Furnace Support Surfaces for Galvanized Sheet-Steel Hardening
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Solution Overview
Problem
Existing methods for producing hardened steel components, particularly in press hardening, result in damage to galvanized surfaces due to efflorescence and abrasion during furnace heating, affecting corrosion protection and visual appearance.
Innovation Solution
Use support surfaces with a maximum size of 200 mm² and made of porous and/or rough oxide ceramic or carbide ceramic materials, or high-temperature resistant cast steel, ensuring oxygen access to promote self-healing of the zinc coating, and reduce the size of support surfaces to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional large support surfaces are used during furnace heating, then the sheet steel blank is adequately supported and positioned, but the galvanized surface suffers from efflorescence and abrasion damage
Solution Approach 1:
The support surface is segmented into multiple small contact points (max 200 mm² each) instead of a large continuous support area. This segmentation reduces the total contact area with the galvanized surface, minimizing the regions where efflorescence and abrasion can occur while still providing adequate support through distributed contact points.
Solution Approach 2:
The support surfaces are made from porous materials that allow oxygen to pass through to the galvanized surface. This oxygen supply enables the zinc coating to self-heal by forming protective zinc oxide, preventing efflorescence damage. The porous structure maintains support functionality while promoting surface repair.
2Strength
If conventional support surfaces are used during heating, then structural support is provided, but corrosion protection is compromised due to surface damage
Solution Approach 1:
The porous support surfaces create a controlled environment that allows oxygen access to the zinc coating, promoting formation of a protective zinc oxide layer. This controlled oxidizing environment at the contact points protects the galvanized surface from corrosion while maintaining structural support.
3Ease of operation
If large support surfaces are used, then adequate support is provided during heating, but visual appearance is degraded due to surface damage
Solution Approach 1:
By segmenting the support surface into small discrete contact points (max 200 mm²), the damage area is minimized and distributed, preventing large visible damaged regions. The small contact areas maintain support functionality while preserving the visual appearance of the galvanized surface between contact points.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces surface damage and maintains corrosion protection by allowing the zinc coating to self-heal, preventing efflorescence and maintaining the integrity of the galvanized surface.
Implementation Method 1
support surfaces made of porous and/or rough oxide ceramic or carbide ceramic materials, or high-temperature resistant cast steel, ensuring oxygen access to promote self-healing of the zinc coating, and reduce the size of support surfaces to prevent damage
Data Source
AI summary
The invention relates to a method for heating a sheet steel blank or preformed component with a zinc or zinc alloy coating, wherein the sheet steel component or blank is guided or positioned in a furnace and heated to a temperature above the austenitizing temperature, the sheet steel component or blank at least temporarily rests on a plurality of support surfaces on at least one carrier in which, on the support surfaces for the sheet steel blank or component, eithera) the support surfaces are each a maximum of 200 mm2 in size, and/orb) the support surfaces consist of a porous and/or rough oxide ceramic or carbide ceramic or high-temperature resistant cast steel so that oxygen access to the surface of the steel sheet blank or component is ensured even in the region of the support surfaceAn apparatus for carrying out the method is also provided.