act like an abrasive, and
the external appearance gradually deteriorates. When the movement distance exceeds
150 mm, the external appearance significantly deteriorates. The movement distance of
the die is more preferably 130 mm or less and still more preferably 110 mm or less.
[0066]
The metal material of the base metal of the die is not particularly determined,
and well-known metallic materials, for example, cold die steel, hot die steel, high speed
steel, cemented carbide, and the like can be used. Regarding this, improved metal
- 43 -
kinds that have been proposed as a kind of steel that can be used in conventional dies,
including standard metal types (kinds of steel) by JIS or the like can also be applied.
[0067]

The hot press-formed article according to the present embodiment is a hot
press-formed article composed of an Al-plated steel sheet having anAl plating layer, in
which the glossiness (Gs60°) that is regulated by JIS Z 8741: 1997 on the surface is 30
or less.
The hot press-formed article according to the present embodiment can be
obtained by the above-described manufacturing method of a hot press-formed article
according to the present embodiment. In the present embodiment, the hot pressformed
article does not necessarily refer only to a formed article formed by hot pressing
accompanying the distortion of the steel sheet shape of anAl-plated steel sheet and also
includes Al-plated steel sheets that have been slid after heating orAl-plated steel sheets
that have been sandwiched by the die after heating and received pressure.
The hot press-formed article according to the present embodiment is obtained
by forming anAl-plated steel sheet including a metal layer composed of at least one
metal of Mg, Ca, V, Ti, and Zn, a metal oxide layer composed of an oxide of Mg, Ca, V,
Ti, and Zn, or a mixed layer made up of the metal layer and the metal oxide layer
formed on the surface of the sliding surface that comes into contact with the die at least
during hot pressing by hot pressing.
Therefore, on the surface of the hot press-formed article according to the
present embodiment, the glossiness (Gs60°) regulated in JIS Z 8741: 1997 is 30 or less,
and the surface external appearance is excellent. The glossiness is preferably 25 or
less.
- 44 -
The glossiness may be measured at the standing wall portion (sliding portion)
where the external appearance is most likely to deteriorate.
[0068]
In addition, the hot press-formed article according to the present embodiment
preferably has a coating layer composed of a metal layer of at least one of Ca, V, Ti, and
Zn, a metal oxide layer of at least one of Mg, Ca, V, Ti, and Zn, or a mixed layer of the
metal layer and the metal oxide layer on the surface of the Al plating layer in order to
obtain the above-described glossiness. In addition, the thickness of the coating layer is
preferably 0.3 to 10.0 !liD.
[Examples]
[0069]
(Example 1)
Al plating was provided by a Sendzimir method on both surfaces of a coldrolled
steel sheet having a chemical composition (unit: mass%, remainder: Fe and an
impurity) shown in Table 1 and having a sheet thickness of 1.4 mm. The annealing
temperature before immer sion in a plating bath was set to about 750°C. The Al plating
bath contained 9.5 mass% of Si and additionally contained Fe that was eluted from the
cold-rolled steel sheet, and the remainder was Al. The thickness (weight per unit area)
of an Al plating layer after plating was adjusted by a gas wiping method, and the
thicknesses (weights per unit area) of the Al plating layers formed on both surfaces of
the cold-rolled steel sheet were both set to 20 !liD, and then cooling were performed.
After that, an operation by which the Al plating layers on both surfaces were
partially coated with each of a Zn oxide, a Ti oxide, a V oxide, a Mg oxide, and/or a Ca
oxide of chemicals (manufactured by Sigma-Aldrich Japan, C. I. Kasei Co., Ltd., Taki
Chemical Co., Ltd., TECNAN Co., Ltd., Tateho Chemical Industries Co., Ltd., and
- 45 -
Suzuki Engineering Co., Ltd.) with a roll coater and baked at about 80°C was
performed, and oxide coatings of Mg, Ca, V, Ti, and/or Zn were formed on both
surfaces. In some of the Al plating layers, the same mass% of a polyurethane resin
was mixed with the Zn oxide, and the Al plating layers were coated and baked, thereby
forming coatings. In all of the coating layers, the total of the content ratio of at least
one element of Mg, Ca, V, Ti, and Zn was 8 mass% or more.
Al-plated steel sheets Al to A35 shown in Table 3-1 to Table 3-4 were obtained
as described above.
[0070]
(Example 2)
Al plating was provided by a Sendzimir method on both surfaces of a coldrolled
steel sheet having a chemical composition (unit: mass%, remainder: Fe and an
impurity) shown in Table 2 and having a sheet thickness of 1.4 mm. The annealing
temperature before immersion in a plating bath was set to about 750°C, the Al plating
bath contained 9.5 mass% of Si and additionally contained Fe that was eluted from the
cold-rolled steel sheet, and the remainder was Al. The thickness (weight per unit area)
of anAl plating layer after plating was adjusted by a gas wiping method, and the
thicknesses (weights per unit area) of the Al plating layers formed on both surfaces of
the cold-rolled steel sheet were both set to 30 11m, and then the Al plating layers were
cooled. In addition, on both surfaces of the Al plating layers, metal layers of Mg, Ca,
V, Ti, and Zn, metal layers in which Zn and Mg were mixed, and metal layers in which
Zn and V were mixed were formed by an ion plating method. In addition, in some of
the Al plating layers, the metal layers were formed on both surfaces of the Al plating
layers in the same manner and then heated in the air at 700°C for 4 minutes, thereby
oxidizing some of the metal layers to form mixed layers of an oxide layer and the metal
- 46 -
oxide layer on the Al plating layers. In all of the coating layers, the total of the content
of at least one element of Mg, Ca, V, Ti, and Zn was 8 mass% or more.
Al-plated steel sheets A36 to A49 shown in Table 3-1 to Table 3-4 were
obtained as described above.
At the same time, Al-plated steel sheets A50 and A51 in which neither a metal
layer nor a metal oxide layer was provided on the Al plating layer were also prepared.
[0071]
c
0.22
c Si
0.23 0.25
[Table 1]
Si
0.27
[0072]
[Table 2]
Mn p
1.19 O.Dl5
[0073]
Mn
1.23
s
0.003
(mass%) (remainder: Fe and impurity)
p s Al Cr Ti B N
0.017 0.003 0.029 0.19 0.024 0.0023 0.0030
(mass%) (remainder: Fe and impurity)
AI Cr Ti B N Ni Cu Nb Sn Ca REM 0
0.022 0.21 0.025 0.0030 0.0030 0.20 0.20 0.013 0.010 0.0022 0.0012 0.0025
A sliding test was performed on the Al-plated steel sheets (A1 to A51) obtained
as described above using a die. This test is a test that simulated sliding between the
die and the Al-plated steel sheet on a surface parallel to a direction in which the die
moved during hot pressing. In the sliding test, a device shown in FIG. 2 was used, the
Al-plated steel sheets were heated to heating temperatures shown in Table 3-1 to Table
3-4, then sandwiched in a die at a pressure of 3 kN, and slid a distance of 100 mm at
forming temperatures Tm (°C) and forming velocities V (mm/s) shown in Table 3-1 to
Table 3-4, thereby forming the Al-plated steel sheets. Times taken from the
completion of heating to the start of forming were set to 3 to 30 seconds. The
- 47 -
atmosphere during heating was set to the atmospheric environment.
In addition, the die used for the sliding test was prepared as described below.
[0074]
<>
Steel corresponding to SKD61 (JIS G 4404: 2015) was prepared as tool steel,
roughly processed into a shape approximate to a die shown by 6A and 6B in FIG. 2 in
an annealed state, heated and held at 1180°C in a vacuum, quenched by cooling with
nitrogen gas, and then thermally refined by tempering at 540°C to 580°C such that the
hardness became HV600. After that, finish processing was performed, thereby
obtaining substrates for a plurality of dies.
On some of the substrates, an ion nitriding treatment was performed under
conditions to be described below. Specifically, the ion nitriding treatment was
performed in an atmosphere having a flow rate ratio of 5% N 2 (remainder: H2) under a
condition of holding the substrate at 5oooc for 5 hours. After that, each of the test
surfaces was finished by polishing to form a nitriding layer. The hardness of the
surface after the formation of the nitriding layer was HV 1200.
In addition, on some of the substrates, a hard layer was formed at a site where
the nitriding layer was formed. The hard layer was a PVD film, and plasma cleaning
was performed with a thermal filament by applying a bias voltage in an Ar atmosphere
using an arc ion plating device. After that, a PVD film was formed at a bias voltage
using a variety of metal targets, which were the evaporation sources of metal
components, N2 gas as a base and CH4 gas, if necessary, as reaction gases. The
hardness of the surface of the die after the formation of the PVD film was prepared to
HV2500, HV3200, or HV7000.
[0075]
- 48 -
Table 3-1 to Table 3-4 show the individual forming conditions, the surface
hardness of the dies used, and the surface temperatures at the start of forming.
[0076]
Regarding the Al-plated steel sheets after the sliding test, the external
appearances were evaluated. In some examples, in a case where a metal layer was
provided on the surface, the metal layer was oxidized by heating on the hot pressformed
article, and an oxide layer was formed.
[0077]
[Evaluation of external appearance after forming]
A position of a sliding distance of 50 mm was cut out by cutting, and the
glossiness (Gs60°) regulated in JIS Z 8741: 1997 was measured using a glossiness
meter.
A glossiness of 25 or less was evaluated as VG (Very Good), a glossiness of
more than 25 and 30 or less was evaluated as G (Good), and a glossiness of more than
30 was evaluated as NG (No Good).
[0078]
[Evaluation of wear resistance]
In addition, the wear resistance of the dies was evaluated.
Specifically, for the shape profile of the surface of the die after forming, the
arithmetic average roughness Ra was measured using a contact-type roughness meter
(Kosaka Laboratory Ltd. SE700, measuring probe diameter R: 2 ~-tm) according to JIS B
0601: 2013. The differences between Ra of a portion that did not slide and Ra of a
portion that had slid were compared, a case where the Ra of the portion that had slid
was 5 11m or more larger than Ra of a portion that did not slide was evaluated as NG
(No Good), and a case where the difference was less than 5 11m was evaluated as G
- 49 -
(Good).
The results are shown in Table 3-1 to Table 3-4.
[0079]
[Table 3-1]
Coating layer
Sliding test
Test conditions
Test Determination 1 Determination 2 Determination 3
No. Metal layer Thickness Heating Temperature Forming (Tm lower limit (Tm upper limit (Tm upper limit
Metal oxide
temperature rising rate temperature comparison) comparison) comparison 2)
layer
[)lfll] [OC] [°C/s] Tm [0C]
000 ~ 850 - (V/4) 850 - (V/2)
HV Die/40 ~ HV Die/100 -HV Die/50
Invention
Example A1 ZnO 1.0 930 6 750 738 OK 815 OK 700 OK
Invention
Example A2 ZnO 1.0 950 6 750 738 OK 815 OK 700 OK
Comparative
Example A3 ZnO 1.0 800 4 600 738 NG 815 OK 700 OK
Comparative A4 ZnO 1.0 ll50 10 750 738 OK 815 OK 700 OK
Example
Invention AS ZnO 1.0 930 6 770 738 OK 815 OK 700 OK
Example
Invention A6 ZnO 1.0 930 6 800 738 OK 815 OK 700 NG
Example
Comparative A7 ZnO 1.0 930 6 600 738 NG 815 OK 700 OK
Example
Comparative AS ZnO 1.0 930 6 ~ 738 OK 815 NG 700 NG
Example
Invention
A9 ZnO 1.0 930 6 750 738 OK 005 OK 760 OK
Example
Invention
AlO ZnO 1.0 930 6 750 738 OK 003 OK 755 OK
Example
Invention
Example All ZnO 1.0 930 6 750 738 OK 798 OK 745 NG
Invention
Example A12 ZnO 1.0 930 6 750 738 OK 775 OK 700 NG
Comparative
Example Al3 ZnO 1.0 930 6 800 7 38 OK 795 NG 740 NG
Comparative
Example A14 ZnO 1.0 930 6 800 7 38 OK 775 NG 700 NG
Comparative
Example A15 ZnO 1.0 930 6 750 785 NG 834 OK 818 OK
Comparative A16 ZnO 1.0 930 6 750 770 NG 828 OK 806 OK
Example
Comparative A17 ZnO 1.0 930 6 800 785 OK 834 OK 818 OK
Example
Comparative A18 ZnO 1.0 930 6 800 770 OK 828 OK 806 OK
Example
Invention A19 ZnO 1.0 930 6 750 720 OK 008 OK 766 OK
Example
Invention A20 ZnO 1.0 930 6 800 720 OK 008 OK 766 NG
Example
Comparative A21 ZnO 1.0 930 6 Jm 625 OK 770 NG 690 NG
Example
Invention
A22 ZnO 0.2 930 6 750 738 OK 815 OK 700 OK
Example
Invention
Example A23 ZnO 0.5 930 6 750 738 OK 815 OK 700 OK
Invention
Example A24 ZnO 3.0 930 6 750 7 38 OK 815 OK 700 OK
Invention
Example A25 ZnO 6.0 930 6 750 7 38 OK 815 OK 700 OK
Invention
Example A26 ZnO 12 .0 930 6 750 738 OK 815 OK 700 OK
[0080]
[Table 3-2]
- 50 -
Sliding test
Hot press-formed article after sliding test
Test condition Die
External
Wear
Test No.
Forming
Hardness
Surface appearance of Coating layer on Al
resistance
velocity temperature formed article plating
of die
(glossiness)
V [mm/s] Hv_Die [OC] Gs [60°] Kind
Thiclmess
[flllll
fuvention
A1 40 2500 20 VG ZnO 1.0 Example G
fuvention
A2 40 2500 20 VG ZnO 1.0 G
Example
Comparative
Example A3 40 2500 20 NG ZnO 1.0 G
Comparative
A4 40 2500 20 NG ZnO 1.0 G Example
fuvention
AS 40 2500 20 VG ZnO 1.0 G
Example
fuvention
Example A6 40 2500 20 G ZnO 1.0 G
Comparative
A7 40 2500 20 NG ZnO 1.0 NG
Example
Comparative
AS 40 2500 20 NG ZnO 1.0 G Example
fuvention
A9 80 2500 20 VG ZnO 1.0 G
Example
fuvention
A10 90 2500 20 VG ZnO 1.0 G
Example
fuvention
All 110 2500 20 G ZnO 1.0 G Example
fuvention
A12 200 2500 20 G ZnO 1.0 G
Example
Comparative
A13 120 2500 20 NG ZnO 1.0 G
Example
Comparative
A14 200 2500 20 NG ZnO 1.0 G
Example
Comparative
A15 40 600 20 NG ZnO 1.0 NG
Example
Comparative
A16 40 1200 20 NG ZnO 1.0 NG
Example
Comparative
A17 40 600 20 NG ZnO 1.0 NG
Example
Comparative
A18 40 1200 20 NG ZnO 1.0 NG
Example
fuvention
A19 40 3200 20 VG ZnO 1.0 G
Example
fuvention
A20 40 3200 20 G ZnO 1.0 G
Example
Comparative
A21 40 7000 20 NG ZnO 1.0 G
Example
fuvention
Example A22 40 2500 20 G ZnO 0.2 G
fuvention
A23 40 2500 20 VG ZnO 0.5 G
Example
fuvention
A24 40 2500 20 VG ZnO 3.0 G Example
fuvention
A25 40 2500 20 VG ZnO 6.0 G
Example
fuvention
A26 40 2500 20 G ZnO 12.0 G
Example
- 51 -
[0081]
[Table 3-3]
Coating layer
Sliding test
Test conditions
Test Heating Temperature Forming
Determination 1 Determination 2 Determination 3
No. Metal layer Thickness temperature rising rate temperature (Tm lower limit (Im upper limit (Im upper limit
Metal oxide oomparison) comparison) oomparison 2)
layer [)llll] [CC] [°C/s] Tm [°C]
000- 850 - (V/4) 850 - (V/2)
HV_Die/40 -HV _Die/100 - HV_Die/50
Invention J>:l.1 ZnO 1.0 930 6 750 720 OK 808 OK 766 OK
Example
Invention /Q.8 ZnO 1.0 930 6 750 720 OK 808 OK 766 OK
Example
Invention
J>:l.9 ZnO 1.0 930 6 750 720 OK 808 OK 766 OK
Example
Invention
A30 MgO 0.5 930 6 750 720 OK 808 OK 766 OK
Example
Invention
Example A31 CaO 0.5 930 6 750 720 OK 808 OK 766 OK
Invention
Example A32 TiO, 0.5 930 6 750 720 OK 808 OK 766 OK
Invention
Ex ample A33 v ,o5 +Tio, 0.5 930 6 750 720 OK 808 OK 766 OK
Invention
Example A34 MgO + ZnO 0.5 930 6 750 720 OK 808 OK 766 OK
Invention
Example A35 ZnO + resin 1.0 930 6 750 720 OK 808 OK 766 OK
Invention A36 Zn 0.5 930 6 750 720 OK 808 OK 766 OK
Example
Invention A37 Mg 0.5 930 6 750 720 OK 808 OK 766 OK
Example
Invention A38 Zn 0.5 930 8 750 720 OK 808 OK 766 OK
Example
Invention
A39 Mg 0.5 930 10 750 720 OK 808 OK 766 OK
Example
Invention A40 Ca 0.5 930 6 750 720 OK 808 OK 766 OK
Example
Invention A41 Ti 0.5 930 6 750 720 OK 808 OK 766 OK
Example
Invention
A42 v 0.5 930 6 750 720 OK 808 OK 766 OK
Example
Invention
Example A4 3 Zn +Mg 0.5 930 6 750 720 OK 808 OK 766 OK
Invention
Example A44 Zn + V 0.5 930 6 750 720 OK 808 OK 766 OK
Invention
Example A4 5 Zn+ZnO 2.0 930 6 750 720 OK 808 OK 766 OK
Invention
Example A4 6 Mg+MgO 2.0 930 6 750 720 OK 808 OK 766 OK
Invention
Example A47 Ca + CaO 2.0 930 6 750 720 OK 808 OK 766 OK
Invention A48 Ti+TiO, 2.0 930 6 750 720 OK 808 OK 766 OK
Example
Invention A49 v + v ,o 5 2.0 930 6 750 720 OK 808 OK 766 OK
Example
Comparative ASO None None 930 6 750 720 OK 808 OK 766 OK
Example
Comparative A51 None None 930 6 750 7 85 NG 834 OK 818 OK
Example
- 52 -
[0082]
[Table 3-4]
Slidillg test
Hot press-formed article after sliding test
Test condition Die
External
Wear
Test No.
Forming
Hardness
Surface appearance of
Coating layer on Al plating resistance
velocity temperature formed article
(glossiness)
of die
V [mm/s] Hv_Die [OC] Gs [60°] Kind
Thickness
[flllll
fuvention A27 40 3200 50 VG ZnO Example 1.0 G
fuvention A28 40 3200 100 VG ZnO 1.0 G
Example
fuvention
Example A29 40 3200 200 G ZnO 1.0 G
fuvention A30 40 3200 20 VG MgO 0.5 G
Example
fuvention A31 40 3200 20 VG CaO 0.5 G
Example
fuvention
A32 40 3200 20 VG Ti0 2 0.5 G
Example
fuvention A33 40 3200 20 VG V20 s +Ti0 2 0.5 G
Example
fuvention A34 40 3200 20 VG MgO +ZnO 0.5 G Example
fuvention A35 40 3200 20 VG ZnO 0.5 G
Example
fuvention A36 40 3200 20 VG ZnO 0.7 G
Example
fuvention A37 40 3200 20 VG MgO 0.7 G
Example
fuvention A38 40 3200 20 G ZnO 0.7 G
Example
fuvention
A39 40 3200 20 G MgO 0.7 G
Example
fuvention A40 40 3200 20 VG CaO 0.7 G Example
fuvention A41 40 3200 20 VG Ti0 2 0.7 G
Example
fuvention
A42 40 3200 20 VG V20 s 0.7 G
Example
fuvention A43 40 3200 20 VG ZnO +MgO 0.7 G
Example
fuvention A44 40 3200 20 VG ZnO + V20 5 0.7 G
Example
fuvention
Example A45 40 3200 20 VG Zn + ZnO 2.5 G
fuvention A46 40 3200 20 VG Mg + MgO 2.5 G
ExampJ e
fuvention A47 40 3200 20 VG Ca + CaO 2.5 G Example
fuvention A48 40 3200 20 VG Ti + Ti0 2 2.5 G
Example
fuvention A49 40 3200 20 VG V + V20 s 2.5 G
Example
Comp arative ASO 40 3200 20 NG None - G Example
Comparative A51 40 600 20 NG None - NG
Example
- 53 -
[0083]
As is clear from Table 3-1 to Table 3-4, according to the present invention, it is
possible to obtain a component in which the sliding portion of a hot press-formed article
is beautiful (the glossiness Gs60o is 30 or less) while improving the wear resistance of a
die.
In comparative examples, the heating temperature was too low inA3. In
addition, the heating temperature was too high in A4. Therefore, a defect was
generated in the Al-plated steel sheet after hot pressing, the glossiness increased to be
more than 30, and the external appearance deteriorated.
In A7, the forming temperature was too low. InA8, Al3, andA14, the
forming temperatures were too high. Therefore, the external appearances of the Alplated
steel sheets after hot pressing deteriorated. In A7, the forming temperature was
too low, and thus the die also worn.
In addition, in Al5 to Al8, the hardness of the surfaces of the dies was too low,
and, inA15 and Al6, the forming temperatures were too low. Therefore, the dies
worn, and the external appearances of the Al-plated steel sheets after hot pressing also
deteriorated.
In A21, the hardness of the surface of the die was too high. Therefore, a
defect was generated in the Al-plated steel sheet after hot pressing, and the external
appearance deteriorated.
In A50 and A51, since neither a metal layer nor a metal oxide layer was
provided on the Al plating, a defect was generated on the surface of the Al-plated steel
sheet after hot pressing, and the external appearance deteriorated. In A51, the hardness
of the die was also low, and the wear of the die also occurred.
[Industrial Applicability]
- 54 -
[0084]
According to the present invention, a manufacturing method of a hot pressformed
article for obtaining a hot press-formed article having an excellent surface
external appearance while suppressing the wear of a die and a hot press-formed article
having an excellent surface external appearance can be obtained.
[Brief Description of the Reference Symbols]
[0085]
1 Al-plated steel sheet
2 Base steel sheet
3AA1 plating layer (upper surface side)
3B Al plating layer (lower surface side)
4A coating layer (upper surface side)
4B coating layer (lower surface side)
5 Heating furnace for Al-plated steel sheet
6A Die (upper die that comes into contact with the upper surface of the Alplated
steel sheet)
6B Die (lower die that comes into contact with the lower surface of the Alplated steel sheet).

CLAIMS
1. A manufacturing method of a hot press-formed article, comprising:
heating anAl-plated steel sheet to 850°C to 1 000°C; and
forming the Al-plated steel sheet using a die to obtain a hot press-formed
article, after the heating,
wherein the Al-plated steel sheet has
a base steel sheet,
anAl plating layer formed on a surface of the base steel sheet, and
a coating layer formed on a surface of the Al plating layer,
the coating layer is a metal layer containing at least one metal ofMg, Ca, V, Ti,
and Zn, a metal oxide layer containing an oxide of one or more of Mg, Ca, V, Ti, and
Zn, or a mixed layer including the metal layer and the metal oxide layer,
the die has a hard layer on a surface, HVDie that is a surface hardness of the die
at a position that the hard layer is present, is HV1500 or more and HV3800 or less, and
when a temperature of the Al-plated steel sheet at a start of forming is indicated
by Tm in a unit of oc, and an average movement velocity of the die from the start of
forming to arrival of a bottom dead point is indicated by V in a unit of mm/s, in the
forming, the Tm and the V satisfy the following formula (1),
claim 1,
800- (HVDiel40) :S Tm :S 850- (V/4)- (HVDiellOO) . .. Formula (1).
2. The manufacturing method of a hot press-formed article according to
wherein the HVDie, the Tm, and the V satisfy the following formula (2),
800- (HVDiel40) :S Tm :S 850 - (V/2)- (HVDiel50) ... Formula (2).
3. The manufacturing method of a hot press-formed article according to
claim 1 or 2,
- 56 -
wherein a thickness of the coating layer is 0.3 to 10.0 1-1m.
4. The manufacturing method of a hot press-formed article according to any
one of claims 1 to 3,
wherein a surface temperature of the die at the start of forming is soc or higher
and 180°C or lower.
5. A hot press-formed article that is composed of anAl-plated steel sheet
having anAl plating layer,
wherein Gs60° that is glossiness regulated by JIS Z 8741: 1997 on a surface is
30 or less.
6. The hot press-formed article according to claim 5,
wherein the Gs60° is 25 or less.
7. The hot press-formed article according to claim 5 or 6, comprising:
a coating layer on a surface of the Al plating layer,
wherein the coating layer is a metal layer composed of at least one metal of
Mg, Ca, V, Ti, and Zn, a metal oxide layer composed of an oxide of one or more of Mg,
Ca, V, Ti, and Zn, or a mixed layer made up of the metal layer and the metal oxide layer.
8. The hot press-formed article according to claim 7,
wherein a thickness of the coating layer is 0. 3 to 10.0 J.lm.