Examination of coating thickness after

heat treatment concerning

22MnB5+AS150 material

Version 2, Status: 15.08.2017

Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico,
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited.
Agenda

• Motivation

• Ziel der Untersuchung / Target of the Examination

• Versuchsaufbau / Experimental Setup

• Versuchsmatrix / Test Matrix

• Ergebnisse (Schichtdickenmessung, Schliffbilder) /

Results (Coating thickness measurement, microscopic picture)

• Weitere Vorgehensweise / Further Agreements

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 2
 Motivation und
Ziel der Untersuchungen

Motivation and
Target of the Examination

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 3
Motivation / Target of the Examination
Requirements from Honda‘s norm „6321Z-T5A“
Request by Honda concerning various parts with
different thicknesses. Target of the examination is the
verfication of the combination of different sheet
thicknesses for toolings with vairous moulds.

During the design of the process it is important to

observe that all parts of one combination do not pass
the interdiffusion layer thickness of 10µm dependant of
their initial position relating to the coating thickness.

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
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Motivation
Evaluation made by company Steinhoff-Engineering
Influence of dwell time on interdiffusion
layer thickness from 870°C blank
temperature onwards concerning
22MnB5+AlSi150 material

Longer dwell time in the furnace

means a thicker diffusion layer
The thinner sheet thickness will show
a faster increase of the interdiffusion
layer
According to the results of company
Steinhoff the Honda norm can be
fullfilled with the requirement of 10 µm.
Concerning sheet thicknesses
of 0.8mm the maximum dwell time
amounts t870°C+180 sec.
1.2mm = t870°C+160 sec. Conclusion:
2.0mm = t870°C+210 sec. Maximum time of process interuption during series process for
The minimum dwell time in series different sheet thicknesses amounts as followed:
production amounts t870°C+75sec. 0,8mm = 105 seconds
It is important to observe that the 1,2mm = 85 seconds (value interpolated)
values between each step need to be 2,0mm = 135 seconds (value interpolated)
interpolated. But a individual consideration is necessary for a series process
window.
Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 5
 Versuchsaufbau, -durchführung und
Versuchsplan
Experimental Setup, Execution and
Trial Plan

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 6
Process of Examination

Material Step 1
- 22MnB5+AS150
- Sheet thickness: 0,8-2,9mm

Heat up sample (furnace)

- Temperature: 950°C
- Dwell time: t870°C +75; +120; 180 and 240 seconds

Documentation
- Temperature measuring data by dint of thermocouples
Furnace

Cooling of sample Step 2

- Put the sample with the thermocouples
- Into the die and close it
Recording of temperature measuring data

Handpress+Tool Experimental setup

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 7
 Examination matrix / Overview of samples

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 8
 Ergebnisse
Results

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
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 Heating curve of different sheet thicknesses

Heating Curve Trial Furnace Furnace Temperature: 950°C

Sheet Thickness 0.8, 1.0, 1.3, 1.5, 2.0 and 2.9 mm Dwell Time: 870°C+75sec.
1000

900
Diagramm zeigt die
800
Verweildauer im
Ofen bis zum
700 Erreichen der
Austenitisierungs-
temperatur für
Temperatur [°C]

600
unterschiedliche
500 Blechdicken
400 Diagramm shows
184sec. the necessary dwell
300
time to reach the
152sec.
200 123sec.
austenitization
temperature for
114sec.
100 different sheet
82sec.
thicknesses.
71sec.
0
0 25 50 75 100 125 150 175 200 225 250 275 300
Zeit [sec.]
0,8mm. 1,0mm 1,3mm 1,5mm 2,0mm 2,9mm

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
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Heating curve of 04th July 2017
Sheet thickness of 2.9mm, t870°C+75; +120; +180; +240sec

240 sec

Welded thermocouples type “K” 180 sec

120 sec

187 sec 75 sec

Furnace Settings

Temperature: 950°C

Furnace dwell time:

870°C+75; +120; +180; +240 sec
Time to reach austenitization TAust = 870°C 187 sec
Sheet thickness: 2.9mm
Coating: AlSi 150 g/m²
Furnace dwell time min. (8t70°C + 45sec+30sec) = 262 sec

Comment: This is an example for different dwell times which shows only one sheet thickness
Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 11
Sample distribution

X.1 X.2 X.3 X.4

Legende:
X.1 = Sample number (Assignment of production parameters) Sheet
Numer of
Furnace dwell time Numer of samples,
X.1 = Position of sample [sec]
thickness
[mm]
samples distributed
into 4 parts
4
4
0,8 4
Sample distribution 4
4
4
4
1 4
4
1) Sample is divided into 4 parts 4
4
4
1,3 4
4
2) Sample examination 870°C +75; +120; +180; +240sec
4
4
X.2 = BGN(Germany) / Laboratory (24 pieces) 1,5 4
4
4
X.3 and X.4 = SLP(Mexico) / Laboratory (48 pieces) 4
4
4
2 4
4

3) Sample back up 4
4

X.1 = BGN(Germany) / Development (24 pieces) 2,9 4

4
4
4

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 12
Testing of samples

Sheet thickness
Interdiffusion layer at 3 positions
(for that it is necessary to divide the metallographic picture into 4 sections)
Whole coating thickness have to be measured at 2 thinnest and 2 thickest position

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 13
 Influence of the dwell realting to the austenitization time

Fazit: Überblick über Gesamtschichtdicke und Interdiffusionsschicht in Abhängigkeit von Ofenverweildauer und Blechdicke.
Summary: Overview about the complete coating thickness and interdiffusionlayer thickness dependant of the dwell time and
sheet thickness
Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 14
 Influence of the austenitization time
relating to the complete dwell time

1 2 3 4

Fazit: Allerdings geben die hier dargestellten Ergebnisse lediglich einen Anhaltspunkt für eine Abschätzung. Folglich muss für ein
Serienprozessfenster jedes Material in dem geplanten Rollenherdofen getestet werden.
Conclusion: The shown results give only an indication for an estimation. Consequently it is necessary to execute an individual
design for the series process at the planed roller hearth furnace.
Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 15
 Influence of the austenitization time
relating to the complete dwell time

Conclusion: For the

combination of the sheet
thicknesses of 1mm and
2mm the diagram shows a
possible process interruption
time of approximately 50
seconds. The graphs were
created by dint of the trial
data from slide 15.
The diagram shows the
allocation of a furnace dwell
time to a certain coating
thickness dependent of the
sheet thickness. For the
whole process the minimum
furnace dwell time is
dependent of the time which
is needed for the
austenitization of the thickest
sheet. In this case it is 2mm
with a duration of 227
seconds. Therefore the lower
process border of the furnace
(interpolated)
dwell time is defined.

In the next step the maximum furnace dwell time will be determined. The time have to be chosen so that the required 10µm of the norm are
not crossed. This is occurring shortly under 275 seconds. Consequently the blue area shows the possible process window for the furnace
dwell time for a combination of 1mm and 2mm sheet thickness.

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 16
 Influence of the austenitization time
relating to the complete dwell time

Conclusion: The diagram

should illustrate the temporal
difference of the maximum
Maximum time of process interruption: 120sec.
time of process interruption in
the series process. To this
85sec.
three combinations with
50sec.
different sheet thicknesses are
demonstrated. A sheet
thickness with 1mm without
combination and a combination
of 1 to 1.4mm as well as 1 to
2.0mm is illustrated. In each
case the colored areas show
the duration of the maximum
possible time of process
interruption. This amounts for
the following combinations:
Without Combination 1mm:
approximately 120 seconds
Combination of 1 to 1.4mm:
approximately 85 seconds
Combination of 1 to 2.0mm:
approximately 50 seconds
It can therefore be concluded
that a increasing sheet
thickness difference of one
combination is reducing the
maximum time of interruption
in the series process.

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 17
 Weitere Vorgehensweise / Further Agreements

• Die aufgeführten Ergebnisse können zur Abschätzung der minimalen und maximalen Grenzen der
Ofenverweilzeit herangezogen werden, um mögliche Kombinationen von Materialdicken zu
ermitteln.
• Daraus ergibt sich die maximale Störungszeit (Reversionsbetrieb) im Serienprozess abhängig von
den eingebrachten Kombinationen.
• Allerdings bleibt eine individuelle Versuchsdurchführung unter Serienbedingungen am
Rollenherdofen unabdingbar (Schleppmessung).
• Die Ergebnisse aus dem Labor SLP sollen durch ergänzende Ergebnisse aus dem Labor
Bergneustadt verifiziert werden. Wesentliche Änderungen sind nicht zu erwarten.
• Klären wie hoch die durchschnittliche Eingriffszeit bei einer Anlagenstörung beträgt.

• The shown results can be taken for an estimation of the minimum and maximum borders of the
furnace dwell time to determine possible combinations of different material thicknesses.
• Hence the maximum time of process interruption (revision operation) is occunring dependant of the
various combinations.
• But an individual trial execution in the roller hearth furnace with series conditions is indispensable
(drag measurement).
• The results from the laboratory in SLP should be verified by additional results from the laboratory in
Bergneustadt. Essential changes are not to be expected.
• Clarify the average operation time in the case of a facility interruption.

Peter Olinger
Copyright © 2016, Metalsa, S.A. de C.V. Carretera Miguel Aleman Km. 16.5 No. 100, Apodaca, Nuevo Leon, Mexico, Rene Zadeh
C.P. 66600. Reproduction in whole or in part, without the previous and express written consent of the owner is prohibited. 15.08.2017 18