Patent Publication Number: US-2022228234-A1

Title: Method for producing light gauge steel

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application depends from and claims priority to U.S. Provisional Application No: 63/139,381 filed Jan. 20, 2021, the entire contents of which are incorporated herein by reference. 
    
    
     FIELD 
     The invention relates to the field of light gauge steel production. 
     BACKGROUND 
     Light gauge heat-treated steel has many uses in industry. One type of such steel known as advanced high strength steel sheet (AHSS) is widely used, for example, in automotive applications. Another type of such steel known as hardened steel plate (HTP) is widely used in wear applications such as mining, earth-moving and heavy vehicles such as dump trucks. 
     Known technologies for the production of light gauge heat-treated steel are relatively expensive as such steels are traditionally produced on expensive process lines with in-line advanced cooling technologies. 
     SUMMARY OF THE INVENTION 
     Forming one aspect of the invention is a method for use with a strip or plate of steel, the steel being of a composition and temperature suitable for heat treatment, the method comprising the following steps:
     austenizing the steel to produce austenitized material;   quenching the austenized material to produce hardened steel;   thermally tempering the hardened steel to produce tempered steel; and   stretching and leveling the tempered steel to produce heat treated steel.   

     According to another aspect, the stretching and leveling of the hardened steel can be carried out using a stretcher leveler. 
     According to another aspect, the steel can be austenized in a reheat furnace. 
     According to another aspect, the austenized material can be quenched using a water quench process. 
     According to another aspect, the steel can be cut into daughter lengths prior to austenizing. 
     According to another aspect, the tempered steel can be cooled prior to the stretching and leveling process that results in the heat treated steel. 
     According to another aspect, the heat treated steel can be cut into blanks. 
     According to another aspect, the stretcher leveler can be defined by a T4 stretcher leveler. 
     According to another aspect, the strip or plate can be produced by rolling a slab through a hot reduction mill. 
     Advantages, features and characteristics of the present invention will become apparent to persons of ordinary skill in the art upon review of the description which follows. 
    
    
     DETAILED DESCRIPTION OF A NON-LIMITING EMBODIMENT 
     A method for producing light gauge steel according to a non-limiting embodiment of the invention consists of the following steps:
         liquid steel, having a chemistry suitable for heat treatment, is cast into a slab;   the slab is rolled through a hot reduction mill into a master coil or master discrete plate and allowed to cool;   the cooled master coil or master discrete plate is cut into specified daughter lengths;   the daughter lengths are austenized in a reheat furnace and then quenched in water; and   the now-hardened daughter lengths are passed through a T4 stretch leveller and cut into blanks for further forming, profiling, or otherwise fabrication into finished parts.       

     Examples of suitable steel materials that may be used in the processes as provided herein include but are not limited to those sold by Algoma Steel, Inc., Ontario. Canada. Illustratively a steel is Algoma 100 steel as provided in Table 1: 
                     TABLE 1                  Chemical Composition-Heat Analysis (% maximum)                                                 Thickness   C   Mn   P   S   Si   Cr   Mo   B               0.188″ (5 mm)   0.17   1.5   0.03   0.015   0.45    0.25   0.2   0.003       to 0.250″                                       (6.35 mm)                                       Over 0.250″   0.21   1.5   0.03   0.015   0.45   0.2   0.2   0.003       (6.35 mm) to                                       1.00″ (25.4 mm)                                       Over 1.00″   0.21   1.5   0.03   0.015   0.45    0.65   0.4   0.003       (25.4 mm) to                                       2.75″ (70 mm)                    
The steel of Table 1 has a minimum tensile strength of 110 ksi, a maximum tensile strength of 130 ksi, a yield strength of 100 ksi, and an elongation (percent) minimum in 2 inches of 16.
 
Illustratively a steel is Algoma 130 steel as provided in Table 2:
 
                     TABLE 2                  Chemical Composition-Heat Analysis (% maximum)                                                 Thickness   C   Mn   P   S   Si   Cr   Mo   B               0.188″ (5 mm) to   0.17   1.5   0.025   0.015   0.45   0.2   0.2   0.003       0.250″ (6.35 mm)                                       Over 0.250″   0.21   1.5   0.025   0.015   0.45    0.65   0.4   0.003       (6.35mm) to                                       1.375″ (35 mm)                                       Over 1.375″   0.26   1.5   0.025   0.015   0.45   0.6    0.45   0.003       (35 mm) to                                       2.5″ (65 mm)                    
The steel of Table 2 has a minimum tensile strength of 136 ksi, a yield strength of 130 ksi, and an elongation (percent) minimum in 2 inches of 12.
 
Illustratively a steel is AlgoTuf 400F steel as provided in Table 3:
 
                     TABLE 3                  Chemical Composition-Heat Analysis (% maximum)                                                 Thickness   C   Mn   P   S   Si   Cr   Mo   B               0.188″ (5 mm)    0.17   1.5   0.025   0.015   0.45   0.2   0.2   0.003       to less than                                       0.472″ (12 mm)                                       0.472″ (12 mm)    0.17   1.5   0.025   0.015   0.45    0.25   0.2   0.003       to 0.787″                                       (20 mm)                                       Over 0.787″   0.2   1.5   0.025   0.015   0.45   0.6    0.35   0.003       (20 mm) to                                       1.00″ (25.4 mm)                                       Over 1.00″    0.26   1.5   0.025   0.015   0.45   0.6    0.45   0.003       (25.4 mm) to                                       2.75″ (70 mm)                    
The steel of Table 3 has a minimum tensile strength of 175 ksi, a yield strength of 145 ksi, and an elongation (percent) minimum in 2 inches of 15.
 
Illustratively a steel is AlgoTuf 450F steel as provided in Table 4:
 
                     TABLE 4                  Chemical Composition-Heat Analysis (% maximum)                                                 Thickness   C   Mn   P   S   Si   Cr   Mo   B               0.188″ (5 mm) to   0.21   1.5   0.025   0.015   0.45   0.2   0.2   0.003       0.394″ (10 mm)                                       Over 0.394″ (10 mm)   0.23   1.5   0.025   0.015   0.45   0.2    0.35   0.003       to 0.787″ (20 mm)                                       Over 0.787″ (20 mm)   0.26   1.5   0.025   0.015   0.45   0.6    0.45   0.003       to 2.5″ (65 mm)                    
The steel of Table 4 has a minimum tensile strength of 200 ksi and an elongation (percent) minimum in 2 inches of 14.
 
Illustratively a steel is AlgoTuf 450F steel as provided in Table 5:
 
                     TABLE 5                  Chemical Composition-Heat Analysis (% maximum)                                                     Thickness   C   Mn   P   S   Si   Cr   Mo   Ni   B               0.236″ (6 mm)   0.33   1.5   0.025   0.015   0.5   0.7   0..5   0.7   0.003       to 1.25″ (31.75 mm)                    
The steel of Table 5 has a typical tensile strength of 255 ksi and an elongation (percent) typical in 2 inches of 14.
 
Illustratively, a steel is Armour steel with the following characteristics at a thickness of 6 mm to 31.75 mm:
 
     
       
         
           
               
             
               
                   
               
               
                 Chemical composition (%) unless a range is 
               
               
                 specified individual values are maximums 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
            
               
                 Carbon 
                 0.22-0.32 
               
               
                 Maganese 
                 0.60-0.90 
               
               
                 Phosphorous 
                 0.02 
               
               
                 Sulfur 
                 0.01 
               
               
                 Silicon 
                 0.2-0.4 
               
               
                 Chromium 
                 0.4-0.7 
               
               
                 Nickel 
                 0.35-0.85 
               
               
                 Molybdenum 
                  0.2-0.35 
               
            
           
           
               
               
            
               
                 Copper 
                 0.25 
               
               
                 Boron 
                 0.003 
               
               
                 Hardness (HBW) (average) 
                 477-534 
               
               
                 CVNL full size min. avg. impact (ft-lbs) @ −40 degrees F. 
                 14 
               
               
                 CVNT full size min. avg. impact (ft-lbs) @ −40 degrees F. 
                 12 
               
               
                 Heat Treatment Requires 
                 Q&amp;T 
               
               
                   
               
            
           
         
       
     
     EXPERIMENTAL 
     A slab was cast for 387-418 BHN grade and was passed through the hot rolling mill at Algoma, Ontario. The coil was later cut to length into master plates at Algoma&#39;s CTL facility. A resultant plate of dimensions 0.1891″×72″×240″ was austenized in a reheat furnace and then sprayed with water so as to get quenched. The quenched plate had a 0.5″ wave every 28″ and had a yield strength of about 163,000 psi, tensile strength of about 198,000 psi and elongation of about 11%. The wave is attributed to uneven cooling rate across the three dimensions. The plate was levelled on a T4 stretcher leveler of a type sold by RedBud Industries for a total of 3.7″. The resultant plate surprisingly turned out to be quite flat. 
     Persons of ordinary skill will also readily appreciate the process is advantageous in that, inter alia, it:
         permits the production of AHSS and HTP without the expense associated with a a discrete plate leveler; and   is relatively easily replicated in comparison to known processes for production of AHSS and HTP given that the operator is largely required merely to ensure that the strip/plate is pulled to a definite stroke length.       

     Whereas a single example is herein described, persons of ordinary will appreciate that the process can be varied widely. For example, any conventional steel alloy used in the production of AHSS and HTP can be used, material of varying size can be used and greater or lesser amounts of stretching will be employed, based upon the starting shape. Accordingly, the invention should be understood to be limited only by the accompanying claims, purposively construed.