合金化热镀锌板镀层脱落机理及评价方法研究
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摘要
汽车车体腐蚀是造成汽车损坏的重要原因之一,它不仅直接影响汽车使用寿命,还造成社会资源的巨大浪费和严重的环境污染,引起严重的交通事故。合金化镀锌板能有效地解决因环境因素造成的汽车车体腐蚀,并具有生产效率高、成本低、综合性能优等特点,愈来愈广泛地应用到汽车生产,尤其是中高档乘用车的车身制造上。然而,合金化镀锌板在冲压成形过程中经常出现镀层脱落现象,严重影响了后续生产工艺与成品性能,极大限制了其使用规模的进一步扩大。因此汽车工业界迫切需要解决合金化镀锌板的镀层脱落问题。国内外学者对此进行了多方面的研究,主要集中在合金化热镀锌生产工艺、镀层成分与结构以及冲压成形工艺参数等因素对镀层脱落性能的影响。这些研究主要考虑镀层成分或成形工艺参数间的调整,没有计入镀层在不同应力应变状态抵抗破坏的能力。另外,这些研究主要基于不同成形条件下的镀层脱落程度的评价,本身具有一定的局限性,难于有效地全面衡量镀层脱落性能。为此,本文综合考虑镀层的失效条件与应力应变的相互关系,开展基于断裂能量释放率的镀层粘附力学性能研究,旨在全面衡量镀层的脱落性能,支持合金化镀锌板产品质量的持续提高。
针对当前镀层脱落研究存在的不足之处,首先开展了复杂变形条件下合金化热镀锌板镀层的破坏机理研究、建立了镀层断裂的失效模型。据此研究了镀层粘附力学性能。为了正确评价镀层的粘附力学性能指标与脱落性能之间的相互关系,开发了一种新的镀层脱落性能评价方法,并研制了相关设备,最后通过实验对本文研究结论的正确性进行验证。主要研究工作如下:
1)合金化镀锌板镀层脱落机理研究
首先分析合金化热镀锌板镀层的微观结构特性、基于镀层材料脆性多层特征,分析了复杂变形条件下镀层的应力应变状态,将层合材料的破坏准则和脆性材料应变能密度S因子失效准则应用于镀层材料,提出单层材料破坏与裂纹扩展相结合是镀层材料脱落的主要原因。由于镀层在压缩时主要以滑开型方式扩展裂纹,因此镀层脱落主要出现在压应变区。基于脆性材料应变能密度S因子失效准则的基础上,根据镀层应力应变状态和裂纹扩展所需能量,推导出镀层断裂的Y因子失效模型。由于Y因子与镀层的剥离释放能与剪切释放能相关,镀层的剥离释放能与剪切释放能反映了自身的粘附力学性能,因此镀层脱落性能与其自身的粘附力学性能相关。以此为基础,进一步判定出镀层脱落必须大于某个压应变值。
2)合金化镀锌板镀层粘附力学性能研究
镀层材料硬脆且薄,无法采用常规的剥离实验方法将镀层从基体上剥离。国内外也未见有关镀层剥离报道。本文根据镀层的特点,设计并开发了不对称T型镀层剥离实验方法与装置,扫描电镜和X射线衍射结果证明该实验方法完全实现了镀层的剥离。根据剥离实验几何与力学条件,理论推导了镀层剥离释放能计算公式。另外,本文沿用测定镀层剪切强度的单向搭接实验方法来分析镀层的剪切释放能,根据剪切实验的力学与位移关系推导镀层剪切释放能计算公式。在此实验基础上研究了常见合金化热镀锌板镀层的粘附力学性能。为了分析镀层微观组织对其粘附力学性能的影响,采用盐浴工艺的实验方法改变镀层的微观相结构,由此研究了镀层的微观组织与镀层粘附力学性能的影响关系,并建立了相关模型。
3)合金化镀层脱落评价方法与智能分级设备研制
为了正确评价镀层的粘附力学性能指标与脱落性能之间的相互关系,需要一种客观正确评价镀层脱落性能指标的方法。在分析了国内外常用镀层脱落分级评价方法的优缺点基础上,考虑企业现场测试的需求,在目测法的评价基础上,采用机器视觉代替人工目测,有效克服目测法缺点。通过引入计算机图形学的相关图像处理原理和算法,成功设计开发了图形采集系统和数据处理系统。针对立体金属表面光线反射和定位困难,设计了专用光照系统,研制出工件定位装置,同时研究有关定位算法以减少定位操作的精度要求和计算量;为了能在油污、指纹、划痕等条件下也能客观正确评价镀层脱落性能指标,设计了相关处理噪音的软件;除此外,基于国内外现有分级经验基础上,设计并提出了合理的分类器和判断规则,并由此开发研制了相关分级设备,快速、简单、自动地正确实现了镀层脱落分级。
4)合金化镀锌板镀层脱落规律研究及验证
借助已研制的智能分级设备对常见合金化热镀锌板进行镀层脱落分级,耦合研究镀层粘附力学性能,发现镀层脱落性能与其粘附力学性能(剥离释放能和剪切释放能)两者之间符合一定的曲线关系,这证实了镀层断裂的Y因子失效模型的成立。其次,通过跟踪分析复杂成形条件下镀层在整个变形过程中脱落动态,借助网格测试和数值分析整个变形过程的应变状态的动态变化,证实了镀层脱落主要出现在压应变区,并且只有当压应变大于一定值时才会脱落的结论。最后,根据测得的这个压应变值,用实例去预测并验证了复杂成形零件镀层脱落分布。
本文在充分吸取和借鉴前人的成果基础上,对合金化镀锌板镀层脱落的评价方法和脱落机理进行了研究,提出基于镀层粘附力学性能衡量镀层脱落性能的方法,研究并总结得出合金化镀锌板镀层脱落规律,通过实验对其进行了验证。该方法不仅有助于揭示镀层脱落的科学实质,而且有助于正确衡量镀层的脱落性能,为合金化工艺的改进提供理论依据。
Auto-body Corrosion is one of the main reasons for automobile damage. It not only shortens service life, but also wastes social public resources with severe environment pollution. What’s more, it results in fatal traffic accidents.Galvannealed steel sheets can provide auto-body protection from road deicing salt and acid rain under harsh environment problem, as well as offering advantages of high productivity and low cost and excellent properties. So they are widely used in auto-body manufacture, especially in the moderate and top-class cars.Unfortunately, Galvannealed coatings occur exfoliating during press-forming process and result in loss of protective capability. Furthermore, it will bring about other harmful mechanical or aesthetic problems caused by corrosion, which greatly limiting the market expand of galvannealed steel sheets in automobile fields.In this reason, coating exfoliating becomes an urgent problem of automotive industry. Both domestic and overseas develop many studies, including the effects of galvanneal conditions, chemical composition, coatings microstructure and press-forming processing parameters on exfoliating resistance of galvannealed steel sheets. However, these researches concern only effects from chemical composition and forming processing parameters, which do not take into account the properties of exfoliating resistance during different stress and strain states. Furthermore, they are all based on a certain forming process, which are difficult to be applicable to the whole situation. Correlation between fracture energy releases rate criterion and exfoliating quantification of galvannealed coatings should be researched detailedly and systematically based on the critical adhesion failure rule of galvannealed coating along different strain paths
Focusing on improvement of exfoliating resistance and quantifying galvannealed coatings adhesions, analysis of galvannealed coating adhesion failure during different strain paths has been performed. A rule of coating adhesion failure is presented on basis of strain energy density factor theory. Further, galvannealed coatings’adhesions mechanical properties are studied. A new exfoliating rating method for galvannealed coatings is developed to evaluate the correlation between exfoliating resistance and adhesions mechanical properties. Work pieces in different forming process are analyzed with FEM attempting to predicate their coatings actual exfoliating location. To fulfill the above research objectives, the following four aspects are performed:
1) Research on exfoliating mechanisms in galvannealed coatings
Aiming at brittle and multilayer microstructure of galvannealed coatings, the exfoliating mechanisms in them are investigated based on laminate composite failure criterion and strain energy density S factor theory. Major factors in inducing coating exfoliation are monolayer occur failure and crack propagates in coating along with different deformation. It is found that coatings exfoliate on compress strain zone because mixed mode brittle fracture of sliding mode fracture exists in the zone. A Y -factor model of coating failure is built on the basis of strain energy density S factor theory. The Y -factor model clarifies correlation between the bond peel energy release and bond shear energy release. It means that galvannealed coatings exfoliating resistance capability are depended on their bond mechanical property. Consequently, it presents that exfoliating occurred only once the compress strain reached a certain point.
2) Research on bond mechanical properties of galvannealed coatings
General peeling experiment can not peel hard and brittle coatings from the substrate and there are no open publications on it. An asymmetry T type cantilever beam is developed to perform a novel kind of peeling test of galvannealed coatings. The results of EDS and XRD prove galvannealed coatings to be peeled off. Single lap joint test is used to tear the coatings from the substrate.Theoretical calculation of bond peel and shear energy release is deduced from the relation between displacement and load. Effect of microstructures of the coatings on their bond mechanical properties is also studied.
3) Development of an automatic coating exfoliating rating apparatus
In order to correctly assess the correlation ship between bond mechanical properties and exfoliating resistance capability of galvannealed coatings, a justice evaluate galvannealed coatings exfoliating method is investigated. Based on traditional evaluate methods and some operating needs of manufacturers, a novel evaluation technology of exfoliating performance of galvanneal sheets products, using a CCD camera and a pc-based image analysis system, is developed. A newly illumination structure style is designed to eliminate lights reflection. Two methods of locating sample region are performed, which reducing requirement of locate precision and calculation time. The apparatus can exactly rate automatically coatings exfoliating even in the case that there are dirties and mark on samples surface. The reasonable rating criterion and scientific classification standard are built on the basic of traditional rating criterion.
5) Research and verification about adhesion failure rule of galvannealed coating
Galvanneal coatings exfoliation is quantified by the devised apparatus. Experimental results reveal that there is curve relationship between the bond mechanical properties and exfoliation quantified of Galvanneal coatings, as Y -factor model studied before, wihich proves that the Y -factor model is correct.The whole exfoliating process of galvanneal coatings during forming processes is shot, and the change of strain state of the deforming coatings is analyzed with the help of numerical simulation of multi-steps forming and strain calculated by the measurement of formed circle grids. It proves that exfoliating is influenced by compressing strain and exfoliating only occurs when the compress strain exceeds above a certain limit. The coated exfoliating locations are predicated and verified based on the former strain critical value.
Based on gradient information and some necessary experiments validation, this dissertation proposed a systematic and detailed study on exfoliating resistance quantification for galvannealed coatings based on their bond energy release rate. It will contribute to not only revealing the exfoliating mechanisms on galvannealed coatings, but also reasonable evaluating the exfoliating resistance galvannealed steel sheets. All in all, the research results presenting in the dissertation have theoretical and practical significance.
针对当前镀层脱落研究存在的不足之处,首先开展了复杂变形条件下合金化热镀锌板镀层的破坏机理研究、建立了镀层断裂的失效模型。据此研究了镀层粘附力学性能。为了正确评价镀层的粘附力学性能指标与脱落性能之间的相互关系,开发了一种新的镀层脱落性能评价方法,并研制了相关设备,最后通过实验对本文研究结论的正确性进行验证。主要研究工作如下:
1)合金化镀锌板镀层脱落机理研究
首先分析合金化热镀锌板镀层的微观结构特性、基于镀层材料脆性多层特征,分析了复杂变形条件下镀层的应力应变状态,将层合材料的破坏准则和脆性材料应变能密度S因子失效准则应用于镀层材料,提出单层材料破坏与裂纹扩展相结合是镀层材料脱落的主要原因。由于镀层在压缩时主要以滑开型方式扩展裂纹,因此镀层脱落主要出现在压应变区。基于脆性材料应变能密度S因子失效准则的基础上,根据镀层应力应变状态和裂纹扩展所需能量,推导出镀层断裂的Y因子失效模型。由于Y因子与镀层的剥离释放能与剪切释放能相关,镀层的剥离释放能与剪切释放能反映了自身的粘附力学性能,因此镀层脱落性能与其自身的粘附力学性能相关。以此为基础,进一步判定出镀层脱落必须大于某个压应变值。
2)合金化镀锌板镀层粘附力学性能研究
镀层材料硬脆且薄,无法采用常规的剥离实验方法将镀层从基体上剥离。国内外也未见有关镀层剥离报道。本文根据镀层的特点,设计并开发了不对称T型镀层剥离实验方法与装置,扫描电镜和X射线衍射结果证明该实验方法完全实现了镀层的剥离。根据剥离实验几何与力学条件,理论推导了镀层剥离释放能计算公式。另外,本文沿用测定镀层剪切强度的单向搭接实验方法来分析镀层的剪切释放能,根据剪切实验的力学与位移关系推导镀层剪切释放能计算公式。在此实验基础上研究了常见合金化热镀锌板镀层的粘附力学性能。为了分析镀层微观组织对其粘附力学性能的影响,采用盐浴工艺的实验方法改变镀层的微观相结构,由此研究了镀层的微观组织与镀层粘附力学性能的影响关系,并建立了相关模型。
3)合金化镀层脱落评价方法与智能分级设备研制
为了正确评价镀层的粘附力学性能指标与脱落性能之间的相互关系,需要一种客观正确评价镀层脱落性能指标的方法。在分析了国内外常用镀层脱落分级评价方法的优缺点基础上,考虑企业现场测试的需求,在目测法的评价基础上,采用机器视觉代替人工目测,有效克服目测法缺点。通过引入计算机图形学的相关图像处理原理和算法,成功设计开发了图形采集系统和数据处理系统。针对立体金属表面光线反射和定位困难,设计了专用光照系统,研制出工件定位装置,同时研究有关定位算法以减少定位操作的精度要求和计算量;为了能在油污、指纹、划痕等条件下也能客观正确评价镀层脱落性能指标,设计了相关处理噪音的软件;除此外,基于国内外现有分级经验基础上,设计并提出了合理的分类器和判断规则,并由此开发研制了相关分级设备,快速、简单、自动地正确实现了镀层脱落分级。
4)合金化镀锌板镀层脱落规律研究及验证
借助已研制的智能分级设备对常见合金化热镀锌板进行镀层脱落分级,耦合研究镀层粘附力学性能,发现镀层脱落性能与其粘附力学性能(剥离释放能和剪切释放能)两者之间符合一定的曲线关系,这证实了镀层断裂的Y因子失效模型的成立。其次,通过跟踪分析复杂成形条件下镀层在整个变形过程中脱落动态,借助网格测试和数值分析整个变形过程的应变状态的动态变化,证实了镀层脱落主要出现在压应变区,并且只有当压应变大于一定值时才会脱落的结论。最后,根据测得的这个压应变值,用实例去预测并验证了复杂成形零件镀层脱落分布。
本文在充分吸取和借鉴前人的成果基础上,对合金化镀锌板镀层脱落的评价方法和脱落机理进行了研究,提出基于镀层粘附力学性能衡量镀层脱落性能的方法,研究并总结得出合金化镀锌板镀层脱落规律,通过实验对其进行了验证。该方法不仅有助于揭示镀层脱落的科学实质,而且有助于正确衡量镀层的脱落性能,为合金化工艺的改进提供理论依据。
Auto-body Corrosion is one of the main reasons for automobile damage. It not only shortens service life, but also wastes social public resources with severe environment pollution. What’s more, it results in fatal traffic accidents.Galvannealed steel sheets can provide auto-body protection from road deicing salt and acid rain under harsh environment problem, as well as offering advantages of high productivity and low cost and excellent properties. So they are widely used in auto-body manufacture, especially in the moderate and top-class cars.Unfortunately, Galvannealed coatings occur exfoliating during press-forming process and result in loss of protective capability. Furthermore, it will bring about other harmful mechanical or aesthetic problems caused by corrosion, which greatly limiting the market expand of galvannealed steel sheets in automobile fields.In this reason, coating exfoliating becomes an urgent problem of automotive industry. Both domestic and overseas develop many studies, including the effects of galvanneal conditions, chemical composition, coatings microstructure and press-forming processing parameters on exfoliating resistance of galvannealed steel sheets. However, these researches concern only effects from chemical composition and forming processing parameters, which do not take into account the properties of exfoliating resistance during different stress and strain states. Furthermore, they are all based on a certain forming process, which are difficult to be applicable to the whole situation. Correlation between fracture energy releases rate criterion and exfoliating quantification of galvannealed coatings should be researched detailedly and systematically based on the critical adhesion failure rule of galvannealed coating along different strain paths
Focusing on improvement of exfoliating resistance and quantifying galvannealed coatings adhesions, analysis of galvannealed coating adhesion failure during different strain paths has been performed. A rule of coating adhesion failure is presented on basis of strain energy density factor theory. Further, galvannealed coatings’adhesions mechanical properties are studied. A new exfoliating rating method for galvannealed coatings is developed to evaluate the correlation between exfoliating resistance and adhesions mechanical properties. Work pieces in different forming process are analyzed with FEM attempting to predicate their coatings actual exfoliating location. To fulfill the above research objectives, the following four aspects are performed:
1) Research on exfoliating mechanisms in galvannealed coatings
Aiming at brittle and multilayer microstructure of galvannealed coatings, the exfoliating mechanisms in them are investigated based on laminate composite failure criterion and strain energy density S factor theory. Major factors in inducing coating exfoliation are monolayer occur failure and crack propagates in coating along with different deformation. It is found that coatings exfoliate on compress strain zone because mixed mode brittle fracture of sliding mode fracture exists in the zone. A Y -factor model of coating failure is built on the basis of strain energy density S factor theory. The Y -factor model clarifies correlation between the bond peel energy release and bond shear energy release. It means that galvannealed coatings exfoliating resistance capability are depended on their bond mechanical property. Consequently, it presents that exfoliating occurred only once the compress strain reached a certain point.
2) Research on bond mechanical properties of galvannealed coatings
General peeling experiment can not peel hard and brittle coatings from the substrate and there are no open publications on it. An asymmetry T type cantilever beam is developed to perform a novel kind of peeling test of galvannealed coatings. The results of EDS and XRD prove galvannealed coatings to be peeled off. Single lap joint test is used to tear the coatings from the substrate.Theoretical calculation of bond peel and shear energy release is deduced from the relation between displacement and load. Effect of microstructures of the coatings on their bond mechanical properties is also studied.
3) Development of an automatic coating exfoliating rating apparatus
In order to correctly assess the correlation ship between bond mechanical properties and exfoliating resistance capability of galvannealed coatings, a justice evaluate galvannealed coatings exfoliating method is investigated. Based on traditional evaluate methods and some operating needs of manufacturers, a novel evaluation technology of exfoliating performance of galvanneal sheets products, using a CCD camera and a pc-based image analysis system, is developed. A newly illumination structure style is designed to eliminate lights reflection. Two methods of locating sample region are performed, which reducing requirement of locate precision and calculation time. The apparatus can exactly rate automatically coatings exfoliating even in the case that there are dirties and mark on samples surface. The reasonable rating criterion and scientific classification standard are built on the basic of traditional rating criterion.
5) Research and verification about adhesion failure rule of galvannealed coating
Galvanneal coatings exfoliation is quantified by the devised apparatus. Experimental results reveal that there is curve relationship between the bond mechanical properties and exfoliation quantified of Galvanneal coatings, as Y -factor model studied before, wihich proves that the Y -factor model is correct.The whole exfoliating process of galvanneal coatings during forming processes is shot, and the change of strain state of the deforming coatings is analyzed with the help of numerical simulation of multi-steps forming and strain calculated by the measurement of formed circle grids. It proves that exfoliating is influenced by compressing strain and exfoliating only occurs when the compress strain exceeds above a certain limit. The coated exfoliating locations are predicated and verified based on the former strain critical value.
Based on gradient information and some necessary experiments validation, this dissertation proposed a systematic and detailed study on exfoliating resistance quantification for galvannealed coatings based on their bond energy release rate. It will contribute to not only revealing the exfoliating mechanisms on galvannealed coatings, but also reasonable evaluating the exfoliating resistance galvannealed steel sheets. All in all, the research results presenting in the dissertation have theoretical and practical significance.
引文
[1] 林忠钦编著 《汽车车身制造质量控制技术》,机械工业出版社(2005)
[2] Akira Yasuda,Hideo Koumura,Koji Yamato “Development of high performance galvannealed steel sheet for outer panels of automotives”, Galvatech’ 01 conference proceedings, Verlag staheisen, 2001, pp.45-53
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