Submitted Successfully!
To reward your contribution, here is a gift for you: A free trial for our video production service.
Thank you for your contribution! You can also upload a video entry or images related to this topic.
Version Summary Created by Modification Content Size Created at Operation
1 The constitutive model, interface binding energy and damage finite element model achieved in this paper can improve the numerical simulation accuracy of galvanized steel sheet stamping to a certain extent. But there is still some deviation from the experi
Gui Li
 + 1125 word(s) 1125 2020-03-25 07:38:39 |
2 format correct
Camila Xu
 -2 word(s) 1123 2020-11-01 13:47:25 |

Video Upload Options

We provide professional Video Production Services to translate complex research into visually appealing presentations. Would you like to try it?
No, upload directly Yes

Confirm

Are you sure to Delete?
Yes No
Cite
If you have any further questions, please contact Encyclopedia Editorial Office.
Li, G.; Long, X. Zinc Coating. Encyclopedia. Available online: https://encyclopedia.pub/entry/490 (accessed on 26 December 2024).
Li G, Long X. Zinc Coating. Encyclopedia. Available at: https://encyclopedia.pub/entry/490. Accessed December 26, 2024.
Li, Gui, Xiaoyu Long. "Zinc Coating" Encyclopedia, https://encyclopedia.pub/entry/490 (accessed December 26, 2024).
Li, G., & Long, X. (2020, April 01). Zinc Coating. In Encyclopedia. https://encyclopedia.pub/entry/490
Li, Gui and Xiaoyu Long. "Zinc Coating." Encyclopedia. Web. 01 April, 2020.
Zinc Coating
Edit
This entry is adapted from the peer-reviewed paper 10.3390/coatings10030202

Advanced high strength galvanized steel sheet has been one of the dominant materials of modern automotive panels because of its outstanding mechanical properties and corrosion resistance. The zinc coating thickness of hot dip galvanized steel sheet is only about 10–20μm, which is a discarded object on the macro level. However, it is obvious to damage and impact on stamping performance. Therefore, this work takes zinc coating as the research object and builds its mechanical constitutive model based on a nano-indentation test and dimensional analysis theory. We separated the zinc coating from the galvanized steel substrate and constructed a sandwich material model by introducing a cohesive layer to connect the zinc coating and the steel substrate. We obtained the interface binding energy between the zinc coating and the steel substrate through the nano-scratch test. The accuracy of the model is verified by the finite element analysis of hemispherical parts. We used the five-layers element model with 0 thickness cohesive layer to simulate the zinc coating damage of galvanized steel sheet. The hemispherical part drawing experiment is used to verify the feasibility of the finite element analysis results. The results demonstrate that it is more accurate to consider the finite element numerical simulation of the zinc coating, introducing the cohesive element to simulate damage between the coating and the substrate. Drawing depth, stamping force, and the strain of the numerical simulation are closer to the experimental results.

hot dip galvanized steel sheet zinc coating mechanical behavior damage cohesive element

1. Introduction

Galvanized advanced high strength steel (AHSS) has become the dominant material of automotive lightweight because of its superior strength, elongation, and outstanding corrosion resistance, which can follow the requirements of collision safety, energy saving, emission reduction, and environmental protection[1]. The coating is an ultra-thin material galvanized on the upper and lower surfaces of the steel substrate. There are two galvanizing methods: hot-dip galvanizing and electro galvanizing [2]. The thickness of the zinc coating is about 8 μm [3], which represents a slight difference between galvanizing methods. It neglects this level of magnitude on macroscopic scales. But zinc coating layer makes the surface characteristics of galvanized steel different from that of non-galvanized steel. These zinc coating layers are easy to damage in severe plastic deformation under external pressure and sliding friction [4][5][6]. It will also affect the formation of welding joints of stamping parts [7]. Typical damages of the coating layers are cracking and powdering flaking. The exfoliated coating adheres to the surfaces of the steel and die, resulting in falling, wearing, and affecting the stamping formability of the steel sheet [8][9]. Therefore, it is of great practical significance to study the mechanical properties of the zinc coating and its influence on the deformation of galvanized AHSS during stamping forming.

2. Specifics

Zinc plating is an alloying process, and its element content will influence the performance of the galvanized layer. Vourlias et al. [10] studied the effect of alloying elements on the interfacial reaction of the galvanized coating. They found that the concentration and distribution of alloying elements played an important role in the phase growth. To improve the coating quality of high strength DP steel, a nickel layer was pre-electroplated on the steel substrate before galvanizing, and an enhancement in the coating quality was discovered [11]. Parisot et al.[12] confirmed the damage mechanisms at work in three different microstructures of a zinc coating on an interstitial-free steel substrate under tension, plain strain, and expansion loading. Two main fracture mechanisms, intergranular fracture and transgranular boundary fracture, were created in cold-rolled coatings, tempered cold-rolled coatings, and uncrystallized coatings. Further investigation shows that the damage between the galvanized layer and substrate depends on the different mechanical behavior and thickness of intermetallic compounds [13]. Petit et al. [14] investigated the galvanization ability of a high strength chromium-rich TRIP800 (transformation induced plasticity steel). Under different loads and deformation conditions, zinc coating also shows different mechanics. The damage behavior of different galvanized steel sheets under tension-bending conditions was explored by Yu et al. [15]. They discovered that the exfoliating and scratching of coating are two types of surface damage. To quantify the damage of galvanized coating, Xu et al. [16] suggested a parameter to illustrate the powdering of galvanized coating and its validity by double reverse Olsen test. Song and Sloof [17] introduced a “macroscopic atomic model” to assess the adhesion of the zinc coating for hot-dip galvanized dual phase steel. Adhesion force is an important property of coated steel, which concluded the quality of the coating. The damage of the coating in the stamping process results from the relative sliding friction between the steel sheet and the die surfaces. Wang et al. [9] considered the evolutionary process of galling of galvanized AHSS DP590 (dual-phase steel) under the condition of friction coupling plastic bending deformation. First, the coating is cracked because of tensile deformation. Then, further powdering of the coating resulted in a notable increase in the surface roughness of the contact interface. Die wear and surface galling of stamping parts will be caused because of the adhesion effect of coating. Therefore, the coating layer must be considered as an essential research branch of AHSS stamping.

Numerical simulation is an effective tool and method to study the strain distribution stamping forming [18]. As a non-negligible factor, we must consider the coating in the numerical simulation of stamping forming. The upper and lower surface of the galvanized steel sheet is zinc coating, and the intermediate substrate is a steel sheet. We can understand it as three-layers of composite material, like a sandwich equivalent to the stamping of multiple layers of material. It includes multi-scale modeling of materials [19], stamping formability [20][21][22], spring-back[23][24], and evolution of interface structure [25]. A three-dimensional finite element (FE) simulation of a thin zinc coating on a galvanized steel sheet has been performed by taking the multicrystalline structure of the coating into account [26]. In addition, Ucun and Aslantas [27] simulated the mechanical properties and force status of the cutting tools with different coating types by the method of single layer and multi-layer finite element modeling. Lee et al. [28] simulated the deep drawing of galvanized steel with a multi-layer element model, and the interface between substrate and coating was set to be adherent. Kim et al. [29] studied the fracture of the coating layer of galvanized steel using V-bending test and numerical simulation of the solid element. The results show that the coating and substrate begin to failure when the local plastic equivalent plastic reaches 0.26–0.28. Bettaieb et al. [30] proposed a solid shell element to describe the coating under T-bending based on the enhanced assumed strain (EAS) technique and the assumed natural strain (ANS) technique, that can avoid locking problems caused by the large aspect ratio of ultra-thin coating elements. It is shown that a higher accuracy simulation of coating can be achieved by using such a solid shell element.

References

  1. D. Anderson; S. Winkler; A. Bardelcik; Michael J. Worswick; Influence of stress triaxiality and strain rate on the failure behavior of a dual-phase DP780 steel. Materials & Design 2014, 60, 198-207, 10.1016/j.matdes.2014.03.073.
  2. S.M.A. Shibli; B.N. Meena; R. Remya; A review on recent approaches in the field of hot dip zinc galvanizing process. Surface and Coatings Technology 2015, 262, 210-215, 10.1016/j.surfcoat.2014.12.054.
  3. Rodolphe Parisot; Samuel Forest; André Pineau; François Grillon; Xavier Demonet; Jean-Michel Mataigne; Deformation and damage mechanisms of zinc coatings on hot-dip galvanized steel sheets: Part I. Deformation modes. Metallurgical and Materials Transactions B 2004, 35, 797-811, 10.1007/s11661-004-0007-x.
  4. Z. Shen; Y. Ding; J. Chen; B. Shalch Amirkhiz; J.Z. Wen; L. Fu; A.P. Gerlich; Interfacial bonding mechanism in Al/coated steel dissimilar refill friction stir spot welds. Journal of Materials Science & Technology 2019, 35, 1027-1038, 10.1016/j.jmst.2019.01.001.
  5. Toko Tokunaga; Munekazu Ohno; Kiyotaka Matsuura; Coatings on Mg alloys and their mechanical properties: A review. Journal of Materials Science & Technology 2018, 34, 1119-1126, 10.1016/j.jmst.2017.12.004.
  6. Wang, X.; Wei, L.; Zhao, J.; Cheng, H.; Wang, X.; Liu, Y.; Hao, Y. Research on dynamic mechanical behavior and damage of steel structure galvanized coating. In Proceedings of the International Conference on Smart City & Systems Engineering, Changsha, China, 11–12 November 2017; pp. 244–247, doi:10.1109/ICSCSE.2017.67.
  7. Thomas Pinger; Eva-Maria Rückriem; Investigation on the corrosion and mechanical behavior of thin film batch galvanized thick plate components in clinch joints. The International Journal of Advanced Manufacturing Technology 2015, 86, 29-36, 10.1007/s00170-015-8141-8.
  8. Ömer Necati Cora; Ali Ağcayazı; Kunio Namiki; Hasan Sofuoglu; Muammer Koc; Ali Agcayazi; Die wear in stamping of advanced high strength steels – Investigations on the effects of substrate material and hard-coatings. Tribology International 2012, 52, 50-60, 10.1016/j.triboint.2012.02.016.
  9. Wurong Wang; Kai Wang; Yuzhang Zhao; Meng Hua; Xicheng Wei; A study on galling initiation in friction coupling stretch bending with advanced high strength hot-dip galvanized sheet. Wear 2015, 328, 286-294, 10.1016/j.wear.2015.02.058.
  10. G. Vourlias; N. Pistofidis; G. Stergioudis; D. Tsipas; The effect of alloying elements on the crystallization behaviour and on the properties of galvanized coatings. Crystal Research and Technology 2004, 39, 23-29, 10.1002/crat.200310144.
  11. N. Zhong; K. Zhang; J. Li; W. B. Hu; Improvement of the Galvanized Coating Quality of High Strength Dual Phase Steels by Pre-Electroplating Nickel Layer. steel research international 2010, 82, 180-186, 10.1002/srin.201000124.
  12. Vittorio Di Cocco; F. Iacoviello; Laura D'agostino; Stefano Natali; Damage micromechanisms in a hot dip galvanized steel. Procedia Structural Integrity 2017, 3, 231-236, 10.1016/j.prostr.2017.04.054.
  13. Rodolphe Parisot; Samuel Forest; André Pineau; François Grillon; Xavier Demonet; Jean-Michel Mataigne; Deformation and damage mechanisms of zinc coatings on hot-dip galvanized steel sheets: Part II. Damage modes. Metallurgical and Materials Transactions B 2004, 35, 813-823, 10.1007/s11661-004-0008-9.
  14. Etienne J. Petit; Y. Grosbety; S. Aden-Ali; J. Gilgert; Z. Azari; Microstructure of the coating and mechanical properties of galvanized chromium-rich martensitic steel. Surface and Coatings Technology 2010, 205, 2404-2411, 10.1016/j.surfcoat.2010.09.032.
  15. Z. Q. Yu; Y. K. Hou; S. H. Li; Z. Q. Lin; W. G. Zhang; SURFACE DAMAGE BEHAVIOR OF GALVANIZED STEEL SHEETS IN FORMING PROCESS UNDER TENSION-BENDING. International Journal of Modern Physics B 2010, 24, 5877-5884, 10.1142/s0217979210057481.
  16. Chun Xu; Z.Q. Lin; S.H. Li; W.G. Zhang; Research on shear strength of galvannealed coatings. Materials & Design 2007, 28, 1668-1671, 10.1016/j.matdes.2006.03.021.
  17. Gui-Ming Song; Willem G. Sloof; Characterization of the failure behavior of zinc coating on dual phase steel under tensile deformation. Materials Science and Engineering: A 2011, 528, 6432-6437, 10.1016/j.msea.2011.04.058.
  18. Sung-Ho Chang; Youngmoo Heo; Study on Characteristics of the Warm Deep Drawability and Simulation for the Galvannealed Steel Sheet. Advanced Science Letters 2013, 19, 3697-3702, 10.1166/asl.2013.5215.
  19. Qizhi He; Heng Hu; Salim Belouettar; G. Guinta; K. Yu; Yin Liu; F. Biscani; E. Carrera; M. Potier-Ferry; Multi-scale modelling of sandwich structures using hierarchical kinematics. Composite Structures 2011, 93, 2375-2383, 10.1016/j.compstruct.2011.03.026.
  20. Bernd-Arno Behrens; Milan Vučetić; A. Neumann; Tomasz Osiecki; Nenad Grbic; Experimental Test and FEA of a Sheet Metal Forming Process of Composite Material and Steel Foil in Sandwich Design Using LS-DYNA. Key Engineering Materials 2015, 651, 439-445, 10.4028/www.scientific.net/kem.651-653.439.
  21. A. Rajabi; Mehran Kadkhodayan; M. Manoochehri; R. Farjadfar; Deep-drawing of thermoplastic metal-composite structures: Experimental investigations, statistical analyses and finite element modeling. Journal of Materials Processing Technology 2015, 215, 159-170, 10.1016/j.jmatprotec.2014.08.012.
  22. S. Shiri; Hakim Naceur; J.M. Roelandt; Numerical modelling of sheet metal forming and crashworthiness of laminated steel structures using multi-layered solid-shell elements. European Journal of Computational Mechanics 2012, 21, 351-364, 10.1080/17797179.2012.714852.
  23. M.H. Parsa; S. V. Mohammadi; A. Jalali Aghchai; Al3105/polypropylene/Al3105 laminates springback in V-die bending. The International Journal of Advanced Manufacturing Technology 2014, 75, 849-860, 10.1007/s00170-014-6173-0.
  24. M.H. Parsa; Saeid Nasheralahkami; M. Ettehad; Experimental and finite element study on the spring back of double curved aluminum/polypropylene/aluminum sandwich sheet. Materials & Design 2010, 31, 4174-4183, 10.1016/j.matdes.2010.04.024.
  25. Chen Li; Cheng-Zhong Chi; Peng Lin; Hua Zhang; Wei Liang; Deformation behavior and interface microstructure evolution of Al/Mg/Al multilayer composite sheets during deep drawing. Materials & Design 2015, 77, 15-24, 10.1016/j.matdes.2015.03.034.
  26. R. Parisot; Samuel Forest; A.-F. Gourgues; A. Pineau; D. Mareuse; Modeling the mechanical behavior of a multicrystalline zinc coating on a hot-dip galvanized steel sheet. Computational Materials Science 2000, 19, 189-204, 10.1016/s0927-0256(00)00155-5.
  27. Irfan Ucun; Kubilay Aslantas; Numerical simulation of orthogonal machining process using multilayer and single-layer coated tools. The International Journal of Advanced Manufacturing Technology 2010, 54, 899-910, 10.1007/s00170-010-3012-9.
  28. Seongwon Lee; ManSoo Joun; Donghwan Kim; Jungmin Lee; Effect of elastic-plastic behavior of coating layer on drawability and frictional characteristic of galvannealed steel sheets. Journal of Mechanical Science and Technology 2016, 30, 3313-3319, 10.1007/s12206-016-0640-5.
  29. S.I. Kim; J.U. Her; Yun-Chan Jang; Youngseog Lee; Experimental and finite element analysis for fracture of coating layer of galvannealed steel sheet. Transactions of Nonferrous Metals Society of China 2011, 21, s111-s116, 10.1016/s1003-6326(11)61072-8.
  30. Bettaieb, A.B.; Tuninetti, V.; Duchene, L. Numerical simulation of T-bend of multilayer coated metal sheet using solid-shell element. 14th International Conference on Metal Forming, Metal Forming 2012, Krakow, Poland, 16–19 September 2012; Wiley-VCH Verlag: Krakow, Poland, 2012; pp. 1311–1314.
More
© Text is available under the terms and conditions of the Creative Commons Attribution (CC BY) license; additional terms may apply. By using this site, you agree to the Terms and Conditions and Privacy Policy.
Upload a video for this entry
Information
Subjects: Materials Science, Coatings & Films
Contributors MDPI registered users' name will be linked to their SciProfiles pages. To register with us, please refer to https://encyclopedia.pub/register :
Gui Li
,
Xiaoyu Long
View Times: 1.4K
Revisions: 2 times (View History)
Update Date: 01 Nov 2020
Table of Contents
    1000/1000
    Hot Most Recent
    Video Production Service
    Feedback