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Table of contents
1. State of the art about coating systems for press-hardened parts
1.1 Hot stamping in the automotive industry
1.1.1 Automotive bodies
1.1.2 Hot stamped body parts
1.2 Press-hardening process
1.3 Direct and indirect hot stamping processes
1.4 Challenges in corrosion protection of press-hardened steel parts
1.4.1 Corrosion of car bodies
1.4.2 Corrosion protection of hot formed components
1.4.3 Assessment criteria and anticorrosion performance of current coatings for hot formed components
1.5 Current coating products for hot stamped body parts
1.5.1 Galvanized coatings
1.5.2 Aluminized coatings
1.5.3 Further protective coating systems
1.5.4 Performance of commercial coatings for the hot stamping application
1.6 Alternative coating systems for press-hardened parts
1.6.1 Identification of promising alternative coatings
1.6.2 Properties of alternative Zn-Mn alloy coatings
1.6.3 Deposition process of Zn-Mn coatings
2 Aim and experimental approach of the present work [EN + FR]
3 Materials and experimental methods
3.1 Steel products investigated
3.2 Study of the electrodeposition of alternative Zn-Mn coatings
3.2.1 Electrodeposition of metallic coatings
3.2.2 Cyclic Voltammetry combined with Electrochemical Quartz Crystal Microbalance studies
3.2.3 Electroplating cells and experimental parameters
3.3 Materials characterization
3.3.1 Global procedure
3.3.2 Metallographic characterization
3.3.3 Crystallographic characterization
3.3.4 Scanning Electron Microscopy SEM
3.3.5 Atomic Absorption Spectroscopy AAS
3.3.6 Focused Ion Beam FIB
3.3.7 Transmission Electron Microscopy TEM
3.3.8 Electron Backscatter Diffraction EBSD
3.3.9 Glow Discharge Optical Emission Spectroscopy GDOES
3.3.10 Raman Spectroscopy
3.3.11 Anticorrosive properties
3.4 High temperature processes
3.4.1 Heat treatment in air
3.4.2 Heat treatment under protective atmosphere
3.4.3 Experimental conditions during hot stamping
4 Deposition and characterization of as-deposited Zn-Mn coatings
4.1 Study of the Zn-Mn electroplating system
4.1.1 CV and EQCM studies for Zn-Mn deposition
4.1.2 Definition of optimal electroplating solutions and electric parameters
4.2 Deposition of Zn-Mn coatings on large-scale plates
4.2.1 Homogeneity of Zn-Mn coatings deposited on large-scale plates
4.2.2 Deposition of Zn-Mn alloy coatings on large-scale plates
4.3 Materials characterization of as-deposited Zn-Mn coatings
4.3.1 Chemical composition of Zn-Mn coatings
4.3.2 Microstructural properties of Zn-Mn coatings
4.3.3 Crystallographic properties of Zn-Mn coatings
4.3.4 Anticorrosive properties of Zn-Mn coatings
4.3.5 Overview of the materials properties of electrodeposited Zn-Mn alloys [EN + FR]
5 Characterization of Zn-Mn coatings post to heat treatment
5.1 Methodical and experimental procedure
5.2 Characterization of Zn-Mn coatings post to heat treatment in air
5.2.1 Heat treatment to 700 °C in air
5.2.2 Heat treatment to 900 °C in air
5.3 Characterization of Zn-Mn coatings post to heat treatment in a protective atmosphere
5.3.1 Crystallographic properties of Zn-Mn coatings post to heat treatment in a protective atmosphere
5.3.2 Surface morphology of Zn-Mn coatings post to heat treatment in a protective atmosphere
5.3.3 Microstructural and anticorrosive properties of Zn-Mn coatings post to heat treatment in a protective atmosphere
5.4 Suitability of Zn-Mn coatings for high temperature processes in air and in a protective atmosphere [EN + FR]
5.4.1 lnfluence of the austenitizing atmosphere on the coating behavior
5.4.2 Behavior of Zn-Mn coatings during austenitizing in a protective atmosphere
6 Hot stamping experiments on commercial and alternative Zn-Mn-coated steels
6.1 Design and startup of press tools with current coated products
6.1.1 Simulation of hot stamping and design of press tools
6.1.2 Startup of the press tools with real specimens
6.1.3 Hot forming behavior of aluminized coatings
6.1.4 Hot forming behavior of galvanized coatings
6.2 Direct hot stamping experiments with Zn-based coatings
6.2.1 Hot stamping of galvanized steel
6.2.2 Hot stamping of Zn-Mn-coated steel
6.3 Suitability of Zn-Mn coatings for direct hot stamping [EN + FR]
7 Summary and outlook
8 Résumé et perspectives
Appendix
Appendix 1: Further protective coating systems
Appendix 2: Preliminary heat treatment studies of Zn-Mn coatings in air
Appendix 3: Zn-Mn-Fe phase diagrams
Appendix 4: Ellingham diagram
Appendix 5: Comparative AAS and SEM-EDS studies
Bibliography



