Controlled-Atmosphere Hot Stamping to Suppress Oxide Scale
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Solution Overview
Problem
Conventional hot stamping processes require significant energy and time for heating, leading to surface oxidation of steel sheet blanks, which results in the formation of oxide scales. These scales are undesirable in automotive applications and reduce productivity due to the need for additional processing steps to remove them.
Innovation Solution
A press system with a controlled atmosphere system that encloses the press tool apparatus, allowing for atmosphere control during the hot stamping process. This system uses a heating device to heat the sheet blank and performs hot blanking with stamping and in-die quenching in a controlled atmosphere to suppress the generation of oxide scales.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional furnace heating is used to heat the steel sheet blank to austenitic temperature, then the steel achieves the required phase transformation, but the heating process consumes excessive energy and time
Solution Approach 1:
The patent replaces the conventional thermal radiation heating system with an induction heating system that uses electromagnetic fields to directly heat the steel sheet blank. The induction heating device generates eddy currents within the steel blank, producing rapid and efficient heating without requiring a large furnace environment, thereby significantly reducing energy consumption and heating time.
Solution Approach 2:
The patent utilizes the phase transition properties of steel during induction heating. By controlling the heating rate and temperature profile through induction heating, the steel rapidly transforms from martensitic or ferritic phase to austenitic phase, achieving the required phase transformation more efficiently than conventional furnace heating.
2Temperature
If conventional furnace heating and transfer process is used, then the steel sheet blank is heated and shaped, but surface oxidation occurs and oxide scales are generated
Solution Approach 1:
The patent introduces an inert or controlled atmosphere environment within the press system to prevent surface oxidation of the steel sheet blank during induction heating and forming. By maintaining a protective atmosphere (such as nitrogen or vacuum conditions) in the pressing chamber, the steel surface is protected from reacting with atmospheric oxygen, thereby eliminating oxide scale formation while achieving the required heating temperature.
3Productivity
If rapid heating and forming is performed to reduce oxidation time, then productivity increases, but the heating system requires more complex equipment
Solution Approach 1:
The patent employs induction heating technology, which uses electromagnetic fields to directly induce eddy currents within the steel blank for rapid internal heating. This substitution of conventional thermal radiation heating with electromagnetic induction heating enables fast heating rates and improved productivity while the modular design of induction heating equipment keeps system complexity manageable.
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 controlled atmosphere press system significantly reduces the formation of oxide scales on hot stamped structural components, improving productivity by eliminating the need for additional cleaning processes and maintaining the mechanical and microstructural properties of the components.
Implementation Method 1
heating device configured to heat a sheet blank
Implementation Method 2
In conventional electrical furnace, the workpiece is heated through radiation
Implementation Method 3
steel sheet blanks such as uncoated boron steel reacts with atmosphere air and steel surface gets oxidized
Implementation Method 4
quickly deformed into the required shape while being rapidly quenched to produce a final product predominately with a martensitic phase
Data Source
AI summary
A press system and a method of manufacturing a hot stamped structural component from a sheet blank within a press system is provided. The press system comprises a controlled atmosphere system and a press tool apparatus. The press tool apparatus comprises a lower body member, an upper body member, an upper die member, a lower die member, and a heating device configured to heat a sheet blank. The upper die member and the lower die member are configured to perform hot blanking with stamping and in-die quenching on the heated sheet blank in the atmosphere controlled by the controlled atmosphere system to form the hot stamped structural component. By controlling the atmosphere during formation of the hot stamped structural component generation of oxides scales are suppressed.