Hot Press-Formed Steel Heating Profile for Weldability and Throughput
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Solution Overview
Problem
Existing methods for manufacturing hot press-formed members using aluminum-based plated steel sheets face challenges in simultaneously improving productivity, weldability, and formability due to the limitations of conventional heating processes that either increase in-furnace maintenance time or heating temperature, leading to poor weldability and formability.
Innovation Solution
A method involving a continuous heating furnace with distinct sections (A, B, and C) that sets specific atmospheric temperatures and maintaining times to rapidly heat the steel sheets, minimizing in-furnace time, and controlling the diffusion layer thickness to achieve optimal heating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heating temperature is increased to reduce in-furnace maintenance time, then productivity is improved, but diffusion layer thickness increases causing poor weldability
Solution Approach 1:
The heating furnace is divided into multiple heating zones with different temperature profiles. The first heating zone operates at a higher temperature for rapid heating, while the second heating zone operates at a lower temperature to complete heating with minimal diffusion layer formation, thereby resolving the contradiction between productivity and weldability
Solution Approach 2:
The patent changes the temperature parameter along the heating direction, creating a temperature gradient in the heating furnace. By adjusting the temperature distribution from high to low across different zones, the process achieves both rapid heating (improving productivity) and controlled diffusion (maintaining weldability)
2Reliability
If heating temperature is continuously increased to improve weldability, then diffusion layer thickness is reduced, but formability is deteriorated
Solution Approach 1:
The heating process is segmented into two distinct zones: the first zone provides rapid heating to reduce diffusion layer thickness (improving weldability), while the second zone maintains lower temperature to preserve formability. This segmentation allows both weldability and formability to be optimized simultaneously
3Device complexity
If conventional heating method is used, then equipment complexity is reduced, but both productivity and material quality are compromised
Solution Approach 1:
The heating furnace is segmented into multiple zones with different temperature characteristics, allowing rapid heating without excessive diffusion. This segmentation improves productivity while maintaining reasonable device complexity by using a structured multi-zone approach rather than a single complex system
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
The method enhances productivity by reducing cycle time while maintaining excellent weldability and formability, ensuring rapid temperature rise without excessive diffusion layer formation.
Implementation Method 1
heating a blank of an aluminum-based plated steel sheet in a heating furnace
Implementation Method 2
continuous heating furnace comprising section A, section B, and section C provided in a conveying direction
Implementation Method 3
a thickness of a diffusion layer in an alloy layer is increased to cause poor weldability
Data Source
AI summary
An method of manufacturing a hot press-formed member comprises heating a blank of an aluminum-based plated steel sheet in a heating furnace, removing the heated blank from the heating furnace and conveying the removed blank between an upper mold portion and a lower mold portion of a mold, mounted on a press, to be seated; and performing a forming process after the upper mold portion of the mold is in contact with the seated blank.