CN105555992A - 设置有锌涂层的涂漆钢板 - Google Patents

设置有锌涂层的涂漆钢板 Download PDF

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CN105555992A
CN105555992A CN201380078629.1A CN201380078629A CN105555992A CN 105555992 A CN105555992 A CN 105555992A CN 201380078629 A CN201380078629 A CN 201380078629A CN 105555992 A CN105555992 A CN 105555992A
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steel plate
steel
coating
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mbar
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丹尼尔·沙莱
丹尼尔·雅克
埃里克·西尔伯贝格
塞尔吉奥·帕切
布鲁诺·施米茨
沙维尔·万登艾恩德
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ArcelorMittal SA
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Abstract

本发明涉及一种设置有包括至少一个锌层和通过阳离子电泳形成的漆的上层的涂层的钢板，所述锌层通过使用声速蒸气射流的真空沉积法在沉积室中形成，沉积室内的压强维持在6×10-2mbar至2×10-1mbar之间。本发明还涉及相关的制造方法。

Description

设置有锌涂层的涂漆钢板
本发明涉及设置有包括被漆覆盖的锌层的涂层的钢板，所述钢板特别旨在用于汽车部件的制造，但是并不限于该应用。
例如，无论是在汽车领域或是在建筑行业中，主要包含锌的镀锌涂层通常用于它们为防腐蚀所提供的有效防护。
在下文中，锌涂层是指纯锌的涂层，可能包含生产过程中获得的并且以痕量存在的不可避免的杂质。
以这种方式涂覆的板然后可以被切割并通过例如冲压、弯曲或成形而被成形，以形成部件，然后可以在所述部件上涂漆以在涂层的顶部形成漆膜。该漆膜一般通过阳离子电泳来施加。
最常用于在钢板的表面上沉积锌涂层的方法是镀锌和电镀锌。然而，这些常规方法不能涂覆含有高水平可氧化元素(如Si、Mn、Al、P、Cr或B)的钢种，这导致了新涂覆方法的开发，特别是真空沉积技术(如射流气相沉积法(JVD，jetdevapeursonique))的开发。
然而，在通过阳离子电泳涂漆的步骤之后，根据这些真空沉积法涂覆的板的表面显示出对成形部件的外观美观有不利影响的表面缺陷。
因此，本发明的目的是通过提供由真空沉积涂覆有锌和具有良好表面外观的漆层的钢板来消除使用现有技术方法涂覆的钢的缺点。
为了该目的，本发明的第一目的是如权利要求1所述的钢板。
该板还可以具有单独或组合考虑的权利要求2至5的特征。
本发明的另一目的是如权利要求6所述的方法。
该方法还可以具有单独或组合考虑的权利要求7至8的特征。
以下将对本发明的另外特征和优点进行更详细地描述。
为了示出本发明，已经进行了测试并且将具体地参照附图通过非限制性实例的方式对测试进行描述，在附图中：
–图1示出了可用于执行本发明所要求保护的方法的射流气相沉积设备；
–图2为根据现有技术涂覆的板的4倍放大照片；
–图3为根据本发明涂覆的板的4倍放大照片。
根据本发明涂覆的板首先包括钢基板，所述钢基板优选地经热轧然后经冷轧，使得其可以用于汽车车身部件的制造。然而，本发明不限于该领域，并且本发明可以用于任何钢部件，而无论其预期的最终用途为何。
钢基板具体地可以是THR(TrèsHauteRésistance，非常高强度，通常在450MPa至900MPa之间)钢或UHR(UltraHauteRésistance，超高强度，通常大于900MPa)钢中的以下钢种中之一，其含有高水平可氧化元素：
–无间隙元素钢(IF，无间隙原子)，其可以含有按重量计高达0.1％的Ti；
–双相钢，例如DP500钢、直至DP1200钢，其可以含有按重量计高达3％的Mn连同按重量计高达1％的Si、Cr和/或Al；
–TRIP(相变诱发塑性)钢，例如TRIP780钢，其含有例如按重量计约1.6％的Mn和按重量计1.5％的Si；
–含磷TRIP钢或含磷双相钢；
–TWIP(孪生诱发塑性)钢，其具有高含量的Mn(通常为按重量计17％至25％)；
–低密度钢，例如Fe-Al钢，其可以含有例如按重量计高达10％的Al；
–不锈钢，其具有高浓度的铬(通常为按重量计13％至35％)，连同其他合金元素(Si、Mn、Al等)。
钢板可以以对于最终产品的期望性质适当的方式、除了锌层之外还可选地涂覆有一个或更多个附加层。锌层将优选为涂层的顶层。
在图1中更具体地示出了根据本发明的用于制造钢板的方法，图1示出了包括真空沉积室2的设备1。该室包括入口锁和出口锁(未示出)，待涂覆的钢板3在入口锁与出口锁之间传送。可以通过任何适当的方式(例如其上可以支承带材的旋转支承辊)移动板3。
位于面对待涂覆的带材的表面的是配备有狭缝8的喷射室7，狭缝8的上部位于距待涂覆的带材的表面的距离d处，距离d例如在20mm至60mm之间。该室7被安装在含有待沉积在钢带3的表面上的液体锌9的蒸发坩锅4上。蒸发坩锅4有利地配备有感应加热装置5，感应加热装置5使得可以形成蒸气。然后蒸气经由将蒸气引导至喷射室7和狭缝8的管道10从坩埚逸出，狭缝8优选地被校准为形成朝向待涂覆的基板的表面的射流。狭缝8的存在使得能够沿着狭缝(声速喉道)以恒定声速调节蒸气的质量流量，这具有实现均匀沉积的优点。下面参考了所述技术，使用了缩写“JVD”(射流气相沉积)。有关该技术的另外的信息示出在专利EP07447056中。
在未示出的另一实施方案中，坩埚和喷射室是一个部件并且是同一部件，其包括朝向待涂覆的基板的表面的狭缝。在该实施方案中，通过加热锌产生的蒸气直接朝向狭缝上升并且形成朝向待涂覆的基板的表面的射流。
沉积室2中的压强P室维持在6×10-2mbar至2×10-1mbar之间的压强处。
可选地维持沉积室2中的压强P室和喷射室7中的压强P喷射，使得P室与P喷射的比在2×10-3至5.5×10-2之间，这使得能够改善这些涂层的临时保护。
油层被可选地施加到由此涂覆的板的表面以当所述板在交货或转化成最终产品之前被存储在潮湿和/或盐水环境中时提供临时保护。
板1可以已经经受或可以未经受光整冷轧步骤，然后板1可以被切割并且成形(例如通过冲压、弯曲或成形)以形成部件，然后可以在所述部件上涂漆以在涂层上形成漆膜。
对于汽车应用，在每一块板经过磷化处理之后，在阳离子电泳浴中进行淬火，并且依次施加底漆层、基漆层和可选地罩光清漆涂层(couchedevernisdefinition)。
在将阳离子电泳层应用到所述部件之前，首先对部件进行脱脂，然后磷化，以确保阳离子电泳层的附着力。
阳离子电泳层对部件的防腐蚀提供附加的保护。底漆层(通常采用喷漆枪来施加)制备部件的最终外观并且保护其不受砂和紫外线辐射的影响。基漆层使部件具有其颜色和其最终外观。清漆层使部件的表面具有良好的机械强度、耐腐蚀性化学试剂和良好的表面外观。
通常，磷化层的重量在1.5g/m2至5g/m2之间。
用于保护和保证部件的最佳表面外观的漆膜例如包括：厚度为15μm至25μm的阳离子电泳层；厚度为35μm至45μm的底漆层；以及厚度为40μm至50μm的基漆层。
在漆膜还包括清漆层的情况下，漆的不同层的厚度一般如下：
-阳离子电泳层：15μm至25μm之间，优选小于20μm，
-底漆层：小于45μm，
-基漆层：小于20μm，以及
-清漆层：小于55μm。
漆膜也可以不包括阳离子电泳层，并且可以仅包括一层底漆和一层基漆，以及可选地清漆层。
优选的是，漆膜的总厚度将小于120μm，或甚至小于100μm。
有时在应用阳离子电泳层之后的板的表面上，观察到火山坑(cratère)型缺陷，在钢板上的所述缺陷是腐蚀起源的特定位点，并且显著劣化了板的表面的外观。这些坑为在阳离子电泳层的表面中出现的截锥形孔的形式，并且可能穿过涂层延伸至到达钢基板的表面，通常，它们在底部处的直径在100μm至500μm之间，并且在顶部处的直径在5μm至20μm之间。
现在将在以下通过非限制性实例的方式基于所进行的测试对本发明进行说明。
测试
验收标准
为了评估产品对火山坑型缺陷的外观的风险的敏感性，在10cm×15cm的涂覆钢板经受抛光之后，存在关于所述板上存在的缺陷数目的标准。
对于待验收的涂覆钢板，在每10×15cm2的板上必须具有少于4个缺陷，这相当于小于每平方分米2.7个缺陷。
测试
建立了具有7.5μm厚的锌涂层的由安赛乐米塔尔销售的类型(DC06型)的3个系列的经冷轧的IF钢板。
对于这两个样品，在沉积室中在不同的压强下通过JVD沉积来施加涂层，其中提取(喷射)室的狭缝的上部与待涂覆的同一带材的表面之间的距离d等于约35mm。
样品 涂层类型
1 JVD–沉积室中的压强<10-2mbar
2* JVD–沉积室中的压强1.1×10-1mbar*
*根据本发明
然后使用QuakerFerrocoatoilN6130以1.2g/m2±0.3g/m2对样品进行涂覆，样品然后经受磷化步骤以及之后的阳离子电泳步骤。然后诸如市售的TalySurfCLI2000的图像捕捉和处理装置可以计算如以上所定义的存在于涂覆带材的表面上的火山坑型缺陷的数目。这些火山坑为在阳离子电泳层的表面上出现的截锥形孔的形式，并且可能穿过涂层延伸至到达钢基板的表面。
样品 缺陷的数目
1 >>>2.7dm2(高达1600/dm2)
2* <2.7/dm2
因此，与样品1号相比，根据本发明的样品2号满足验收标准。
图2为已经使用阳离子电泳方法施加了漆涂层的现有技术的钢板的4倍放大照片。DC06的冷轧IF钢板的板使用JVD方法涂覆有7.5μm的锌，在JVD方法中沉积室中的压强维持在小于10-2mbar的压强处，距离d等于35mm。以这种方式涂覆的板以1.2g/m2±0.3g/m2涂覆有QuakerFerrocoatoilN6130层，以提供表面的临时保护，并且然后经受阳离子电泳涂漆步骤。在该板的表面上观察到如以上所定义的火山坑型缺陷11。这些缺陷显著劣化了板的表面的外观。
图3为根据本发明的钢板的4倍放大照片。DC06的冷轧的IF钢板的板使用JVD方法涂覆有7.5μm的锌，在JVD方法中沉积室中的压强维持在1.1×10-1mbar的压强处，距离d等于35mm。以这种方式涂覆的板以1.2g/m2±0.3g/m2涂覆有QuakerFerrocoatoilN6130层，以提供表面的临时保护，并且然后经受阳离子电泳涂漆步骤。这种钢板的表面上明显不存在火山坑型缺陷。附图中出现的灰色阴影与钢板的表面的粗糙度有关，并且与上述意义上的缺陷无关。
在以1.2g/m2使用FuchsAnticoriteoilRP4107s来替代QuakerFerrocoat的情况下可以观察到相同的结果。
本发明人还注意到，沉积室内的压强的变化不影响钢板的表面上的涂层的沉积速率。

Claims (9)

1.一种设置有涂层的钢板，所述涂层包括至少一个锌层和通过阳离子电泳施加的漆的顶层，所述锌层通过真空沉积法通过声速蒸汽射流在沉积室中形成，所述沉积室内的压强P室维持在6×10-2mbar至2×10-1mbar之间。
2.根据权利要求1所述的钢板，所述钢板通过以下方法来获得：其中所述沉积室内的压强P室与锌喷射室内的压强P喷射之间的比在2×10-3至5.5×10-2之间。
3.根据权利要求1或2所述的钢板，所述钢板通过以下方法来获得：其中喷射室7的狭缝8的上部与待涂覆的所述钢板之间的距离d在20mm至60mm之间。
4.根据权利要求1至3中任一项所述的钢板，其中在施加漆层之前所述锌层是所述涂层的顶层。
5.根据权利要求1至4中任一项所述的钢板，其中所述板的表面具有不超过每平方分米2.7个火山坑型缺陷。
6.根据上述权利要求中任一项所述的钢板，其中被涂覆的钢是非常高强度的钢。
7.一种用于制造涂覆且涂漆板的方法，所述方法包括通过在沉积室内的锌的声速蒸气射流来涂覆所述板，所述沉积室内的压强P室维持在6×10-2mbar至2×10-1mbar之间。
8.根据权利要求7所述的方法，其中所述沉积室内的压强P室与喷射室内的压强P喷射之间的比在2×10-3至5.5×10-2之间。
9.根据权利要求7所述的方法，其中喷射室7的狭缝8的上部与待涂覆的钢板之间的距离d在20mm至60mm之间。
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