CN100535191C - 磷酸盐处理镀锌钢板 - Google Patents

磷酸盐处理镀锌钢板 Download PDF

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CN100535191C
CN100535191C CNB2005800286309A CN200580028630A CN100535191C CN 100535191 C CN100535191 C CN 100535191C CN B2005800286309 A CNB2005800286309 A CN B2005800286309A CN 200580028630 A CN200580028630 A CN 200580028630A CN 100535191 C CN100535191 C CN 100535191C
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zinc
steel sheet
phosphate
zinc coating
bonderite
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CN101006202A (zh
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中丸裕树
多田千代子
山下和美
屉冈英男
加藤千昭
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JFE Steel Corp
JFE Engineering Corp
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NKK Corp
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    • C23C2/04Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
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Abstract

一种磷酸盐处理镀锌钢板,包括钢板,该钢板的至少一面上的含有10质量ppm以上、固溶界限以下的Ni的η单相的镀锌层,以及该镀锌层上的含有0.1质量%以上、小于2.0质量%的Mg的磷酸盐处理层。该钢板没有进行封闭,但具有与经过封闭的现有产品同等以上的耐腐蚀性,而且还具有优良的耐黑变性。

Description

磷酸盐处理镀锌钢板
技术领域
本发明涉及适用作实施涂装的底层钢板的磷酸盐处理镀锌钢板。该磷酸盐处理镀锌钢板适合作为建材、家用电器的材料使用。
背景技术
用于建材、家用电器等方面时,实施镀锌、镀锌合金等的钢板被用在要求耐腐蚀性的部位。这些含锌镀层钢板很少直接使用,通常经涂装后使用。涂装时,一般实施前处理。作为众所周知的前处理的例子,有磷酸盐处理。
磷酸盐处理是指使含有磷酸根离子的酸性溶液与含锌镀层钢板接触,从而在该镀层表面形成以磷酸锌为主要成分的结晶性被膜的处理。通过该处理,与涂膜的密合性提高,对各种涂装稳定的底层性能也显示出来。因此,实施了磷酸盐处理的含锌镀层钢板可以面向建材、家用电器等,作为经过涂装的底层钢板而广泛地使用。
但是,只进行磷酸盐处理时,由于有细孔残留故耐腐蚀性不充分。因此,通常在磷酸盐处理后实施封闭(sealing),从而维持耐腐蚀性。以往,作为该封闭处理,通常实施用喷射、浸渍等方法使含6价铬的水溶液与钢板接触后干燥的处理。但是,由于6价铬是环境限制物质,所以期待不使用含6价铬的水溶液封闭或其他的提高耐腐蚀性的方法。
针对这些期望,例如特开2000-313967号公报中公开了在含锌镀层的表面上设有由含磷酸的结晶性物质构成的化学转换处理被膜,以及设于其上的非晶质的磷酸被膜的磷酸锌处理钢板。另外,特开2004-143475号公报中公开了在含锌镀层钢板的表面上具有磷酸锌处理被膜和将水性溶液涂布其上后干燥得到的封闭被膜的磷酸锌处理钢板,该水性溶液含有选自铜化合物、钛化合物和锆石化合物中的至少一种金属化合物、或进一步与双酚A、胺类和甲醛反应的缩聚树脂化合物。这些技术都完全不使用铬而进行封闭。
但是,在形成最上层的被膜的工序中,上述各种技术都需要在涂布水性溶液后加热烧结。因此,有必要在已有的磷酸盐处理镀锌钢板的制造设备的基础上添加新的涂布设备和烧结设备,这就出现了导致制造成本增加的问题。
而且,还在尝试不通过封闭而使磷酸盐处理被膜本身的耐腐蚀性提高的技术。
例如,特开平1-312081号公报中公开了在金属材料的表面形成含锌镀层,并在该镀层上形成由含有0.1重量%以上、优选5重量%以下的Mg的磷酸盐化合物构成的被膜的磷酸盐处理含锌镀层金属材料。另外,特开2002-285346号公报中公开了一种磷酸锌处理的含锌镀层钢板,其含锌镀层上的磷酸锌被膜含有2%以上的Mg和0.01~1%的选自Ni、Co、Cu的一种以上的元素,附着量在0.7g/m2以上。
但是,在这些技术中,由于最上层的磷酸盐被膜层含有Mg,所以当被暴露在高温多湿的环境下时出现表面变黑(以下也称为黑变性)的问题。而且,在最后列举的技术中,由于磷酸锌被膜含有高浓度的Ni、Co、Cu,因此还会产生磷酸锌被膜的色调变暗的问题。
鉴于这些现有技术存在的问题,本发明的目的在于,提供不进行封闭,而与以往实施封闭的磷酸盐处理镀锌钢板具有同等的耐腐蚀性,且耐黑变性也很优良的磷酸盐处理镀锌钢板。
发明内容
本发明提供一种磷酸盐处理镀锌钢板,其包括钢板,该钢板的至少一面上的含有10质量ppm以上、固溶界限以下的Ni的η单相的镀锌层,以及该镀锌层上的含有0.1质量%以上、小于2.0质量%的Mg的磷酸盐处理层。
另外,本发明还提供一种耐腐蚀性和耐黑变性优良的磷酸盐处理镀锌钢板,钢板的至少一面具有镀锌层和作为该镀锌层的上层的磷酸盐处理层,其特征在于,所述镀锌层是含有10质量ppm以上、固溶界限以下的Ni的η单相,所述磷酸盐处理层含有0.1质量%以上、小于2.0质量%的Mg。
具体实施方式
本发明人为了完成上述课题,对影响磷酸盐处理镀锌钢板的耐腐蚀性和耐黑变性的因素进行了认真的研究。结果发现,通过在钢板表面形成由含有规定量的Ni的η单相构成的镀锌层,然后在该镀锌层上形成含有规定范围的Mg的磷酸盐处理层,可以不进行封闭而得到耐腐蚀性和耐黑变性都很优良的磷酸盐处理镀锌钢板。
在本发明中,在钢板的至少一面上形成的镀锌层的晶体结构是只由η相构成的单相。在本发明中,将10质量ppm以上、固溶界限以下的Ni固溶在该η相中。由此,磷酸盐处理镀锌钢板的耐黑变性提高。如果η单相的镀锌层中所含的Ni量小于10质量ppm,则不能防止在该镀层上形成含Mg的磷酸盐处理被膜时,尤其在高温多湿的环境下发生的黑变。而且,该Ni含量越高,防止黑变的效果越好。通常,该Ni含量优选在50质量ppm以上,更优选在100质量ppm以上。另一方面,该Ni含量若超过对η相的Ni固溶界限,则δNi-Zn相、γNi-Zn相析出,上层的磷酸盐处理层上产生外观斑。到目前为止其原因还不清楚,推断是由于下层镀锌的相结构的变化,磷酸锌的析出状态变得不均匀的缘故。而且,所谓对η相的Ni固溶界限是指用X射线衍射检测不出镀锌层中η相以外的相的Ni含量的上限值。
因此,在本发明中,将该Ni含量限定在10质量ppm以上、固溶界限以下。而且,在电镀锌时,固溶界限随着镀浴组成、电解条件等的变化而变化,所以不能一概地定义该Ni含量的上限。但是,通常调整镀浴组成、电解条件等,从而控制镀锌层中的Ni含量小于5质量%、优选小于1质量%、更优选在0.1质量%以下,由此可以达到要求。
另外,本发明的镀锌层的附着量可以根据用途作适当的选择,但从耐腐蚀性的观点出发,优选在1g/m2以上。通常为1~100g/m2左右。更优选为5~70g/m2
本发明的磷酸盐处理镀锌钢板,在上述镀锌层上具有含0.1质量%以上、小于2.0质量%的Mg的磷酸盐处理层。通过使其含有如上的Mg,可以使盐水喷雾试验中出现白锈的时间延迟,不实施封闭磷酸盐处理镀锌钢板的耐腐蚀性也提高。即,若使该Mg含量在0.1质量%以上,则可以得到与以往实施封闭的磷酸盐处理镀锌钢板大致相同的耐腐蚀性。另一方面,即使将该Mg含量增加到2.0质量%以上,由于提高耐腐蚀性的效果达到饱和,随着该Mg含量的增加,黑变性反而表现出变强的倾向。因此,磷酸盐处理层的Mg含量以小于2.0质量%为上限。而且,从耐黑变性的观点出发,该Mg含量优选在1.4质量%以下,更优选为0.5~1.0质量%。另外,在本发明的磷酸盐处理层中,磷酸盐处理液中不可避免地含有作为杂质的其他阳离子,例如Ni、Mn、Co等,若其含量为0.01~0.4质量%左右则没有问题。
另外,本发明的磷酸盐处理层的附着量优选在0.2g/m2以上,更优选在1.0g/m2以上,最优选在1.5g/m2以上。在0.2g/m2以上时,可以充分地达到耐腐蚀性和涂料密合性两个特性。而且,由附着量的增加而获得的上述效果在3g/m2以上达到饱和,所以从经济方面考虑,优选3g/m2为上限。
接着,说明本发明的磷酸盐处理镀锌钢板的优选制造方法。在本发明中,优选依次实施在作为基板的钢板的至少一面上镀锌,接着在该镀锌上形成磷酸盐处理层的磷酸盐处理。
而且,作为前处理,优选根据需要进行电解脱脂、酸洗和水洗等,使钢板表面净化,然后进行镀锌处理。
作为本发明的镀锌层的形成方法,可以列举真空蒸镀法、热浸镀法和电镀法等,哪一种方法都可以应用。但是,从容易控制镀锌层的Ni量出发,优选使用电镀法。以下说明应用电镀法的情况。
例如,向通常组成的锌电镀浴中加入Ni源,在钢板的至少一面实施电镀,形成含有10质量ppm以上、固溶界限以下的Ni的η单相的镀锌层。电镀法的情况下,由于形成的电镀被膜的相结构通常变为非平衡状态,故η相中含有的Ni也有可能固溶到过饱和。因此,调整镀浴组成和/或电解条件等可以容易地控制固溶状态的Ni量,所以优选电镀法。
作为上述锌电镀浴,只要能形成纯锌镀层就没有必要特别限定,可以利用通常的溶液。例如,可以列举硫酸锌溶液、氯化锌溶液等。另外,作为Ni源,只要在镀锌浴中能生成Ni离子即可,没有特别的限定。例如可以列举硫酸镍、氯化镍等。优选根据镀锌层的Ni含量调整Ni源的添加量,从而调整镀锌浴中的Ni量。另外,还可以根据镀锌层的附着量、Ni含量等条件调整电流密度等通电条件。而且,镀锌层的附着量在1g/m2以上时能获得充分的耐腐蚀性故而优选。更优选为1~100g/m2
另外,在磷酸盐处理工序中,形成含有0.1质量%以上、小于2.0质量%的磷酸盐处理层。磷酸盐处理层优选用喷射或浸渍等常规方法使镀锌层与磷酸盐处理液接触而形成。为了使磷酸盐处理层中含有Mg,在本发明中,优选使用Mg离子浓度与Zn离子浓度的质量比(Mg2+/Zn2+)大于0.05的磷酸盐处理液。该比(Mg2+/Zn2+)优选在5以下。而且,除了处理液中的Mg2+/Zn2+,进入磷酸盐处理层的Mg量还受到处理液中的Zn浓度、溶液温度、pH等的影响。在进行通常的化学转换处理的条件下,上述Mg2+/Zn2+的范围特别优选例如,Zn浓度为0.5~5g/L、溶液温度为30~70℃、pH为1.0~2.5的范围。Mg2+/Zn2+在0.05以上时,容易形成含Mg在0.1质量%以上的磷酸盐处理层。另外,Mg2+/Zn2+小于5时,更容易维持磷酸盐处理层的Mg量处于适当的范围。为了使磷酸盐处理液中的Mg2+/Zn2+在适当的水平,必须溶解适当浓度的Mg盐。因此,与Mg对应的阴离子的选择很重要。作为Mg离子源,可以列举氢氧化镁、碳酸镁、硫酸镁、氯化镁和/或硝酸镁等。但是,使用氢氧化镁、碳酸镁、硫酸镁等时,对于水,有不能得到充分的溶解度的倾向。虽然氯化镁对水的溶解度充分,但高浓度的氯离子与Mg离子同时混入磷酸盐处理液中,对磷酸盐被膜的形成有不良的影响。因此,作为Mg离子源,优选硝酸镁。作为本发明中使用的磷酸盐处理液,可以优选利用含有锌离子、磷酸根离子,还含有促进剂等的市售的处理液。作为这样的物质,例如,可以列举添加了规定量的日本帕卡濑精株式会社制造的商品名「PB3312M」等或者上述的Mg离子源的物质。另外,磷酸盐处理层的附着量优选调整到0.2~3.0g/m2的范围。这种调整可以通过控制镀锌层与磷酸盐处理液的接触时间的常规方法进行。
而且,优选在实施磷酸盐处理前进行镀锌层的表面调整。该表面调整优选喷射胶钛活化剂。作为该胶钛活化剂,可以列举日本帕卡濑精株式会社制造的プレパレンZN(商品名)。
实施例
接着,以实施例为基础更详细地说明本发明。
从板厚1.0mm的冷轧钢板上截取大小为210×100mm的试验板。对这些试验板实施前处理。首先,在添加了原硅酸钠(60g/L)的碱脱脂液(溶液温度:70℃)中,用不锈钢板作为对电极,以5A/dm2的电流密度进行30秒钟的电解脱脂。接着,水洗,进而在30g/L的硫酸水溶液(溶液温度:30℃)中浸渍5秒钟酸洗,然后再水洗。该前处理后,对试验板实施电镀锌,在试验板的一面上形成附着量为5~40g/m2的镀锌层。
电镀锌方法如下。
向添加了440g/L的七水磷酸锌的镀锌液中,加入作为Ni源的六水硫酸镍,使其在0~10g/L的范围内变化,得到Ni含量不同的电镀浴。添加硫酸,将各镀锌液的pH调整到1.5。而且,使各电镀浴的温度为50℃。电镀锌是以覆盖了氧化铱的Ti板电极作为对电极,配置在与试验板平行且极间距离为10mm处,使电镀液在极间以1.5m/s的流速循环,同时以70A/dm2的电流密度通电。
如上操作,在试验板表面形成镀锌层,然后水洗。
接着,作为磷酸盐处理的前处理,将该镀锌层的表面用表面调整剂(日本帕卡濑精株式会社制造,商品名「プレパレンZ」)处理。
向完成了表面调整的镀锌层喷射磷酸锌处理液(向日本帕卡濑精株式会社制造、商品名「PB3312M」中添加硝酸镁的溶液,Zn浓度:3.5g/L,溶液温度:60℃,pH:2.2),水洗后干燥,形成磷酸盐处理层。此时,改变Mg源的添加量,得到Mg量不同的磷酸盐处理液。另外,可以改变喷射时间,使磷酸盐处理层的附着量变化。
如上操作,得到磷酸盐处理镀锌钢板(试验板)。
作为比较例,在与实施例相同的试验板上进行通常的镀锌操作,形成不含Ni的纯锌镀层,再进行通常的磷酸盐处理,在该纯锌镀层上形成不含Mg的磷酸盐处理层。将其作为试验板No.24。另外,在与试验板No.24相同的试验板上,用以铬(VI)酸酐为主要成分的水溶液(日本帕卡濑精株式会社制造,商品名「LN62」)实施封闭。将其作为试验板No.26。另外,电镀的前处理、表面调整处理、电镀条件等其他条件按照实施例进行。
对于得到的试验板,评价其处理表面的外观、镀锌层及磷酸盐处理层的附着量、镀锌层的相结构、耐腐蚀性和耐黑变性。评价方法如下。
(1)钢板表面的外观
目测评价磷酸盐处理后的钢板(试验板)表面的均匀性。均匀时以○表示,不均匀时以×表示。
(2)镀锌层及磷酸盐处理层的附着量
镀锌层的附着量和Ni含量根据JIS H0401-1999中规定的附着量试验方法求得。即,将镀锌层溶解在六亚甲基四胺溶液中,然后用JIS K0121-1993中规定的电加热式原子吸收光谱分析装置分析得到的溶液。磷酸盐处理层的附着量通过溶解在重铬酸铵水溶液中,从而由重量法求得。另外,磷酸盐处理层的Mg含量通过将磷酸盐处理层溶解在重铬酸铵水溶液中,然后用感应耦合等离子发光分析(ICP分析)装置分析得到的溶液而求得。
(3)镀锌层的相结构
用X射线衍射法检查镀锌层的相结构以及Ni含量是否在固溶界限以下。通过有无η相以外的峰而进行判断。即,当在底层的钢板上只检测出来自α-Fe的峰和来自η-Zn相的峰时,以○表示,而除了α-Fe的峰和来自η-Zn相的峰以外,还出现来自Zn-Ni合金的δ相或γ相的峰时,则以×表示。
(4)耐腐蚀性
由得到的试验板切得试验片(大小:100×50mm),将试验片的端部和背面用胶粘带密封后,根据JIS Z 2371-2000的规定实施盐雾试验。定期观察试验片的表面,记录白锈产生面积相对于试验片的全部评价面积达到5%的时间(白锈产生时间),评价耐腐蚀性。白锈产生时间在24小时以上时表示为◎,小于24小时、8小时以上时表示为○,小于8小时、4小时以上时表示为△,小于4小时时表示为×。
(5)耐黑变性
由得到的试验板切得试验片(大小:100×50mm),使用分光色差计SQ2000(日本電色制造),首先测定试验片的初期亮度(L0值)。接着,将试验片在温度80℃、相对湿度95%的恒温恒湿槽中放置24小时,同样地测定放置后的亮度(Lt值)。求出Lt值与L0值的差ΔL(ΔL=Lt-L0)。ΔL≥-1时表示为◎,-1>ΔL≥-2时表示为○,-2>ΔL≥-4时表示为△,-4>ΔL时表示为×,从而评价耐黑变性。得到的结果如表1所示。
可知本发明例的磷酸盐处理镀锌钢板不进行封闭,然而与以往经封闭的磷酸盐处理钢板具有同等以上的耐腐蚀性,而且还具有优良的耐黑变性。另一方面,在本发明的技术范围之外的比较例,耐腐蚀性、耐黑变性、表面外观中每一项都较差。
表1
Figure C20058002863000121
*:不添加
**:不规则地存在色调不同的区域
工业实用性
本发明可以不进行封闭,容易且廉价地制造与以往经封闭的磷酸盐处理镀锌钢板具有同等以上的耐腐蚀性,而且具有优良的耐黑变性的磷酸盐处理镀锌钢板。另外,本发明可以制造因不需要进行铬酸盐处理而不会对环境产生不良影响的优良的磷酸盐处理镀锌钢板,所以在工业上发挥了特别的效用。

Claims (1)

1.一种磷酸盐处理电镀锌钢板,其特征在于,包括:钢板;该钢板的至少一面上的含有10质量ppm以上、400ppm以下的Ni的η单相的电镀锌层;以及该电镀锌层上的含有0.5质量%以上、小于1.0质量%的Mg的磷酸盐处理层。
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