Patent Description:
Environmental restrictions are forcing automakers to continuously reduce the CO2 emissions of their vehicles. To do that, automakers have several options, whereby their principal options are to reduce the weight of the vehicles or to improve the efficiency of their engine systems. Advances are frequently achieved by a combination of the two approaches. This invention relates to the first option, namely the reduction of the weight of the motor vehicles. In this very specific field, there is a two-track alternative:
The first track consists of reducing the thicknesses of the steels while increasing their levels of mechanical strength. Unfortunately, this solution has its limits on account of a prohibitive decrease in the rigidity of certain automotive parts and the appearance of acoustical problems that create uncomfortable conditions for the passenger, not to mention the unavoidable loss of ductility associated with the increase in mechanical strength.

The second track consists of reducing the density of the steels by alloying them with other, lighter metals. Among these alloys, the low-density ones have attractive mechanical and physical properties while making it possible to significantly reduce the weight.

In particular, <CIT> discloses a Fe-AI-Mn-Si light steel having good formability and high strength. However, the ultimate tensile strength of such steels does not go beyond <NUM> MPa which does not allow taking full advantage of their low density for parts of all kinds of geometry.

<CIT> discloses the high strength low specific gravity steel plate excellent in the ductility, and a method of manufacturing the same.

The purpose of the invention therefore is to provide a manufacturing method for a steel sheet presenting a density below <NUM>, an ultimate tensile strength of at least <NUM> MPa, a yield strength of at least <NUM> MPa and a uniform elongation of at least <NUM>%.

This object is achieved by the method according to claims <NUM> to <NUM>.

Without willing to be bound by any theory it seems that the low density steel sheet according to the invention allows for an improvement of the mechanical properties thanks to this specific microstructure.

Regarding the chemical composition of the steel, carbon plays an important role in the formation of the microstructure and reaching of the targeted mechanical properties. Its main role is to stabilize austenite which is the main phase of the microstructure of the steel as well as to provide strengthening. Carbon content below <NUM>% will decrease the proportion of austenite, which leads to the decrease of both ductility and strength of the alloy. However, since it is a main constituent element of the intragranular kappa carbide (Fe,Mn)<NUM>AlCx, a carbon content above <NUM>% can promote the precipitation of such carbides in a coarse manner on the grain boundaries (intergranular kappa carbide (Fe,Mn)<NUM>AlCx), what results in the decrease of the ductility of the alloy.

Preferably, the carbon content is between <NUM> and <NUM>%, more preferably between <NUM> and <NUM>% by weight so as to obtain sufficient strength.

Manganese is an important alloying element in this system, mainly due to the fact that alloying with very high amounts of manganese and carbon stabilizes the austenite down to room temperature, which can then tolerate high amounts of aluminium without being destabilized and transformed into ferrite or martensite. To enable the alloy to have a superior ductility, the manganese content has to be equal or higher to <NUM> %. However, when the manganese content is over <NUM>%, the precipitation of β-Mn phase will deteriorate the ductility of the alloy. Therefore, the manganese content should be controlled to be equal or greater than <NUM>%, but lower than equal to <NUM>%. In a preferred embodiment, it is equal or greater than <NUM>% or even than <NUM>%. Its amount is more preferably between <NUM> and <NUM>%.

Aluminium addition to high manganese austenitic steels effectively decreases the density of the alloy. In addition, it considerably increases the stacking fault energy (SFE) of the austenite, leading in turn to a change in the strain hardening behavior of the alloy. Aluminium is also one of the primary elements of nanosized kappa carbide (Fe,Mn)<NUM>AlCx and therefore its addition significantly enhances the formation of such carbides. The aluminium concentration of the present alloys should be adjusted, on one hand, to guarantee the austenite stability and the precipitation of kappa carbides, and on the other to control the formation of ferrite. Therefore, the aluminium content should be controlled to be equal or greater than <NUM>%, but lower than equal to <NUM>%.

Silicon is a common alloying element for high manganese and aluminium steels. It has a very strong effect on the formation of ordered ferrite with a D0<NUM> structure. Besides, silicon was shown to enhance the activity of carbon in austenite and to increase the partitioning of carbon into the kappa carbides. In addition, silicon has been described as an effective alloying element that can be used to delay or prevent the precipitation of brittle β-Mn phase. However, above a content of <NUM>%, it reduces the elongation and tends to form undesirable oxides during certain assembly processes, and it must therefore be kept below this limit. Preferably, the content of silicon is below <NUM>% and advantageously below <NUM>.

Sulfur and phosphorus are impurities that embrittle the grain boundaries. Their respective contents must not exceed <NUM> and <NUM>% so as to maintain sufficient hot ductility.

Nitrogen content must be <NUM>% or less so as to prevent the precipitation of AIN and the formation of volume defects (blisters) during solidification.

Nickel has a positive effect on penetration of hydrogen into the steel and, therefore it can be used as a diffusion barrier to hydrogen. Nickel can also be used as an effective alloying element because it promotes the formation of ordered compounds in ferrite, such as the B2 component, leading to additional strengthening. However, it is desirable, among others for cost reasons, to limit the nickel addition to a maximum content of <NUM>% or less and preferably between <NUM> and <NUM>% or between <NUM> and <NUM>%. In another embodiment, the nickel amount is below <NUM>%.

Chromium may be used as optional element for increasing the strength of the steel by solution hardening. It also enhances the high temperature corrosion resistance of the steels according to the invention. However, since chromium reduces the stacking fault energy, its content must not exceed <NUM>% and preferably between <NUM>% and <NUM>% or between <NUM> and <NUM>%. In another embodiment, the chromium amount is below <NUM>%.

Likewise, optionally, an addition of copper with a content not exceeding <NUM>% is one mean of hardening the steel by precipitation of copper rich precipitates. However, above this content, copper is responsible for the appearance of surface defects in hot-rolled sheet. The amount of copper is below <NUM>%.

Boron has a very low solid solubility and a strong tendency to segregate at the grain boundaries, interacting strongly with lattice imperfections. Therefore, boron can be used to limit the precipitation of intergranular kappa carbides. Preferably, the amount of boron is below <NUM>%.

Niobium can simultaneously increase strength and toughness in the steel since it is an effective grain refiner. In addition, tantalum, zirconium, niobium, vanadium, titanium, molybdenum and tungsten are also elements that may optionally be used to achieve hardening and strengthening by precipitation of nitrides, carbo-nitrides or carbides. However, when their cumulated amount is above <NUM>%, preferably above <NUM>%, there is a risk that an excessive precipitation may cause a reduction in toughness, which has to be avoided.

The microstructure of the steel sheet, which is not claimed, comprises optionally up to <NUM>% of kappa carbides, optionally up to <NUM>% of granular ferrite, the remainder being made of austenite.

The austenitic matrix presents an average grain size below <NUM> and preferably below <NUM>, more preferably below <NUM> and has an average aspect ratio between <NUM> and <NUM>, preferably between <NUM> and <NUM> and more preferably between <NUM> and <NUM>.

During quenching, possible modulations in austenitic grains may indicate the beginning of L'<NUM> ordering and thus, the presence of intragranular kappa carbides. Therefore, kappa carbides (Fe,Mn)<NUM>AlCx can be present in the microstructure of the steel sheet, up to an amount of <NUM>% in area fraction. The presence of intergranular kappa carbides is not admitted as such intergranular coarse kappa carbides may cause a decrease in the ductility of the steel. Ferrite can also be present in the microstructure of the sheet up to an amount of <NUM>% in area fraction, preferably up to <NUM>% or more preferably up to <NUM>%. However, the ferrite morphology is limited to a granular geometry, excluding ferrite in form of bands, as they drastically degrade the ductility and formability of the steel. When present, the ferritic grains have an average grain size below <NUM> and preferably below <NUM>. The average aspect ratio of the ferrite, when present, is below <NUM> and preferably below <NUM>. Such ferrite can be under the form of regular disorded ferrite α or ordered as a B2 structure with a (Fe,Mn)Al composition or as a D0<NUM> structure with a (Fe,Mn)<NUM>Al composition, so that α, B2 and D0<NUM> structures can be observed in the steel according to the invention.

To protect the steel sheet from corrosion, in a preferred embodiment, the steel sheet is covered by a metallic coating. The metallic coating can be an aluminum-based coating or a zinc-based coating.

Preferably, the aluminium-based coated comprises less than <NUM>% Si, less than <NUM>% Fe, optionally <NUM> to <NUM>% Mg and optionally <NUM> to <NUM>% Zn, the remainder being Al.

Advantageously, the zinc-based coating comprises <NUM>-<NUM>% Al, optionally <NUM>-<NUM>% Mg, the remainder being Zn.

The steel sheet is produced by the method according to the invention, which is defined in claim <NUM>.

The steel sheets produced through a method in which an semi product, such as slabs made of a steel according to the present invention having the composition described above, is cast, the cast input stock is heated to a temperature above <NUM>, preferably above <NUM> and more preferably above <NUM> or <NUM> or used directly at such a temperature after casting, without intermediate cooling.

The final hot-rolling step is performed at a temperature above <NUM>. To avoid any cracking problem through lack of ductility by the formation of ferrite in bands, the end-of-rolling temperature is preferably above or equal to <NUM>° C.

After the hot-rolling, the strip has to be coiled between <NUM> and <NUM> to avoid excessive kappa carbide precipitation.

The hot-rolled product obtained by the process described above is cold-rolled after a possible prior pickling operation has been performed in the usual manner.

The cold-rolling step is performed with a reduction rate between <NUM> and <NUM>%, preferably between <NUM> and <NUM>%.

After this rolling step, a short annealing is performed by heating the sheet up to an annealing temperature comprised between <NUM> and <NUM>, holding it at such temperature during less than <NUM> minutes and cooling it at a rate of at least <NUM>/s, more preferably of at least <NUM>/s and even more preferably of at least <NUM>/s. Preferably, this annealing is carried out continuously. By controlling annealing temperature and time, either a fully austenitic or a two phase structure with the characteristics above can be obtained.

After this annealing step, the steel sheet may optionally be submitted to a metallic coating operation to improve its protection against corrosion. The coating process used can be any process adapted to the steel of the invention. Electrolytic or physical vapor deposition can be cited, with a particular emphasis on Jet Vapor Deposition. The metallic coating can be based on zinc or on aluminium, for example.

Nine grades, which compositions are gathered in table <NUM>, were cast in slabs and processed following the process parameters gathered in table <NUM>.

The resulting samples were then analyzed and the corresponding microstructure elements and mechanical properties were respectively gathered in table <NUM> and <NUM>.

Claim 1:
A method for producing a steel sheet comprising the following steps :
- feeding a slab which composition comprises by weight : <MAT> <MAT> <MAT> <MAT> <MAT> <MAT> <MAT>
possibly one or more optional elements chosen among Ni, Cr, Cu in an respective amount of up to <NUM>%, up to <NUM>% and below <NUM>% and
possibly one or more elements chosen among B, Ta, Zr, Nb, V, Ti, Mo, and W in a cumulated amount of up to <NUM>%, the remainder of the composition making up of iron and inevitable impurities resulting from the elaboration,
- reheating such slab at a temperature above <NUM> and hot rolling it with a final rolling temperature of at least <NUM>,
- coiling the hot rolled steel sheet at a temperature between <NUM> and <NUM>,
- cold-rolling such hot rolled steel sheet at a reduction comprised between <NUM> and <NUM>%,
- annealing such cold rolled sheet by heating it up to an annealing temperature comprised between <NUM> and <NUM>, holding it at such temperature during less than <NUM> minutes and cooling it at a rate of at least <NUM>/s.