CN112143995B - 一种超厚无花镀锌板及其生产方法 - Google Patents
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Abstract
本发明涉及金属涂镀技术领域,具体公开一种超厚无花镀锌板及其生产方法。所述生产方法包括:将酸洗后的钢卷开卷并剪切,调节焊接参数至预设值进行焊接,得到连续带钢;将带钢经入口活套至退火炉,控制无氧化加热段、辐射管加热段、均热段和喷冷段的温度,进行连续退火;将退火后的带钢送入含有特定铝成分锌液的锌锅中,调节气刀参数进行镀锌处理;将镀锌后的带钢进行光整表面处理和钝化处理,再进入出口活套缓冲,卷取成卷。本发明提供的镀锌板是具有超厚镀锌层(760g/㎡)的无花镀锌板,锌层厚度均匀且表面质量优异,达到了FA及以上级别。
Description
技术领域
本发明涉及金属涂镀技术领域,尤其涉及一种超厚无花镀锌板及其生产方法。
背景技术
镀锌钢板是为防止钢板表面遭受腐蚀延长其使用寿命,在钢板表面涂以一层金属锌,这种涂锌的钢板称为镀锌板。镀锌板利用牺牲阳极的阴极保护法来达到防腐目的。由于镀锌板具有耐腐蚀性强,表面质量优异,加工性能好,性价比高等优点,受到广大客户的青睐。
当前连续镀锌产品的国标(GB/T 2518-2019)最厚锌层仅为600g/㎡,受设备能力和技术限制,具有极厚锌层的镀锌板产品较难生产。但是随着技术的不断进步和设备能力的不断提升,连续热镀锌板的锌层厚度和板厚在不断突破。生产超厚锌层的热浸镀锌工艺,也已逐渐被连续热镀锌工艺所取代。然而,对于超厚锌层>600g/㎡无花高表面质量镀锌板的生产,采用连续热镀锌工艺仍存在较大难度,产品质量始终达不到要求,如镀锌层厚度不达标、锌层厚度不均匀、表面质量差、产生严重锌流纹、气刀斜纹等缺陷以及由炉温控制不合理导致的锌层脱落等问题。因此,在提升设备能力的同时,更需要对工艺参数进行优化改进。
发明内容
针对现有连续热镀锌工艺生产超厚锌层>600g/㎡无花镀锌板时存在的上述问题,本发明提供一种超厚无花镀锌板及其生产方法。
为达到上述发明目的,本发明实施例采用了如下的技术方案:
一种超厚无花镀锌板的生产方法,以酸洗后的卷材钢板为原料,经过焊接、连续退火、镀锌、光整、钝化、卷取得超厚无花镀锌板,镀锌层重量为760g/㎡,包括如下步骤:
S1:将卷材钢板开卷并剪切,调节焊接参数至预设值进行焊接,得到连续带钢;
S2:将带钢经入口活套至退火炉,控制无氧化加热段、辐射管加热段、均热段和喷冷段的温度,进行连续退火;
S3:将退火后的带钢送入含有特定铝成分锌液的锌锅中,调节气刀高度、气刀压力、气刀角度、气刀刀唇间隙及气刀距带钢的距离,进行镀锌处理;
S4:将镀锌后的带钢经冷却和吹干后,进行光整表面处理和钝化处理,再进入出口活套缓冲,卷取成卷。
其中,镀锌层重量为双面镀锌层的重量之和(g/㎡),本发明中镀锌层重量为760g/㎡,为公称镀层重量。对于等厚镀层,镀层重量三点试验平均值应不小于规定公称镀层重量;镀层重量单点试验值应不小于规定公称镀层重量的85%;单面单点镀层重量试验值应不小于规定公称镀层重量的34%。
相对于现有技术,本发明提供的超厚无花镀锌板的生产方法,以卷材钢板为原料,通过优化焊接参数、控制连续退火温度、调节气刀相关参数及限定锌液成分与带钢运行速度相配合,在基层钢板表面形成760g/㎡超厚镀锌层的同时,能够保证镀锌层厚度的均匀性和表面质量。本发明焊接工艺能够确保一次焊接成功,避免了工艺段的降速,并根据带钢的尺寸规格、力学性能和板形制定了镀锌线全线的张力和光整机轧制力,确保生产所得的镀锌板的锌层厚度、表面质量、卷形及锌层附着力均满足技术要求,所得镀锌板的表面质量能够达到FA级的无花镀锌板,可作为新能源、海绵城市、建筑行业等领域用钢。
进一步地,步骤S1中,焊接过程中激光功率为5~8kw,对接间隙为0.05~0.15mm,送丝速度为0~5m/min,焊接速度为4-7m/min,焊后退火功率为15~22KW。通过对焊接参数的优化保证了两卷钢之间的焊接熔透率、高度差和焊缝余高,可有效避免焊接功率不足,焊缝不合格等问题,并极大提升了焊接成功率,为产线的连续性生产提供了保障。焊接过程中根据带钢强度和厚度判断是否填丝焊接。
进一步地,所述无氧化加热段(NOF段)的温度为600~670℃,所述辐射管加热段(RTF段)的温度为630~680℃,所述均热段(ESF段)的温度为630~680℃,所述喷冷段(JCS段)的温度为420~450℃,所述退火炉炉内露点≤-40℃,炉内含氧量≤50ppm,退火炉全长140米,通过调节带钢速度保证各段的保温时间,完成退火处理。本发明中退火炉前未增加清洗段,带钢上的杂质通过退火炉内NOF段的直燃喷嘴进行燃烧去除,有效减少了产线长度和清洗成本;同时采用上述范围的退火温度,既有效保证了带钢组织的再结晶,又避免了带钢发生过烧现象,可有效节约能源消耗;此外,露点和氧含量的限定确保了带钢表面被充分还原,形成海绵状还原铁,有助于提升锌层的附着力。
进一步地,步骤S3中,带钢入锌锅板温为420~450℃。
进一步地,所述锌液中铝的质量含量为0.18%~0.21%,铁的质量含量为0.01%~0.02%,对铝含量的控制可改善锌液流动性,有利于提升锌层附着力和锌层厚度的增加,并保证形成无锌花表面。
进一步地,步骤S3中,上表面和下表面的气刀距离锌液面垂直高度均为75~100mm,上表面和下表面的气刀压力均为60~90mbar,上表面和下表面气刀刀唇间隙均为1.3~1.5mm,上表面和下表面气刀刀唇距带钢距离均为8~18mm,上表面气刀与水平面角度为-0.1~-1°,下表面气刀与水平面角度为-0.2~-1.1°,且上、下表面气刀角度相差0.1°,上、下气刀角度差有助于减轻气流在带钢边缘处汇合形成的涡流效应,进而降低对带钢边部刮锌的干扰,超厚镀锌层带钢表面易出现锌层厚度不够、表面锌流纹、边厚、气刀斜纹等严重缺陷,生产难度大,通过对气刀相关参数的调节可有效控制锌层厚度,减少锌流纹等缺陷产生。有助于提升无花镀锌板表面质量。
进一步地,步骤S4中,光整的轧制力为2000~3000KN,光整机辊的粗糙度Ra≤0.30μm,有效改善镀锌板板形的同时,将工作辊粗糙度复制到带钢表面,进一步地提升镀锌板的表面质量。
进一步地,退火和镀锌过程中张力为20-80KN,光整过程中张力为50-150KN,钝化处理过程中张力为40-110KN,卷取张力为50-160KN。通过对全线的张力进行控制,确保带钢连续生产过程中带钢平直不跑偏,同时在退火过程中有效防止了带钢在炉内瓢曲或断带,在光整机段可有效减少轧机负荷,在钝化处理段有效提升了钝化均匀性,在卷取段有效提升了成品卷形,防止塌卷、溢出边等缺陷的产生,保证了镀锌板的质量。
进一步地,带钢运行速度为40-80m/min,与各工序参数相配合,实现带钢连续热镀锌,实现超厚锌层(760g/㎡),并确保锌层厚度的均匀性和表面质量,
本发明还提供了一种超厚无花镀锌板,由上述述的超厚无花镀锌板的生产方法制得,所述镀锌板的厚度为3~5mm,宽度为900~1600mm。
相对于现有技术,本发明提供的超厚无花镀锌板,是具有超厚镀锌层(760g/㎡)的无花镀锌板,镀锌层厚度均匀且表面质量优异,达到了FA及以上级别。同时该镀锌板的屈服强度可达390-550MPa,抗拉强度可达450-650MPa。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅用以解释本发明,并不用于限定本发明。
实施例1
一种超厚无花镀锌板的生产方法,以酸洗后的卷材钢板为原料,经过焊接、连续退火、镀锌、光整、钝化、卷取得超厚无花镀锌板,镀锌层重量为760g/㎡,包括如下步骤:
S1:将卷材钢板开卷并剪切,调节焊接参数至预设值进行焊接,得到带钢,其中,激光功率为5kw,对接间隙为0.05mm,送丝速度为5m/min,焊接速度为6m/min,焊后退火功率为18KW;
S2:将带钢经入口活套至退火炉,控制NOF段温度为670℃、RTF段的温度为680℃、ESF段的温度为680℃和JCS段的温度为450℃,进行连续退火;
S3:将退火后的带钢送入含有锌液(铝的质量含量为0.21%和铁的质量含量为0.01%)的锌锅中,入锌锅温度为450℃,调节上、下表面气刀距离锌液面垂直高度为100mm,气刀压力为90mbar,气刀刀唇间隙中间缝隙为1.3mm,向两端每经过一个调隙处,增加0.02mm,直到增加至1.5mm,其余均为1.5mm,气刀刀唇距带钢距离为8mm,上表面气刀角度为-1°,下表面气刀角度-1.1°,进行镀锌处理;
S4:将镀锌后的带钢经冷却和吹干后,采用粗糙度Ra为0.30μm的光整机辊(毛化工作辊),以3000KN的轧制力进行光整表面处理,并进行铬酸钝化处理,再进入出口活套进行缓冲,卷取成卷,得镀锌板。
生产过程中对全线进行张力控制,退火和镀锌过程中张力为20KN,光整过程张力为50KN,钝化处理过程中张力为40KN,卷取张力为50KN,且运行速度为80m/min。
实施例2~12
实施例2至12在实施例1提供的生产方法的基础上对焊接参数、退火温度、气刀参数、锌液成分及轧制力和张力进行调整获得,实施例2至12中对应的焊接参数如表1所示,退火温度如表2所示,锌液成分如表3所示,气刀参数如表4所示,光整轧制力及带钢运行速度参数如表5所示,全线张力控制参数如表6所示。
表1焊接参数
实施例 | 焊接速度(m/min) | 激光功率(KW) | 焊接间隙(mm) | 焊后退火功率(KW) | 送丝速度(m/min) |
2 | 6 | 5 | 0.05 | 17 | 5 |
3 | 7 | 4.9 | 0.05 | 15 | 0 |
4 | 7 | 4.9 | 0.05 | 15 | 0 |
5 | 5 | 5.2 | 0.05 | 16 | 4 |
6 | 5 | 5.2 | 0.05 | 16 | 4 |
7 | 5 | 5.2 | 0.05 | 16 | 0 |
8 | 5 | 5.2 | 0.05 | 16 | 0 |
9 | 4 | 8 | 0.15 | 22 | 3.5 |
10 | 4 | 7.5 | 0.15 | 21 | 3.5 |
11 | 4.5 | 7.3 | 0.15 | 20 | 3.5 |
12 | 4.5 | 7.3 | 0.15 | 20 | 0 |
表2退火温度
表3锌液成分
表4气刀参数
表5光整轧制力及带钢运行速度
实施例 | 轧制力(KN) | 速度(m/min) |
2 | 2700 | 80 |
3 | 2500 | 75 |
4 | 2300 | 75 |
5 | 2800 | 70 |
6 | 2500 | 70 |
7 | 2400 | 65 |
8 | 2200 | 60 |
9 | 2600 | 55 |
10 | 2400 | 50 |
11 | 2300 | 45 |
12 | 2000 | 40 |
表6张力控制参数
实施例 | 退火和镀锌段/KN | 光整段/KN | 钝化处理/KN | 卷取/KN |
2 | 24 | 56 | 49 | 60 |
3 | 28 | 65 | 57 | 70 |
4 | 31 | 72 | 62 | 77 |
5 | 41 | 68 | 54 | 84 |
6 | 45 | 83 | 64 | 109 |
7 | 52 | 96 | 74 | 126 |
8 | 58 | 106 | 82 | 139 |
9 | 59 | 99 | 77 | 104 |
10 | 63 | 113 | 88 | 125 |
11 | 73 | 131 | 102 | 145 |
12 | 80 | 150 | 110 | 160 |
为了更好的说明本发明实施例提供的超厚无花镀锌板的生产方法的特性,下面将实施例1~12制备的镀锌板进行性能测试,屈服强度和抗拉强度结果如表7所示。
表7
实施例 | 厚度(mm) | 宽度(mm) | 屈服强度(MPa) | 抗拉强度(MPa) |
1 | 3.0 | 900 | 550 | 650 |
2 | 3.0 | 1250 | 450 | 550 |
3 | 3.0 | 1450 | 420 | 500 |
4 | 3.0 | 1600 | 390 | 450 |
5 | 4.0 | 900 | 550 | 650 |
6 | 4.0 | 1250 | 450 | 550 |
7 | 4.0 | 1450 | 420 | 500 |
8 | 4.0 | 1600 | 390 | 450 |
9 | 5.0 | 900 | 550 | 650 |
10 | 5.0 | 1250 | 450 | 550 |
11 | 5.0 | 1450 | 420 | 500 |
12 | 5.0 | 1600 | 390 | 450 |
由表中数据可知,本发明实施例制备得到了厚度为3~5mm,宽度为900~1600mm的超厚无花镀锌板,该镀锌板的屈服强度可达390~550MPa,抗拉强度可达450~650MPa。
同时,对实施例1、5、12中所得的镀锌板的锌层进行检测,结果如表8所示。
表8
由以上数据可知,本发明实施例提供的镀锌板是具有超厚镀锌层(760g/㎡)的无花镀锌板,镀锌层厚度均匀且表面无明显锌起伏、锌粒压入、划伤凹坑、气刀条痕等缺陷,质量优异,达到了FA及以上级别。本发明其他实施例中所得的镀锌板与实施例1、5、12中镀锌板具有基本相当的性能。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换或改进等,均应包含在本发明的保护范围之内。
Claims (2)
1.一种超厚无花镀锌板的生产方法,其特征在于:以酸洗后的卷材为原料,经过焊接、连续退火、镀锌、光整、钝化、卷取得超厚无花镀锌板,镀锌层双面重量为760g/㎡,包括如下步骤:
S1:将卷材钢板开卷并剪切,调节焊接参数至预设值进行焊接,得到连续带钢;
S2:将带钢经入口活套至退火炉,控制无氧化加热段、辐射管加热段、均热段和喷冷段的温度,进行连续退火;
S3:将退火后的带钢送入含有特定铝成分锌液的锌锅中,调节气刀高度、气刀压力、气刀角度、气刀刀唇间隙及气刀距带钢的距离,进行镀锌处理;
S4:将镀锌后的带钢经冷却和吹干后,进行光整表面处理和钝化处理,再进入出口活套缓冲,卷取成卷;
其中,步骤S1中,焊接过程中激光功率为5~8kw,对接间隙为0.05~0.15mm,送丝速度为0~5m/min,焊接速度为4-7m/min,焊后退火功率为15~22KW;
步骤S2中,所述无氧化加热段的温度为600~670℃,所述辐射管加热段的温度为630~680℃,所述均热段的温度为630~680℃,所述喷冷段的温度为420~450℃,所述退火炉炉内露点≤-40℃,炉内含氧量≤50ppm;
步骤S3中,带钢入锌锅板温为420~450℃;所述锌液中铝的质量含量为0.18%~0.21%,铁的质量含量为0.01%~0.02%;上表面和下表面的气刀距离锌液面垂直高度均为75~100mm,上表面和下表面的气刀压力均为60~90mbar,上表面和下表面气刀刀唇间隙均为1.3~1.5mm,上表面和下表面气刀刀唇距带钢距离均为8~18mm,上表面气刀与水平面角度为-0.1~-1°,下表面气刀与水平面角度为-0.2~-1.1°,且上、下表面气刀角度相差0.1°;
步骤S4中,光整的轧制力为2000~3000KN,光整机辊的粗糙度Ra≤0.30μm;
退火和镀锌过程中张力为20-80KN,光整过程中张力为50-150KN,钝化处理过程中张力为40-110KN,卷取张力为50-160KN;
带钢运行速度为40-80m/min。
2.如权利要求1所述一种超厚无花镀锌板的生产方法,其特征在于:所述镀锌板的厚度为3~5mm,宽度为900~1600mm。
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