Hot forming system for producing high strength components

Abstract

The present invention relates to a hot roll forming system for making high strength components. A method includes loading a cold formed press hardened steel (CFPHS) into a roll forming system. The CFPHS includes an alloy matrix of carbon (C); a first layer directly on the alloy matrix, the first layer being continuous, having a first thickness greater than or equal to about 0.01 pm to less than or equal to about 10 pm, and including oxides rich in Cr and Si; and a second layer directly disposed on the first layer, the second layer being continuous, having a second thickness greater than or equal to about 0.01 pm to less than or equal to about 30 pm, and including oxides rich in Fe. The method further includes heating the CFPHS prior to roll forming the CFPHS into a component; and roll forming the CFPHS into the component using a roll after heating the CFPHS. The heating is performed in-line with the roll forming.

Description

Technical Field

[0001] This disclosure relates to systems and methods for forming high-strength components from uncoated stamp-hardened steel (CFPHS) by hot rolling. Background Technology

[0002] The information provided in this section is for the purpose of generally presenting the background of this disclosure. The work of the currently named inventors (to the extent described in this section) and aspects of the description that may not constitute prior art at the time of filing are neither expressly nor implied to be considered prior art to this disclosure.

[0003] Roll forming is a continuous metal forming process that involves bending a long sheet of metal (usually in coil) into a desired cross-section. This is achieved by passing the metal through a series of rolls. Each roll performs an incremental bending step until the final shape is obtained. The metal strip is fed through multiple rolling stations, each gradually shaping the metal until the desired profile is achieved. Roll forming is used in a variety of industries, including both automotive and non-automotive sectors. In automotive applications, roll forming can be used to form reinforced safety structures, bumpers, door frames, and more. Non-automotive applications of roll forming include, but are not limited to, construction (for beams and studs), aerospace (for wing supports), and home appliances (for refrigerator and oven components). Roll forming offers advantages such as high-volume production, precise and consistent shapes, minimal waste, and the ability to handle complex profiles. Summary of the Invention

[0004] This disclosure provides, in various features, a method for loading uncoated stamp-hardened steel (CFPHS) into a roll forming system. The CFPHS comprises: an alloy matrix having a carbon (C) concentration greater than or equal to about 0.05 wt% to less than or equal to about 0.35 wt%, a chromium (Cr) concentration greater than or equal to about 0.6 wt% to less than or equal to about 4.0 wt%, a silicon (Si) concentration greater than or equal to about 0.5 wt% to less than or equal to about 2.0 wt%, and the balance being iron (Fe); a first layer directly disposed on the alloy matrix, the first layer being continuous and having a first thickness greater than or equal to about 0.01 μm to less than or equal to about 10 μm, and comprising Cr and Si-rich oxides; and a second layer directly disposed on the first layer, the second layer being continuous and having a second thickness greater than or equal to about 0.01 μm to less than or equal to about 30 μm, and comprising Fe-rich oxides. The method further includes: heating the CFPHS before roll forming it into a part; and roll forming the CFPHS into a part using rollers after heating. The heating and roll forming are performed sequentially (inline) on a shared roll forming line.

[0005] In a further characteristic, the alloy matrix contains martensite of greater than or equal to about 95% by volume when fully hardened.

[0006] In a further feature, the alloy matrix further comprises at least one of the following: manganese (Mn) at a concentration greater than or equal to about 0.5 wt% to less than or equal to about 5.0 wt%; and niobium (Nb) at a concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.05 wt%.

[0007] In a further feature, the alloy matrix further comprises yttrium (Y) at a concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.3 wt%.

[0008] In a further feature, the alloy matrix further comprises cerium (Ce) at a concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.3 wt%.

[0009] In further characteristics, the alloy matrix includes a yield strength of 700-1.8 GPa, an ultimate tensile strength of 1.0-2.1 GPa, and a hardness of 300-600 HV.

[0010] In a further feature, the alloy matrix includes a surface oxide layer of 0.1–5.0 μm.

[0011] In a further feature, the component defines a gap between a first surface and a second surface of the component, and the method further includes laser welding the first surface and the second surface together at the gap to close the gap.

[0012] In a further feature, the gap is less than or equal to 0.1 mm prior to laser welding.

[0013] In a further feature, rolling CFPHS into a component includes rolling the component into an angle radius of less than or equal to 2.0t.

[0014] In a further feature, heating includes induction heating.

[0015] In a further feature, the heating temperature is 850°C-980°C for 1-100 seconds.

[0016] In a further feature, the heating includes at least one of the following: heating the CFPHS to an austenitizing temperature at least A3 to provide the component with a first strength greater than 1,500 MPa; heating the CFPHS to an intercritical temperature between A1 and A3 to provide the component with a second strength between 1,000 and 1,500 MPa; and heating the CFPHS to a subcritical temperature below A1 to provide the component with a second strength between 500 and 1,000 MPa.

[0017] In a further feature, heating includes heating a first region of the CFPHS to a first temperature and heating a second region of the CFPHS to a second temperature different from the first temperature.

[0018] In a further feature, the heating of the CFPHS prior to roll forming into a part is an initial heating, and the method further includes a secondary heating during roll forming.

[0019] In a further feature, the component is configured to be contained within the battery pack protective housing of the vehicle.

[0020] This disclosure also provides a method for forming a component by roll forming with various features. The method includes loading uncoated stamp-hardened steel (CFPHS) into a roll forming system. The CFPHS comprises: an alloy matrix having a carbon (C) concentration greater than or equal to about 0.05 wt% to less than or equal to about 0.35 wt%, a chromium (Cr) concentration greater than or equal to about 0.6 wt% to less than or equal to about 4.0 wt%, a silicon (Si) concentration greater than or equal to about 0.5 wt% to less than or equal to about 2.0 wt%, a manganese (Mn) concentration greater than or equal to about 0.5 wt% to less than or equal to about 5.0 wt%, a niobium (Nb) concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.05 wt%, and the balance being iron (Fe), wherein the alloy matrix, upon complete hardening, contains martensite greater than or equal to about 95% by volume. The CFPHS further comprises: a first layer directly situated on an alloy matrix, the first layer being continuous and having a first thickness greater than or equal to about 0.01 μm to less than or equal to about 10 μm, and containing Cr and Si-rich oxides; and a second layer directly disposed on the first layer, the second layer being continuous and having a second thickness greater than or equal to about 0.01 μm to less than or equal to about 30 μm, and containing Fe-rich oxides. The method further comprises: heating the CFPHS with an induction heater before roll forming the CFPHS into a part, the heating comprising heating a first portion of the CFPHS to a first temperature and heating a second portion of the CFPHS to a second temperature different from the first temperature; after heating the CFPHS, roll forming the CFPHS into a part using a roll, the part defining a gap of less than or equal to 1.5 mm between a first surface and a second surface of the part; and welding the first surface and the second surface together at the gap to close the gap. Heating and roll forming are performed sequentially on a shared roll forming line.

[0021] In a further feature, the heating of the CFPHS prior to roll forming into a part is an initial heating, and the method further includes a secondary heating during roll forming.

[0022] This disclosure also provides a system for forming parts by roll forming with various features. The system includes uncoated stamp-hardened steel (CFPHS) comprising: an alloy matrix having a carbon (C) concentration greater than or equal to about 0.05 wt% to less than or equal to about 0.35 wt%, a chromium (Cr) concentration greater than or equal to about 0.6 wt% to less than or equal to about 4.0 wt%, a silicon (Si) concentration greater than or equal to about 0.5 wt% to less than or equal to about 2.0 wt%, and the balance being iron (Fe), wherein the alloy matrix, when fully hardened, contains martensite greater than or equal to about 95% by volume. The CFPHS further comprises: a first layer directly situated on the alloy matrix, the first layer being continuous and having a first thickness greater than or equal to about 0.01 μm to less than or equal to about 10 μm, and comprising Cr and Si-rich oxides; and a second layer directly disposed on the first layer, the second layer being continuous and having a second thickness greater than or equal to about 0.01 μm to less than or equal to about 30 μm, and comprising Fe-rich oxides. The method further includes: heating the CFPHS with an induction heater before roll forming it into a part, the heating including heating a first portion of the CFPHS to a first temperature and heating a second portion of the CFPHS to a second temperature different from the first temperature; after heating the CFPHS, roll forming the CFPHS into a part using rollers, the part defining a gap of less than or equal to 1.5 mm between a first surface and a second surface of the part; and welding the first surface and the second surface together at the gap to close the gap. Heating and roll forming are performed sequentially on a shared roll forming line.

[0023] In a further feature, the heater includes a plurality of heating elements configured to heat a first region of the CFPHS to a first temperature and a second region of the CFPHS to a second temperature different from the first temperature.

[0024] The present invention discloses the following solutions:

[0025] Option 1. A method for forming a component by roll forming, the method comprising:

[0026] Uncoated stamp hardened steel (CFPHS) is loaded into a roll forming system, wherein the CFPHS comprises:

[0027] The alloy matrix has a carbon (C) concentration greater than or equal to about 0.05 wt% to less than or equal to about 0.35 wt%, a chromium (Cr) concentration greater than or equal to about 0.6 wt% to less than or equal to about 4.0 wt%, a silicon (Si) concentration greater than or equal to about 0.5 wt% to less than or equal to about 2.0 wt%, and the balance being iron (Fe).

[0028] A first layer directly situated on the alloy matrix, the first layer being continuous and having a first thickness greater than or equal to about 0.01 μm and less than or equal to about 10 μm, and comprising Cr and Si-rich oxides; and

[0029] A second layer is disposed directly on the first layer, the second layer being continuous and having a second thickness greater than or equal to about 0.01 μm to less than or equal to about 30 μm, and comprising Fe-rich oxides;

[0030] The CFPHS is heated before being rolled into a component; and

[0031] After heating the CFPHS, the CFPHS is rolled into a component using rollers.

[0032] The heating and the rolling forming are carried out in an orderly (inline) manner on a common rolling forming line.

[0033] Option 2. According to the method of Option 1, wherein the martensite in the alloy matrix is ​​greater than or equal to about 95% by volume when fully hardened.

[0034] Option 3. The method according to Option 1, wherein the alloy matrix further comprises at least one of the following:

[0035] Manganese (Mn) at concentrations greater than or equal to about 0.5% by weight and less than or equal to about 5.0% by weight; and

[0036] Niobium (Nb) concentration greater than or equal to about 0.0% by weight and less than or equal to about 0.05% by weight.

[0037] Option 4. The method according to Option 1, wherein the alloy matrix further comprises yttrium (Y) at a concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.3 wt%.

[0038] Option 5. The method according to Option 1, wherein the alloy matrix further comprises cerium (Ce) at a concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.3 wt%.

[0039] Option 6. The method according to Option 1, wherein the alloy matrix comprises a yield strength of 700-1.8 GPa, an ultimate tensile strength of 1.0-2.1 GPa, and a hardness of 300-600 HV.

[0040] Option 7. The method according to Option 1, wherein the alloy matrix comprises a surface oxide of 0.1-5.0 μm.

[0041] Option 8. The method according to Option 1, wherein the component defines a gap between a first surface and a second surface of the component, the method further comprising laser welding the first surface and the second surface together at the gap to close the gap.

[0042] Option 9. The method according to Option 8, wherein the gap is less than or equal to 0.1 mm before laser welding.

[0043] Option 10. The method according to Option 1, wherein rolling the CFPHS into a component includes rolling the component into an angle radius of less than or equal to 2.0t.

[0044] Option 11. The method according to Option 1, wherein the heating includes induction heating.

[0045] Option 12. The method according to Option 11, wherein the heating is 850°C-980°C for 1-100 seconds.

[0046] Option 13. The method according to Option 1, wherein the heating comprises at least one of the following:

[0047] The CFPHS is heated to an austenitizing temperature of at least A3 to provide the component with a first strength greater than 1,500 MPa;

[0048] The CFPHS is heated to a critical temperature between A1 and A3 to provide the component with a second strength between 1,000 and 1,500 MPa; and

[0049] The CFPHS is heated to a subcritical temperature below A1 to provide the component with a second strength between 500 and 1,000 MPa.

[0050] Option 14. The method according to Option 1, wherein the heating includes heating a first region of the CFPHS to a first temperature and heating a second region of the CFPHS to a second temperature different from the first temperature.

[0051] Option 15. The method according to Option 1, wherein the heating of the CFPHS before roll forming the CFPHS into a part is an initial heating, and the method further includes a secondary heating during roll forming.

[0052] Option 16. The method of Option 1, wherein the component is configured to be contained within a battery pack protective housing of the vehicle.

[0053] Option 17. A method for forming a component by roll forming, the method comprising:

[0054] Uncoated stamp hardened steel (CFPHS) is loaded into a roll forming system, wherein the CFPHS comprises:

[0055] The alloy matrix has a carbon (C) concentration greater than or equal to about 0.05 wt% to less than or equal to about 0.35 wt%, a chromium (Cr) concentration greater than or equal to about 0.6 wt% to less than or equal to about 4.0 wt%, a silicon (Si) concentration greater than or equal to about 0.5 wt% to less than or equal to about 2.0 wt%, a manganese (Mn) concentration greater than or equal to about 0.5 wt% to less than or equal to about 5.0 wt%, a niobium (Nb) concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.05 wt%, and the balance being iron (Fe), wherein the alloy matrix, when fully hardened, contains martensite greater than or equal to about 95 vol%.

[0056] A first layer directly situated on the alloy matrix, the first layer being continuous and having a first thickness greater than or equal to about 0.01 μm and less than or equal to about 10 μm, and comprising Cr and Si-rich oxides; and

[0057] A second layer is disposed directly on the first layer, the second layer being continuous and having a second thickness greater than or equal to about 0.01 μm to less than or equal to about 30 μm, and comprising Fe-rich oxides;

[0058] Before the CFPHS is rolled into a component, the CFPHS is heated with an induction heater, the heating including heating a first portion of the CFPHS to a first temperature and heating a second portion of the CFPHS to a second temperature different from the first temperature;

[0059] After heating the CFPHS, the CFPHS is rolled into a component using rollers, the component defining a gap of less than or equal to 1.5 mm between a first surface and a second surface of the component; and

[0060] The first surface and the second surface are welded together at the gap to close the gap.

[0061] The heating and the rolling forming are carried out in an orderly manner on a shared rolling forming line.

[0062] Option 18. The method according to Option 17, wherein the heating of the CFPHS before roll forming the CFPHS into a part is an initial heating, and the method further includes a secondary heating during roll forming.

[0063] Option 19. A system for forming a component by roll forming, the system comprising:

[0064] Uncoated stamped hardened steel (CFPHS), which includes:

[0065] The alloy matrix has a carbon (C) concentration greater than or equal to about 0.05 wt% to less than or equal to about 0.35 wt%, a chromium (Cr) concentration greater than or equal to about 0.6 wt% to less than or equal to about 4.0 wt%, a silicon (Si) concentration greater than or equal to about 0.5 wt% to less than or equal to about 2.0 wt%, and the balance being iron (Fe), wherein the alloy matrix, when fully hardened, contains martensite greater than or equal to about 95 vol%.

[0066] A first layer directly situated on the alloy matrix, the first layer being continuous and having a first thickness greater than or equal to about 0.01 μm and less than or equal to about 10 μm, and comprising Cr and Si-rich oxides; and

[0067] A second layer is disposed directly on the first layer, the second layer being continuous and having a second thickness greater than or equal to about 0.01 μm to less than or equal to about 30 μm, and comprising Fe-rich oxides;

[0068] A dewinding device configured to unwind the CFPHS;

[0069] A flattening device configured to flatten the CFPHS;

[0070] A stamping device configured to punch holes in the CFPHS;

[0071] Multiple rolls configured to roll the CFPHS rolls into components; and

[0072] A heater, located between the stamping device and the plurality of rolls, is configured to heat the CFPHS after punching by the stamping device and before roll forming by the plurality of rolls.

[0073] The unwinding device, the flattening device, the stamping device, the multiple rollers, and the heater are all located on a common roll forming line.

[0074] Option 20. The system according to Option 19, wherein the heater includes a plurality of heating elements configured to heat a first region of the CFPHS to a first temperature and to heat a second region of the CFPHS to a second temperature different from the first temperature.

[0075] Other applications of this disclosure will become apparent from the detailed description, claims, and drawings. These detailed descriptions and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0076] This disclosure will be more fully understood from the detailed embodiments and accompanying drawings, in which:

[0077] Figure 1 An exemplary roll forming system according to this disclosure is shown;

[0078] Figure 2 It shows Figure 1 The roll forming system has multiple heating elements configured to heat different areas of uncoated stamped hardened steel (CFPHS) to different temperatures;

[0079] Figure 3 An exemplary method for roll forming of a component by CFPHS according to this disclosure is shown;

[0080] Figure 4 This is a perspective view of an exemplary component formed by CFPHS through roll forming according to this disclosure;

[0081] Figure 5 It shows Figure 4 Area 5;

[0082] Figure 6 This is a perspective view of an exemplary battery pack protective case formed by roll forming from CFPHS according to this disclosure; and

[0083] Figure 7 Uncoated stamped hardened steel (CFPHS) according to this disclosure is shown.

[0084] In the accompanying drawings, reference numerals may be used repeatedly to identify similar and / or identical elements. Detailed Implementation

[0085] This disclosure generally provides methods and systems for forming components from uncoated stamped hardened steel (CFPHS) by roll forming. The component can be any suitable automotive or non-automotive part. Suitable automotive components include, but are not limited to, structural components that enhance vehicle safety. For example, the component can be any suitable structural component located in or near the vehicle's A-pillar, B-pillar, door frame, etc. The component can also be part of a battery pack protective shell, such as a side rail of the protective shell.

[0086] Before forming the part by roll forming, the CFPHS is heated. Heating the CFPHS softens the material, thus enabling faster bending during roll forming with fewer roll stations. Heating before roll forming also allows the part to form sharp corner radii, such as radii less than or equal to 2.0t. Heating further allows the part to form a consistent and narrow gap (such as less than or equal to 1.5mm) between opposite edges after roll forming, which is beneficial for joining edges by laser welding. Using CFPHS allows for the use of rapid heating methods and systems, such as induction heating, with short immersion times (e.g., 5s), to achieve high-strength components, such as those greater than or equal to 1,500MPa.

[0087] Figure 1 and Figure 2 An example of a roll forming system 10 according to the present disclosure is shown. Figure 3 The present disclosure illustrates a method 110, which uses a roll forming system 10 or any other suitable roll forming system to form a part made of uncoated stamped hardened steel (CFPHS). Figure 4 , 5 Figures 6 and 7 show exemplary parts formed by CFPHS using roll forming system 10 and / or method 110. Figure 7 An exemplary part of CFPHS 310 is shown.

[0088] Figure 1 The roll forming system 10 is configured to roll form CFPHS 310 into any suitable part. Figure 1 In this example, the roll 320 of CFPHS 310 is processed by the roll forming system 10. The roll 320 is unwound (or unrolled) by the unwinding device 20. The unwinding device 20 is any suitable device configured to unwind the CFPHS 310 from the roll 320. The CFPHS 310 is conveyed online from the unwinding device 20 to the flattening device 30. The flattening device 30 is any suitable device configured to flatten or level the CFPHS 310 that has been unwound from the roll 320. The CFPHS 310 is conveyed online from the flattening device 30 to the stamping device 40. The stamping device 40 is any suitable device configured to punch holes in the CFPHS 310 or provide any other surface features to the CFPHS 310 for inclusion in the part to be roll-formed. After roll forming is complete and the opposite edges are welded together, any suitable additional processing can be performed on the roll-formed part, such as, but not limited to, additional perforations, laser cutting, etc.

[0089] CFPHS 310 is conveyed online from the stamping device 40 to the heater 50. The heater 50 is any suitable device configured to heat the CFPHS 310 online before reaching the roll-formed assembly 60. The heater 50 can be, for example, an induction heater. The heater 50 is configured to heat the CFPHS 310 to any suitable temperature and sustain it for any suitable time. For example, the heater 50 is configured to heat the CFPHS 310 to 850°C–980°C and sustain it for 5 seconds, or about 5 seconds. The temperature to which the CFPHS 310 is heated can vary based on the desired strength or hardness of the CFPHS 310. For example, the heater 50 can be configured to heat the CFPHS 310 to an austenitizing temperature at least A3 to provide the part with a first strength greater than 1,500 MPa. The heater 50 can be configured to heat the CFPHS 310 to a critical temperature between A1 and A3 to provide the part with a second strength between 1,000 and 1,500 MPa. Heater 50 can be configured to heat CFPHS 310 to a subcritical temperature below A1 to provide the component with a third strength between 500-1,000 MPa.

[0090] refer to Figure 2 The heater 50 may include one or more heating elements to heat the CFPHS 310. Figure 2 In this example, six heating elements 52A, 52B, 52C, 52D, 52E, and 52F are included. Each of the heating elements 52A-52F is arranged to heat different areas of the CFPHS 310. For example, and as... Figure 2 As shown, a first heating element 52A is arranged to heat a first region 312A of the CFPHS 310, a second heating element 52B is arranged to heat a second region 312B, a third heating element 52C is arranged to heat a third region 312C, a fourth heating element 52D is arranged to heat a fourth region 312D, a fifth heating element 52E is arranged to heat a fifth region 312E, and a sixth heating element 52F is arranged to heat a sixth region 312F. Heating elements 52A-52F are controlled by any suitable controller 100. The controller 100 is configured to individually control the temperature of each of the heating elements 52A-52F to heat different regions 312A-312F of the CFPHS 310 to different temperatures. Heating regions 312A-312F to different temperatures facilitates the roll forming of the CFPHS 310 into specific parts. Heating elements 52A-52F can be arranged side-by-side in a direction perpendicular to the length of CFPHS 310, side-by-side in a direction parallel to the length of CFPHS 310, or in any other suitable direction to heat any desired area of ​​CFPHS 310.

[0091] CFPHS 310 is conveyed online from heater 50 to roll forming assembly 60. Roll forming assembly 60 includes any suitable number of rolls configured to roll forming CFPHS 310 into the desired part. In the illustrated example, roll forming assembly 60 includes a first roll 62A, a second roll 62B, a third roll 62C, and a fourth roll 62D. Rolls 62A-62D may include rolls on both sides of CFPHS 310. Heating CFPHS 310 using heater 50 reduces the number of rolls required for roll forming assembly 60 to form the part. Roll forming assembly 60 may include a secondary heater 54, which may be the same as or substantially similar to heater 50. Secondary heater 54 is controlled by controller 100. Secondary heater 54 may be included to maintain CFPHS 310 at the desired temperature throughout the roll forming process performed by roll forming assembly 60. Then, depending on the desired physical properties, the CFPHS workpiece is subjected to air cooling, water cooling, or post-roll quenching heating.

[0092] CFPHS 310 is conveyed online from roll-formed assembly 60 to cutting device 70. Cutting device 70 is any suitable device configured to cut CFPHS 310 to separate the different parts formed by roll-formed assembly 60. Roll-formed parts continue to be conveyed from cutting device 70 to run-out table 80. At or after run-out table 80, roll-formed parts can be welded using any suitable welding machine 90 (such as a laser welder) or any other suitable joining method or device (such as resistance spot welding or high-frequency welding). Welding machine 90 is configured to weld opposing surfaces of roll-formed parts together. This document will combine Figure 5 and Figure 6 The exemplary component shown further illustrates the welding process. Optional drilling operations can be added to create holes in the component using laser cutting.

[0093] Now we will describe it in more detail. Figure 3 Method 110 for forming parts by roll forming. Method 110 can be performed by... Figure 1The roll forming system 10 and controller 100 may be used, or may be used by any other suitable roll forming system and controller. Method 110 will now be described with reference to the roll forming system 10 and controller 100 for illustrative purposes only. Method 110 begins at block 120, where controller 100 is operated to initiate roll forming system 10. At block 130, a roll 320 of CFPHS 310 is loaded into roll forming system 10, and at block 140, controller 100 operates flattening device 30 to flatten and / or level the roll 320 into a generally flat and generally level CFPHS 310 sheet. Method 110 continues from block 140 to block 150. At block 150, controller 100 operates stamping device 40 to stamp any holes (or form any other surface features) contained in the final part to be formed. Method 110 continues from block 150 to block 160. At box 160, heater 50 and / or secondary heater 54 are operated by controller 100 to heat CFPHS 310 as described above. Heating of box 160 includes individually activating one or more different heating elements 52A-52F to heat different areas 312A-312F to different temperatures to appropriately facilitate roll forming.

[0094] Method 110 continues from block 160 to block 170. At block 170, controller 100 operates roll forming assembly 60 to form a part by roll forming. The roll forming process includes the operation of controller 100 on different rollers 62A-62D. Rollers 62A-62D may include sets of rollers, for example, as arranged on opposite sides of CFPHS 310. Rollers 62A-62D are arranged, operated, and otherwise configured to form a part by roll forming. To maintain CFPHS 310 at a high temperature during roll forming, secondary heaters 54 may be included in the roll forming assembly, such as between adjacent rollers in rollers 62A-62D. Any suitable number of secondary heaters 54 may be included. Controller 100 operates the secondary heaters 54 in the same or similar manner as the heaters 50. Method 110 continues from block 170 to block 180, where the part is appropriately cooled, such as by air cooling or using any suitable cooling device.

[0095] Method 110 continues from block 180 to block 190. At block 190, controller 100 operates cutting device 70 to cut CFPHS 310 and separate the parts formed therein by roll forming. Method 110 continues from block 190 to block 210. At block 210, controller 100 operates laser welding machine 90 or any other suitable joining method to weld the edges of the parts together and close the gaps formed between the edges, as described below. Method 110 continues from block 210 to block 220, where controller 100 terminates method 110 when all desired parts have been formed by roll forming CFPHS 310. However, any suitable piercing operation may be added to the roll-formed parts before the end of method 110.

[0096] Figure 4 An example of a component 410 formed according to this disclosure by one or both of roll forming system 10 and method 110 is shown. Component 410 can be any suitable automotive or non-automotive component. Regarding automotive components, component 410 can be a structural reinforcement member, such as an A-pillar, B-pillar, or included in a battery pack protective housing. Component 410 is roll-formed from a flat and horizontal (or substantially flat and substantially horizontal) sheet of CFPHS 310. Special Reference Figure 5 Component 410 includes a first edge 420 and a second edge 422 separated by a gap 424. Sharp and parallel first and second edges 420 and 422 can be formed by heating the CFPHS 310 with a heater 50 prior to roll forming (and / or with a secondary heater 54 during roll forming), and the gap 424 is very small. For example, the gap 424 can be less than or equal to 1.5 mm. The gap 424 is filled and closed by a weld 430. The weld 430 is formed by a welding machine 90 (such as a laser welder) or any other suitable joining method. Due to the very small gap 424 and the sharp and parallel nature of the first and second edges 422, the weld 430 has high integrity. However, any other suitable welding technique, such as high-frequency welding, can be used. For high-frequency welding, such a gap does not exist (the two edges are pressed together for welding). Component 410 further includes an angle 440 having an angular radius less than or equal to 2.0t. By heating the CFPHS 310 using heater 50 and / or secondary heater 54, as described above, a tight corner radius can be achieved.

[0097] Figure 6A battery pack 510 is shown, such as a battery pack for a vehicle. The battery pack 510 is protected by a battery pack protective shell 520. The battery pack protective shell 520 can be any suitable structure configured to protect the battery pack 510. In the illustrated example, the battery pack protective shell 520 includes a first side rail 530, a second side rail 532, and a base plate 534. One or both of the first side rail 530 and the second side rail 532 are formed by roll forming using system 10 and / or method 110 by CFPHS 310. The first side rail 530 and / or the second side rail 532 may each include Figure 4 and Figure 5 The first edge 420, the second edge 422, the gap 424, the weld 430, and the corner 440.

[0098] refer to Figure 7 CFPHS 310 will be described in more detail below. CFPHS 310 typically comprises an alloy matrix 340, a first layer 350, and a second layer 360. The alloy matrix 340 is in the form of a coil or sheet and comprises carbon (C), chromium (Cr), silicon (Si), and iron (Fe). During the hot stamping process, portions of the Cr and Si combine with atmospheric oxygen to form the first layer 350, which contains oxides rich in the portions of Cr and Si. When there is sufficient oxygen in the atmosphere, a portion of the Fe combines with atmospheric oxygen to form the second layer 360, which contains oxides rich in Fe. When referring to the first layer 350 and the second layer 360, the terms "first" and "second" structurally distinguish the layers from each other and are independent of the order of formation during hot stamping. Therefore, when both the first layer 350 and the second layer 360 are formed during the hot stamping process, the first layer 350 may be formed before the second layer 360, the second layer 360 may be formed before the first layer 350, or the first layer 350 and the second layer 360 may be formed simultaneously. The first and second layers prevent, inhibit, or minimize further oxidation, eliminating the need for descaling steps such as shot blasting or sandblasting.

[0099] C is present in the steel alloy matrix 340 at concentrations greater than or equal to about 0.05 wt% to less than or equal to about 0.35 wt%, concentrations greater than or equal to about 0.01 wt% to less than or equal to about 0.35 wt%, and subranges thereof. In various embodiments, the steel alloy matrix 340 comprises C at concentrations of about 0.01 wt%, about 0.02 wt%, about 0.04 wt%, about 0.06 wt%, about 0.08 wt%, about 0.1 wt%, about 0.12 wt%, about 0.14 wt%, about 0.16 wt%, about 0.18 wt%, about 0.2 wt%, about 0.22 wt%, about 0.24 wt%, about 0.26 wt%, about 0.28 wt%, about 0.3 wt%, 0.32 wt%, about 0.34 wt%, or about 0.35 wt%.

[0100] Cr is present in the steel alloy matrix 340 at concentrations greater than or equal to about 0.6 wt% to less than or equal to about 4.0 wt%, greater than or equal to about 1 wt% to less than or equal to about 9 wt%, greater than or equal to about 1 wt% to less than or equal to about 6 wt%, greater than or equal to about 1 wt% to less than or equal to about 4 wt%, or greater than or equal to about 1 wt% to less than or equal to about 3 wt%. In various embodiments, the steel alloy matrix 340 comprises concentrations of about 1 wt%, about 1.2 wt%, about 1.4 wt%, about 1.5 wt%, about 1.6 wt%, about 1.8 wt%, about 2 wt%, about 2.2 wt%, about 2.4 wt%, about 2.5 wt%, about 2.6 wt%, about 2.8 wt%, about 3 wt%, about 3.2 wt%, about 3.4 wt%, about 3.5 wt%, about 3.6 wt%, about 3.8 wt%, about 4 wt%, about 4.2 wt%, about 4.4 wt%, about 4.5 wt%, about 4.6 wt%, and about [other concentrations]. Cr in the amounts of 4.8 wt%, about 5 wt%, about 5.2 wt%, about 5.4 wt%, about 5.5 wt%, about 5.6 wt%, about 5.8 wt%, about 6 wt%, about 6.2 wt%, about 6.4 wt%, about 6.5 wt%, about 6.6 wt%, about 6.8 wt%, about 7 wt%, about 7.2 wt%, about 7.4 wt%, about 7.5 wt%, about 7.6 wt%, about 7.8 wt%, about 8 wt%, about 8.2 wt%, about 8.4 wt%, about 8.5 wt%, about 8.6 wt%, about 8.8 wt%, or about 9 wt%.

[0101] Si is present in the steel alloy matrix 340 at concentrations greater than or equal to about 0.5 wt% to less than or equal to about 2.0 wt%, greater than or equal to about 0.5 wt% to less than or equal to about 2 wt%, or greater than or equal to about 0.6 wt% to less than or equal to about 1.8 wt%. In various embodiments, the steel alloy contains Si at concentrations of about 0.5 wt%, about 0.6 wt%, about 0.7 wt%, about 0.8 wt%, about 0.9 wt%, about 1 wt%, about 1.1 wt%, about 1.2 wt%, about 1.3 wt%, about 1.4 wt%, about 1.5 wt%, about 1.6 wt%, about 1.7 wt%, about 1.8 wt%, about 1.9 wt%, or about 2 wt%.

[0102] Fe constitutes the balance of the steel alloy matrix 340. The microstructure of the steel alloy matrix 340, when fully hardened, contains martensite greater than or equal to approximately 95% by volume. In its original state (received from the rolling mill), the material consists of a mixture of ferrite, carbides, and bainite. Heat treatment of the original CFPHS material produces microstructures with different combinations of ferrite, bainite, retained austenite, martensite, and carbides. CFPHS 310 does not contain and does not include, for example, zinc (Zn) or aluminum-silicon (Al-Si) coatings.

[0103] In various embodiments, the steel alloy further comprises manganese (Mn) at concentrations greater than or equal to about 0.5 wt% to less than or equal to about 5.0 wt%, greater than or equal to about 0 wt% to less than or equal to about 3 wt%, greater than or equal to about 0.2 wt% to less than or equal to about 3 wt%, greater than or equal to about 0.25 wt% to less than or equal to about 2.5 wt%, greater than or equal to about 0.5 wt% to less than or equal to about 2 wt%, greater than or equal to about 0.75 wt% to less than or equal to about 1.5 wt%, or greater than or equal to about 1 wt% to less than or equal to about 1.5 wt%. In some embodiments, the steel alloy matrix 340 is substantially free of Mn. As used herein, “substantially free” means trace component levels, such as levels less than or equal to about 1.5%, less than or equal to about 1%, less than or equal to about 0.5%, or undetectable levels. In various embodiments, the steel alloy is substantially free of Mn, or contains Mn at concentrations of less than or equal to about 3 wt%, less than or equal to about 2.5 wt%, less than or equal to about 2 wt%, less than or equal to about 1.5 wt%, less than or equal to about 1 wt%, or less than or equal to about 0.5 wt%, such as concentrations of about 3 wt%, about 2.8 wt%, about 2.6 wt%, about 2.4 wt%, about 2.2 wt%, about 2 wt%, about 1.8 wt%, about 1.6 wt%, about 1.4 wt%, about 1.2 wt%, about 1 wt%, about 0.8 wt%, about 0.6 wt%, about 0.4 wt%, about 0.2 wt%, or lower.

[0104] In various embodiments, the steel alloy matrix 340 further comprises nitrogen (N) at a concentration greater than or equal to about 0% by weight and less than or equal to about 0.01% by weight, or greater than or equal to about 0.0001% by weight and less than or equal to about 0.01% by weight. For example, in various embodiments, the steel alloy matrix 340 is substantially free of N, or contains N at concentrations less than or equal to about 0.01 wt%, less than or equal to 0.009 wt%, less than or equal to 0.008 wt%, less than or equal to 0.007 wt%, less than or equal to 0.006 wt%, less than or equal to 0.005 wt%, less than or equal to 0.004 wt%, less than or equal to 0.003 wt%, less than or equal to 0.002 wt%, or less than or equal to 0.001 wt%, such as at concentrations of about 0.01 wt%, about 0.009 wt%, about 0.008 wt%, about 0.007 wt%, about 0.006 wt%, about 0.005 wt%, about 0.004 wt%, about 0.003 wt%, about 0.002 wt%, about 0.001 wt%, or lower.

[0105] In various embodiments, the steel alloy matrix 340 further comprises molybdenum (Mo) at a concentration greater than or equal to about 0 wt% to less than or equal to about 0.8 wt%, greater than or equal to about 0.01 wt% to less than or equal to about 0.8 wt%, or less than or equal to about 0.8 wt%. For example, in various embodiments, the steel alloy matrix 340 is substantially free of Mo, or contains Mo at a concentration less than or equal to about 0.8 wt%, less than or equal to about 0.7 wt%, less than or equal to about 0.6 wt%, less than or equal to about 0.5 wt%, less than or equal to about 0.4 wt%, less than or equal to about 0.3 wt%, less than or equal to about 0.2 wt%, or less than or equal to about 0.1 wt%, such as at concentrations of about 0.8 wt%, about 0.7 wt%, about 0.6 wt%, about 0.5 wt%, about 0.4 wt%, about 0.3 wt%, about 0.2 wt%, about 0.1 wt%, or lower.

[0106] In various embodiments, the steel alloy matrix 340 further comprises boron (B) at a concentration greater than or equal to about 0 wt% to less than or equal to about 0.005 wt%, greater than or equal to about 0.0001 wt% to less than or equal to about 0.005 wt%, or less than or equal to about 0.005 wt%. For example, in various embodiments, the steel alloy matrix 340 is substantially free of B, or contains B at a concentration less than or equal to about 0.005 wt%, less than or equal to about 0.004 wt%, less than or equal to about 0.003 wt%, less than or equal to about 0.002 wt%, or less than or equal to about 0.001 wt%, such as concentrations of about 0.005 wt%, about 0.004 wt%, about 0.003 wt%, about 0.002 wt%, about 0.001 wt%, about 0.0005 wt%, about 0.0001 wt%, or lower.

[0107] In various embodiments, the steel alloy matrix 340 further comprises niobium (Nb) at a concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.05 wt%, a concentration greater than or equal to about 0 wt% to less than or equal to about 0.3 wt%, a concentration greater than or equal to about 0.01 wt% to less than or equal to about 0.3 wt%, or less than or equal to about 0.3 wt%. For example, in various embodiments, the steel alloy is substantially free of Nb, or contains Nb at a concentration less than or equal to about 0.3 wt%, less than or equal to about 0.25 wt%, less than or equal to about 0.2 wt%, less than or equal to about 0.15 wt%, or less than or equal to about 0.1 wt%, such as at concentrations of about 0.3 wt%, about 0.25 wt%, about 0.2 wt%, about 0.15 wt%, about 0.1 wt%, or lower.

[0108] In various embodiments, the steel alloy matrix 340 further comprises vanadium (V) at a concentration greater than or equal to about 0 wt% to less than or equal to about 0.3 wt%, greater than or equal to about 0.01 wt% to less than or equal to about 0.3 wt%, or less than or equal to about 0.3 wt%. For example, in various embodiments, the steel alloy matrix 340 is substantially free of V, or contains V at a concentration less than or equal to about 0.3 wt%, less than or equal to about 0.25 wt%, less than or equal to about 0.2 wt%, less than or equal to about 0.15 wt%, or less than or equal to about 0.1 wt%, such as at concentrations of about 0.3 wt%, about 0.25 wt%, about 0.2 wt%, about 0.15 wt%, about 0.1 wt%, or lower.

[0109] The steel alloy matrix 340 may further contain any suitable concentration of yttrium (Y), such as a concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.3 wt%. The steel alloy matrix 340 may also contain any suitable concentration of cerium (Ce), such as a concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.3 wt%.

[0110] CFPHS 310 is produced by hot pressing an alloy matrix 340. Therefore, CFPHS 310 includes an alloy matrix 340, a first layer 350, and a second layer 360 (which is optional). Figure 7 A cross-sectional view of a portion of CFPHS 310 is shown, illustrating a first layer 350 and a second layer 360 (optional) surrounding an alloy matrix 340. The ultimate tensile strength (UTS) of CFPHS 310 is greater than or equal to about 500 MPa, greater than or equal to about 750 MPa, greater than or equal to about 1,000 MPa, greater than or equal to about 1,250 MPa, greater than or equal to about 1,600 MPa, greater than or equal to about 1,700 MPa, or greater than or equal to about 1,800 MPa. In some embodiments, the UTS of CFPHS 310 is greater than or equal to about 1,600 MPa and less than or equal to about 2,000 MPa. The microstructure of the steel alloy matrix 340, when fully hardened, contains martensite greater than or equal to about 95% by volume. In its original state (received from the rolling mill), the material consists of a mixture of ferrite, carbides, and bainite. Heat treatment of the original CFPHS material can produce microstructures with different combinations of ferrite, bainite, retained austenite, martensite, and carbides. According to this disclosure, the alloy matrix 340 includes a yield strength of 700-1.8 GPa, an ultimate tensile strength of 1.0-2.1 GPa, and a hardness of 300-600 HV in various configurations.

[0111] The first layer 350 is directly applied to the alloy matrix 340 during the hot pressing process and contains Cr and Si-rich oxides, including Cr oxides and Si oxides. In the first layer 350, the concentration of the Cr-rich oxides is greater than or equal to about 1 wt% and less than or equal to about 30 wt%, such as concentrations of about 1 wt%, about 2 wt%, about 4 wt%, about 6 wt%, about 8 wt%, about 10 wt%, about 12 wt%, about 14 wt%, about 16 wt%, about 18 wt%, about 20 wt%, about 22 wt%, about 24 wt%, about 26 wt%, about 28 wt%, or about 30 wt%. In the first layer 350, the concentration of Si-rich oxides is greater than or equal to about 1 wt% and less than or equal to about 30 wt%, such as concentrations of about 1 wt%, about 2 wt%, about 4 wt%, about 6 wt%, about 8 wt%, about 10 wt%, about 12 wt%, about 14 wt%, about 16 wt%, about 18 wt%, about 20 wt%, about 22 wt%, about 24 wt%, about 26 wt%, about 28 wt%, or about 30 wt%. The Cr and Si in the first layer 350 originate from within the alloy matrix 340 and migrate from the alloy matrix 340 into the oxides. In this respect, the Cr and Si in the enriched oxides of the first layer 350 are derived from the steel alloy or alloy matrix 340. In other words, the first layer 350 is formed from a portion of the Cr and Si contained in the steel alloy or alloy matrix 340.

[0112] The first layer 350 has a thickness TL1 greater than or equal to about 0.01 μm and less than or equal to about 10 μm, such as thicknesses of about 0.01 μm, about 0.05 μm, about 0.1 μm, about 0.15 μm, about 0.25 μm, about 0.3 μm, about 0.35 μm, about 0.4 μm, about 0.45 μm, about 0.5 μm, about 0.55 μm, about 0.6 μm, about 0.65 μm, about 0.7 μm, and about 0. 0.75μm, about 0.8μm, about 0.85μm, about 0.9μm, about 0.95μm, about 1μm, about 1.5μm, about 2μm, about 2.5μm, about 3μm, about 3.5μm, about 4μm, about 4.5μm, about 5μm, about 5.5μm, about 6μm, about 6.5μm, about 7μm, about 7.5μm, about 8μm, about 8.5μm, about 9μm, about 9.5μm, or about 10μm.

[0113] In some variations, the first layer 350 is continuous and uniform. Therefore, in embodiments without a second layer 360, the first layer 350 provides an exposed surface that does not require descaling by means of, for example, shot peening or sandblasting. Furthermore, when the second layer 360 is absent, the first layer 350 prevents, inhibits, or minimizes further surface oxidation.

[0114] When processed under various conditions, CFPHS 310 includes a second layer 360. The second layer 360 is disposed directly on the first layer 350 during the hot pressing process and comprises a Fe-rich oxide. In various embodiments, the Fe-rich oxide includes FeO, Fe2O3, Fe3O4, or combinations thereof. In the second layer 360, the Fe concentration of the Fe-rich oxide is greater than or equal to about 10% by weight, greater than or equal to about 15% by weight, greater than or equal to about 20% by weight, greater than or equal to about 25% by weight, or greater than or equal to about 30% by weight. The Fe in the second layer 360 originates from within the alloy matrix 340 and migrates from the alloy matrix 340 into the oxide. In this respect, the Fe in the second layer 360 is derived from the steel alloy or alloy matrix 340. In other words, the second layer 360 is formed from a portion of the Fe contained in the steel alloy or alloy matrix 340.

[0115] The second layer 360 has a thickness TL2 greater than or equal to about 0 μm and less than or equal to about 30 μm, or greater than or equal to about 0.01 μm and less than or equal to about 30 μm, such as thicknesses of about 0.01 μm, about 0.05 μm, about 0.1 μm, about 0.15 μm, about 0.25 μm, about 0.3 μm, about 0.35 μm, about 0.4 μm, about 0.45 μm, about 0.5 μm, about 0.55 μm, about 0.6 μm, about 0.65 μm, about 0.7 μm, about 0.75 μm, about 0.8 μm, about 0.85 μm. μm, approximately 0.9 μm, approximately 0.95 μm, approximately 1 μm, approximately 1.5 μm, approximately 2 μm, approximately 2.5 μm, approximately 3 μm, approximately 3.5 μm, approximately 4 μm, approximately 4.5 μm, approximately 5 μm, approximately 5.5 μm, approximately 6 μm, approximately 6.5 μm, approximately 7 μm, approximately 7.5 μm, approximately 8 μm, approximately 8.5 μm, approximately 9 μm, approximately 9.5 μm, approximately 10 μm, approximately 12 μm, approximately 14 μm, approximately 16 μm, approximately 18 μm, approximately 20 μm, approximately 22 μm, approximately 24 μm, approximately 26 μm, approximately 28 μm, or approximately 30 μm.

[0116] The second layer 360 is continuous and uniform. Therefore, the second layer 360 provides an exposed surface and does not require descaling by means of shot peening or sandblasting. Furthermore, the second layer 360 prevents, inhibits, or minimizes further surface oxidation. When both the first layer 350 and the second layer 360 are formed during hot stamping, the first layer 350 may be formed before the second layer 360, the second layer 360 may be formed before the first layer 350, or the first layer 350 and the second layer 360 may be formed simultaneously. CFPHS 310 does not include or contain any layers that are not derived from the steel alloy or alloy matrix 82. Nevertheless, it does not require descaling.

[0117] The foregoing description is illustrative in nature and is in no way intended to limit this disclosure, its application, or its use. The broad teachings of this disclosure can be implemented in many forms. Therefore, although this disclosure includes specific examples, its true scope should not be so limited, as other modifications will become apparent upon examination of the drawings, description, and appended claims. It should be understood that one or more steps within the method may be performed in a different order (or simultaneously) without altering the principles of this disclosure. Furthermore, although each embodiment is described above as having certain features, any one or more of those features described with respect to any embodiment of this disclosure may be implemented in any other embodiment and / or combined with features in any other embodiment, even if such combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations and combinations of one or more embodiments with each other exist within the scope of this disclosure.

[0118] Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including “connection,” “joint,” “coupled,” “adjacent,” “closely adjacent,” “above,” “under,” and “set.” Unless explicitly described as “direct,” the relationship between the first and second elements described in the foregoing disclosure can be a direct relationship, where no other intermediary element exists between the first and second elements, or an indirect relationship, where one or more intermediary elements exist between the first and second elements (spatially or functionally). As used herein, the phrase at least one of A, B, and C should be interpreted as meaning the logic of using non-exclusive OR (A OR B OR C), and should not be interpreted as meaning “at least one A, at least one B, and at least one C.”

[0119] In the accompanying drawings, the direction of the arrows, as indicated by the arrows, typically shows the flow of information (such as data or instructions) of interest to the illustration. For example, when element A and element B exchange various types of information, and the information sent from element A to element B is relevant to the illustration, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is being sent from element B to element A. Furthermore, for information sent from element A to element B, element B may send a request for the information or an acknowledgment of receipt of the information to element A.

[0120] In this application, the term "module" or "controller" may be replaced by the term "circuit" as defined below. The term "module" may refer to a portion including or comprising: an application-specific integrated circuit (ASIC); digital, analog, or mixed-signal analog / digital discrete circuits; digital, analog, or mixed-signal analog / digital integrated circuits; combinational logic circuits; field-programmable gate arrays (FPGAs); processor circuitry (shared, dedicated, or grouped) that executes code; memory circuitry (shared, dedicated, or grouped) that stores code executed by the processor circuitry; other suitable hardware components that provide the aforementioned functionality; or combinations of some or all of the above, such as in a system-on-a-chip.

[0121] A module may include one or more interface circuits. In some instances, the interface circuits may include wired or wireless interfaces that connect to a local area network (LAN), the Internet, a wide area network (WAN), or a combination thereof. The functionality of any given module disclosed herein may be distributed among multiple modules connected via the interface circuits. For example, multiple modules may allow for load balancing. In a further instance, a server (also referred to as a remote or cloud) module may perform some functions on behalf of a client module.

[0122] As used above, the term "code" can include software, firmware, and / or microcode, and can be referred to as a program, routine, function, class, data structure, and / or object. The term "shared processor circuit" includes a single processor circuit that executes some or all of the code from multiple modules. The term "group processor circuit" includes a combination of processor circuitry and additional processor circuitry that executes some or all of the code from one or more modules. References to multiple processor circuitry include multiple processor circuitry on discrete dies, multiple processor circuitry on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above. The term "shared memory circuit" includes a single memory circuitry that stores some or all of the code from multiple modules. The term "group memory circuit" includes a combination of memory circuitry and additional memory that stores some or all of the code from one or more modules.

[0123] The term memory circuit is a subset of the term computer-readable medium. As used herein, the term computer-readable medium does not include transient electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); therefore, the term computer-readable medium can be considered tangible and non-transient. Non-limiting examples of non-transient, tangible computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or masked read-only memory circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog or digital magnetic tape or hard disk drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0124] The apparatus and methods described in this application can be implemented, in part or in whole, by a dedicated computer, which is generated by configuring a general-purpose computer to perform one or more specific functions embodied in a computer program. The aforementioned functional blocks, process components, and other elements serve as software specifications that can be compiled into a computer program through the routine work of a skilled technician or programmer.

[0125] A computer program includes processor-executable instructions stored on at least one non-transitory, tangible, computer-readable medium. A computer program may also include or depend on stored data. A computer program may include a basic input / output system (BIOS) that interacts with the hardware of a special-purpose computer, device drivers that interact with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0126] Computer programs may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), or JSON (JavaScript Object Notation); (ii) assembly code; (iii) object code generated by a compiler from source code; (iv) source code for interpreter execution; (v) source code for compilation and execution by a real-time compiler; and so on. As an example only, source code may use languages ​​including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, etc. Fortran, Perl, Pascal, Curl, OCaml, HTML5 (Hypertext Markup Language 5th Edition), Ada, ASP (Dynamic Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Visual Lua, MATLAB, SIMULINK, and Syntax writing for the language.

Claims

1. A method for forming a component by roll forming, the method comprising: Uncoated stamp hardened steel (CFPHS) is loaded into a roll forming system, wherein the CFPHS comprises: The alloy matrix has a carbon (C) concentration greater than or equal to about 0.05 wt% to less than or equal to about 0.35 wt%, a chromium (Cr) concentration greater than or equal to about 0.6 wt% to less than or equal to about 4.0 wt%, a silicon (Si) concentration greater than or equal to about 0.5 wt% to less than or equal to about 2.0 wt%, and the balance being iron (Fe). A first layer directly situated on the alloy matrix, the first layer being continuous and having a first thickness greater than or equal to about 0.01 μm and less than or equal to about 10 μm, and comprising Cr and Si-rich oxides; and A second layer is disposed directly on the first layer, the second layer being continuous and having a second thickness greater than or equal to about 0.01 μm to less than or equal to about 30 μm, and comprising Fe-rich oxides; The CFPHS is heated before being rolled into a component; and After heating the CFPHS, the CFPHS is rolled into a component using rollers. The heating and the rolling forming are carried out in an orderly (inline) manner on a common rolling forming line.

2. The method of claim 1, wherein the martensite in the alloy matrix, when fully hardened, is greater than or equal to about 95% by volume.

3. The method according to claim 1, wherein the alloy matrix further comprises at least one of the following: Manganese (Mn) at concentrations greater than or equal to about 0.5% by weight and less than or equal to about 5.0% by weight; and Niobium (Nb) concentration greater than or equal to about 0.0% by weight and less than or equal to about 0.05% by weight.

4. The method of claim 1, wherein the alloy matrix further comprises yttrium (Y) at a concentration greater than or equal to about 0.0% by weight and less than or equal to about 0.3% by weight.

5. The method of claim 1, wherein the alloy matrix further comprises cerium (Ce) at a concentration greater than or equal to about 0.0 wt% to less than or equal to about 0.3 wt%.

6. The method according to claim 1, wherein the alloy matrix comprises a yield strength of 700-1.8 GPa, an ultimate tensile strength of 1.0-2.1 GPa, and a hardness of 300-600 HV.

7. The method according to claim 1, wherein the alloy matrix comprises a surface oxide layer of 0.1-5.0 μm.

8. The method of claim 1, wherein the component defines a gap between a first surface and a second surface of the component, the method further comprising laser welding the first surface and the second surface together at the gap to close the gap.

9. The method of claim 8, wherein the gap is less than or equal to 0.1 mm prior to laser welding.

10. The method of claim 1, wherein rolling the CFPHS into a component comprises rolling the component into an angular radius of less than or equal to 2.0t.

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