CN107406956A - 具有优异耐腐蚀性的锌铝合金镀覆的异形钢丝及制造其的方法 - Google Patents
具有优异耐腐蚀性的锌铝合金镀覆的异形钢丝及制造其的方法 Download PDFInfo
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Abstract
本发明涉及一种缠绕线，其螺旋地卷绕在主缆的外周上，该主缆中多根金属线平行地紧密排列，其中该缠绕线是具有优异的耐腐蚀性的锌铝合金镀覆的异形钢丝，其具有镀覆有锌铝合金的S形横截面，并且在该S形横截面的外周的任何部分都具有至少20μm的镀层厚度。生产根据本发明的锌铝合金镀覆的异形钢丝的方法包括以下步骤：对材料盘条进行一次轧制；在300～500℃的温度下对一次轧制的线材进行应力消除热处理；用锌铝合金对经热处理的一次轧制的线材进行镀覆；然后以5～40％的轧制量对经镀覆的一次轧制的线材进行二次轧制，以获得S形横截面的异形钢丝。
Description
技术领域
本发明涉及一种缠绕线，其螺旋地缠绕在吊桥主缆的外周表面，更具体地说，涉及一种具有优良的耐腐蚀性的锌铝合金镀覆的异形钢丝，其中在形状轧制过程中进行了应力消除热处理操作和锌铝合金镀覆操作，然后进行了额外的形状轧制操作，使得最终形成具有优异耐腐蚀性的镀层以在“S”形横截面钢丝的外周部分的所有区域都具有均匀的厚度，还涉及制造其的方法。
背景技术
用于吊桥的主缆通常被构造成在多根金属线彼此平行地紧密排列的同时，缠绕线没有间隙地紧紧地缠绕并且螺旋地围绕主缆的外周表面，从而防止水等渗透到主缆中。
在使用圆形横截面线材作为缠绕线的缠绕线的情况下，由于施加到主缆的负载的变化和热膨胀导致的重复的膨胀和收缩引起的缠绕线的接触部之间产生间隙，由此雨水等渗透通过该间隙或通过缠绕线外部的厚涂层的裂纹、伴随间隙的裂纹，导致耐腐蚀性能的劣化。
因此，已经使用偏离圆形横截面线材的异形横截面线材作为吊桥主缆的缠绕线。代表性的异形横截面线材可以是Z形和C形的横截面线材。
日本专利第2986288号公开了一种Z形缠绕线。如图1所示。当Z形横截面缠绕线2螺旋地缠绕在由彼此平行地紧密排列的多根金属线1组成的圆柱形金属线束的外周表面上时，进行缠绕，使得相邻的缠绕线部分彼此部分地重叠，使得缠绕线的表面和底表面在完成状态下形成平坦表面，从而消除了相邻缠绕线部分2之间的间隙的产生。
此外，韩国专利10-1396764公开了一种C形横截面的缠绕线。如图2所示，当C型横截面缠绕线2'螺旋地缠绕在由多根金属线1'构成的圆筒形金属线束的外周表面上时，在主缆的外周表面上进行缠绕，使得具有不同间距的缠绕线2'的弯曲表面部分相反地组合以彼此互锁。
通常，常规的Z形或C形横截面缠绕线是通过将圆形横截面盘条轧制成具有预定的异形横截面而成型的，并且在成型成这样的异形横截面之前的步骤中在材料钢丝的表面进行镀锌，以提供耐腐蚀性。
然而，在将镀锌钢丝成型成具有对应于复杂横截面形状的C形或Z形横截面的过程中，形成在线材表面上的镀层的厚度不可避免地由于施加到各截面区域的负载的差异和各截面区域中的加工量的差异而改变。换句话说，即使在轧制之前在材料钢丝的表面上形成具有均匀厚度的镀锌层，由于在轧制成复杂形状的加工过程中所施加的负载的差异和加工量的差异，镀层的厚度也会有差异。在一些情况下，镀层在加工相对集中的拐角部分可能变得非常薄或部分地剥落。
因此，当镀锌层变得非常薄或剥落时，缠绕线的耐腐蚀性降低，因此不能实现相对于主缆的缠绕功能。
发明内容
技术问题
本发明是鉴于上述常规异形横截面缠绕线的问题而做出的，本发明的一个方面是提供一种锌铝合金异形钢丝，其是一种S型横截面的缠绕线，镀覆有锌铝合金，具有与现有锌相比优异的耐腐蚀性，其中在S形横截面线材的外周部分的所有区域上提供了具有足够厚度的锌铝镀层，而没有镀层特别薄的任何区域，从而发挥了优异的耐腐蚀性。
本发明的另一方面是提供一种制造S形横截面缠绕线的方法，其中当通过轧制材料钢丝以将材料钢丝成型成具有S形横截面来制造异形横截面缠绕线时，进行应力消除的热处理，然后在轧制过程中形成锌铝合金镀层，然后进行额外的轧制操作，从而在S形横截面缠绕线的外周表面的所有区域都形成均匀厚度的镀层。
技术方案
根据本发明的一个方面，提供了一种具有优异的耐腐蚀性的锌铝合金镀覆的异形钢丝，其是镀覆有锌铝合金的S形横截面缠绕线，其中，锌铝镀层在S形横截面线材的外周部分的所有区域都至少为20μm，并且其中所镀覆的锌铝量为250g/m2以上。
图3是本发明的S形截面异形钢丝的剖视图。如图所示，具有整体S形的异形钢丝10具有形成在其整个外周表面上的锌铝镀层11。这里，在轧制过程中大量加工处理的异形钢丝10的拐角区域(图中箭头所示)中，锌铝镀层11可能变得非常薄或者剥落。然而，本发明的异形钢丝10即使在这些拐角区域也显示出至少20μm的厚度。
本发明的具有优异耐腐蚀性的锌铝合金镀覆的异形钢丝的制造方法包括：对盘条进行拉制以制备钢丝；对钢丝进行一次轧制；在300～500℃下对一次轧制的线材进行热处理；用锌铝合金对经热处理的线材进行镀覆；并且以5～40％的轧制量对经镀覆的线材进行二次轧制，以获得S形横截面的缠绕线。
根据本发明的异形钢丝的化学组成以重量％计包含：0.06～0.15％的C，0.15～0.25％的Si，0.4～0.6％的Mn，0.015％以下的S，0.015％以下的P，余量为Fe和不可避免的杂质。
对具有上述组成的盘条进行拉制以制备钢丝，然后将其供应到轧制设备以进行一次成型轧制。在一次轧制结束之后处于立即状态的异形轧制钢丝使用热处理装置进行热处理，以减轻线材内通过一次轧制工序产生的应力。
这种应力消除热处理的温度优选为300～500℃。因此，如果热处理温度低于300℃，则由于一次轧制加工，内部结构发生时效硬化，因此降低了材料线材的延展性，导致二次轧制中裂纹的产生。如果热处理温度高于500℃，渗碳体的球化发生于一次轧制的材料线材，从而导致线材软化，从而降低二次轧制过程中的拉伸强度。
同时，通过将热处理温度保持在300～500℃，热处理时间设定为30秒的应力消除热处理，能够确保线材的线性，从而提高作为后续工艺的镀覆锌铝时的镀层质量并确保必要的延展性，同时在二次轧制期间保持适当的拉伸强度。
然后，在应力消除热处理完成后，对一次轧制的钢丝进行锌铝镀覆工艺。对于一次轧制的钢丝的镀覆，首先对一次轧制的钢丝进行酸洗和预处理(氯化+干燥后形成氯化物膜)，然后进行熔融镀锌，然后将所得到的线材浸入到熔融锌铝复合物镀浴中，从而最终进行锌铝镀覆。
这里，相对于一次轧制的钢丝的镀覆量优选为400～430g/m2。
在完成锌铝合金镀覆之后，在经镀覆的一次轧制的钢丝上进行作为后续工艺的二次镀覆。通过这种二次轧制，获得最终的S形横截面缠绕线。
这里，二次轧制中的轧制量优选在5～40％的范围内。如果轧制量低于5％，则可能无法确保最终线材的截面形状或尺寸，而如果轧制量高于40％，则镀层在轧制加工相对集中的拐角区域可能变得非常薄或剥落。因此，轧制量需要保持在5～40％的范围内。
在二次轧制后得到的最终的S形横截面缠绕线中，锌铝合金镀层的厚度在S形横截面的外周部分的任何区域都至少为20μm，镀覆量为250g/m2以上。
有益效果
与现有的镀锌缠绕线相比，本发明的锌铝合金镀覆的异形钢丝可以通过使用具有优异耐腐蚀性的锌铝合金进行缠绕线的镀覆来首先提高耐腐蚀性，另外，即使在S形横截面钢丝的包括轧制加工相对集中的拐角区域，也可以将锌铝镀层的厚度保持在20μm以上，从而二次提高耐腐蚀性。
此外，在本发明的锌铝合金镀覆的异形钢丝中，在材料线材的成型轧制过程中，进行应力消除热处理，并且以维持拉伸强度于所需范围的状态提供合适的延展性，从而可以顺利地进行作为后续精加工的二次轧制，而不会对轧制钢丝或轧制模具造成损伤或变形，并且最终产品的镀层的质量特性和缠绕线的拉伸强度可得以确保。
附图说明
图1是采用常规Z形缠绕线的主缆的立体图。
图2是采用常规C形缠绕线的主缆的立体图。
图3是根据本发明实施方案的S形异形钢丝的横截面图。
图4是S形异形钢丝样品的横截面图。
具体实施方式
具体的制造方法，包括上述技术目的和本发明的其他特征，将通过以下实施例更明显地得以了解。
首先，准备盘条，其由以重量％计0.10％的C，0.17％的Si，0.5％的Mn，0.00176％的P，0.00086％的S，余量为Fe和不可避免的杂质组成。
将材料盘条进行一次拉制，然后进行一次轧制和高频处理。然后，对接受应力消除的一次轧制钢丝进行酸洗和预处理，然后进行熔融镀锌，然后将所得到的线材浸渍在熔融的锌铝复合物镀浴中，由此最终形成锌铝镀层。对具有镀层的一次轧制的线材原样进行二次轧制，以得到最终的S形横截面异形钢丝。
在通过上述工艺制造异形钢丝时，改变一次轧制量、应力消除热处理温度和二次轧制量，以评价镀层厚度和腐蚀特性的行为。评价结果示于下表1。
同时，测量S形异形钢丝中的区域镀层厚度。下表1中的T1至T4表示图4中的S形异形钢丝样品的横截面图中所示的各自T1至T4区域。
[表1]根据轧制量和热处理温度的镀覆特性的评价结果
如上表1所示，当一次轧制后的应力消除温度低于300℃时，二次轧制时产生裂纹，导致加工性下降(比较例2)，而当应力消除温度为600℃以上时，拉伸强度降低至所要求的水平以下(比较例3)。
此外，二次轧制的量小于5％，使得难以匹配S形横截面形状的精确尺寸(比较例1)；而如比较例4那样，在高于40％(45％)的情况下，T3区域的镀层厚度为15μm以下，在某些拐角部位镀层剥落，盐雾试验中的耐腐蚀性显著降低(700小时)。
同时，在传统例1的样品中，其中镀层仅由现有的锌形成，在盐雾试验中经过300小时后观察到生锈。而实施例1～8的样品的生锈时间为1300小时以上，确认了优异的耐腐蚀性。
Claims (6)
1.一种具有优异的耐腐蚀性的锌铝合金镀覆的异形钢丝，其中缠绕线螺旋地缠绕在主缆的外周，该主缆具有多根彼此平行地紧密排列的金属线，该缠绕线具有S形横截面并且镀覆有锌铝合金，其中镀层的厚度在S形横截面的外周部分的任何区域都至少为20μm。
2.根据权利要求1所述的锌铝合金镀覆的异形钢丝，其中所镀覆的锌铝合金的量为250g/m2以上。
3.一种制造缠绕线的方法，该缠绕线螺旋地缠绕在主缆的外周，该主缆具有多根彼此平行地紧密排列的金属线，该方法包括：
对盘条进行拉制以制备钢丝；
对钢丝进行一次轧制；
在300～500℃下对一次轧制的线材进行应力消除热处理；
用锌铝合金对经热处理的一次轧制的线材进行镀覆；以及
以5～40％的轧制量对经镀敷的一次轧制的线材进行二次轧制，以得到S形横截面的异形钢丝。
4.根据权利要求3所述的方法，其中该盘条的化学组成以重量％计包含：0.06～0.15％的C，0.15～0.25％的Si，0.4～0.6％的Mn，0.015％以下的S，0.015％以下的P，余量为Fe和不可避免的杂质。
5.根据权利要求3所述的方法，其中，在通过二次轧制最终成型的S形横截面的外周部分的任何区域，镀层的厚度都至少为20μm。
6.根据权利要求3所述的方法，其中，在通过二次轧制最终成型的S形横截面中，所镀覆的锌铝合金的量为250g/m2以上。
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| PCT/KR2015/004957 WO2016159438A1 (ko) | 2015-04-02 | 2015-05-18 | 내부식성이 우수한 아연-알루미늄 합금 도금 이형 강선 및 그 제조방법 |
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| CN112453099A (zh) * | 2020-11-24 | 2021-03-09 | 梓兰特线（厦门）科技有限公司 | 一种z形异形钢丝生产方法 |
| CN112547818A (zh) * | 2020-11-24 | 2021-03-26 | 梓兰特线（厦门）科技有限公司 | 一种z形异形钢丝生产方法 |
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| WO2016159438A1 (ko) | 2016-10-06 |
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