CN103080385A - 具有类似不锈钢成品特征的镀锌碳钢 - Google Patents

具有类似不锈钢成品特征的镀锌碳钢 Download PDF

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CN103080385A
CN103080385A CN2011800418036A CN201180041803A CN103080385A CN 103080385 A CN103080385 A CN 103080385A CN 2011800418036 A CN2011800418036 A CN 2011800418036A CN 201180041803 A CN201180041803 A CN 201180041803A CN 103080385 A CN103080385 A CN 103080385A
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carbon steel
coating
veining
steel
galvanizing
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F·A·迈尔斯
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Cleveland Cliffs Steel Properties Inc
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    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04—Hot-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

本发明涉及一种“仿不锈钢”，其可通过将镀锌碳钢通过平整机并使用纹理化的辊进行处理获得抛光型表面来制造。镀锌涂层不会被研磨而除去，而是被压缩从而获得比传统的抛光或拉丝更均匀的基底。所产生的带随后被涂覆有机薄膜，从而提供额外的外观和抗腐蚀优势，包括防指纹性。

Description

具有类似不锈钢成品特征的镀锌碳钢
相关申请的交叉引用
本申请在此要求2010年8月30日提交的、序号为No.61/378,194的标题相同的临时专利申请的权益，在此通过引用其全部内容将其所公开的内容并入本文。
背景技术
相比于碳钢，抛光不锈钢更加昂贵。同时，制造的不锈钢组件(例如厨房用具)上的指纹和斑点是不易去除的。出于这些原因，开发出了一些低成本“仿不锈钢”替代品，包括涂漆碳钢、抛光或拉丝的热镀锌(HDG)或电镀锌(EG)的碳钢。然而，涂漆产品不具备抛光不锈钢的纹理。抛光/拉丝的HDG/EG产品的纹理与抛光不锈钢更加相似。但是，它们更加难于生产，因为用于产生纹理化表面的研磨操作去除了部分或全部的镀锌涂层。这会影响外观的一致性和材料的耐蚀性。
发明内容
在一个实施例中，可通过将镀锌碳钢通过平整机并使用纹理化的辊进行处理以获得“抛光”型表面来制造“仿不锈钢”。在这种情况下，镀锌涂层不会被研磨而除去，而是被压缩从而获得比传统的抛光或拉丝更均匀的基底。所产生的带随后被覆盖透明的有机薄膜，从而提供额外的外观和腐蚀益处，包括防指纹性。
在一个方面，纹理化碳钢包括具有镀锌涂层的碳钢，其中镀锌涂层被压缩并纹理化。在一个实施例中，纹理化碳钢具有有机涂层。
在一个方面，制造纹理化碳钢的方法包括步骤：压缩碳钢上的镀锌涂层，其中该压缩在镀锌涂层上产生纹理。在一个实施例中，该方法还包括步骤：在镀锌涂层上涂覆有机涂层。
这些及其它的目的及优点可从附图及其描述中获得。
附图说明
合并到其中并组成本说明书的一部分、示出了各实施例的附图，连同上面的概述，以及下面对于各实施例的详细描述，用于解释本发明的原理。
图1a描绘了抛光EG碳钢横截面的扫描电子显微镜显微图。未纹理化顶面。
图1b描绘了抛光EG碳钢横截面的扫描电子显微镜显微图。纹理化底面。大量的EG涂层已经被去除掉了。
图2描绘了在抛光EG碳钢和平整机纹理化的EG碳钢上进行循环腐蚀测试的结果。
图3a描绘了传统的抛光不锈钢的光显微镜图像。
图3b描绘了拉丝的EG碳钢的光显微镜图像。
图4为纹理化方法的一个实施例的简图。
图5描绘了平整机纹理化后EG涂覆的碳钢板的横截面的扫描电子显微镜显微图。
图6描绘了不锈钢、纹理化EG碳钢和具有有机涂层的纹理化EG碳钢的循环腐蚀测试的结果。
图7描绘了在具有有机涂层的平整机纹理化EG碳钢上进行成形测试的结果。
具体实施方式
基于碳钢的材料通常为具有合金添加剂的铁和碳的合金，添加剂改善了可加工性、可成形性、耐蚀性及其他希望的性能特征。由于富含铁的表面性质，当暴露于大气湿度、化学物品等时，这些材料容易受到腐蚀。在很多情况下，碳钢涂覆有其他金属，如锌或铝，从而改善抗腐蚀性。镀锌钢被广泛地用于汽车车身板件、家用器具和建筑设备中。金属涂覆的碳钢通常不会形成常规的铁基“红锈”腐蚀产物。形成于这些被涂覆的产品的表面上的氧化物从镀锌钢情况下的“白锈”到富含铝表面上的更不显眼铝氧化物不等。在很多情况下，金属涂覆的钢被有机涂层覆盖，从而获得额外的防腐性以及外观属性。
除了铁、碳及与碳钢相关的其他合金组分之外，不锈钢包括铬、镍、或者同时包括二者。这些元素的存在提供了改进的耐蚀性以及外观优势。多数不锈钢不是涂漆的，而是加工有抛光表面，这可给予材料期望的纹理。除了例如商业厨房设备、浴室装置、汽车内饰和建筑板材的应用之外，抛光不锈钢在家电应用中正日益流行。不锈钢的一个缺点是，由于存在铬和镍以及处理差异，其成本会超过碳钢2倍或更多。不锈钢同样易受不易去除的指纹和其它美观污迹的影响。所以，存在使用更低成本的碳钢基产品的需求，它们具有与不锈钢相似的视觉外观并且其表面对指纹等的敏感度更低。因此，引入了基于多种“仿不锈钢”类型碳钢的产品来满足这些需求。
在一个实施例中，使用多个相同纹理化的工作辊将镀锌碳钢带通过平整机，以对不锈钢实施商业化的“轧制(rolled on)”成品特征(图4)。与上面讨论的研磨过程的一个主要区别是，在纹理化操作过程中轧辊施加的力压缩锌涂层而不是研磨它。因此，在处理过程中所去除的锌涂层的量是最小的。作为平整机的代替方案，可以使用钢加工轧机，该轧机装备有将纹理赋予基底的纹理化工作辊。轧辊所连带的压力压缩基底表面，与去除了表面多个部分的带抛光或拉丝相关的研磨操作相反。平整机的轧制力可以在500,000-1100,000磅的力的范围内，或者在600,000-900,000磅的力的范围内，从而确保从工作辊的充分的纹理传递而不损坏EG涂层。
纹理可具有大约5至大约60微英寸，或者大约20至大约40微英寸的表面粗糙度。纹理可以主要为单向的平行的粒纹或条纹。表面光泽可通过Byk Mirror Tri Gloss装置在60°测量，其也可以是100或更大，或者200或更大。该光泽测量是针对纹理化碳钢上面没有有机涂层的情况下的。
由于通过平整机施加在不锈钢表面上的很大的力，以及被纹理化的表面是厚度小于0.5密耳(0.0005英寸)的金属涂层的事实，一个顾虑是更柔软的锌表面不能像不锈钢一样对工作辊产生响应。此外，多数不锈钢在不使用润滑流体的情况下通过“干燥的”平整机，而碳钢回火在许多情况下在过程中使用润滑流体淹没表面。因此，这些问题可以被预见到因为锌的磨损、开裂或脱落而导致积聚在工作辊上，进而引起表面外观的变形和不一致。在当前的工序中，通过平整机施加在EG表面上的压力被控制为确保工作辊图案的充分传递，但不足以破坏锌涂层。
可通过电镀锌碳钢来创造镀锌涂层。在一个实施例中，涂层可从锌、锌-镍、锌-铁、铝或锌-铝中选择。替代地，可通过热浸渍碳钢带来施加这些涂层。由于该方法的压缩性质，可使用相对来说较轻的锌或其他金属涂层重量，如30G/30G(每个面上30g/m2)。涂层重量可以为约20至约90g/m2或者约30至约60g/m2。轻涂层重量难以使用研磨技术进行加工，这是因为相对较薄的涂层的完整性将更容易被损坏。通过该方法制成的纹理化的碳钢的显微图展示了大部分的EG涂层被保留(图5)。
该程序向柔软的锌表面赋予了与抛光不锈钢上所看到的图案相似的纹理。工艺条件与向不锈钢实施“轧制”成品特征时所应用的条件相似。一旦纹理化操作完成，盘卷(coil)随后会被涂覆提供外观、抗腐蚀、防指纹保护的聚合物薄膜。该薄膜还可含有抗菌添加剂，如基于银离子/沸石的AGION
在一个实施例中，纹理化的碳钢被涂上有机涂层，该涂层可提供额外的抗腐蚀保护和外观属性，根据最终应用有所不同。该涂层可以是透明的聚酯薄膜，但是也可以使用环氧树脂、丙烯酸树脂、聚氨酯。该涂层厚度可以是0.5密耳(0.0005英寸)，但是可以在大约0.1密耳至大约1.0密耳之间变化，或者在大约0.2密耳至0.6密耳之间。可以调整该涂层的光泽以提供期望的反射率水平及防指纹性。通过Byk Mirror Tri Gloss装置测量的典型的60°光泽度范围可以是10-85，较低反射性的低水平提升了防指纹性能，而较高的范围提供了“闪亮的”或反光的外观。光泽度可以在20-40的范围内以获得防指纹性，或者在65-85的范围内以获得最大反射率。在一个实施例中，涂层可以是半透明的或不透明的，从而为基底提供颜色或特殊的色彩。涂层配方中可包括诸如基于银的抗菌剂或聚合物蜡的添加剂，用于提供例如抗菌保护的额外的益处，或用于提高可成形性。涂层的铅笔硬度可具有F-5H的范围，或者H-3H的范围。
生成的涂覆有机物的、纹理化的、具有金属涂层的碳钢可以使用传统的金属成形或造型设备进行加工，并且进行弯曲、拉拔、拉伸操作，而没有对外观临界表面造成脱落、剥落或其它损坏。可在纹理化后、覆盖涂层前对碳钢进行表面处理，从而改善有机薄膜对表面的粘附性。表面处理的实例包括锌或铁磷酸盐、铬酸盐或水基环氧树脂，它们可用于提升有机涂层对金属基底的粘附性。对于某些应用，优选的是使用透明型(clear type)的水基环氧树脂。
在一个实施例中，有机涂层的纹理化碳钢具有的表面粗糙度为5-40微英寸，或者15-30微英寸的范围。60°光泽度可在10-85，或者15-80的范围内。通过拉伸压边模拟测试(Draw Bead Simulatortest)所测量的摩擦系数可在0.03-0.07的范围内，或者0.4至0.06的范围内。有机涂层的厚度可以是0.1至大约1.0密耳，或者大约0.2至大约0.6密耳。铅笔硬度可在F-5H，或者H-3H的范围内。
实施例1
可在用于抛光不锈钢的生产线上加工电镀锌碳钢带。表面纹理是通过与研磨带的接触获得的。通常纹理化只限于一个表面。钢带的速度、研磨带的速度、施加的压力、研磨剂的性质和磨料粒度以及所加工的材料的硬度都对抛光产品的外观有影响。由于电镀锌钢上的锌表面相对于不锈钢表面更加柔软的性质，需要进行调整以确保抛光过程中锌涂层不被完全去除。对用这种方式加工的盘卷的样品进行锌涂层完整性的检查发现，从涂层重量的角度，加工后大约余留50％的锌。但是，已加工的材料的横截面显示出，存在一些隔离的区域，其中的锌涂层几乎被全部去除(图1)。随后对这种抛光的碳钢涂覆透明的聚合物薄膜，以提供额外的屏障型抗腐蚀以及防指纹保护。可将涂层制定为具有多种级别的光泽度和反射率。但是，对于使用基于研磨的工艺来控制被去除的锌的量、进而外观和性能的一致性的能力是存在忧虑的。
当在涂覆有机物之前暴露于室内环境条件时，用这种方式加工的面板产生多个很小隔离的“红锈”区域，表明余留的锌不足以保护钢基底。如图2所示，在循环腐蚀测试后，涂覆有机物的面板同样产生了与腐蚀相关的小表面瑕疵。测试条件与实施例3中所讨论的相同。这将限制材料应用于那些需要最小腐蚀或表面外观要求的情况。
实例2
使用电镀锌碳钢带进行第二个测试，其中表面连续地受到研磨刷类型的辊的作用，而不是研磨带。该程序趋向于在锌的去除方面提供更小的侵蚀性。但是，该程序会导致视觉外观偏离与典型抛光不锈钢相关的期望的纹理(图3)。通过改变加工条件，如相对的辊速度和带速度、辊压力和辊粒度和纹理，从而可开发出更期望的外观。但是，与其他基于研磨的加工一样，存在同样的顾虑，即难于控制去除的锌的量。因而，可能难于保持外观和抗腐蚀性的一致。加工后对材料的目视检查表明，所开发出的并在图3中展示的表面纹理与抛光不锈钢十分不同，从而限制材料对于专门应用(如装饰建筑面板)的应用。因此，使用研磨刷类型辊不适于用在大体积的家用电器类型的应用中。
实施例3
对使用平整机加工并后继涂覆有透明的聚合物薄膜的电镀锌碳钢盘卷的多个样本实施了性能评估测试。被去除的镀锌涂层的量是最小的。样本经过了抗腐蚀性和可成形性测试。以下在图6中展示了抗腐蚀性的结果。
潮湿/干燥循环腐蚀测试表明，具有轧制纹理成品特征和有机涂层的电镀锌钢具有的表面点蚀比抛光的430不锈钢更少。没有有机涂层的样本的测试也没有点蚀，但是具有镀锌钢典型的白锈区域。4x6英寸的样本边缘用带子捆起来以消除切边效果，并且将这些样本浸入5％盐溶液中15分钟。随后将样本风干90分钟并在60℃置于湿度箱中大约72小时。重复循环的潮湿/干燥部分，在移除前将样本再次置于湿度箱中大约24小时。对样本进行视觉评估以比较表面上出现的腐蚀的范围和类型。
实例4
利用典型的金属成形操作，可顺利将具有透明有机涂层的纹理化的电镀锌碳钢的样本弯曲、抻拉、伸展(图7)。在这些操作过程中，表面没有任何剥离、龟裂或裂纹。材料具有低摩擦系数有机涂层的固有优势，这提高了材料的可成形性。在很多情况下，不需要使用额外的湿式拉拔润滑剂或黏性塑料薄膜。
利用Hille Wallace Universal Cup测试机器来形成大约1.25英寸深的正方形杯。使用的工具为1.375英寸穿孔机和具有31/64的半径的1.483英寸的模具。利用Model MTS-866成形压力机形成大约0.875英寸深的“平顶”Marciniak穹顶。使用的工具包括直径3.875英寸的穿孔机和4.0英寸的模具。利用Diacro Finger Brake和Wabash液压机形成弯曲的样本。全部样本在没有施加额外的油基成形润滑剂或塑料保护薄膜的情况下形成加工的(碳钢基底+具有轧制后成品特征的EG涂层+有机透明涂层)。
尽管通过描述几个实施例示出了本发明，并且尽管对这些示意性实施例进行了相当详细的描述，但是，申请人的目的不是将所附权利要求的范围约束或以任何方式限制为这些细节。本发明的额外的优点和变型对于本领域技术人员是明显的。

Claims (11)

1.一种纹理化碳钢，包括具有镀锌涂层的碳钢，其中镀锌涂层被压缩并纹理化，其中纹理具有大约5至大约60微英寸的表面粗糙度。
2.按照前述权利要求中任一项所述的纹理化碳钢，其中镀锌涂层选自锌、锌-镍、锌-铁、铝或锌-铝。
3.按照前述权利要求中任一项所述的纹理化碳钢，其中镀锌涂层是电镀锌的。
4.按照前述权利要求中任一项所述的纹理化碳钢，其中镀锌涂层具有大约20至大约90g/m2的涂层重量。
5.按照前述权利要求中任一项所述的纹理化碳钢，其中钢还包括有机涂层，该有机涂层是从聚酯纤维、环氧树脂、丙烯酸塑料和聚氨酯中选择的。
6.按照前述权利要求中任一项所述的纹理化碳钢，其中钢还包括有机涂层，该有机涂层具有0.1密耳至大约1.0密耳的厚度。
7.按照权利要求5和6中任一项所述的纹理化碳钢，其中涂覆有机物的钢具有F-5H范围的铅笔硬度。
8.按照权利要求5-7中任一项所述的纹理化碳钢，其中涂覆有机物的纹理化碳钢的表面具有5至40微英寸的表面粗糙度、10-85的60°光泽度、0.03-0.07的摩擦系数。
9.一种制造纹理化碳钢的方法，包括步骤：压缩碳钢上的镀锌涂层，其中该压缩在镀锌涂层上产生纹理。
10.按照权利要求9的方法，还包括步骤：在镀锌涂层上涂覆有机涂层。
11.按照权利要求9或10中任一项所述的方法，其中压缩是通过平整机以500,000-1100,000磅的力提供的。
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CN113227447B (zh) * 2018-12-19 2023-08-25 浦项股份有限公司 光泽度和表面特性优异的镀覆钢板及其制造方法

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