CN107109666A - 粘附性优异的镀覆钢板及其制造方法 - Google Patents
粘附性优异的镀覆钢板及其制造方法 Download PDFInfo
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Abstract
本发明涉及一种可用于汽车、家电产品、建筑材料等的镀覆钢板及其制造方法。
Description
技术领域
本发明涉及一种可用于汽车、家电产品、建筑材料等的镀覆钢板及其制造方法。
背景技术
一般,可防止钢铁腐蚀的方法有通过镀覆制造成镀覆钢板而使用。具有代表性的镀覆钢板有镀锌钢板。所述镀锌钢板利用锌的牺牲式防腐蚀作用,其种类有电镀锌钢板、熔融镀锌钢板、合金化熔融镀锌钢板等。电镀锌钢板由于表面外观优异,用作汽车用外板,但其不利于后镀作业时的作业性、制造成本及环境方面,因此总体上电镀锌钢板的使用量在减少。并且,熔融镀锌钢板与电镀锌钢板相比,在制造成本方面更低廉,但与电镀锌钢板相比,由于后镀而对机械性能及镀覆粘附性的成型性、连续打点时的电极寿命的焊接性等是不利的。并且,合金化熔融镀锌钢板由于基材铁和锌的合金化反应而形成Fe-Zn系金属间化合物,镀膜粘附性的涂装性及电极寿命的焊接性优异,但由于在加工钢板时镀层脱落的粉化(POWDERING)特性而降低加工性。
所述镀锌钢板是利用牺牲式防腐蚀来保持耐蚀性,但钢板的耐蚀性不一定充分,因此,正在提出或开发添加合金成分以提高镀锌钢板的耐蚀性的镀锌合金钢板、多层镀覆钢板等。由于减小镀锌层的厚度时耐蚀性会降低,因此为了提高耐蚀性,近年来研发了通过添加Mg来获得镀锌-镁合金钢板的方法。
但是,由于所述镀锌-镁合金钢板的粘附性差,因此会发生通过加工来使用的产品上产生脱落等的问题,最终导致镀覆钢板的加工性降低的结果。为了解决这种粘附性的问题,虽然提出了改变镀层组成成分等的多种方案,但依然无法完全克服。
发明内容
(一)要解决的技术问题
根据本发明的一方面,其目的在于提供一种粘附性和加工性优异的镀覆钢板及其制造方法。
(二)技术方案
根据本发明的一方面,提供一种粘附性优异的镀覆钢板,其包括:母材;镀层,形成在所述母材上;及粘接层,形成在所述母材与镀层之间,其中,所述粘接层具有柱状结构(columnar structure)。
根据本发明的另一方面,提供一种粘附性优异的镀覆钢板的制造方法,其包括以下步骤:准备母材;利用干式镀覆方法在所述母材上形成粘接层;及在所述粘接层上形成镀层。
(三)有益效果
本发明可提供一种提高母材与发挥耐蚀性的镀层之间的粘附性的镀覆钢板,由此增加镀覆钢板的粘附性和加工性,从而相比目前所应用的场所及环境,能够应用于更多的场所和环境。
附图说明
图1是示出本发明的镀覆钢板的一个例子的图。
图2是示出本发明的镀覆钢板的粘接层的柱状结构的图。
图3是表示本发明的实施例中的电磁悬浮-物理气相沉积(EML-PVD)方法的概念的示意图。
图4是观察本发明的实施例中的比较例1的镀覆钢板截面的设计、微细组织及粉化测试后的弯曲面表面的照片。
图5是观察本发明的实施例中的比较例2的镀覆钢板截面的设计、微细组织及粉化测试后的弯曲面表面的照片。
图6是观察本发明的实施例中的比较例3的镀覆钢板截面的设计、微细组织及粉化测试后的弯曲面表面的照片。
图7是观察本发明的实施例中的比较例4的镀覆钢板截面的设计、微细组织及粉化测试后的弯曲面表面的照片。
图8是观察本发明的实施例中的发明例1的镀覆钢板截面的设计、微细组织及粉化测试后的弯曲面表面的照片。
图9是观察本发明的实施例中的发明例2的镀覆钢板截面的设计、微细组织及粉化测试后的弯曲面表面的照片。
图10是观察本发明的实施例中的发明例3的镀覆钢板截面的设计、微细组织及粉化测试后的弯曲面表面的照片。
图11是观察本发明的实施例中的发明例4的镀覆钢板截面的设计、微细组织及粉化测试后的弯曲面表面的照片。
图12是观察本发明的实施例中的发明例5的镀覆钢板截面的设计、微细组织及粉化测试后的弯曲面表面的照片。
图13是观察本发明的实施例中的发明例6的镀覆钢板截面的设计、微细组织及粉化测试后的弯曲面表面的照片。
最佳实施方式
本发明的发明人认识到通过在母材与镀层,尤其与脆性强的镀层之间包括结构独特的能够赋予延展性的层(以下,本发明中称为粘接层),能够提高母材和镀层的粘附性,改善镀覆钢板的加工性,从而得出了本发明。
下面,参照附图对本发明的优选实施方式进行说明。但本发明的实施方式可变形为其他多种形式,本发明的范围并不限定于以下说明的实施方式。并且,本发明的实施方式是为了向本发明所属技术领域的普通技术人员更加完整地说明本发明而提供的。
图1是示意表示本发明的镀覆钢板的一个例子的图,图2是进一步示意表示粘接层的图。如图1所示,本发明包括:母材;镀层,形成在所述母材上;及粘接层,形成在所述母材与镀层之间。
如图2所示,在本发明的镀覆钢板中,所述粘接层具有柱状结构(columnarstructure)。所述柱状结构(columnar structure)是单晶或多晶结构,表示晶粒纵向生长形成的结构,而不是横向生长。在本发明中,所述粘接层具有基于晶粒纵向生长的柱状结构,从而能够确保镀覆钢板的优异的粘附性。
另外,所述粘接层具有柱状结构,同时具有包括很多气孔的多孔性(porosity)结构。该结构是由所述晶粒纵向生长的同时晶粒之间形成的气孔而形成的。在本发明中,所述粘接层具有多孔性结构,从而在发生加工等变形(strain)时,起到缓冲(buffer)作用,能够确保优异的粘附性和加工性。
所述粘接层可包括Zn、Al、Si、Cr、Ni、Ti、Nb、Mo等物质。
所述粘接层的厚度优选超过0.5μm。所述粘接层具有前述的柱状结构,且为了确保粘附力,优选具有超过0.5μm的厚度。由于所述柱状结构是由结晶的核生成之后生长而形成,因此粘接层的厚度小于所述厚度时难以确保柱状结构。另外,所述粘接层的厚度越厚,越有利于确保粘附力,因此在本发明中并不特别限定所述粘接层厚度的上限,其可根据镀覆钢板的种类、用途等特性而发生变化。
对于所述镀层,只要是能够确保耐蚀性的镀层,在本发明中并不特别限定,例如,所述镀层可以是镀Zn、镀Al、镀Ni、镀Mg等单一金属层,也可以是Zn-Mg合金、Al-Mg合金、Zn-Ni合金、Zn-Fe合金、Zn-Mg-Al合金等合金金属层。
所述镀层可以形成为单一层,也可以形成为两层以上的复合层。
对于所述母材,在本发明中并不特别限定,只要能够用于镀覆材料的金属薄板(sheet),便可以任意使用。通常可以使用钢板,所述钢板有热轧钢板、冷轧钢板、高张力钢板、不锈钢板、镀覆钢板等,并且,Al等一般的金属薄板也可以用作母材。
下面,对本发明的镀覆钢板的制造方法进行详细说明。
本发明的镀覆钢板的制造方法包括准备母材后在母材上形成粘接层,并在所形成的粘接层上形成镀层的步骤。
为了在所述母材上形成粘接层,优选利用干式镀覆方法,具有代表性的有化学气相沉积(Chemical Vapor Deposition,CVD)、物理气相沉积(Physical Vapor Deposition,PVD)等。在本发明中,为了使所述粘接层具有多孔质(porosity)的同时实现柱状结构(columnar structure),优选利用所述干式镀覆方法来制造。所述粘接层通过晶粒的核生成和生长而形成,因此优选利用干式镀覆方法来制造。
例如,所述化学气相沉积方法有等离子体CVD等,物理气相沉积方法有溅射、电磁悬浮-物理气相沉积(EML(Electron-Magnetic Levitation)-PVD)等。并且,对所述化学气相沉积和物理气相沉积方法的种类并不特别限定,只要是能够形成所述粘接层结构的方法,可以任意使用。
另外,EML-PVD涂覆方法是利用电磁悬浮(Electron-Magnetic Levitation)源的沉积技术,在图3中示出了其示意图。如图3所示,EML-PVD涂覆方法是向位于液滴(Droplet)中的涂覆物质施加高频电源(High Frequency Power),通过电磁力汽化涂覆物质,并使其聚集在蒸汽分配装置(Vaper Distribution Box,VDB)中,通过VDB的喷嘴向带钢(strip)喷射以形成粘接层。
形成所述粘接层后,形成镀层。所述镀层不仅可以使用电镀、熔镀等所代表的湿式镀覆方法,还可以使用化学气相沉积和物理气相沉积等干式镀覆方法,因此在本发明中对所述镀覆方法并不特别限定,只要是本发明所属技术领域的普通技术人员能够识别的方法即可。
具体实施方式
下面,对本发明的实施例进行详细说明。以下实施例仅用于理解本发明,并不限定本发明。
(实施例)
本发明中,在准备冷轧钢之后,如以下表1及图4至13所示,形成粘接层和镀层。
图4至图13中示出了利用透射电子(TEM)显微镜观察各试片的截面的结果和观察粉化试验(powdering test)后的弯曲(bendind)面的表面的结果。
[表1]
图4至7分别表示比较例1至4的观察结果,图8至图13分别表示发明例1至6的观察结果。
如图4至7所示的结果可知,在没有形成粘接层的比较例4和即使形成粘接层但粘接层没有构成柱状结构(columnar structure)的比较例1至3中,进行粉化测试后,弯曲面发生多个裂纹。尤其,可确认比较例2和3没有达到本发明所要求的粘接层厚度,从而可判断其没有形成柱状结构,因此在弯曲面发生多个裂纹。
与此相反,在图8至13所示的发明例1至6的情况下,可知形成有粘接层,且所述粘接层具有柱状结构。其结果可确认,在粉化测试后,弯曲面发生的裂纹数明显变少。
因此,本发明的镀覆钢板的镀层的粘附性优异,从而能够确保优异的加工性。
Claims (7)
1.一种粘附性优异的镀覆钢板,其包括:
母材;
镀层,形成在所述母材上;及
粘接层,形成在所述母材与所述镀层之间,
其中,所述粘接层具有柱状结构。
2.根据权利要求1所述的粘附性优异的镀覆钢板,其中,
所述粘接层呈多孔性。
3.根据权利要求1所述的粘附性优异的镀覆钢板,其中,
所述粘接层的厚度超过0.5μm。
4.根据权利要求1所述的粘附性优异的镀覆钢板,其中,
所述粘接层包括选自Zn、Al、Si、Cr、Ni、Ti、Nb及Mo中的一种以上的物质。
5.根据权利要求1所述的粘附性优异的镀覆钢板,其中,
所述镀层是选自镀Zn、镀Al、镀Ni、镀Mg、镀Zn-Mg合金、镀Al-Mg合金、镀Zn-Ni合金、镀Zn-Fe合金、镀Zn-Mg-Al合金中的一种以上的镀层。
6.一种粘附性优异的镀覆钢板的制造方法,其包括以下步骤:
准备母材;
利用干式镀覆方法在所述母材上形成包括柱状结构的粘接层;及
在所述粘接层上形成镀层。
7.根据权利要求6所述的粘附性优异的镀覆钢板的制造方法,其中,
所述干式镀覆方法是化学气相沉积方法或物理气相沉积方法。
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