Methods of forming components utilizing ultra-high strength steel and components formed thereby

Abstract

Components and methods for forming components utilizing ultra-high strength steel are provided. A first method includes the steps of providing a blank of ultra-high strength steel, cold forming the blank into an unfinished component, and applying a coating to the outer surface of the unfinished component that is adapted to inhibit the formation of a ferrite soft layer on the component during heating thereof. A second method includes the steps of providing a blank of heavy gauge thickness ultra-high strength steel, cold forming the blank into a finished component, heating the finished component and quenching the component without the use of tooling.

What is claimed is: 
     
         1 . A method of forming a component utilizing ultra-high strength steel including the steps of:
 providing a blank of ultra-high strength steel;   cold forming the blank into an unfinished component;   applying a coating to the outer surface of the unfinished component, wherein the coating is adapted to inhibit the formation of a ferrite soft layer on the unfinished component during heating of the component;   heating the unfinished component; and   quenching the unfinished component.   
     
     
         2 . The method as set forth in  claim 1  wherein the outer surface of the unfinished component includes at least a first portion and a second portion, and wherein applying a coating to the outer surface of the unfinished component includes applying the coating to only the first portion of the outer surface of the component. 
     
     
         3 . The method as set forth in  claim 2  wherein the first portion of the outer surface of the unfinished component extends about an opening defined by the outer surface such that the coating is applied about the opening. 
     
     
         4 . The method as set forth in  claim 1  wherein the coating is applied to at least substantially the entire outer surface of the unfinished component. 
     
     
         5 . The method as set forth in  claim 1  wherein the coating includes at least one of a nickel electrolyte coating, a high-temperature graphite oil, or a water-based ceramic coating. 
     
     
         6 . The method as set forth in  claim 1  wherein the component is at least one of a differential housing, a CVT plunger, inner diameter splines of a clutch housing, and external gears. 
     
     
         7 . A method of forming a component utilizing ultra-high strength steel including the steps of:
 providing a blank of heavy gauge thickness ultra-high strength steel;   cold forming the blank into a finished component;   heating the finished component; and   quenching the finished component without the use of tooling.   
     
     
         8 . The method as set forth in  claim 7  wherein a thickness of the blank is between approximately 3.5 and 6.5 mm. 
     
     
         9 . The method as set forth in  claim 7  wherein the blank has the composition of:
 carbon 0.08 to 0.33 wt %; 
 manganese 0.8 to 1.50 wt %; 
 boron 0.0005 to 0.005 wt %; 
 silicon less than or equal to 0.50 wt %; 
 phosphorous less than or equal to 0.030 wt %; 
 sulfar less than or equal to 0.0025 wt %; and 
 chromium less than or equal to 0.35 wt %. 
 
     
     
         10 . The method as set forth in  claim 7  wherein the component is at least one of a differential housing, a CVT plunger, inner diameter splines of a clutch housing, and external gears. 
     
     
         11 . The method as set forth in  claim 7  wherein heating the finished component includes heating the component with one of an electric furnace, a gas furnace, or an induction heat source. 
     
     
         12 . The method as set forth in  claim 7  wherein heating the finished component includes heating the finished component to 930 degrees Celsius. 
     
     
         13 . The method as set forth in  claim 7  wherein quenching the finished component includes quenching only a portion of the finished component. 
     
     
         14 . The method as set forth in  claim 7  wherein quenching the finished component includes quenching the entire finished component. 
     
     
         15 . A method of forming a powertrain component for a vehicle utilizing ultra-high strength steel including the steps of:
 providing a blank of ultra-high strength steel;   cold forming the blank into an unfinished powertrain component;   applying a coating to the outer surface of the unfinished powertrain component, wherein the coating is adapted to inhibit the formation of a ferrite soft layer on the unfinished component during heating of the component;   heating the unfinished powertrain component; and   quenching the unfinished powertrain component.   
     
     
         16 . The method as set forth in  claim 15  wherein the outer surface of the unfinished powertrain component includes at least a first portion and a second portion, and wherein applying a coating to the outer surface of the unfinished powertrain component includes applying the coating to only the first portion of the outer surface of the component. 
     
     
         17 . The method as set forth in  claim 6  wherein the first portion of the outer surface of the unfinished powertrain component extends about an opening defined by the outer surface such that the coating is applied about the opening. 
     
     
         18 . The method as set forth in  claim 15  wherein the coating is applied to at least substantially the entire outer surface of the unfinished powertrain component. 
     
     
         19 . The method as set forth in  claim 15  wherein the coating includes at least one of a nickel electrolyte coating, a high-temperature graphite oil, or a water-based ceramic coating. 
     
     
         20 . The method as set forth in  claim 15  wherein the unfinished powertrain component is at least one of a differential housing, a CVT plunger, inner diameter splines of a clutch housing, and external gears.